Veeder-Root HydrX Parts list manual

Manual No: 577014-466  Revision: B
Setup & Operation Manual
HydrX™ Fuel Conditioning Controller

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Table of Contents
iii
Introduction
Overview ...........................................................................................................................1
FCC Setup
Auto Run Time Overview ..................................................................................................3
Auto Run Time Setup ...............................................................................................3
Cycle Time Parameters Overview ....................................................................................4
Cycle Time Parameters Screen................................................................................4
Conditioner Tank Settings Screen............................................................................5
Conditioner Processing Cycles Overview .........................................................................6
Conditioner Processing Cycles Screen ....................................................................6
Filter End of Life (EOL) Overview .....................................................................................7
Filter EOL (End of Life) Notes: .................................................................................7
Filter EOL Settings Screen.......................................................................................7
ATG Device Mapping Overview ........................................................................................8
ATG Device Mapping Screen...................................................................................8
Service
FCC Service Home Screen ...............................................................................................9
New Filter Button ......................................................................................................9
Auto Cycle Button...................................................................................................10
Auto Cycle Notes....................................................................................................10
Auto Drain...............................................................................................................10
Filter Performance Screen ..............................................................................................11
Water Collection Screen .................................................................................................11
Service Counter Screen ..................................................................................................12
Operational Mode History Screen ...................................................................................12
FC Comm Diagnostic Screen .........................................................................................13
FC Probe Comm Diagnostic Screen ...............................................................................13
Fault Diagnostic One Screen ..........................................................................................13
Fault Diagnostic Two Screen ..........................................................................................14
ATG Sensor Data ...........................................................................................................14
FCC Software Upgrade ..................................................................................................15
FCC Clock Setup ............................................................................................................16
TLS-450PLUS Setup
Install HydrX Fuel Conditioning System Software ..........................................................18
FC Mag Probe Setup ......................................................................................................19
FC Pressure Sensor Setup .............................................................................................20
External Input Setups .....................................................................................................20
FCC Switch Contact Setup.....................................................................................20
Diesel Pump Switch Hook SetuP ...........................................................................21
Relay Setup (Output Relay that will engage the STP) ....................................................22
Pumps and Lines Setup ..................................................................................................23
Pump Setup............................................................................................................23
Line Setup ..............................................................................................................24
Custom Alarms Setup .....................................................................................................25
Fuel Conditioner Setup ...................................................................................................26
Operation
HydrX System Maintenance Alerts .................................................................................27
HydrX System Specifations and Default Settings
Specifications ..................................................................................................................29
Recommended HydrX Fuel Conditioning Controller Settings .........................................30

Table of Contents
iv
Figures
Figure 1. HydrX Fuel Conditioning Controller Front Display ..................................2
Figure 2. FCC Display Home Screen .....................................................................2
Figure 3. Auto Run Time Screen ...........................................................................3
Figure 4. Data Entry ...............................................................................................3
Figure 5. Data Entry Keypad Popup ......................................................................4
Figure 6. Cycle Time Parameters Screen ..............................................................4
Figure 7. Conditioner Tank Settings Screen ..........................................................5
Figure 8. Conditioner Processing Cycles Screen ..................................................6
Figure 9. Filter EOL Settings Screen .....................................................................7
Figure 10. ATG Device Mapping Screen .................................................................8
Figure 11. FCC Service Home Screen ....................................................................9
Figure 12. Filter Performance Screen ....................................................................11
Figure 13. Water Collection (Hour/Day) Screen ....................................................11
Figure 14. Water Collection (Month/Year) Screen .................................................12
Figure 15. Service Counters Screen ......................................................................12
Figure 16. Mode Cycle History Screen ..................................................................12
Figure 17. FC Pressure Sensor Diagnostic Screen ...............................................13
Figure 18. FC Probe Diagnostic Screen ................................................................13
Figure 19. ATG Sensor Data Screen .....................................................................13
Figure 20. FCC USB Ports .....................................................................................14
Figure 21. FCC Software Upgrade Screen ............................................................14
Figure 22. Accessing Maintenance Screen ...........................................................15
Figure 23. Maintenance Screen .............................................................................15
Figure 24. System Mode Top Page .......................................................................15
Figure 25. Main Menu Page ...................................................................................16
Figure 26. Clock Set Page .....................................................................................16
Figure 27. TLS-450PLUS USB Ports .....................................................................17
Figure 28. TLS-450PLUS Upgrade Features Screen ............................................17
Figure 29. Accessing TLS-450PLUS Probe Setup Screen ....................................18
Figure 30. Accessing TLS-450PLUS Line Pressure Sensor Setup Screen ..............19
Figure 31. TLS-450PLUS External Input Setup Screen For FCC Switch Contact ....19
Figure 32. Relay Setup Screen ..............................................................................21
Figure 33. Pumps Setup Screen ............................................................................22
Figure 34. Line Setup Screen ................................................................................23
Figure 35. Line Setup Screen - Last Page .............................................................24
Figure 36. Custom Alarms Setup Screen Example ...............................................24
Figure 37. TLS-450PLUS Fuel Conditioner Setup Screen ....................................25
Figure 38. TLS-450PLUS HydrX Overview Screen ...............................................26

