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FPS Compact Fuel Polishing System - 80 GPH - 12V-60Hz


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FPS Compact Fuel Polishing System - 80 GPH - 24V-50Hz


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Converter - 90 V to 305 V AC IN to 12V DC OUT


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Smart FPS Compact Series

Fuel Polishing Systems

Smart FPS Compact Series Systems

FPS Compact Systems
FPS Compact

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FPS Compact Systems Installed in Generator Cabinet
FPS Compact

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Smart FPS Compact System Specifications

Series

FPS Compact

Flow Rate

1.3 GPM / 80 GPH
(4.9 LPM / 302.8 LPH)

Serviceable Tank
Size

200 to 900 gallons
(750 to 3,400 ltr)

Pump & Motor

1/3 HP Helical Spur Gear Pump

Power

12V DC 10A /
24V DC 5A

Max. Fluid Viscosity

5 cSt

Plumbing

Stainless Steel

Port Size

1/2" Hose Barb In & Out
Other Connections Available

Filtration
Controller

Digital Programmable Timer - Remote Mountable

Fuel
Conditioner

LG-X 500

Filter/Water
Separator

Separ SWK 2000/5 Particulate 10, 30 or 60 µ

Filter Elements

10µ, 30µ & 60&Micro;-SS

Operating Temperature

32 - 104 deg. F
0 - 40 deg. C

Alarm Features

Pump Shut-Down
High Vacuum
High Pressure
Leak Detection

Weight
(System/Controller

20/9 lbs

Construction

Powder Coated Aluminum
Back Plate

Dimensions
(HxWxD)

14" x 10" x 85"
(35.6 x 25.4 x 20.3 cm)

Not for use with fluids that
have a flash point below 100 deg. F.

Replacement Filter Elements for
the FPS-Compact Series System

Filter Element Options for the SEPAR SWK 2000/5

SEPAR 2000/01 Filter Elements

Available Options for
the FPS-Compact Series System

Converter -- Accepts 90 V to 305 V AC Input and provides the 12 V DC Output required to power the TK 240 from your handy wall outlet

FPS Compact Series Extended Warranty -- AXI Standard Warranty provides protection against defects in material and workmanship for a period of one (1) year. AXI offers an extended warranty plan that can extend your coverage for one, two, three, or four additional years. Contact us for additional information.


Other Products that Enhance
the Operation of the
FPS-Compact Series System

AFC-705 Diesel Fuel Catalyst -- A POWERFUL Full Spectrum Additive and tank cleaning agent. It is a unique broad-spectrum fuel additive that provides Superior Diesel Fuel Quality for Engines and Storage Tanks, lowering operating cost, maintenance and downtime.

AFC-710 Diesel Fuel Catalyst -- A unique and powerful Tier 4 compliant broad-spectrum fuel additive concentrate for use in Diesel, Biofuels, Gasoline, Kerosene, and HFO.

AFC-805 Diesel Fuel Catalyst -- An effective means of decontaminating and cleaning storage tanks and stabilizing fuel fuel, 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.

Fluid Tank Sampler -- Obtain samples from larger tanks using the AXI Stainless Steel Tank Samplers, available in 4 oz., 8 oz., and 16 oz. capacities

Fluid Sample Pump & Sample Bottles -- Use this hand pump to obtain samples of fuel. Sample is deposited directly into 4 oz. or 16 oz. bottle for further testing.

Liqui-Cult Fuel Test KitsTest kits are used to detect microbial growth in fluids and determines the type and degree of infestation.

Desiccant Fuel Tank Breathers -- Unlike tank installations that utilize open vents or conventional breathers, Desiccant Breathers provide a simple yet dependable defense against not only particulate contamination from entering the tank, but also moisture in the air from entering your storage or equipment tanks.

Water Eliminator -- Water Eliminator crystals are water specific and will swell many times their weight in water. Water specific means they will only absorb the water in your tank and will not absorb or adversely affect gasoline, diesel fuel, fuel oil, JP5 or hydraulic oil. Place a Water Eliminator in your fuel tank and monitor at each fill up for accumulated water.

