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STS 6040 40 GPM Automated Fuel Maintenance System
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AXI (formerly ALGAE-X®) STS 6000 Series Fuel Conditioning and Tank Cleaning Systems are programmable, fully automated Fuel Maintenance Systems that remove water, sludge and contaminants wherever fuel is stored or used. Adding an STS 6000 Series System that meets your requirements and needs will remove particulate, separate water, and condition fuel. This fuel polishing process conditions and stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures fuel remains clean and dry. Review the article on this web site that explains that Most Diesel Engine Failures Originate in the Fuel Tank (the Real Story of Bad Diesel Fuel).
The STS 6000 Series systems are specifically designed for permanent installations outdoors and are self contained within a lockable NEMA standard enclosure. The STS 6000 Series Systems keep your tanks clean and your fuel in "Clear & Bright" pristine condition at all times providing maximum efficiency and minimal emissions. AXI’s patented unique LG-X Fuel Conditioner, included on every STS System, reverses fuel deterioration and removes sedimentation to sub micron levels, preventing clogged filters, extending injection system service life, and reducing smoke, emissions and downtime.
All FPS Systems feature:
The STS 6000 Series are designed with a range of safety features that allows for remote and unattended operation. The Filtration Controller features the following:
An STS Series Fuel Polishing System is the central component of a Fuel Management Plan. Establishing a fuel management and maintenance protocol must include periodic monitoring and removal of accumulated water from the tank, periodic treatment with an AXI Diesel Fuel Catalyst for tank cleaning, residual water removal, particulate filtration, microbe neutralization, and polishing of the fuel, returning the fuel to its clear and bright appearance, and to a state of optimal performance.
When the Lights Go out ... it is Too Late to Clean Your Tanks.
The STS-6040 Automated Fuel Conditioning and Tank Cleaning System is designed to optimize and maintain diesel fuel indefinitely. Adding an STS 6040 system to your fuel management program will remove particulate, separate water, and condition the fuel. This innovative process stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures clean reliable fuel at all times. The STS 6010 is sized for facilities that require single tank fuel storage of 20,000 to 60,000 gallons (75,700 to 227,000 liters).
A fuel storage tank that is used to support multiple generators at a data center, office building, remote island or wilderness resort, secure government facility or military base operations are likely to have a need for the periodic conditioning and tank cleaning of a large fuel storage tank. Major institutional facilities, such as hospitals or universities, may have centralized emergency power generating that provides for the backup power to be distributed over many floors of a high rise building or to several buildings.
The STS 6040 Fuel Filtration Systems are self contained, stand-alone and fully automated. They recondition and stabilize fuel, eliminate & prevent microbial contamination and remove water, sludge and contaminants from tanks; preserving the integrity of stored fuel, providing reliable power whenever it is needed. The STS 6040 is available 480V 3 Phase 60Hz 150A -- 230V 3 Phase 50Hz 15A, (other options are available).
Implementing STS Fuel Maintenance Systems assures Optimal Fuel Quality & Reliable Engine Performance at all times. It prevents costly downtime, periodic tank cleaning, replacing out of spec fuel and injection system repairs.
The principal STS-6040 components include a 5 HP single phase continuous duty motor with coupled gear pump and Viton Seals, a Pre-Filter Y-Strainer (20-Mesh) to prevent foreign objects that may damage the pump from entering the system, a Primary Filtration with an FP90 Centrifuge Filter/Water Separator and Purifier, a two phase Secondary Filter configuration, consisting of a first phase made up of two spin on filters aligned in parallel to be equipped with fine particulate filters, and a second phase of two spin on filters aligned in parallel to be equipped with water block filters, an AXI Fuel Conditioner to optimize fuel quality, increase filterability and eliminate microbial contamination, and an AXI Programmable, Fully Automated UL508A Filtration Controller. All components and control devices are contained within a fully enclosed, lockable, weatherproof NEMA cabinet.
For safe operation the STS 6040 Fuel Conditioning and Tank Cleaning System is equipped with alarm indicators and system shutdown when filters need service. Additional safety elements include automatic system shut-down and leak detection within the enclosure, water detection in both the Secondary and Tertiary Filter bowl, high pump vacuum, high pump pressure, low fuel flow alert (or a flow interruption is detected), flow meter with "no flow" alarm indicator, and system shutdown (pressure transmitter).