1
Introduction
Overview
The Veeder-Root HydrX system has been designed to help maintain diesel underground storage tanks (UST) and
their fuel contents in optimal condition by continuously removing water as well as filtering fuel. As the HydrX
system is removing water, it is preventing the establishment of an environment that supports the development of
bacterial colonies that, left unchecked, will foul fueling system components, such as, check valves, shear valves,
filters and nozzles causing equipment down time and loss of business. The bacteria that thrive in these very
specific conditions, where they access nutrients from fuel at the fuel water interface, will also create acids in the
UST that contribute to corrosion and possible long-term failure of fueling system components, including,
submersible turbine pump (STP) columns, shear valves or other ferrous components within the fueling system.
Along with direct water removal, the HydrX system provides a multi-stage filtration system and provides a means
for continuous “polishing” of the UST fuel contents. The multi-stage filters provide a combined 25-micron (um)
particle filter with a coalescing element that separates any entrained water from the fuel. In addition, a second
element provides a fine water separation as well as another 25-micron (um) filtration barrier. This second stage
prevents any possibility of returning emulsified fuel and water back to the UST. A novel water intake device (WID)
provides direct access to water at the tank bottom at it’s farthest reaches. As water is removed from the tank
bottom, only clean fuel is returned through the multi-stage filtering. The unique configuration of the WID and
filtering provides long life for the filter element as well as providing the cleanest, “driest” fuel that protects the
critical flash point and cetane rating of the fuel product necessary for today’s high performance diesel engines.
The HydrX system is comprised of several components that operate together to provide optimal water removal and
intelligent pump control while minimizing impact to site operations. Intelligent pump control continuously monitors
the HydrX system and determines the best strategy for water removal while managing the STP to minimize run time
while providing the required time to remove water and clean fuel in the UST. In addition, the intelligent pump
control prioritizes line and tank testing to maintain site compliance. If water is not collected over the course of a
daily auto run cycle, the HydrX system will halt processing until a new delivery into the tank occurs. HydrX
components include:
• TLS-450 Plus Automatic Tank Gage (ATG)
• HydrX Fuel Conditioner Controller (FCC)
• HydrX Fuel Conditioner (FC)
• Water Intake Device (WID)
• Guide Tube and Guide Tube Riser

Introduction Overview
2
The HydrX Fuel Conditioning Controller (FCC) is installed in a non-hazardous location and it operates in
combination with a TLS-450PLUS Automatic Tank Gauge (ATG) using existing USM interfaces to Veeder-Root
protocol digital devices as well as switched pump control via UIOM relays (see Figure 1).
This setup manual assumes the FCC is installed and wired both to the TLS-450PLUS and the HydrX Fuel
Conditioner according to the instructions in the HydrX Installation Manual 577014-446.
Figure 1. HydrX Fuel Conditioning Controller Front Display
The FCC display has a touch screen which is used to enter HydrX setup parameters, view operating status,
manually initiate system tasks, and check system history logs. The FCC display home screen is shown in Figure 2.
Figure 2. FCC Display Home Screen

