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STS 6040 40 GPM Automated Fuel Maintenance System

Your Price: $33253.11

STS 6040 40GPM
Automated Fuel Filtration Systems

Ensures Safe & Reliable Emergency Generator Operation.

STS 6040 40-GPM Automated Systems

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STS 6040
40 GPM

Flow Rates

40 GPM / 2,400GPH - 151.4 l/m (208-230V/60Hz)
32 GPM/1,920GPH - 121.3 l/m (230V/50Hz)

Tank Size

20,000 to 75,000 gal.

Port Sizes

2" NPT Suction - 1.5" NPT Discharge


480V/60Hz 20A
230V/50Hz 15A
Others Available**

Smart Filtration Controller

SMART PLC Controller


Internal Gear Pump


Stainless Steel Lines
& Fittings


3 hp three phase, continuous duty

Smart Filtration Controller

Programmable, Fully Automated UL508a SMART Filtration Controller with BMS/BAS Interface and Digital Text Readout


+/-688 lbs (312 kg)

Operating Temperature

41 - 104 deg. F
5 - 40 deg. C

Suction capability (primed)

15 ft vertical or 100 ft horizontal life (lines > 2", primed)

Max. Fluid Viscosity

5 cST

Dimensions (HxWxD)

56" x 72" x 17"
(142 x 183 x 43 cm)

LG-X Model

LG-X 4000

Leak Sensor

Alarm indicator (system shutdown)

Mechanical Water Separator (Primary)

Specific Gravity Separation

Secondary Filter - Phase I

Dual Screw-on Filter Elements - 1, 5, 10, or 25 µ Particulate Filter Element

Secondary Filter/Water Block - Phase II

Dual Screw-on Filter Elements - 10 µ Water Block / Coalescer Filter Element

Weatherproof Cabinet

NEMA 12 (IP55), 13 (IP65), 3R (IP 32), 4 (IP 66) Powder Coat (Stainless Steel Enclosure available as an option)**

Flow Meter

"No Flow" alarm indicator and system shutdown (flow switch)

Not for use with fluids that have a flash point below 100 deg. F (38 deg. C) (e.g. Gasoline, Alcohol, etc.)

** Choose option during checkout (addition cost may apply)

Available Options

  • STS 6030 AWD -- Automatic Water Drain

  • STS 6030 HTR -- Cabinet Enclosure Heater - 425 Watt

  • STS 6030 OPT-SS -- Stainless Steel Enclosure

  • STS 6030 CLRS -- Cabinet Color Options

  • STS 6030 EXTWAR -- Extended Warranty Options - Up to Four Years (contact us for more information)

Replacement Filter Options

STS 6040 - 40 GPM

Secondary Filtration Phase I (Dual Filter Elements):

  • FF-1 Fine Filter Element - particulate - 1-Micron

  • FF-3 Fine Filter Element - particulate - 3-Micron

  • FF-10 Fine Filter Element - particulate - 10-Micron

  • FF-25 Fine Filter Element - particulate - 25-Micron

Secondary Filtration Phase II (Dual Filter Elements):

  • WB-3 Water Block 3-Micron Filter (standard Secondary)

  • WB-10 Water Block 10-Micron Filter

STS 6040 Literature

Articles on Automated Fuel Cleaning

Diesel & Gas Turbine Worldwide - Automated Fuel Cleaning North American Diesel Progress - Automated Fuel Cleaning
STS 6040 40-GPM Programmable Automated Systems

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1) Y-Strainer (20 Micron Std, - 40-Micron Opt.)

9) Outlet Ball Valve

2) Mechanical Water Separator

10) Flow Switch with Sight Glass

3) Vacuum Switch

11) Secondary Final Filter (2)

4) Internal Gear Pump

12) Primary Final Filter (2)

5) Pressure Switch

13) Leak Detector

6) AXI Inline LG-X 4000 Conditioner

14) Water Drain Valve

7) HMI Touchscreen Controller

15) Fuel Inlet (From Tank)

8) Fuel Outlet (Discharge)


The STS-6040 Programable Automated Fuel Filtration System is designed to optimize and maintain diesel fuel indefinitely. Adding an STS 6030 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.

  • Fully Automated Filtration System

  • Easy Integration with Building Maintenance Systems

  • SMART Filtration Controller (UL508a)

  • Continuous Duty Pump with Viton Seals

  • Powder Coated & Stainless Enclosures

  • Stainless Steel Plumbing

  • Stand Alone, Reliable Turn-Key Equipment

When the Lights Go out ... it is Too Late to Clean Your Tanks.

