Installation, Operating and Maintenance Manual MTC HC-90 AFR (Adjustable Flow Rate)
Installation, Operating and Maintenance Manual MTC HC-90 AFR (Adjustable Flow Rate) High Capacity Mobile Tank Cleaning, Fuel Optimization and Transfer System • Multi-Stage Filtration & Tank Cleaning • Minimal Consumables • Negligible Fuel Loss • Low Operating Costs • No Tank Entry Needed Optimal Fuel Quality • Reliable Power MTC HC-90 AFR ® AXI International 2014-Rev.A Page 2 of 26 MTC HC-90 AFR - INSTALLATION, OPERATION, AND MAINTENANCE MANUAL Table of Contents Table of Contents.........................................................................................................................3 MTC HC-90 AFR Specifications and Features.............................................................................4 Tank Cleaning and Fuel Maintenance - Why, Where, and How...................................................7 Preparations.................................................................................................................................7 MTC HC-90 AFR - Initial Inspection............................................................................................8 Overview – MTC HC-90 AFR High Capacity Mobile Tank Cleaning System...............................8 Components of the MTC HC-90 AFR...........................................................................................9 MTC HC-90 AFR Controls.........................................................................................................13 Smart Filtration Controller................................................................................................................... 13 KB Genesis VFD Inverter Speed Controller........................................................................................ 13 Basic Operation - Tank Cleaning and Fuel restoration...............................................................13 System Shutdown and Preparation for Transport......................................................................17 MTC HC-90 AFR Filter Change Out..........................................................................................18 Changing Primary Bag Filter............................................................................................................... 18 Changing Final Filter Element............................................................................................................. 19 MTC HC-90 AFR Maintenance..................................................................................................20 AXI FP-90 Water Separator................................................................................................................. 20 Pump and pump motor........................................................................................................................ 20 ALGAE-X Fuel Conditioner................................................................................................................. 20 Suction and Discharge Hoses............................................................................................................. 20 AFC-705 Fuel catalyst................................................................................................................21 SAFETY NOTES:.......................................................................................................................22 AXI Tank Cleaning Systems (LIMITED WARRANTY)................................................................23 Warranty Claim Procedure.........................................................................................................24 Technical Assistance and Ordering............................................................................................24 Replacement Filter Elements.....................................................................................................25 Primary (Bag) Filters:.......................................................................................................................... 25 Secondary (Fine) Filter:....................................................................................................................... 