Product Submittal Package STS 7030 Automated Fuel Filtration System • Modbus, TCP/IP, LAN and Internet Connectivity • E-mail & SMS Maintenance Alerts • Maintenance Alert Log File • Multiple-tank Functionality • Runtime Totalizer • On-screen Help • Alarm History Optimal Fuel Quality • Reliable Power
Product Submittal Package Section 1 CSI Specifications Optimal Fuel Quality • Reliable Power
CSI - GUIDE SPECIFICATION Possible Sections: Section 26 32 00 Packaged Generator Assemblies Section 23 11 13 Facility Fuel Oil Piping Section 23 13 00 Facility Fuel-Storage Tanks Section 23 10 00 Facility Fuel Systems Other sections applicable Automated Fuel Filtration System Model: STS 7030 FUEL QUALITY MAINTENANCE SYSTEM A. Manufacturers: Subject to compliance with requirements, provide product by the following: 1. AXI International B.
b. Stage 2: LG-X 4000 Fuel Conditioner – to reduce the size and mass of fuel sediments which naturally form in fuel, and to eliminate microbial contamination thus eliminating the need for toxic biocides c. Stage 3: Primary Filtration 10 micron Fine Filter as standard, with water sight-glass and water drain valve – Cartridges shall be available in 1, 5, 10, and 25 micron ratings d.
9. Motor: UL Listed, TEFC, Thermal overload protection, continuous duty C. Performance / Design Criteria: System shall be capable of filtering the entire tank volume with a required filtration run-time of ideally 24 hours, but no more than 48 hours. Sufficient sediment as well as water-holding capacity should be ensured. System run-time requirements will vary with climate, tanklayout, fuel delivery, refueling intervals, etc.
Product Submittal Package Section 2 Installation, Operation & Maintenance Manual Optimal Fuel Quality • Reliable Power
Installation, Operating and Maintenance Manual STS 7030 Automated Fuel Filtration System • Modbus, TCP/IP, LAN and Internet Connectivity • E-mail & SMS Maintenance Alerts • Maintenance Alert Log File • Multiple-tank Functionality • Runtime Totalizer • On-screen Help • Alarm History Optimal Fuel Quality • Reliable Power
2
INSTALLATION, OPERATING AND MAINTENANCE MANUAL TABLE OF CONTENTS GENERAL SPECIFICATIONS .................................................................................................................................................. 8 STS 7030 ..................................................................................................................................................................................................................................................................
4
STS 7030 Programmable Automated Fuel Filtration System STS 7030 Programmable Automated Fuel Filtration Systems are self-contained, stand-alone systems that remove and prevent the buildup of water, sludge and contaminants in tanks. They stabilize diesel and bio-fuels, eliminate microbial contamination to optimize and maintain fuel quality. STS systems guarantee Optimal Fuel Quality for Reliable Power at All Times.
11 Preventive Maintenance Plans for mission-critical power are essential. However, most service agreements do not cover fuel-related engine failures. Fuel has a limited shelf-life and even “fresh fuel” could contain water, sediment, microbes and bio-fuel components upon delivery. 5 4 6 20 10 17 18 19 To Tank (Discharge) Periodic generator tests-runs are too short to determine if fuel 1 quality is adequate for the demands of continuous, full-load operation.
11 5 wer are cover e and es and F JG GVFM -load MFSBUF turning back to JOH every OUBJOT 4 6 20 10 17 18 19 To Tank %JTDIBSHF 1 From Tank (Suction) 2 3 7 8 9 12 13 14 16 15 Inside the STS 7030 1.
GENERAL SPECIFICATIONS STS 7030 Flow Rate ............................................................................... 30 gpm / 1800 gph 14,400 Gallons per 8 hour shift 43,200 Gallons per 24 hours Outline Dimensions (Enclosure) ............................. 57” x 72” x 14” (H x W x D) System Weight ................................................................... approx. 510 lbs Operating Temperature ............................................... 41 to 104° F; 5 to 40° C Electrical ...................