An optional Automatic Water Drain System is available that detects a high water level in the Primary FP90 Centrifuge Filter/Water Separator. A solenoid valve opens and the drain pump discharges the water into a 15 gallon storage tank next to the system (outside the cabinet enclosure). A water storage tank heater is available.
The cabinet enclosure may be equipped with an optional heater to allow for proper operation in cold climates. The system components require heating within the cabinet to function properly and to provide expected service-life. A 100W heater is available for either 110V/60Hz or 230V/50Hz systems. Note the heater does not heat the diesel fuel, only the System components.
The Smart Filtration Controller also provides a maintenance alert log file, runtime totalizer, alarm history and on-screen help.
The fuel flow first enters the AXI Fuel Conditioner LG-X 4000 immediately upon exiting the pump. Operating on the principal of induction on the process of combining kinetic and magnetic energy to influence the behavior of electrons, the AXI Fuel Conditioner provides a powerful magnetic field and the flow of fuel provides the kinetic energy.
Click on Graphic
As fuel deteriorates, clusters of fuel components break down and residue begins to accumulate, resulting in dark, hazy fuel with poor combustibility. The increase in size and mass of the fuel breakdown products lead to clogged filters and the build up of tank sludge. The AXI Fuel Conditioner dissolves the clusters, stabilizes the fuel, and eliminates tank sludge. The results are Clear & Bright Fuel, improved filterability, optimal combustion and clean fuel systems. The process of how the AXI Fuel Conditioner makes clear, bright and more combustible fuel as well as restoring degraded fuel and eliminating the effects of microbial contamination is compelling. As the AXI Fuel Conditioner does not filter the fuel, but treats it as it passes through the unit, there is seldom any reason to suspect that a restriction is in the AXI Fuel Conditioner. But you can remove the face plate, remove the magnet and wipe it off with a shop rag and replace the magnet and face plate. A spare parts kit for the AXI Fuel Conditioner includes a new face panel O-Ring and replacement screws to fasten the face plate.
The AXI FP90 Water Separator-Purifier utilizes the principle of centrifugal force to split water, fuel sludge, and particles of dirt from fuels, and separate them so that the waste can be isolated and drained out without the use of filter elements that must be purchased, inventories and consumed. The heavier fluid (water), sludge and particulates are heavier than diesel fuel (water, sludge and particulates have a specific gravity greater than diesel fuel). When spun around inside the cylinder, guided by baffles inside the cylinder, these materials are forced to the outside wall of the cylinder and then drops down along the outside wall of the cylinder to collect at the bottom of the cylinder for removal by opening a valve and depositing these contaminants into a container for proper disposal.
A major benefit of the FP90 Water Separator-Purifier is that it does not utilize a filter element in the process of removing particulates, sludge and water from the diesel fuel, thereby not requiring the changing of a filter element or incurring the associated cost with purchasing or inventorying replacement filter elements.
A water sensor is be fitted to the Separator-Purifier to alert to the accumulation of a sufficient amount of water requiring removal. An operator can then drain the water from the system via the tap in the bottom. The sensor is available in either 9V DC power, or 12-24v DC Hard Wired.
An optional Automatic Water Drain System is available that would be activated by a WATECT water sensor connected to the Fuel/Water Separator and Purifier to allow for automated drainage of water and sludge into a proper container without a full shutdown event. An in-line strainer is incorporated to protect the water removal pump. A 15-gallon waste water drum with removable lid and EPDM gasket is included. The drum is made of translucent 3/16" polyethylene to show the level of waste water in the drum. A water level float switch is installed in the drum to assure the waste water drum does not over-fill. An optional heater is available for the water drum to prevent water freezing in colder temperatures.
A connection on the fitting between the Water Separator-Purifier and the Pump is used for the vacuum switch. Should the system lose vacuum for any reason, the system will shut down.
The STS 6040 Secondary Filter utilizes four spin-on filters, two filters operating in parallel utilizing fine filtration elements capable of removing particulates down to 1 micron, and a pair of filters, also working in parallel, utilizing Water Block filter elements for removal of free and emulsified water. Each of the filter housings include a gauge that reads the back pressure and, when the back pressure increases indicating that the flow of fuel is being restricted by the accumulation of particulates or other debris on the filter element inside the spin-on filters, it is time to change the filter. This assures that you are not leaving a filter on too long, compromising the filtration process, or changing the filter too soon and not receiving all the value for the filter and increasing your operating costs. No more guessing or changing the filter too soon. A pressure switch, located between the pump and Secondary Filters, monitors pressure to determine if an increase in pressure occurs indicating a restriction exists in either Secondary filter or in the discharge line and shuts down the pump.