Water Finding Paste -- Use some "Kolor Kut" paste on the end of a stick or a tank measuring rod that reaches through the top fill opening all the way to the bottom of the tank. Kolor Kut paste will show the water level in the tank by changing color where it comes in contact with water, indicating how much water and sludge will need to be removed.


FPS Compact Literature:


FPS-Compact System

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Description of Components
FPS-SX

FPS-Compact System

FPS SX
Components

1. Fuel Inlet (From Tank)

7. Motor with Coupled Gear Pump

2. ALGAE-X® Fuel Conditioner

8. Drain Valve

3. Vacuum Switch

9. Leak Detector

4. SEPAR SWK 2000/5
Primary Filter/Water Separator

10. Drip Tray

5. Vacuum Gauge

11. Outlet (To Tank)

6. Watect Water Sensor

 


Smart-FPS-Installation

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FPS Series Automated and Programmable Functionality

AXI (formerly ALGAE-X®) SMART Fuel Polishing Systems (FPS) are programmable, fully automated Fuel Maintenance Systems that remove water, sludge and contaminants wherever fuel is stored or used. Adding a SMART FPS System that meets your requirement 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. These compact fuel maintenance systems are specifically designed for permanent installations indoors, as well as confined spaces, such as inside gen-set enclosures or engine rooms. SMART FPS Systems keep your tanks clean and your fuel in "Clear & Bright" pristine condition at all times providing maximum efficiency and minimal emissions. AXI’s LG-X Fuel Conditioner, included on every FPS 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:

  • SMART Filtration Controllers


  • Fully Automated & Programmable Operation


  • Integration with Equipment Monitoring Systems


  • Modular "Plug & Play" Flexibility


  • Unique Safety and Alarm Features


  • Continuous-Duty Pumps, Viton Seals


  • Leak Detection with Emergency Shut-Down

An FPS Series Fuel Polishing System is the central component of a Fuel Management Plan. Establishing a fuel management and maintenance protocol should include removal of accumulated water, periodic fuel circulation for particulate filtration and polishing of the fuel, and treatment with a Diesel Fuel Catalyst made to work hand-in-glove with the Fuel Polishing System to clean the fuel tank without removing the fuel, assuring that the lights stay on when the power goes off.

The FPS Compact System

The SMART FPS Compact Fuel Treatment and T ank Cleaning System is a programmable, fully automated, fuel maintenance system that removes water, sludge, and contaminants wherever fuel is stored or used. Adding a SMART FPS Compact system will remove particulate, separate water, and condition fuel. This fuel polishing process stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures fuel remains clean and dry. These compact fuel maintenance systems are specifically designed for permanent installations indoors, as well as confined spaces, such as inside gen-set enclosures or engine rooms. The FPS Compacy is capable of circulating fuel at the flow rate of 78 Gallons per Hour, and is sized for applications that require fuel storage of 200 to 900 gallons (750 to 3,400 liters).

Applications

The FPS Compact System is specifically designed to be located within the enclosure of a emergency power generator or within a similarly confined space. This style of generator is very popular as it is available in a wide range of sizes to address many applications and has a small footprint when installed. Some generator installations must have one or more below or above ground fuel tanks and provide for special considerations in loading fuel. These compact generators have the fuel tank built into the generator structure and often can be installed in an area of a single parking space of a parking lot. They are ideal for first responder stations (police, fire, & EMS), bank branch offices, small office buildings, event venues, etc.

FPS Compact Functionality

The FPS Compact System operates on either 12 Volt or 24 Volt DC power. This allows the system to operate from the power created by your generator in remote locations or from battery power. When connected to the optional Converter, it can be adapted to operate from a 110V or 230V power supply.

In order to ensure safe operation, the SMART FPS Compact System will shut down the pump and illuminate an alarm light whenever a fault condition occurs. Fault conditions that trigger pump shut down are: filter servicing is required (high suction level), high water level in the separator bowl, or a leak is detected in the fuel containment tray. In addition, the pump motor is protected from overload by a resettable circuit breaker/switch.

The FPS Compact system is automatically operated by the programmable control panel. The controller’s alarm functions and pump shut-down are triggered if filter elements require service, if high pump vacuum, leak detection or if there is water in the separator. The wiring harness with plugs easily connects the SMART Filtration Controller with the FPS allowing for greater flexibility in installation and access where it’s most convenient.