3
FCC Setup
Touch the Setup button on the Home screen to begin the FCC setup procedure and display the Auto Run Time
screen (see Figure 3).
Auto Run Time Overview
Auto Run Time is a user adjustable setting that tells the FCC which hours the HydrX can run the STP and is
typically programmed for quiet hours or overnight shutdowns when sales are slow, or a site is closed for business.
The FCC only runs for the duration of the programmed start and end hours if water is being
removed or if fuel is being circulated through the Fuel Conditioner.
If water extraction and any required fuel circulation ends before the programmed Auto Run end time, the FCC
automatically shuts down the pump and goes into an idle state.
Auto Run Time Setup
1. Touch the Setup button on the Home screen to display the Auto Run Time screen (see Figure 3).
Figure 3. Auto Run Time Screen
2. Touch the Start Hour field to display the number keypad and enter the hour (24 hour format) you wish to start
the HydrX Auto Run Time. To start the FCC auto cycle at midnight, program this value to 00 hour and 00
minute. Start time can be any value between 00 hour 00 minute and 23 hour 59 minute.
Figure 4. Data Entry
3. To use the keypad, touch a number to enter that value. Touch CLR to clear a field’s entry, touch CAN to cancel
a keypad selection, and touch ENT to enter a keypad selection into the associated field and close the keypad.

FCC Setup Cycle Time Parameters Overview
4
Figure 5. Data Entry Keypad Popup
4. Touch the Start Minute field and enter the minutes of the Start Hour, e.g., 00.
5. Touch the End Hour field to program the FCC ending hour in 24 hour format.
6. Touch the End Minute field and enter the minutes of the FCC ending hour.
Cycle Time Parameters Overview
The Cycle Time and Conditioner Processing Cycle parameters described below include
typical, recommended or required settings. These parameters should initially be set as
outlined below and modified only after observing site operations and the HydrX systems
water loading behavior and fuel quality. While highly configurable for any unique site
conditions or operating requirements, the values below will provide acceptable performance
in most circumstances while balancing STP running hours. Reducing run time, while lowering
the utilization of the STP, can reduce water extraction efficiency. Conversely, more water can
be removed or more fuel can be polished at the expense of running the STP.
Cycle Time Parameters determine how long each operating sequence in the FCC runs. All Cycle Time Parameters
are user settable and break down into four discreet settings: Fill Time, Sweep Time, Vacuum Time and Polish Time.
Cycle Time Parameters Screen
1. Touch the Next button to display the Cycle Time Parameters screen (see Figure 6).
Figure 6. Cycle Time Parameters Screen
2. Fill Time - is the amount of time used to fill the fuel conditioner (FC) after a system has been installed or the
filters have been serviced. This cycle fills the FC with clean fuel that is fed from the STP through the inlet filter.
The inlet filter is a two-stage cartridge type that contains a particle and coalescing element that can separate
entrained water. Fill time is typically set to 15 minutes.
3. Sweep Time - is used to reverse flow through the WID by using pressure from the STP to push fuel to the
bottom of the tank. This pushes any standing water towards the lowest point in the tank for more efficient pick