It is the condition of the fuel in your tanks that determines Engine Performance and Emergency Power Reliability.

Fuel is inherently unstable. It naturally forms sediments, solids and tank sludge. Clogged filters, excessive exhaust smoke, loss of power, and premature damage or failure of fuel injection systems are often symptoms of less than optimal fuel quality causing engines to be unreliable and ultimately fail. Water naturally accumulates in storage tanks due to condensation or leaks in fills and vents. Water and temperature changes create an environment for microbial growth and natural oxidation, accelerating formation of sludge, acids and tank corrosion.

Today's diesel injection systems with pressures of 30,000 psi or more require that the particle size of your fuel does not exceed the tolerances of your engine. Primary filter water-separators dramatically improve engine protection. However, they can only do so much.

In the industry, terms like algae, gum, wax, resin, varnish, tar, asphaltene, etc. are often used to describe the organic contaminant that clogs filters and is responsible for cargo deposits, corrosion, failing injection systems, loss of power, incomplete combustion (black exhaust smoke), and excessive emissions.

A program established to assure continuous optimal fuel quality will reduce overall operating costs

Most Engine Performance Problems
Start in The Fuel Tank

Over the last number of years we have seen a sudden, dramatic and worldwide increase in Filter Plugging Tendencies. What has changed? Oil supply and environmental concerns have resulted in important changes in fuel production, such as cracking, blending, ultra low sulfur, and the introduction of bio-fuels.

These changes have negatively impacted the inherent instability of our fuel and significantly shortened its shelf life. Additives, storage and transportation challenges further accelerate fuel degradation.

Fuel degradation is an inevitable, natural process. And unless an adequate fuel sampling, testing, monitoring and maintenance program is implemented, fuel breakdown will continue to be a potentially expensive liability and a major contributor to your overall operating costs.

Diesel is a very complex fluid. It is not homogenous and no two batches will ever be identical. Fuel deterioration, filterability and shelf life depend on a variety of factors including good housekeeping.

Reliable Power requires the implementation of a unique and innovative Fuel Optimization and Maintenance Technology to adequately protect engines and preserve the integrity of stored fuel beyond filtration and separation.

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.

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.

For safe operation the STS 6040 is equipped with alarm indicator and system shutdown when filters need service. Additional safety elements include automatic system shut-down and leak detection, water detection in the filter, high pump vacuum, high pump pressure, low fuel flow alert or a flow interruption is detected and flow meter with " no flow " alarm indicator and system shutdown (pressure transmitter).

The Smart Filtration Controller also provides a maintenance alert log file, runtime totalizer, alarm history and on-screen help.

All STS Systems feature multi-stage water removal and particulate filtration, NEMA 12, 13, 3R, 4 Powder Coated or Stainless Steel enclosure, UL508a Smart Filtration Controller and stainless steel plumbing, and is available power for 480 Volt / 60 Hz (20 Amp) or 230 Volt / 50 Hz (15 Amp), and other voltages are available.

A System that will Assure Your Equipment Runs at Peak Efficiency with Optimal Performance

The STS 6040 Automated Fuel Maintenance System suctions fuel from your storage tank at 2,400 Gallons per Hour and may be specified for use on up to four separate fuel tanks. Ideally, fuel should be suctioned from the very bottom of the tank, and also from a low point in the tank, or even a tank sump, where water would normally accumulate. Fuel passes through a Magnetic Y-Strainer that removes any particulate or other item that may damage the fuel pump. The principal components are a continuous-duty motor with coupled gear pump, a Y-strainer removes unexpected debris that can damage downstream components. The mechanical water separator, utilizing Specific Gravity Separation, removes water and particulates. Fuel is pulled into the Internal Gear Pump, through a vacuum switch and gauge, and out through a pressure switch and gauge. Fuel then passes through the AXI Inline Fuel Conditioner and on through the Primary/Final screw-on particulate filters (two configured in parallel) and on to the Secondary/Final screw-on Water Block fine filters (two configured in parallel) with pressure gauge and Flow Switch sensor and Sight Glass. The patented AXI Fuel Conditioner prevents and reverses fuel degradation, agglomerization and microbial contamination. The four secondary filters are spin-on filters designed to remove dissolved and emulsified water and contaminants down to 1 µ.

