Fueltec Model 908E Diesel Fuel Polisghing Tank Cleaning System

Not for use with fluids that have a flash point below

100 deg. F (e.g.: Gasoline, Alcohol, ...)

Operation Manual Specifications

Fueltec Systems LLC 828-212-1141

www.fueltecsystems.com

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WARNING This product operates in the highly combustible atmosphere of a diesel or gasoline storage tank.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS COULD CAUSE

DAMAGE TO PROPERTY, ENVIRONMENT, RESULTING IN SERIOUS INJURY OR DEATH. • This fuel polishing system should NEVER BE OPERATED inside a truck cargo body, enclosed trailer, or

within fifty (50) feet of an operating or hot engine, motor or fuel dispenser. • All work must comply with the latest issue of the National Electrical Code (NFPA 70), the Code for

Motor Fuel Dispensing Facilities and Repair Garages (NFPA 30A), and any European, national, state, and local code requirements that apply. • When servicing unit, use non-sparking tools and use caution when removing or installing equipment to

avoid generating a spark. • To protect yourself and others from serious injury, death, or substantial property damage, carefully

read and follow all warnings and instructions in this manual.

Warnings and Instructions This section introduces the hazards and safety precautions associated with operating, 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, or pressure release could occur and cause damage to property, environment, resulting in serious injury or death, if these safe service procedures are not followed.

PRELIMINARY PRECAUTIONS You are working in a potentially dangerous environment of flammable fuels, vapors, and fluid pressures. Only trained or authorized individuals knowledgeable in the related procedures should operate, inspect, maintain or service this equipment.

Read the Manual Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand a procedure, call 1-828-212-1141 to locate a qualified technician. It is imperative to your safety and the safety of

others to understand the procedures before beginning work. Make sure your employees and any service contractors read and follow the instructions. Follow the Regulations Applicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Field Dispensing Facilities and Repair Garages, NFPA 70; National Electrical Code (NEC), Occupational Safety and Hazard Association (OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to operate, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment. OSHA fall protection rules apply when working on above ground fuel storage tanks.

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Prevent Explosions and Fires Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels and used filters cause vapors. All used filters should be promptly placed in an approved safety container until disposed of. Even filling air compressor fuel tanks will cause potentially dangerous vapors in the vicinity of the work area.

Working Alone It is highly recommended that someone who is capable of rendering first aid be present during operation. Familiarize your-self with Cardiopulmonary Resuscitation (CPR) methods, while working around fuel vapors. This information is available from the American Red Cross. Always advise other personnel about where you will be working, and caution them not to ac-tivate power tools or engines while you are working with fuel filtration equipment. Use the OSHA Lockout/Tagout proce-dures. If you are not familiar with this requirement, refer to OSHA documentation.

Hazardous Materials Some materials may present a health hazard if not handled correctly. Ensure that you clean hands after handling equip-ment. Do not place any equipment in the mouth.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS COULD RESULT IN PROPERTY DAMAGE, INJURY OR DEATH. FIRE HAZARD! Do NOT use power tools (Class I Division I and Class I Division II) during the operation or maintenance of equipment. Sparking could ignite fuel or vapors, resulting in fire.

CHEMICAL EXPOSURE HAZARD! Wear appropriate safety equipment during operation or maintenance of equipment. Avoid exposure to fuel and vapors. Prolonged exposure to fuel may cause severe skin irritations and possible burns.

REQUIREMENTS FOR USE

• Fueltec fuel polishing and tank cleaning systems are designed for use only by trained personal. Free training is available at Fueltec’s factory located in Granite Falls, NC USA. Call 1- (828) 212-1141

• The operation of Fueltec’s systems must be consistent with NFPA Code 30A, OSHA regulations, and federal, state and local fire codes, and other applicable local regulations.

OPERATING PRECAUTIONS

• NO SMOKING. Extinguish all open flames and pilot lights, such as on RV appliances.

• TURN OFF cell phones and other electronic devices to prevent sparks which could cause an explosion or fire.

PERSONAL SAFETY Stay alert, watch what you are doing and use common sense when operating or maintaining the system. Do not operate or maintain the system while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating or maintaining the system may result in serious personal injury or death. Dress properly while operating this system. Do not expose bare skin or eyes to fuels. Prolonged contact with fuel can damage the skin. Use safety apparel and equipment. Use safety goggles or safety glasses. Also use non-skid safety shoes, hardhat, gloves, and fall protection when appropriate.