FCC Setup Cycle Time Parameters Overview
5
up as well as clearing any potential clogs that may have built up from vacuuming the tank bottom. This is
typically set to 2 minutes.
4. Vacuum Time - is the amount of time used to vacuum from the bottom of the UST. This is the primary means
for extracting water from the tank. A vacuum cycle is also run at the completion of the fill cycle to remove any
trapped air from the fuel conditioner housing. Typically set to 15 minutes.
5. Polish Time - is the amount of time that the user allows for circulating fuel through the FC. Polishing simply
recycles fuel from the UST at a rate of approximately 6 gallons per minute (gpm) or 360 gallons per hour
(gph). Any entrained water and fine water droplets are continuously separated from the fuel in this process as
well as any particulate or contamination down to 25 micron (um) in size. Polish time is typically set to 4 hours,
however, this value can be increased or decreased to balance STP run time against a site operator’s specific
needs for fuel cleanliness.
Conditioner Tank Settings Screen
Conditioner Tank Settings provide information to the FCC needed to control the maximum drain time (spill
protection) for the auto drain function as well as holding capacity and height to volume conversion. For a typical 5
gallon capacity fuel conditioner, the following parameters should be used, however, these are modifiable for future
FC variations.
1. Touch the Next button to display the Conditioner Tank Settings screen (see Figure 7).
Figure 7. Conditioner Tank Settings Screen
2. Drain Time - is the maximum time the STP is allowed to run if the FC measuring probe doesn’t reach a 0
gallon, minimum, drain. This prevents the pump from running excessively to help avoid spills or accidental
discharges if a drain out is not completed, for any reason. Touch the Drain Time field and select the time in
minutes to drain the FC tank, This should be set to 10 minutes, maximum, for the 5 gallon FC.
3. Extended Drain - is a fine adjustment that lets the drain extend briefly to allow water to clear below the FC
measuring probe’s lower detection limit of 0.75”. Touch the Extended Drain field to select an extra amount of
time in seconds to continue the draining process. Default is 0 seconds.
Unlike the drain time, which shuts down the pump once the water level reaches 0”, this
setting allows the pump to run the programmed amount of time after the water float has
touched bottom on the HydrX Fuel Conditioner (FC) tank. This setting should be limited to 30
seconds, maximum, to prevent any possibility of spilling fuel or ejecting excessive amounts
of fuel into the waste water.
4. Tank Volume - is the maximum volume of water that the FC tank can hold before indicating that a drain out is
required. For the 5 gallon capacity FC, this cannot exceed 5 gallons, however, could be lower if the site
operator chooses. Touch the Tank Volume field and enter an FC tank max volume, typically set to 5.00
gallons.
5. Volume/Inch - is the height to volume conversion used by the FCC for the 5 gallon tank in the Fuel
Conditioner. Touch the Volume/Inch field and enter the required value of 0.3536 gallons per inch (with 5
gallons in the FC tank, the water height measured in the tank will be 14.14”).

FCC Setup Conditioner Processing Cycles Overview
6
Conditioner Processing Cycles Overview
Conditioner Processing Cycles are FCC settings that limit the number of times the FCC runs the STP for water
extraction in it’s different operating modes as described below.
Conditioner Processing Cycles Screen
1. Touch the Next button to display the Conditioner Processing Cycles screen (see Figure 8).
Figure 8. Conditioner Processing Cycles Screen
2. Low Water Cycles - limits the number of vacuum cycles used by the FCC to determine that water is not
being extracted when the FC measuring probe float is below it’s 0.75” minimum detection limit and the float is
resting on the FC tank bottom. This is typically set to 4 cycles and typically higher than Water Cycles limit
used when the float is off the FC tank bottom. See Water Cycles below.
3. Water Cycles - limits the number of vacuum cycles used by the FCC to determine that water is not being
extracted when the FC measuring probe float is above it’s 0.75” minimum detection limit and the float is off the
FC tank bottom. This is typically set to 2 cycles.
4. Sweep Cycles - limits the number sweeps intended to move any standing water along the tank bottom to the
lowest point. Sweeping improves the overall water collection efficiency of the HydrX FC by encouraging water
to move to the end vacuum point that is optimized for water extraction as well as keeping the lines clear from
debris buildup in the WID. This is typically set to 2 cycles. A Sweep cycle combines a sweep period, as
programmed by the sweep time parameter, with a vacuum period, as programmed by the vacuum time
parameter. The combined sweep and vacuum intervals count as a single sweep cycle.
5. Min Water Change - provides the minimum height change in the FC measuring probe’s water float. If the
water float does not meet this minimum change criteria, the FCC logic will determine that water is not being
extracted and will move on to the next cycle or mode. This is typically set to 0.05”.
This does not prevent the FCC from accumulating the water measurement, it only provides a
minimum water detection threshold for the operating logic of the controller to limit STP run
time if water is not being removed from the UST. The water measurement calculator in the
FCC accumulates all the water removed from UST independent of these settings or state of
the HydrX operation.