The Following Guides
Tell the Story
•  Understanding Diesel
Fuel Problems


•  Fuel Treatment and
Continuing Management


•  In-line Fuel Cleaning


•  Determining What Fuel
Treatment System
is Right for You


•  Cleaning a Fuel Tank

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.

The fuel then continues to a double Secondary Filtration stage. The first Secondary Filter would typically be a ten micron or three micron rated Water Block Filter spin-on element, designed to remove entrained and emulsified water from the fuel stream. The second Secondary Filter would typically be a 10, 3, or 1 micron particulate filter element. A pressure gauge is provided on the Secondary Filter housing to allow for visual monitoring to determine when filter elements require replacement, and a Pressure Switch is provided downstream from the Secondary Filter housing for monitoring by the controller. A restricted Secondary Filter would result in an alert from the Controller of low pressure. Low fuel flow may also cause an alert. Ball valves are provided at the inlet port and outlet port to allow for shutting off fuel flow in the event fuel flows back into the cabinet when filters are being replaced.

Fuel is then directed back into the storage tank. Ideally, the return line should be at the opposite end of the tank from the suction pipe pickup so that the agitation of the fuel will move water and particulates towards the suction line.

Leak Detection by way of a float switch in the bottom of the cabinet should the unexpected happen and fuel collects in the sump in the cabinet. Upon detection, the Controller will shut down the system.

An Enclosure Heater is available as an option for exterior mounting of the STS 6040 Automated Fuel Maintenance System outdoors in cold climates to protect the electronic components inside the enclosure. In cold climates, separate steps should be taken to assure the fuel temperature does not drop below 40 deg. F (5 deg. C) which may result in crystal formation in the fuel thereby clogging filters.

Cleaning the Fuel is not Cleaning the Tank

Your fuel is cleaned as it is circulated by the STS 6040 Fuel Maintenance System, but it takes something extra to remove the debris and organic matter from the tank sides, top, bottom, and from the baffles. The AXI Fuel Catalyst (AFC) is a concentrated, industrial quality, full spectrum fuel additive and fuel tank cleaning agent for use with diesel, gasoline, bio-fuels, kerosene, and HFO. AFC will stabilize fuel, prevent sludge build-up, improve combustion, reduce harmful emissions, and eliminate the need for expensive and toxic biocides.

AFC provides superior fuel quality for engines and storage tanks - lowering operating costs, maintenance, and downtime. AFC-705 accelerates tank cleaning and fuel restoration processes by cleaning heavily contaminated fuel systems and storage tanks. It dissolves tank sludge, stabilizes the fuel, restores Optimal Fuel Quality, and preserves the integrity of stored fuel up to 12 months.

When AFC is added to storage tanks with each refueling, it enhances combustion, eliminates carbon deposits, reduces harmful emissions, and lowers fuel consumption an all downstream power plants into which the fuel is transferred. AFC is an integral part of an ongoing regimen that will keep fuel tanks clean, free of water, and fuel in optimal quality.

AFC-710 Fuel Catalystis formulated to be Tier 4 Complaint for use with engines manufactured in 2007 and later. AFC-710 has a chemical affinity to the hydrocarbons in your diesel fuel, helping your engine tap into your fuel’s full potential by burning it more completely. While it is doing so, it’s also cleaning out your fuel system from the fuel tank, to your injectors, to your combustion chamber, and through to your exhaust.

AFC-705 Fuel Catalyst is a unique and powerful broad-spectrum fuel additive concentrate for use in Diesel, Biofuels, Gasoline, Kerosene, and HFO. Including AFC-705 as part of a preventative fuel maintenance program, in combination with good housekeeping, will stabilize your fuel, prevent sludge build-up, and eliminate the need for expensive and toxic biocides. Trust AFC-705 Fuel Catalyst to help ensure Optimal Fuel Quality at All Times. Using AFC-705 accelerates tank cleaning and the fuel restoration process. It enhances the breakdown and removal of sludge, slime, and bio-fouling from tank walls and baffles that are difficult to access. AFC-705 effectively decontaminates and cleans the entire fuel and injection system. It continues to work in storage tanks cleaning and stabilizing fuel for 6 months or longer.

Using AFC with one of AXI's fuel treatment systems, such as the STS7040 system, will loosen and begin the process of dissolving the debris, clean microbial and fungal growth from tank walls, top and bottom, and speed the return of fuel to optimal fuel quality.