FUEL CONDITIONER • Inline Algae-X Fuel Conditioner eliminates and prevents microbial contamination and the formation of sediments that naturally occur in diesel fuel.
manual should install, operate and maintain the system. MOUNTING The STS 7030 is a totally enclosed system and should be permanently wall mounted on a hard, level surface. Use provided mounting feet for proper fastening. This weatherproof unit is designed for wellventilated indoor or outdoor use within specified temperature range and should be located as close to the tank as possible. Please allow about 1 ft of space between the side louvers of the enclosure and nearby objects.
PLUMBING Use proper quality approved fuel line materials with at least 2” inner diameter on the suction side from the tank and at least 1-1/2” inner diameter on the return / discharge side back to the tank. Note: Do not put any stress on plumbing of STS 7030 and use a backing wrench when connecting the external plumbing. Whenever possible a FLEXIBLE CONNECTION SHOULD BE USED TO REDUCE STRESS on the plumbing and prevent damage from thermal expansion.
Note: Plumbing and Installation must be in accordance with all applicable Federal, State and Local rules, laws, standards and regulations. TYPICAL PLUMBING / ABOVE GROUND TANK INSTALLATION (SCHEMATICALLY) IMPORTANT INSTALLATION PRECAUTIONS The suction line of the system should be independent and separate from the suction line of the engine.
PRIMING THE SYSTEM The pump supplied with the STS 7030 is NOT automatically self-priming and must not be run dry. ! WARNING ! If the pump is allowed to run without fuel, pump damage will occur. The pump head of the STS 7030 unit is shipped from the factory filled with Diesel #2 to facilitate initial lubrication. This will not eliminate the necessity to prime the complete system. The STS 7030 is primed by using the externally installed priming tee (not provided) on the suction side of the system.
TOUCH-SCREEN CONTROLLER - ALARM FEATURES The STS 7030 is equipped with an AXI INTERNATIONAL Touch-Screen Controller. System and alarm status are displayed on the industrial control panel (on the door) via indicator lights and on the text display directly on the controller.
INITIAL START-UP / COMMISSIONING CHECKLIST FLOW SWITCH SETTING / ADJUSTMENT (“NO FLOW ALARM”) Note: Flow switch needs to be adjusted to actual flow rate for proper system operation. Please make sure system is properly primed and check when pump running for a steady stream of fuel without air bubbles in the mechanical flow meter (indicator) inside the STS 7030 enclosure.
OPERATION ` ` ! WARNING ! Do not use with gasoline. This System is not meant for use with gasoline nor with other flammable liquids having a flash point less than 100°F. Use with gasoline or use with any flammable liquids at a temperature exceeding their flash point, presents an immediate explosion and fire hazard. ! WARNING ! Never use the STS 7030 at a temperature exceeding the flash point of its contents.
PROGRAMMING THE TIMER Note: The PLC uses military time – all times must be programmed in that format. 1. From the STS 7004 Home Screen, touch the “AUTO TIMER CONFIG” screen to navigate to the Auto Pump Timer Configuration Screen. 2. Touch the day button to select the day of the week you want the Auto Timer to run. 3. Touch the time values to set the Pump Start and Stop times in Auto (use 24hr time format.) 4. Up to three separate timers can be set for each day of the week. 5.
Depending on the condition of the fuel and the amount of sludge build-up, it is recommended to initially use a double dose of one to twenty-five hundred (1:2500) instead of one to five thousand (1:5000) This has proven to be essential in accelerating the tank cleaning process. AFC-705 contains detergent, surfactant, dispersant, corrosion inhibitor, lubricity enhancer and combustion catalyst. It does not contain biocides.
3. Slide the flow switch located on the side of the mechanical flow meter slightly upwards away from the flow indicator inside the sight tube (mark original position before doing so). The “NO FLOW ALARM” indicator should start blinking for 10 seconds and then illuminate constantly as the pump is turned off. Slide flow switch back into original position and reset alarm by pushing the “RESET ALARM” button.
