INSTALLATION GUIDE FUELTEC- FUEL POLISHING SYSTEM

Transcription

1 INSTALLATION GUIDE FUELTEC- FUEL POLISHING SYSTEM WARNING: Read carefully and understand all INSTRUCTIONS before installing this system. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury. This machine is designed for certain applications only. FuelTec Systems cannot be responsible for issues arising from modification. We strongly recommend this system is not modified and/or used for any application other than that for which it was designed. If you have any questions relative to a particular application, DO NOT use the system until you have first contacted FuelTec Systems to determine if it can or should be performed on the product. For technical questions please call INTENDED USE The System is designed to be used with diesel fuel only. The system is designed to draw fluid from the bottom of a diesel fuel storage tank, through a filter water separator, to remove contamination, then return the fuel tank under minimum back pressure conditions. General Safety Regulations WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. WARNING: The warnings, cautions, and instructions discussed in this instruction guide cannot cover all possible conditions or situations that could occur. It must be understood by the installer that common sense and caution are factors which cannot be built into this product, but must be supplied by the installer. FUELTEC SYSTEMS LLC PO BOX 487 GRANITE FALLS, NC

2 IMPORTANT SAFETY INFORMATION This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining, or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, electrical shock or pressure release could occur and cause death or serious injury, if these safe service procedures are not followed. Preliminary Precautions You are working in a potentially dangerous environment of flammable fuels, vapors, and high voltage or pressures. Only trained or authorized individuals knowledgeable in the related procedures should install, inspect, maintain, or service this equipment. Emergency Pump Shut Off The first and most important information you must know is how to stop all fuel flow. PRESS E-STOP on the control panel. Total Electrical Shut-Off Before Access Any procedure that requires access to electrical components requires total electrical shut-off of that unit. Understand the location and function of the electric service circuit breaker before inspecting, installing, maintaining, or servicing Fueltec Systems equipment. Evacuating, Barricading, and Shutting Off Any procedure that requires access to the fuel polishing system or fuel tank requires the following action: An evacuation of all unauthorized persons and vehicles from the work area. Use of safety tape, cones, or barricades around the work area. Total electric shut off of the system. Read the Manual Read, understand and follow this manual. If you do not understand a procedure, call Fueltec Systems, LLC at Replacement Parts Use only genuine Fueltec replacement parts. Using parts other than genuine Fueltec replacement parts could create a safety hazard and violate local regulations. 2

3 Important Safety Information Working With Fuels and Electrical Energy Prevent Explosions and Fire Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. No Open Fire Open flames from matches, lighters, welding torches or other sources can ignite fuels and their vapors. No Sparks-No Smoking Sparks from starting vehicles, starting or using power tools, burning cigarettes, cigars or pipes can also ignite fuels and their vapors. Static electricity, including an electrostatic charge from your body, can cause a spark sufficient to ignite fuel vapors. Every time you get out of a vehicle, touch the metal of the vehicle, to discharge any electrostatic charge before you approach the fuel polishing system. Working With Electricity Safely Ensure that you use safe and established practices in working with electrical devices. Poorly wired devices may cause a fire, explosion or electrical shock. Ensure that grounding connections are properly made. Follow OSHA Lockout/Tagout Requirements. Warning Gasoline or diesel ingested may cause unconsciousness and burns to internal organs. Do not induce vomiting. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately. Warning Fuel inhaled may cause unconsciousness and burns to the lips, mouth and lungs. Keep airway open. Oxygen may be needed at scene. Seek medical advice immediately. Warning Fuel spilled on skin may cause burns. Wash area with clear water. In an Emergency Inform Emergency Personal Location of accident Nature of accident Age of victim Whether or not victim has received first aid Whether or not victim has vomited or is conscious and awake. 3

4 FIELD INSTALLED VALVES, PIPING, & ELECTRIC FuelTec Polisher Installation Guide ANTI-SIPHON VALVE RETURN TO TANK SUPPLY FROM TANK BOTTOM PRIMING TEE FUELTEC POLISHING SYSTEM 1025SS-UL 115V 1PH 60HZ SERVICE TO HERE 1. Mount the Equipment Enclosure to a stable post or wall. 2. Install optional Tank Flange Assembly 3. Install an Anti-Siphon Valve if fuel level is above the Equipment Enclosure 4. Install a supply drop pipe from upper tank flange to storage tank bottom. 5. Install 1 supply and return piping with a priming Tee as shown. 6. Install 115V 1PH 60Hz 20A electric service to System 4