For most applications where fuel is stored for future use in equipment, a circulation system that consistently maintains water-free fuel storage and fuel filtered to a particulate level of 10 microns is considered acceptable. Emergency power generator installations generally utilize secondary filtration to 3 micron, with more critical applications using 1 micron filtration. AXI offers seven different filters for the STS 6040. The fine filter spin-on filter elements are rated at 1, 3, 10, 25 and a 3 micron filter that is an X-Glass element. For the second phase filters, AXI offers 3 and 10 micron Water Block Filter elements. (see pricing at the links in the table to the left under "Replacement Filter Elements for the STS 6040 System".
The 3 micron Water Block filter is usually the preferred filter in the Secondary Phase II position for ongoing preventative maintenance, using a 10 or 30 micron filter in the Secondary Phase I position. The WB3 filter element will remove free water and emulsified water from the fuel stream along with the removal of particulates. Most engine manufacturers want the fuel entering their engine to be filtered at 4 microns, removing particulates and organic debris from the fuel preventing these contaminants from causing problems with the tolerances of fuel injector systems. Although modern engines have a factory-provided filter, usually in the 4 micron range, supplying fuel to the filter that already meets these requirements will extend the life of the factory filter and also assure the fuel is in optimal condition for use in these highly developed injector systems.
The system is automatically operated by the a SFC-50 programmable UL508A SMART Filtration Controller with BMS/BAS Interface and digital text readout. The controller’s alarm functions and pump shut-down are triggered if filter elements require service, if high pump vacuum or pressure occurs, if system flow rate varies or if there is water in the secondary or tertiary fuel filter/water separators. The wiring harness with plugs easily connects the SMART Filtration Controller, which can be remotely mounted, with the STS 6040 allowing for greater flexibility in installation and access where it’s most convenient.
Water Level Probes are provided on both the Secondary and Tertiary Filter bowl to sense when the water level in the bowl reaches a critical level. The WATECT Water Sensor is monitored by the Controller and will provide an alert when the water level is too high. Upon receiving an alert, the water may be manually drained. An Automatic Water Drain is available as an option to automatically discharge the accumulated water from the Primary Filter bowl into a holding container for later disposal.
As clean fuel leaves the Primary Filter via the outlet port and passes through the Vacuum Switch connected to the Controller, constantly monitoring vacuum and, upon detection of high vacuum, caused by a clogged Primary Filter screen or obstruction in the suction line, the Controller will send an alert that high vacuum is occurring, and likely the filter screen requires cleaning. The fuel then continues to the suction side of the Internal Gear Pump. Fuel then exits the pressure port of the pump and passes through a Pressure Switch with Gauge that allows for both visual reading of the pressure in the discharge side of the pump and monitoring of the discharge pressure by the Controller. If discharge pressure is too high, an alert will shut down the system. This typically indicates a clogged Secondary or Tertiary Filter or obstruction in the discharge pipe.
Leak Detection by way of a float switch in the bottom of the drip tray should the unexpected happen and fuel collects in the tray. Upon detection, the Controller will shut down the system.
The STS 6030 may be upgraded to utilize the more advanced and connected TSC-7000 Touch-Screen Controller. The TSC 7000 series controller is an HMI PLC UL508A controller with Modbus, TCP/IP, LAN and Internet connectivity for more intuitive system setup and monitoring from remote locations. The significant features are:
It is recommended that diesel fuel be treated with the AXI Fuel Catalyst AFC-705 (for pre-2007 engines) or AFC-710 (Tier 4 compliant) Diesel Fuel Catalyst prior to the initial tank cleaning and at least every six months thereafter to assure the fuel tank remains clean and the fuel is stabilized. This will enhance and accelerate the tank cleaning process by breaking down and dissolving existing tank sludge. Always check the fuel tank for an accumulation of water in the bottom of the tank. Using a rod, sometimes used to measure fuel in a storage tank, or a length of PVC pipe, spread a line of Kolor Kut Water Finding Paste on the side of the rod or pipe and insert to the bottom of the tank. If the paste touches water, it will change colors, showing how much water is in the tank requiring removal.