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SAVE THESE INSTRUCTIONS WORK AREA

• Mark work area with orange colored safety cones placed in a radius of at

least forty(40’) feet from fuel tank cleaning equipment, fuel

containers, and fuel tank openings.

• Place Flammable Liquid Warning Signs within work area

• Keep work area clean, free of clutter and well lit. Cluttered and

dark work areas can cause accidents.

• Keep children and bystanders away while operating this system.

Distractions can cause you to lose control, so visitors should re-

main at a safe distance of at least forty (40’) feet from the work

area.

• Be aware of all power lines, electrical circuits, water pipes and

other mechanical hazards in your work area, particularly those

hazards below the work surface hidden from the operator’s view

that may be unintentionally contacted and may cause personal

harm or property damage.

• Be alert of your surroundings. Using your system in confined work areas may put

you dangerously close to unsafe conditions.

• Keep one or more Fire Extinguishers U.L. rated 10A-80B:C in the work area.

• Keep Air Compressor at least 40 feet (40’) feet from fuel tank cleaning

equipment, fuel containers, and fuel tank openings.

40 ft.

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Fueltec’s mobile electric systems are designed to clean fuel tanks, remove water and particulates from diesel down to engine manufacturer’s ISO fuel cleanliness levels.

• For use on above ground, underground, generator, and mobile fuel tanks.

• This fuel polishing system is designed to draw fluids from the storage tank bottom removing water and particulate matter including rust, sludge, pipe scale, bacteria, and fungus to as low as one (1) micron then returning the clean dry fuel back to the storage tank.

• Filtration and water separator housings are built to resist today’s corrosive fuels with type 304 stainless steel and equipped with quick opening tops fastened with swing bolts.

• A clear sight tube allows the operator to observe the water as it is being separated from the fuel in real time.

• Fueltec’s systems do not require water absorbing filters, back-washing, or magnetic devices to meet engine manufacturer’s ISO fuel cleanliness levels.

• The primary filter housing is located upstream of the fuel pump to remove particulates, rust, scale, and sludge before the fluid enters the pump.

• Primary filter elements are bag type one or five micron with a filter area of no less than 263 square inches each.

• The vacuum gauge on the primary filter housing shall indicate when a filter change is required.

• The system’s water separator housing is pressurized and capable of draining separated water while in continuous operation by opening a drain valve and observing the fluid level in the clear sight tube.

• The separated water is directed to a waste container at the same time the clean fuel is returning to the storage tank.

• The system’s military type water separator consist of two elements:

• Micro-glass element that coalesces and removes water from the fuel down to less than 100ppm.

• Teflon coated stainless steel hydrophobic water separator that repels the enlarged water drop-lets which then fall to the water trap.

• The separated water trap shall have capacity of at least two (2) gallons.

• System shall be capable of bypassing the water separator for filtration only.

• Fuel suction and return hoses are equipped with cam-locking fittings for quick coupling.

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

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PART # 908E

DESCRIPTION 115/220 Volt FUEL TANK CLEANING SYS-TEM 8 GPM PUMP W/ 12’ SUPPLY & RETURN HOSES

SKU

100004

HOUSING TOP SEAL BUNA (STANDARD) HOUSING TOP SEAL VITON (OPTIONAL)

181019 181020

FILTER BAG 1MICRON X 24 INCH FILTER BAG 5 MICRON X 24 INCH FILTER BAG 10 MICRON X 24 INCH

241004 241097 241001

COALESCER/FILTER FOR 908E 10 INCH

241023

MANIFOLD M-2 FOR ACCESS TO 2 IN. TANK OPENING

100010

FUEL HOSE 1 INCH X 12 FEET FUEL HOSE 1 INCH X 25 FEET WITH CAM-LOCK ENDS

100033 100034

Elictric Tank Cleaning Systems Common Replacement Filters, Hose, and Seals

Fueltec Systems 828-212-1141 PO Box 487, Granite Falls, NC 28630

www.fueltecsystems.com

© 2016 LENZ

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Today’s diesel engines require aircraft quality fuel. • Not to many years ago diesel engines were quite simple, not too efficient,

smoked, and burned high sulfur fuel (as much as 5,000 parts per million). The older diesel injection systems only use about 1⁄2 the fuel pressure modern engines do, and older injectors send the fuel through much larger passages. If there was a little moisture in the storage tank, the high sulfur content killed most of the filter clogging bacteria and fungi.

• Today’s diesel fuel is ultra-low sulfur (15 parts per million) which allows

bacteria and fungi to grow rapidly if any moisture is in the fuel storage tank.