25 System Identification (MTC HC-90 AFR )...................................................................................25 MTC HC-90 AFR ® AXI International 2014-Rev.A Page 3 of 26 MTC HC-90 AFR High Capacity Mobile Tank Cleaning System with Adjustable Flow Rate The MTC HC-90 AFR (Adjustable Flow Rate) is a four-stage mobile tank cleaning and fuel restoration system. Connected stores, conditions, and optimizes fuel. The MTC HC-90 AFR features an electronic Variable Frequency Drive Pump Motor Speed Controller which can be set for AXI’s Mobile Tank Cleaning Systems excel in combining High Capacity Filtration, Water Separation, and Fuel Conditioning with a Low Operating Cost Industrial Design. Flow Rate Adjustable 10 GPM to 90 GPM Primary Filter Bag Filter Vessel, Carbon Steel, 3-bolt swing cover, Stainless Steel liner Filter Bags Replaceable Filter Bags 1 – 1500 µ Secondary Filter Carbon Steel Filter Housing, Quick release 3-Bolt Swing Cover, Drain valve, & Air Vent Filter Cartridges Particulate Filter 2-30 µ Water Block Filters 5, 10, 30 µ Absolute Microglass Filters 3-10 µ Water Separator AXI FP-90 With Drain Valve and Air Vent Port LG-X 4000 SFC-55 MTC Fuel Conditioner Smart Filtration Controller MTC HC-90 AFR Systems features: •High Capacity, Four-Stage Diesel Fuel Processing •Multiple Discharge and Sampling Ports •Large Contaminant Holding Capacity •Robust Industrial Design •Tank Cleaning and Decontamination •Fuel Restoration and Optimization by Decontamination, Drying, and Fuel Conditioning •Liquid-Filled Vacuum and Pressure Gauges •AXI Watect Water Sensor •PLC System Controller to monitor and provide an alert alarm for high input suction, high output pressure, and water in the water separator motor Instrumentation & Automation Vacuum Gauges on Primary Filter Pressure Gauge on Pump Discharge Pressure Gauges on Secondary Filter AXI Watect 550 Water Sensor Alarm Module Pump 2”, Sliding-vane, Positive Displacement, Viton Seals Power Required 220V 50/60Hz. 20A. Single Phase - or 240V 50/60Hz. 20A. Three Phase - or 480V 50/60Hz. 12A. Three Phase Ports One suction, three discharge Connectors Cam & Groove Fittings with Covers Hoses 2”, 25 ft Clear Suction Hose 2”, 25 ft Discharge Hose Skid Powder Coated Carbon Steel, Lifting Eyes & Forklift Channels, and Drip Tray with Drain Dimensions 36” x 45” x 59” Weight 710 lbs. Not for use with fluids that have a flash point below 100°F. 1-239-690-9589 1-877-425-4239 Toll Free www.AXI-International.com Global Fuel Quality Ingenuity MTC HC-90 (08/13) The MTC HC-90 AFR utilizes a positive displacement sliding-vane pump with an integral gear-reducer, coupled to a additionally passed through the AXI FP-90 water separator. At the third discharge port, the fuel has additionally passed through Water Seperator Suction Port (From Tank) Discharge Port 2 Discharge Port 1 Final Filter Primary Base Filter Pump Algae-X Fuel Conditioner Discharge Port 3 1-239-690-9589 1-877-425-4239 Toll Free www.AXI-International.com Global Fuel Quality Ingenuity Automation The HC-90 AFR utilizes an SFC-55MTC PLC controller to monitor and control system operation. The SFC-55MTC includes an digital text output screen on the PLC and indicator lights that show alarm and alert states and also system operation state. MTC HC-90 Options • Digital Flow Meter • Wheels – skid mounted, 8” Pneumatic • AFC-705 Fuel Catalyst / Stabilizer / Dispersant Digita Flow Meter The digital flow meter is an excellent tool to monitor flow rate and system performance as well as count the total amount of fluid that has been processed. 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. AFC-705 features: • Cleans Fuel, Storage Tanks & Injection systems • Improves Combustion, Lowers Emissions & Fuel Consumption • Removes & Prevents Carbon Build Up and Corrosion • Adds Lubricity and Inhibits Corrosion • Extends Lube Oil & Equipment Life • Optimizes Engine, Generator & Boiler Efficiencies • Reduces Harmful Emissions, Soot & Particulates (CO, HCs, NOX, SOX, VOCs, Carbonyls, PAH) 1-239-690-9589 1-877-425-4239 Toll Free www.AXI-International.com Global Fuel Quality Ingenuity Page 6 of 26 Tank Cleaning and Fuel Maintenance - Why, Where, and How All diesel fuel storage tanks naturally accumulate water, inorganic solids, and sludge as the result of condensation and the degradation of fuel. The more often that the fuel is used and then replaced, the more debris and water will accumulate at the bottom of the tank. A step beyond Tank Cleaning: AXI STS Automated Fuel Conditioning and Filtration Systems eliminate the need for costly, periodic manual tank cleaning, while stabilizing and extending the shelf life of fuel. This is extremely important for all applications where fuel is stored long-term, especially emergency power generator operations. If an STS Automated System is not installed on a fuel storage tank, an AXI MTC Mobile Tank Cleaning System can be used to periodically clean the tank and restore the stored