FPS Compact Systems Installed in Generator Cabinet

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The FPS Compact system is automatically operated by the programmable control panel. The controller’s alarm functions and pump shut-down are triggered if filter elements require service, if high pump vacuum, leak detection or if there is water in the separator. The wiring harness with plugs easily connects the SMART Filtration Controller with the FPS allowing for greater flexibility in installation and access where it’s most convenient.

The principal components of the FPS Compact system are a continuous-duty pump with primary filter/water separator with vacuum sensor and gauge, an ALGAE-X Fuel Conditioner and a SMART Filtration Controller. The SEPAR primary filter protects the pump, coalesces and removes water and particulate. The patented AXI Fuel Conditioner prevents and reverses fuel degradation, agglomeration and microbial contamination.

AXI Fuel Conditioner

The fuel flow first enters the FPS DX-S System through the AXI Fuel Conditioner. 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.

AXI LG-X 500 Fuel Conditioner

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to Enlarge

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 filter 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.

Primary Filtration

SMART FPS Compact System reverse fuel deterioration while decontaminating, cleaning and optimizing the fuel for guaranteed continuous, uninterrupted service.

The FPS Company System utilizes a Separ SWK 2000/5 Fuel Filter / Water Separator that incorporates an effective five stage system for the separation of water and particulates from the fuel. Both water and particulate matter can result in high levels of wear for fuel pumps and injectors, resulting in reduced reliability and expensive engine repairs:

Separ Fuel Filter/Water Separator

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to Enlarge

The following is the five stage fuel system of the Separ 2000/10 Fuel Filter/Water Separator:

  • Stage 1: From the inlet port, fuel flows through the interior vane system which imparts a circular motion to the fuel.


  • Stage 2: Still in circular motion fuel reaches the bowl section where, due to this centrifugal motion water droplets and heavier particles are forced to the wall of the bowl eventually settling in the bottom of the bowl.


  • Stage 3: In this stage the fuel has to pass the vane system positioned on the "outside" of the central housing. Due to differing length of the vanes and the twofold rapid change of fuel flow direction, smaller water droplets and finer particles will settle on the vanes. These settlements will agglomerate and when heavy enough fall to the bottom of the bowl. Already at this point the major portion of any contaminates in the fuel have been separated.>

  • Stage 4: Just below the filter element the flow area of the filter is increased significantly thus reducing the fuel flow rate. This calming effect allows even smaller water droplets and particulate to fall out settling on the inner surfaces of the housing forming larger droplets which eventually fall into the bottom of the bowl by gravity. Due to the before described pre-separation process the major portion of water and particulate present in the fuel will be in the bowl or on the inner surfaces of the filter thus greatly extending the filter element life.


  • Stage 5: The final filtration of the remaining water and particulates still contained in the fuel will be effected by a replaceable filter element. These filter elements are produced from a special filter media and are available in different pore sizes. The clean fuel leaves the filter via one of the two outlet ports.

A Vacuum Gauge is provided on the top lid of the Separ Fuel Filter/Water Separator to allow for visual monitoring of Vacuum. When the Vacuum reading increases, indicating that the replaceable filter element has reached its capacity for holding particulate material, you know the filter needs changing. No more guessing or changing the filter too soon.

The System Controller

The Programmable Digital Timer offers a variety of weekly programs. It is equipped with a replaceable battery to retain the program and memory backup. After setting the clock and timer, the Programmable Digital Timer will operate on the schedule you set, and will shut down and provide an alert in the event of high vacuum, high exit pressure, or as a result of receiving a signal from the float switch, located in the tray, that an accumulation of fluid has occurred.

Recommended Tank Cleaning & Fuel Treatments

AFC-705 Diesel Fuel Additive

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.

AFC-710 Diesel Fuel Additive

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.

AFC-710 Powder Diesel Fuel Additive

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.

AFC-710 Powder

Tank Cleaning & Fuel Treatment for Cold Weather Use

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 Following Guides
Tell the Story

Fuel Management System Operation

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.

Fuel Maintenance Plans

Clogged Fuel Filter

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.