• Today’s diesel engines use high pressure, 27,000 to 35,000 psi fuel

injectors with tiny fuel passages which are easily clogged with dirty fuel and damaged by water.

• The days of using grandpa’s old style boat or tractor filters on your diesel

fuel tank are over. • The old style filters and water separators that remove 75% to 99% of the

contamination are not good enough for today’s diesel engines.

• Magnets and filter-less devices won't clean fuel to ISO 18/16/13 or remove water to 0.05%

• Both Caterpillar and Cummins call for fuel to meet or exceed ISO

cleanliness levels of 18/16/13 with a water content of less than 0.05% • Fueltec’s systems meet or exceed these ISO levels with a one micron

primary filter, micro-glass filter/coalescer, and Teflon coated stainless steel hydrophobic water separator. Fueltec uses this type of system on aircraft “Jet-A or JP-8 Jet fuel.

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TECHNICAL SPECIFICATIONS Model 908 Diesel Chassis Construction Steel and Aluminum Brite Tread Maximum lift 15 feet primed Working pressure fuel max. 40 PSI Maximum Flow rate 480 Gallons per hour * Water Trap two (2) Gallons US Power 115/230V 1PH 60Hz 1/2HP Width: 32” Depth: 47” Overall Height 50” Pump positive displacement, with internal bypass Inlets/Outlets 1” Cam-Loc w/ Ball Valves Hose Supply& Return 1” X 12’ each Vacuum Gauge 2” liquid filled Sludge Filters 24” Fueltec Bag Water Coalescer micro-glass (military type) Water Separator Teflon hydrophobic Wheels 13” flat free

* Flow rates may vary with filter type and condition, length and size of hoses, and size and shape of fluid pickup and return tubes.

Caution: Not for fluids with a flash point below 100 degrees F.

SPECIFICATIONS

Fuel Pump

Pump off/on switch Pump motor circuit breaker reset Pump pressure relief valve

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Inlet valve Sludge filter inlet port Vacuum gauge Valve settings Sludge filter housing Contaminate drain port

Air Bleed Valve

Filtered only fuel & direct pump transfer port

Coalescer Housing

Separated &Filtered fuel return port

Separated Water

Sight Tube

Drip Pan

Pressure Gauge

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Sludge Filter inlet Port

Pressure Gauge shows the condition of the filter/coalescer

Vacuum Gauge shows the condition of the primary filter

Fuel Transfer Outlet

Separated Water Drain Valve Water Drain Port

Remove swing bolts from housing cover then prime system with two (2) gallons of clean fuel before starting the pump.

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High water level Clear Sight Tube Low water level

You can watch the water rise in the water trap as it is separated from the fuel.

As the water is separated from the fuel it falls to the bottom of the water trap. The water level can be seen in the clear sight tube. The water separator section is pressurized so when the high water level is reached you open the water drain valve and the separated water can be drained to a waste container. It is not necessary to stop the system while draining the water. Water can be drained while it is being separated from the fuel. To see a Fueltec Mobile System in action separating water from fuel, watch the video at: www.fueltecsystems.com

Water Drain Valve

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BAG FILTER REPLACEMENT

PRIMARY FILTER SELECTION

Gasoline: 1 micron primary filter (1M24), Kerosene: 1 micron primary filter (1M24)

No. 2 Diesel: 5 or 1 micron primary filters: (5M24 or 1M24)

Coalescer and Separator Replacement

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Maximum Water Separation & Filtering Connect Return to Tank Hose to Port 2.

Connect Pickup Tube Hose to Filter Port 1. Open Valves 1. & 2. Close Air Bleed Valve 4. Set 3-way valve as shown below

Bulk Fuel Transfer & Fast Filter Without Water Sepa-ration Connect Pickup Tube Hose to Port 1. Connect Return Hose to Port 3. Open Valves 1. Close Valve 2. Fluid is now bypassing the water separator. Note 3-way Valve position

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23. Observe Vacuum Gauge. two minutes after fluid appears in sight tube; The

initial Vacuum reading will be determined by the elevation of the supply port

relative to the elevation of the fluid level in the tank being serviced. Make note of

this first gauge reading. As the bag filter accumulates debris the vacuum reading

will increase. When the gauge reading has increased 8” Hg. above the initial

reading; the filter bag needs to be changed.

Observe Vacuum Gauge on primary

filter housing.

24. Observe the Pressure Gauge. When the gauge reads 22 PSI, the coalescer

filter needs changing.