5 FUELTEC FUEL POLISHING SYSTEM INSTALLATION: 1) Install system equipment enclosure on a wall or optional 6x6 aluminum mounting post. 2) Replace existing tank vent with optional vent flange assembly if required. 3) Add 1 in. sch 40 pipe between the top flange and the telescopic fuel pickup or stainless steel flex tube so that fuel pickup contacts tank bottom. 4) Install optional ball valves on supply and return flange assembly. 5) Install optional mechanical anti-siphon valve on supply pipe above the storage tank s high fuel level. 6) Install supply and return piping (1 in. SCH 40) to fuel polisher with a priming Tee outside the equipment enclosure. 7) Air Test piping for leaks. 8) Paint all black iron piping with yellow epoxy. (Stainless steel piping may be used without painting) 9) Prime supply piping with a priming pump attached to the priming Tee 10) Prime System: Close supply inlet valve then fill Primary Filter with clean diesel fuel. Attach a priming pump to priming Tee; run priming pump until fuel appears with a steady stream. Plug priming Tee and open supply inlet valve. Attach a fuel hose to the water drain port and secure open end to a container above storage tank fuel level. Jog system pump until fuel appears with a steady stream into the container. ( do not run system pump at more than a jog until system is fully primed) When system is fully primed, close drain valve and remove hose. Pump should now run without cavitation noise. ( if pump cavitates re-prime the system) CAUTION!! DO NOT RUN PUMP DRY as pump seals will be damaged. (not covered by warranty) Read and understand PLC manual before operating system. 5

6 TANK FLANGE OPTION 1 Replace existing tank fitting with flange assembly Supply from tank bottom to fuel Polishing System Clean fuel return to tank FUEL TANK piping Optional Tank Flange Assembly 6

7 TANK FLANGE SPECIAL VENT FITTING OPTION 2 RELOCATE VENT AND INSTALL SUPPLY DROP PIPE IN FLANGE INSTALL CLEAN FUEL RETURN PIPE IN TEE FITTING. SUPPLY TO POLISHER CLEAN FUEL RETURN 7

8 DROP LOWER DROP PIPE ASSEMBLY THROUGH TANK FLANGE ASSEMBLY OPTIONAL VALVE DROP PIPE ASSEM- FABRICATE 1 SCH 40 PIPE NOZZLE TO BE AT TANK BOT- TOM WHEN FLANGES ARE CON- NECTED TELESCOPIC NOZZLE 19 OPTIONAL VALVE TANK FLANGE ASSEM- TELESCOPIC PICKUP KIT ADD 1 SCH 40 PIPE IN FIELD TO REACH TANK BOTTOM FUEL STORAGE TANK 8

9 FUEL SUPPLY TO POLISHER CLEAN FUEL RETURN TO TANK FUEL STORAGE TANK TELESCOPIC TUBE NOZZLE POSITIONED ON TANK BOTTOM 9

10 FIELD INSTALLED VALVES, PIPING, & ELECTRIC 10

11 ALUMINUM EQUIPMENT ENCLOSURE FuelTec Polisher Installation Guide EMERGENCY STOP ELECTRIC SERVICE 115VAC 20A 60 HZ SWING BOLTS DISCONNECT CLEAN FUEL RETURN TO TANK STAINLESS STEEL WATER SEPARATOR HOUSING WATER SENSOR BRONZE FUEL PUMP HMI TOUCH SCREEN OR DIGITAL TIMER SUPPLY INLET VALVE PRIMARY FILTER WATER DRAIN VALVE LEAK DETECTOR FLOAT SWITCH DRIP PAN To prime system; 1. Close supply inlet valve then fill Primary Filter with clean diesel fuel. 2. Attach a priming pump to priming Tee; run priming pump until fuel appears with a steady stream. 3. Plug priming Tee and open supply inlet valve. 4. Attach a fuel hose to the water drain port and secure open end to a container above storage tank fuel level. 5. Jog system pump until fuel appears with a steady stream into the container. ( do not run system pump at more than a jog until system is fully primed) 6. When system is fully primed, close drain valve and remove hose. 7. Pump should now run without cavitation noise. ( if pump cavitates re-prime the system) 8. CAUTION!! DO NOT RUN PUMP DRY as pump seals will be damaged. (not covered by warranty) 9. Read and understand PLC manual before operating system. ron lenz

12 WARNING! 1. The fuel supply piping from the fuel storage tanks and the return piping to the fuel storage tanks must be filled with fuel BEFORE STARTING THE FUEL PUMP ON THIS SYSTEM 2. All air must be purged from the System BEFORE STARTING FUEL PUMP. 3. Open fuel supply valve located in the equipment enclosure BE- FORE STARTING FUEL PUMP. OPERATING THE FUEL PUMP IN A DRY CONDITION WILL DAMAGE THE PUMP AND VOID THE WARRANTY. 12