Pump accumulated water out of the tank for proper disposal. It is often the case that all of the water is impossible to remove. AFC-705 contains a surfactant that will emulsify the residual water up into the fuel for removal by a Water Block Filter on the AXI Fuel Polishing System AFC-710 does not include this surfactant component). 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 - one oz. to 20 gallons of fuel) and circulate the capacity of the tank five times. Always treat the tank when the tank is full of fuel. If you perform a treatment with a half tank of fuel, you will only be cleaning the bottom half of the tank. The use of AXI Fuel Catalyst has proven to be essential in accelerating the tank cleaning process. AFC-705 and 710 contains detergent, dispersant, corrosion inhibitor, lubricity enhancer and combustion catalyst. AXI Additives do not contain biocides.
For engines manufactured in 2007 and later, use AFC-710, available in both liquid and powdered form. AFC-710 does not contain the surfactant (used to emulsify residual water into the fuel for removal in the circulation process as does AFC-705), a component that does not allow for qualification as a Tier 4 product. AFC-705 and AFC-710 should always be used periodically in particular to stabilize fuel that is stored for longer periods of time.
After the initial cleaning, the AFC-705 or AFC-710 in the fuel will continue to stabilize the fuel for six months or more. Every six months, or more often if the region in which you reside is a humid climate, treat the fuel again and circulate the capacity of the tank three times. In applications where fuel from a treated tank is distributed to other equipment, the additive will also clean the downstream tanks and continue to stabilize the fuel.
For cold weather operations, AXI Fuel Catalyst AFC-805 is a unique and powerful anti-gelling broad-spectrum fuel additive specifically formulated for use in Diesel, Bio-fuels, Gasoline, Kerosene, and HFO. AFC-805 should be used as part of any preventative fuel maintenance program, and is ideal for use in bulk storage fuel tanks in cold weather environments. AFC-805 enhances the breakdown and removal of sludge, slime, and bio-fouling from tank walls and baffles that are difficult to access.
AFC-805 effectively decontaminates and cleans an engine&rsquot;s entire fuel and injection system. It continues to work in storage tanks cleaning and stabilizing fuel for up to 12 months with a single dose. AFC-805 is ideally used for cold weather applications where there is long term fuel storage, such as bulk fuel farms, winterized recreational and work boats, and also smaller engines. AFC-805 is recommended at a ratio of 1:5000 (one oz of AFC-805 to 40 gallons of fuel)
The fuel you depend on should always be in optimal condition. Periodic circulation of fuel assures optimal combustibility and fuel cleanliness. All major diesel engine manufacturers have set minimum fuel standards for the diesel fuel to be used in their engines, and failing to maintain fuel that meets those standards could lead to engine component failures and denied warranty claims. As an example, Caterpillar has published "Cat Commercial Diesel Engine Fluids Recommendations" (SEBU6251-17 September 2014 [a more recent version may be available]) that states "In order to meet expected fuel system component life, 4 micron(c) absolute or less secondary fuel filtration is required for all Cat diesel engines that are equipped with common-rail fuel systems." (Page 34) You should not assume that fuel being delivered to you meets the engine manufacturer’s requirements, and certainly fuel that has been in your storage tank for an extended period of time is unlikely to meet requirements of diesel engine manufacturers without a Fuel Management Program.
Cleanliness standards for diesel fuel, established in the late 1990&rsquot;s by the International Organization for Standardization (ISO), apply to diesel fuel. Caterpillar recommends that the fuel dispensed into the machine tank meets "ISO 18/16/13" cleanliness level." (Page 49) For more information on fuel cleanliness specifications and what those requirements mean to you, review the "Diesel Fuel & Injector Failure" web page on this site.
Continued vigilance to assure that your fuel is in the best condition possible and always meets the requirements to maintain engine manufacturer's warranty requirements is a major challenge without the use of an AXI Fuel Conditioning & Tank Cleaning System to address the need for periodic Fuel Polishing.