Observe the Pressure Gauge on the bot-tom of the coalescer/ water separator housing

Fueltec Systems, LLC 3821 N Main Street Granite Falls, NC 28630

www.fueltecsystems.com (828) 212-1141

© 2014 RLENZ

100% Made in USA

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Many Sub-base tanks have Compartments divided by one or more baffle plates with clipped corners that allow fuel to flow at a very low velocity making it difficult to properly clean the tank.

When removing contamination from a fuel storage tank: • Insert the supply and return

tubes at opposite ends of the tank.

• If there is not a opening on each end of the tank; create one by purging the tank with nitrogen or CO2 gas, use a hole saw to make a hole then install a flange and cap to secure the tank.

• Thereafter any time the tank needs service you will have easy access.

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

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TYPE “D” CAM-LOCK INCLUDED WITH SYSTEM

FUELTEC’S FUEL SUCTION HOSE

FLUID PICKUP TUBE MADE IN FIELD TO REACH FUEL STORAGE TANK BOTTOM. TUBE CAN BE MADE FROM STEEL PIPE, ALUMINUM, STAINLESS STEEL, PVC, NYLON-6, POLYURETHANE, OR ANY MATERIAL IMPERVIOUS TO THE FUEL THAT YOU ARE IN CONTACT WITH.

CUT TUBE BOTTOM AT 30 DEGREES

FUEL TANK BOTTOM

ATTACH PICKUP TUBE TO CAM-LOCK “D” WITH A STREET ELBOW FITTING

FLUID PICKUP TUBE BUILDING FOR FUELTEC’S MOBILE SYSTEMS

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1” SUCTION HOSE

RETURN TO TANK HOSE

FUEL TANK BOTTOM

CLEAN DRY FUEL RETURNING TO TANK THROUGH SHORT PIPE

SUCTION INTAKE ON TANK BOTTOM

1” SUCTION TUBE

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

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TANK CLEANING USING THE FUELTEC M-2 SUPPLY & RETURN MANIFOLD ALLOWING SUPPLY AND RETURN THROUGH ONE 2” TANK FITTING TYPICAL ON GENERATOR BASE TANKS

FUEL TANK BOTTOM

SUCTION HOSE

RETURN TO TANK HOSE

CLEAN DRY FUEL RETURNING TO TANK THROUGH MANI-

SUCTION INTAKE ON TANK BOTTOM

1/2 INCH PIPE FUEL PICKUP SUCTION TUBE

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

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CONTAMINATED DIESEL FUEL

Off road Diesel dyed red

Bacteria & Fungus

Water

Dead bacteria & fungus

• The fuel found above the tank bottom water is usually clean and water free. • Water being heavier than fuel will be found at fuel tank bottoms. • In fuel tanks, bacteria and fungus are commonly found at the fuel/ water interface. • These microbes need water to live, without water they will die. • They feed on components of the fuel while they float on the water. • The dead microbes are heavier than fuel or water and sink to the tank bottom • When the fuel is added to a tank where microbes are living, the microbes get mixed with

both the fuel and water and can easily clog filters.

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Microbes found in diesel fuel Virtually all diesel fuel contains some moisture. Additional water accumulates in tanks as atmospheric moisture condenses. Moisture accumulates in diesel tanks as condensate droplets on exposed tank surfaces, as dissolved water in the fuel and as water bottoms beneath the fuel microbes depend on this water for growth. Additionally, microbes depend on the organic and inorganic molecules in diesel fuel for nutrition. Consequently, some species attack the fuel directly, growing at the expense of hydrocarbons and non-hydrocarbon fuel components. The biodegradation of fuel, in support of microbial growth, is a direct impact of contamination. Color, heat of combustion, pour point, cloud point, detergent and anti-corrosive properties change as microbes selectively attack fuel components. Sulfur-containing molecules are metabolized by a series of species, leading ultimately to the production of high concentrations of hydrogen sulfide. In addition to creating new cells, many microbes produce metabolites which promote further attack. Surfactants facilitate the emulsification of fuel, leading to the formation of a cloudy, invert-emulsion layer above the fuel/water interface. Polysaccharide slimes create microenvironments wherein mixed populations (consortia) of bacteria and fungi carry out biodegradation reactions that would be impossible for a single species outside the microenvironment. The slime also serves as a barrier, protecting the microbes from preservatives. A variety of organic acids (primarily 2 - 4 carbon atoms) are also produced as by-products of bacterial and fungal growth.

Diesel Fuel Microbial Growth Water