fuel to Optimal Quality. Preparations Before operating the MTC HC-90 AFR we recommend you first determine the amount of contaminants, free water and sludge in the tank. AXI provides a variety of tank sampling equipment including Sampling Pumps, tubing and bottles as well as AXI Stainless Steel Tank Samplers – please see our FS Fluid Sampling line of products. Please make sure the samples are taken from the bottom of the tank (in the deepest spot). A simple and quick method of determining the amount of water in the tank is to use Kolor Kut Water Finding Paste. Apply a small amount of Kolor Kut paste along the first few inches of ½” PVC pipe and insert the pipe into the tank until it touches the bottom. Remove the pipe and inspect the Kolor Kut for a color change where water has contacted the paste. Call AXI International for further information on other fuel sampling equipment. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 7 of 26 MTC HC-90 AFR - Initial Inspection Congratulations on your purchase of an AXI MTC HC-90 AFR High Capacity Tank Cleaning System! Upon delivery, the MTC HC-90 AFR System and accessories must be visually inspected. Shipping and handling may cause physical or electrical problems. Note any damages with the shipping company or refuse the shipment in cases of severe damage. Overview – MTC HC-90 AFR High Capacity Mobile Tank Cleaning System AXI Mobile Tank Cleaning Systems are easy to operate and extremely versatile. The MTC HC-90 AFR efficiently removes sludge, inorganic contaminants, and water from fuel tanks, and then restores and optimizes fuel quality after the tank has been cleaned. The MTC HC-90 AFR is a four-stage mobile fuel conditioning and tank cleaning system that is mounted a steel forklift-style skid. The system is designed as a “fuel dialysis system” that circulates and cleans fuel by pumping it from the tank, processing it through the HC-90 AFR, and then returning the fuel back into the tank. The system can also be used to clean or transfer fuel or light oils by pumping the fuel from one tank through the MTC HC-90 AFR into another tank or suitable container. The MTC HC-90 AFR is equipped with a self-priming, positive-displacement sliding vane pump that is rated at a nominal flow rate of 90 GPM. The system’s operational flow rate depends on factors such as: suction lift, discharge head, hose length and diameter, and pressure drop over the primary and secondary filters. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 8 of 26 Components of the MTC HC-90 AFR (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) MTC HC-90 AFR Spill-containment Skid with Drain Plug Wheels (Optional) SFC 55 Smart Filtration Controller SFC 55 Status Lights SFC 55 Manual-Off-Auto Switch SFC 55 Circuit Breakers (Motor AC Power – Left Gang, Electronics – Right Gang) SFC 55 PLC Controller Power Supply Cable (See ? for Power Requirements) VFD Pump Motor Speed Controller VFD Motor Speed Adjustment Dial Clear High-vacuum Suction Hose – 2” ID, 25 Ft., with Cam and Groove Connector Suction Port with Cam and Groove Connector Suction Port Ball Valve Bag Filter Vessel with Eye-bolt Closures Bag Filter Vessel Vent Valve Bag Filter Vessel Vacuum Gauges Bag Filter Vessel Vacuum Switch Bag Filter Vessel Drain Valve Blackmer 2” Sliding Vane Pump Pump Motor Discharge Port #1 Ball Valve Discharge Port #1 with Cam and Groove Connector Pump Output and Discharge Port #1 Pressure Gauge AXI FP-90 Water Separator Isolation Ball Valve AXI FP-90 Water Separator AXI FP-90 Vent Port Watect 550 Water Sensor Probe AXI FP-90 Water Separator Drain Valve Discharge Port #2 Ball Valve Discharge Port #2 with Cam and Groove Connector Final Filter Pressure Switch Final Filter Isolation Ball Valve ALGAE-X LG-4000 Fuel Conditioner Final Filter Vessel with Eye-bolt Closures Final Filter Vessel Vent Valve Final Filter Pressure Gauges Final Filter Sample Port Valve Discharge Port #3 Ball Valve Discharge Port #3 with Cam and Groove Connector Discharge Hose - 2” ID, 25 Ft., with Cam and Groove Connector ® AXI International 2014-Rev.A Page 9 of 26 15 3 12 13 9 14 11 22 21 40 18 8 23 20 19 1 2 MTC HC-90 AFR ® AXI International 2014-Rev.A Page 10 of 26 8 26 15 25 13 12 35 29 16 34 14 17 30 22 31 21 32 27 33 18 19 36 37 1 38 39 MTC HC-90 AFR ® AXI International 2014-Rev.A 2 Page 11 of 26 4 5 7 6 3 9 10 22 21 18 28 24 23 20 19 1 2 MTC HC-90 AFR ® AXI International 2014-Rev.A Page 12 of 26 MTC HC-90 AFR Controls Smart Filtration Controller MANUAL – OFF – AUTO Switch Manual – normal pump/system On/Off control Auto – Provides “timed” operation – Unsupervised timed operation of the MTC HC-90 AFR is not recommended or supported by AXI International. The MTC HC-90 AFR requires full-time technician monitoring whenever in operation. Please call AXI with any questions. Circuit Breakers 1 Phase models: 2-gang breaker for VFD Speed control and pump motor (left gang) 2-gang breaker for electronics (right gang) 3 Phase models: 3-gang breaker for VFD Speed control and pump motor (left gang) 3-gang breaker for electronics (right gang) PLC Controls – not used for manual operation - see manual for timed operation Alarm Reset button System Power, Pump Running, and Alarm indicator lights KB Genesis VFD Inverter Speed Controller In normal operation the KB Genesis VFD Speed Controller is used ONLY to change the speed of the pump. When the Smart Filtration Controller is switched to “Manual” the Speed Controller will receive power. For the first operating cycle after a power-up, the Speed Controller Start switch must be toggled to the Start position to begin pumping. The pump speed will increase to the level that is set on the Speed Control Adjustment Dial. The Speed Control Adjustment Dial is then used to vary speed according to need and conditions. Basic Operation - Tank Cleaning and Fuel restoration ` ! WARNING ! Never leave an MTC HC-90 AFR System unattended during operation. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 13 of 26 • Connect a “snorkel” to the tank end of the suction hose. The snorkel is obtained locally and fashioned according to the requirements of the particular job. In general, the snorkel is a piece of PVC pipe cut at an angle to facilitate removal of water and contaminants, when the “snorkel” is inserted into the fuel tank. Note: Avoid restricting the flow on the suction side of the MTC HC-90 AFR. If it is necessary to use a smaller ID suction hose, a smaller ID Snorkel, or if the length of the suction hose is increased, reduce pump speed with the Speed Control Adjustment Dial so that the vacuum gauge remains in the green color band. It may also be necessary to reduce pump speed if the fuel is being “lifted” from an underground tank. The HC-90 PLC controller will halt system operation automatically if the suction vacuum exceeds safe limits. • Connect the Suction hose to the Suction Port Note: If your MTC HC-90 AFR is equipped with the optional flow meter please make sure to use at least 400 micron filtration upstream of the Digital Flow Meter in order to protect the Digital Flow Meter. • • • • • • • • • • • • • Connect the Discharge Hose to the Discharge Port #3 Check all connections for integrity Install a bag filter in the Bag Filter Vessel and close vessel securely Install a filter element in the Final Filter Vessel and close vessel securely Open the Suction Port Ball Valve Close the Discharge Port #1 Ball Valve Close the Discharge Port #2 Ball Valve Open the FP-90 Water Separator Isolation Ball Valve Close the FP-90 Water Separator Drain Valve Open the Final Filter Isolation Ball Valve Open the Discharge Port #3 Ball Valve Recheck all connections and valves SECURE the discharge hose into the tank Note: DISCHARGE HOSE DEVELOPS CONSIDERABLE BACK-THRUST! Insert suction “snorkel” into tank and secure VERIFY THAT THE MANUAL-OFF-AUTO SWITCH IS IN THE ”OFF” POSITION Connect the MTC HC-90 AFR to an appropriate power source Verify that the VFD Speed Controller dial is set at 20 – 30 (so that the pump motor will start at 20 – 30 % of maximum speed) • Switch the Smart Filtration Controller circuit breakers to on – the “System Power” light illuminates • Switch Smart Filtration Controller to “MANUAL” to begin pumping • If the pump does not start, toggle the VFD Speed Controller Lever switch to “Start”. This will be necessary for the first cycle after the Smart Filtration Controller circuit breakers are switched on • • • • MTC HC-90 AFR ® AXI International 2014-Rev.A Page 14 of 26 • OBSERVE System Priming (Suction line is transparent) • CHECK FOR LEAKS OR OTHER ABNORMALITIES Note: The AXI FP-90 Water Separator has to be full of fuel at all times to perform properly. Purge the AXI FP-90 Water Separator of air upon beginning tank cleaning operations. Loosen the air bleed port on the top of the AXI FP-90 Water Separator to evacuate the trapped air. • Increase pump motor speed as appropriate to continue tank cleaning and fuel restoration process. • If “High Suction” conditions/alarms halt the operation, it is most likely possible to continue operations at reduced flow rates – adjust the VFD Speed Adjustment Dial accordingly • Monitor process and change bag filters