A Fuel Maintenance Plan should be a part of every periodic engine Preventative Maintenance Program. Preventative Maintenance Programs are common in all major industries today, but monitoring the fuel condition is often taken for granted and not included in the Preventative Maintenance Program. Many of today's maintenance personnel have many years of experience, but until changes in sulfur content in diesel fuel were regulated within the past decade, and with the government&rsquot;s push for blending some amount of bio-diesel into regular diesel fuel, maintenance professionals were never presented with the problems that we are experiencing today. With today&rsquot;s advances in design and engineering of diesel engines, especially the new fuel injection systems, and with more emphasis being placed on critical requirements that equipment have longer life cycles and near 100% uptime, fuel management can no longer be ignored. It is now just as important as changing the oil, ensuring the batteries are charged, and the air filter is clean.
Service Agreements with an outside contract company to perform Preventative Maintenance typically do not cover fuel-related management and monitoring unless specified. In-house maintenance personnel are usually pressed for time, and fuel management can be easily glossed over. Fuel has a limited shelf-life and even "fresh fuel" could contain water, sediment, microbes, asphaltene agglomeration, or other contaminate components upon delivery and cause immediate engine performance issues.
Emergency power installations are especially susceptible to unexpected interruptions due to fuel related issues. Periodic generator tests-runs are too short to determine if fuel quality is adequate for the demands of continuous, full-load operation. In fact, generator test runs have been found to significantly accelerate the fuel polymerization and degradation process, resulting in the accumulation of gums and resins in the fuel system, by returning fuel that has been compromised by heat and pressure back to the tank. Thirty minute tests, often performed every month, create the environment in the tank for problems to grow. After extended periods of testing, sometimes years, without having been subjected to an extended full load, operation is interrupted by clogged filters when the lights go out.
Now that you have decided to institute a Fuel Management Plan for your operations, there is work to do. Consider the following as the basis for your Fuel Management Program to further assure that your equipment will run when it is needed most at it&rsquot;s peak level of performance and repair costs will remain under control:
Place in service an AXI Fuel Treatment & Tank Cleaning System appropriate to your operations that are capable of performing a complete tank cleaning and fuel conditioning on each fuel tank in service at least once per year (more often in regions of high humidity). Evaluate what other aspects of fuel monitoring and testing is needed to assure that critical equipment needs, including down-stream equipment, may need to be included in your Fuel Management Plan.
Use AXI Broad Spectrum Fuel Catalyst Ultra Concentrate AFC-705 or AFC-710 every six months to enhance the breakdown and removal of sludge, slime, gums, resin, and bio-film from tank walls and baffles that are difficult to access and normal fluid flow does not break loose. Having this unique fuel additive present when fueling downstream equipment also assures that these downstream tanks are being cleaned in the normal course of operations (although separate water removal will be necessary).
Periodically (every 30 to 60 days, depending on your climate) use a Fluid Sampler or a hand Fuel Sample Pump to take samples of your fuel from each storage tank and critical equipment fuel tanks for in-house testing for acidity (pH) and use Liqui-Cult Fuel Test Kits to perform testing for microbial contamination. If initial tests indicate fuel problems, utilize laboratory analysis to evaluate the condition of your fuel to assure your fuel supplier is providing fuel that meets the specification of the engine manufacturer you depend on to keep your equipment running.
Use a Portable Particle Counter to test each incoming load of fuel to assure that the cleanliness of fuel provided by your supplier meets the specifications established by the manufacturers of the engines that power your equipment. Your engine warranty depends on it!
If the quality of your fuel is suspect, consider establishing a quarantine tank to accept new shipments (do not add new shipments of fuel to your stored fuel that has been de-watered and to which you have performed fuel polishing, and is known to meet your Fuel Management protocols).
Use Kolor Kut Water Finding Paste at least every 30 to 60-days to monitor the accumulation of water in your storage and equipment fuel tanks due to condensation or from fuel fills. If any amount of water is detected, take steps to remove it.
Install Desiccant Breathers on all your fuel storage tanks to help prevent moisture from entering your tanks through the vent as fuel is consumed.
Use Water Eliminators in each storage and equipment fuel tank to capture water and remove it before it can cause problems with engine operations or seasonally prevent water from freezing in fuel lines?
With only moderate effort, you can be assured that your diesel fuel will provide optimal performance and enjoy the expected life of your engine’s fuel filters, fuel system components, and your substantial investment in the diesel engine.