SERVICING Y-STRAINER Excessive debris in the Nexus Y strainer will result in pump shutdown and activate the alarm “HIGH VACUUM ALARM”. This indicates that it is time to clean the strainer basket. Servicing Y-Strainer: 1. Turn key switch to the “OFF” position – make sure pump will not turn on 2. Close the inlet and outlet ball valve 3. Place a fuel waste container below the drain valve on the bottom of the Y-Strainer 4. Open the drain valve 5. Allow all fluid to drain from the Y-Strainer 6.
13. Insert a new cartridge into the housing. Position housing (with cartridge) underneath filter head. Push/twist cartridge onto head spigot. The head “conical spring” will seat/seal the cartridge in the housing. 14. “Rotate” housing onto the collar bolts, hand tighten knobs until head is “snug” to housing. Note: A torque wrench is recommended. Tighten all collar bolts to 100 in lbs. 1. 2. 3. 4. 5. Close the drain valve on the bottom of the housing.
TROUBLESHOOTING No fuel delivery 1. Pump does not run 2. Pump is not primed 3. Fuel supply line blocked 4. Excessive lift 5. Air leak in fuel supply to pump 6. Pump rotation direction incorrect 7. Intake or outlet valve closed 8. Check valve installed backwards Insufficient fuel delivered 1. Air leak at inlet 2. Defective pressure relief valve or check valve 3. Excessive lift 4. Pump worn 5. Inoperative foot valve 6. Piping improperly installed or dimensioned 7.
5. Pump coupler out of balance Pump requires frequent re-priming 1. Inoperative foot valve 2. Inoperative check valve 3. Inoperative solenoid valve (optional) 4. Pump cavitations 5. Plumbing air leaks 6. Lift too high 7. Leaking pump seal Motor does not turn or turns intermittently 1. Control power not available 2. Motor thermal overload condition 3. Pump failed and seized 4. Motor failure 5. Emergency Button depressed Pump leaks fuel 1. Loose pump plumbing fittings 2. Worn pump shaft seal 3.
AUTOMATIC FUEL FILTRATION SYSTEMS WARRANTY LIMITED WARRANTY AXI International makes every effort to assure that its products meet high quality and durability standards and expressly warrants the products described herein, against defects in material and workmanship for a period of one (1) year from the date of purchase.
TECHNICAL ASSISTANCE AND ORDERING Please write, fax, email or call: AXI International International 5400 Division Drive Fort Myers, FL 33905 Tel: 239-690-9589 Fax: 239-690-1195 Email: info@axi-international.com Internet: www.axi-international.com Please provide the following information: Serial Number of your STS 7030, the required part numbers and quantity. The drawings / parts list included in this manual are the most accurate source of part numbers for your STS 7030.
APPENDIX A - ABBREVIATIONS USED IN THIS MANUAL Abbreviations of terms used with STS 7030 Automatic Fuel Filtration Systems. When following a drawing utilize this guide to define abbreviated system and component names. This is a master list. The drawings and text pertaining to your equipment may not contain all these terms. AC AHR AH BPRV BRK BV C CB CSR CV DC DPDT F FLWS FS GA GAL GPM HFL HG HP HZ I.D. JB “ HG L L.E.D.
APPENDIX B – DRAWINGS 28
Product Submittal Package Section 3 Electrical Drawing Optimal Fuel Quality • Reliable Power
Product Submittal Package Section 4 Installation Notes & Recommendations for Site and/or Tank Plumbing Optimal Fuel Quality • Reliable Power
There are no additional installation notes or recommendations. Please see the product manual included in this submittal for installation information.
AXI designs and manufactures standardized and custom-engineered Automated Fuel Conditioning, Fuel Polishing and Transfer Systems, Tank Cleaning Equipment, Fuel Additives and In-line Fuel Conditioners to ensure optimal fuel quality at all times. Our scope of expertise covers fuel storage and fuel supply systems from single engine installations to power plants. AXI is your single source for all fuel conditioning related equipment and support available world-wide.