and filter elements as necessary. • The Bag Filter Vessel has two vacuum gauges. The upper gauge indicates the vacuum loss in the suction line, and the bottom gauge indicates the total vacuum at the pump inlet. The difference between the two gauges is the vacuum loss across the filter bag. Replace the filter bag when the difference between the two gauges exceeds 15 Inches Hg. The SFC Smart Filtration Controller monitors the vacuum level during operation, and will halt the system and illuminate the Alarm light when the filter bag needs to be replaced. • The Final Filter Vessel has two pressure gauges - the difference between the two gauges is the deltaP across the final filter element. Replace the final filter element when the deltaP reached 20 PSI. The SFC Smart Filtration Controller monitors return line pressure during operation, and will halt the system and illuminate the Alarm light when the Final Filter needs to be replaced. • Water Alarm: If significant water accumulates in the AXI FP-90 Water Separator, operation will be halted by the Smart Filtration Controller and the Alarm light will illuminate on the Smart Filtration Controller. Using the Water Separator Drain Valve, drain the water from the Water Separator into an appropriate container, and then resume operation RECOMMENDED: When beginning a tank cleaning operation, first slowly “sip” water, contaminants, sludge, etc., from the bottom of the tank using varying/sweeping “snorkel” positions across the bottom of the tank as best as is possible. Consider using Discharge Port #1, or Discharge Port #2, as appropriate, to “trash pump” into a separate waste containment vessel. Pump into the waste containment vessel until there is no more water/sludge being removed and fuel begins to appear in the outflow, and then begin filtering operations utilizing Discharge Port #3. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 15 of 26 Information: The Smart Filtration Controller will indicate an “Alarm” and interrupt pump operation whenever suction is too high (change the appropriate bag filter(s)), Pressure is too high (change f the final filter), or water is detected in the bottom of the AXI FP-90 (drain the AXI FP-90 water into a containment vessel via the DRAIN Valve). After correcting the “Alarm” event, press the “Alarm Reset” button to clear the alert and re-start the pump. Pump will ramp-up to the pump speed as set by the Speed Adjustment Dial. ` ! WARNING ! Never leave an MTC HC-90 AFR System unattended during operation! MTC HC-90 AFR ® AXI International 2014-Rev.A Page 16 of 26 System Shutdown and Preparation for Transport • Set pump motor to operate at a low speed Using the Speed Adjustment Dial • Remove Suction Hose snorkel from tank allowing air to be drawn into the system through the snorkel • Continue at low pump speed until the system is purged of fuel as indicated by a lack of fuel being returned to the tank • Terminate pump operation when all fuel is purged • Close the Suction Port and Discharge Port Ball Valves • Disconnect all hoses and contain any fuel remaining in hoses • Cap hoses as appropriate ! IMPORTANT ! Do not operate the pump “dry” at high speeds or for extended periods of time – premature pump vane wear will occur Note: Disposal of tank sludge, water and filter elements should be done in accordance with Federal, State and Local regulations. ! IMPORTANT ! It is recommended that only qualified, experienced personnel, familiar with this equipment, who have read and understood all the instructions in this manual should operate and maintain the system. ! WARNING ! Do not use with gasoline, solvents, corrosive liquids, food liquids, or other liquids having a flash point less than 100°F. Use with gasoline or use with any flammable liquids at a temperature exceeding their flash point, presents an immediate explosion hazard and fire hazard ` ! IMPORTANT ! All safety measures and practices involving fuel / oil handling should be observed and followed at all times. ` ! WARNING ! For operator safety the MTC HC-90 AFR System needs to be properly grounded. Additionally all tanks, containers, hoses as well as the MTC HC-90 AFR System itself need to be bonded protective earth ground to prevent built-up of static electricity. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 17 of 26 MTC HC-90 AFR Filter Change Out Changing Primary Bag Filter When the difference in the vacuum reading between the lower vacuum gauge on the bag filter vessel and the upper vacuum gauge on the bag filter vessel is in excess of 15” Hg, the bag filter needs to be changed. 1. For a “no mess” bag filter change the bag filter vessel should be pumped empty or the fuel in the filter should be drained to a lower level 2. While operating the pump motor at minimum speed, close the inlet ball valve for the bag filter vessel and then open the air purge valve on the top of the bag filter housing to allow air to enter and the fuel to be drawn out of the vessel 3. The pump will begin to purge the fuel out of the filter vessel as air enters the vent. After a few moments when most of the fuel has been withdrawn from the vessel, turn the MANUAL-OFFAUTO switch to OFF, and then remove the lid to access the bag filter 4. Replace bag filter element and make sure it seals tight within the perforated basket. If a holddown spring is included with the vessel, place the hold-down spring on top of the filter bag to hold it down during operation. For best results bag should be fully extended into the basket 5. Apply a film of lubricating oil to the lid gasket. Replace O-Ring if worn or damaged 6. Tighten lid screws evenly (alternating the screws) to ensure no air can enter the system and lid is fully seated onto O-Ring gasket 7. Close the vent valve. 8. Open the bag filter vessel inflow valve and resume pumping operation. Check for leaks and air intrusion. 9. The material collected inside the filter bag can be inspected to better understand the types of contaminants that have been removed from the tank. Note: Disposal of tank sludge, water and filter elements should be done in accordance with Federal, State and Local regulations. Note: Always maintain an adequate supply of filter bags. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 18 of 26 Changing Final Filter Element When the difference in the gauge readings on the final filter pressure gauges exceeds 20 PSI, the final filter element will need to be changed. 1. It will be necessary to purge as much fuel as possible from the final filter vessel 2. Remove the suction snorkel from the tank to draw air into and through the MTC HC-90 AFR System. 3. Operate the pump at low speed until the fuel has been pushed through the system and no more fuel is being returned to the tank 4. Turn the pump off using the Smart Filtration Controller MANUAL-OFF-AUTO switch 5. Close the Discharge Port #3 Ball Valve 6. Fuel level in the final filters should now be low enough to change the elements 7. Open the vent valve on the final filter vessel to release any remaining pressure. Open the lid and replace the elements 8. Apply a film of lubricating oil to the lid gasket. Replace O-Ring if worn or damaged. 9. Tighten lid screws evenly (alternating the screws) to ensure lid is fully seated onto O-Ring gasket. 10. CLOSE final filter vent valve 11. Open the Discharge Port #3 Ball Valve 12. Resume pump operation and check for leaks The material trapped inside the filter can be inspected to better understand the types of contaminants that have been removed from the tank. There are two types of AXI® fine filters available. Both types are available with various micron ratings 1. Particulate filters: 2, 3, 5, 7, 10, 30 μ (micron) 2. Water block filters: 5, 10, 30 μ (micron) The Water Block removes entrained and emulsified water from the fuel stream. The saturation of the water block filter will cause the pressure drop over the filter to increase, necessitating filter element replacement, even if the filter is not plugged by particulate contaminants. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 19 of 26 MTC HC-90 AFR Maintenance ` ! IMPORTANT ! It is recommended that only qualified, experienced personnel, familiar with this equipment, that have read and understood all the instructions in this manual, should install, operate, or maintain the system. ` ! IMPORTANT ! Always disconnect the system from the electric power supply before working or servicing it. Do not proceed with any maintenance unless the pressure and vacuum has been released, the system has been allowed to reach ambient temperature, and all fluids have been drained. AXI FP-90 Water Separator The AXI FP-90 separator is a closed dynamic separator that does not require any consumables. When draining water and sludge from the separator: 1. Place an appropriate container under the drain fitting 2. Open the drain valve and close when fuel is observed in the effluent 3. Open the air-purge port to allow air in and fuel to flow out, if necessary Pump and pump motor Consult the pump manual and motor manual for service requirements and intervals! Check pump for leaks, worn and damaged parts. Detailed safety, operation and maintenance instructions are available in the supplied pump and motor manuals. ALGAE-X Fuel Conditioner Ferrous particles and rust can collect inside the ALGAE-X unit and over time cause a flow restriction and/or diminish its effectiveness. Open the lid of the ALGAE-X Fuel Conditioner by unscrewing the lid screws and then clean the magnet and fuel chamber. Inspect O-rings prior to reassembly. Replace Orings if necessary. Contact AXI for replacement O-rings. Suction and Discharge Hoses We recommend replacing the suction hose every year and the discharge hose every two years. Heavy use, visual deterioration, damage or poor condition and excessive wear can require an even earlier change. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 20 of 26 AFC-705 Fuel catalyst The use of AXI AFC-705 Fuel Catalyst is an essential part of any tank cleaning procedure, to more rapidly and efficiently decontaminate and clean the entire fuel system. The application rate is 1:5000. Before dosing the tank with AFC-705, remove as much of the sludge and free water as possible. Adding the AXI Fuel Catalyst (AFC-705) to the tank will speed up the cleaning process by breaking down and dissolving the sludge covering the tank walls and baffles. AFC-705 will promote the cleaning of the areas and sections of the tank that are out of reach of the suction hose. Using a higher concentration of one to twenty five hundred (1:2500) instead of the usual one to five thousand (1:5000) has proven to be very helpful in accelerating the rate of dissolving fuel sediments and sludge. Even higher concentrations of AFC-705 may be applied as necessary, depending on contamination level of fuel. AFC-705 is a full-spectrum fuel additive containing a combustion catalyst, surfactant, detergent, dispersant, corrosion inhibitor, lubricity enhancer, and fuel stabilizer. Periodic applications of AFC-705 will reduce or eliminate the need for expensive and toxic biocides. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 21 of 26 SAFETY NOTES: The MTC HC-90 AFR Pump is designed to be used with diesel fuel and low viscosity oils only. The pump is NOT designed for gasoline, alcohol, or other explosive/corrosive liquids. Please contact us if you are not sure if the liquid you are intending to polish and clean is compatible with the MTC HC-90 AFR System. Biocides are extremely toxic and may enter the body through the skin. It is recommended to use adequate protection and avoid skin contact with biocide-treated fuels and oil. ` ! WARNING ! DO NOT USE WITH GASOLINE. This System is not meant for use with gasoline nor with other flammable liquids having a flash point less than 100°F (38°C). Use with gasoline or any flammable liquids at a temperature exceeding their flash point, presents explosion and fire hazards. ` ! WARNING ! Care must be taken not to operate the pump with either the suction (inlet) or discharge (outlet) lines closed or obstructed. Only operate the system under full-time operator supervision. Unattended Operating of the MTC HC-90 AFR is NOT recommended. ` ! WARNING ! Some fuels may have been treated with biocides. Biocides are extremely toxic and may enter the body through the skin. Use adequate protection and avoid contact with fuels that have been treated with a biocide. Note: Disposal of tank sludge, water and filter elements should be done in accordance with Federal, State and Local regulations. These materials need to be treated as chemical waste. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 22 of 26 AXI Tank Cleaning Systems (LIMITED WARRANTY) AXI International makes every effort to assure that its products meet high quality and durability standards, and expressly warrants the products described herein, against defects in material and workmanship for a period of one (1) year from the date of purchase. This warranty is not intended to supplant normal inspection, care, and service of the products covered by the user, and shall not obligate AXI to provide free service during the warranty period to correct breakage, maladjustment or other difficulties arising out of abuse, misuse, or improper care and maintenance of such products. Our express warranty is subject to the following terms and conditions: This warranty shall only extend to, and is only for the benefit of original purchaser(s) who use the products covered hereby Any warranty claim received by AXI after one (1) year from the date of purchase will not be honored even if it is claimed that the defect occurred prior to one (1) year from the date of purchase. This warranty shall not apply to products (1) which have been tampered with, altered or repaired by anyone other than AXI without the express prior written consent of AXI (2) which have been installed improperly or subject to misuse, abuse, accident, negligence of others, improper operation or maintenance, neglect or modification, or (3) which have had the serial number altered, defaced or removed. The liability of AXI under this warranty is limited to the repair or replacement of the defective product. AXI assumes NO LIABILITY for labor charges or other costs incurred by any purchaser incidental to the service, adjustment, repair, return, removal or replacement of products. AXI ASSUMES NO LIABILITY FOR ANY GENERAL, SPECIAL, INCIDENTAL, CONSEQUENTIAL, CONTINGENT OR OTHER DAMAGES UNDER ANY WARRANTY, EXPRESS OR IMPLIED AND ALL SUCH LIABILITY IS HEREBY EXPRESSLY EXCLUDED. AXI MAKES NO WARRANTIES, EXPRESS OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE, WITH RESPECT TO THE PRODUCTS COVERED BY THIS WARRANTY POLICY, EXCEPT AS EXPRESSLY PROVIDED FOR HEREIN. NO EMPLOYEE, AGENT, REPRESENTATIVE OR DISTRIBUTOR IS AUTHORIZED TO MAKE ANY WARRANTY ON BEHALF OF AXI OTHER THAN THE EXPRESS WARRANTY PROVIDED FOR HEREIN. AXI reserves the right to make changes in the design, material, function, and specifications of its products at any time. Any such changes shall not obligate AXI to make similar changes in such products that were previously manufactured. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 23 of 26 Warranty Claim Procedure To make a claim under this warranty please be prepared to provide the following information: name and location where unit was purchased, the date and receipt of purchase, model number, serial number, and a detailed explanation of the problem you are experiencing. The Customer Service Representative may, at the discretion of AXI, arrange for a Field Engineer to inspect your system. If the inspection discloses a defect covered by its limited warranty, AXI will either repair or replace the defective parts or products. AXI assumes no liability, if upon inspection, AXI or its representative determines that there is no defect, or that the damage to the system resulted from causes not within the scope of this limited warranty. For sales or service please contact AXI directly at one of the numbers listed below. Technical Assistance and Ordering AXI International 5400 Division Drive Fort Myers, Florida 33905 Phone: Fax: Toll Free: (239) 690-9589 (239) 690-1195 (877) 425-4239 Website: www.AXI-International.com *Must provide serial number for all warranty issues. MTC HC-90 AFR ® AXI International 2014-Rev.A Page 24 of 26 Replacement Filter Elements Primary (Bag) Filters: PFB-150-1 PFB-150-5 PFB-150-10 PFB-150-25 PFB-150-75 PFB-150-250 1 Micron bag, felt, polyester 5 Micron bag, felt, polyester 10 Micron bag, felt, polyester 25 Micron bag, felt, polyester 75 Micron bag, felt polyester 250 Micron bag, Multifilament Mesh *Other micron sizes and materials available Secondary (Fine) Filter: CF-618-5 CF-618-10 CFWB-618-5 CFWB-618-10 Filter Cartridge - particulate - 5 micron Filter Cartridge - particulate - 10 micron Filter Cartridge - Water Block - 5 micron Filter Cartridge - Water Block - 10 micron *Other micron sizes available System Identification (MTC HC-90 AFR Serial Number:_____________________________________ (e.g. B 090010 – HC80) Power Configuration: O 220V 50/60 Hz. 1 Phase O 220V 50/60 Hz. 3 Phase O 480V 50/60 Hz. 3 Phase Inspected by:______________________________ MTC HC-90 AFR ® AXI International Date: ________________ 2014-Rev.A Page 25 of 26 AXI designs and manufactures standardized and custom-engineered Automated Fuel Conditioning, Fuel Polishing and Transfer Systems, Tank Cleaning Equipment, Fuel Additives and In-line Fuel Conditioners to ensure optimal fuel quality at all times. Our scope of expertise covers fuel storage and fuel supply systems from single engine installations to power plants. AXI is your single source for all fuel conditioning related equipment and support available world-wide. • Peak Engine Performance • Reliable Power Supply • Lower Maintenance Costs • Lower Exhaust Emissions Read about the secret life of fuel and find solutions in the AXI Brochure, available at www.AXI-International.net. See the full product line in the AXI Systems and Equipment Catalogue, available at www.AXInternational.net. AXI International 5400-1 Division Dr Fort Myers, FL 33905 1 877-425-4239 +1 239-690-9589 www.AXI-International.com Distributed By ©Copyright 2011 ALGAE-X International
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