Common Issues

When setting up any machine, we understand not everyone has the time to consider all variables. And sometimes its just simpler to ask for help - we are here to support you.

The manual provided with your machine will offer great advice, and the information on this page should help as well.

Remember

If you are carrying out any electrical work, you must be qualified to do so
Isolate from fuel supply before opening any filters
Prime the system before use
Never run the system dry

W-10 AC and DC range help

To avoid the risk of electric shock, make sure that the power supply is disconnected. Ensure that the power supply is at zero volts with a multi-meter before making any electrical connections. Make sure that your unit and power supply are configured for the same voltage rating.

AC models should be supplied with 220-240v 50hz 1ph AC models, please check to ensure you have the correct supply voltage for your model. Brown wire = Live, Blue wire = Neutral, Green/Yellow wire = Earth.

DC models should be supplied with 12v DC (for 12v specific units) or 24v DC (for 24v specific units). The two wire colours are Brown - 12 or 24v DC and blue - 0v DC.

The unit has been developed to be used with EN590/diesel fuel only, do not use this system with gasoline. Some fuels may have been treated with alcohol base additives; these additives will harm the unit’s seals. When using additives, be sure they are alcohol free and compatible with the unit seals.

If the option has been taken, the blue D-shaped component is a fuel conditioner; it is highly magnetic and as such should not be approached by pacemaker owners.

Do not run system dry, prime before use. Do not open the control box unless you are a qualified electrician.

The vacuum sensor is adjustable via a screw from 200-900mbar (cw triggers early, ccw triggers later). It has been pre-set to a value of 680mbar. On rare occasions, for example if the input pipe work is causing a high vacuum due to frictional losses, this vacuum switch can be adjusted up to allow the system to work for longer between service requirements.

This model is controlled by the user, apply power to the pump and switch the pump on via its I/O control switch.

Before starting any service work, first switch off the power to your system. Next isolate the system from the fuel supply, as per our note earlier in this manual, we recommend installing isolating ball valves before and after this system.

Draining water

Stop the flow of fuel to the engine
Isolate the filter from the fuel supply if possible
Place a suitable container under the water drain tap
Slightly unscrew the water drain tap on the bottom of the filter
If possible, open an air bleed valve or one of the unused ports on the filter top to allow air in, and hence let the water out
Once fuel emerges, close the drain tap
Re-tighten any valves opened to allow air in
Open all isolating ball vales
Re-prime if necessary
Dispose of the waste water in accordance with local environmental rules

Before starting any service work, first switch off the power to your system. Next isolate the system from the fuel supply, as per our note earlier in this manual, we recommend installing isolating ball valves before and after this system.

Changing the filter element

Stop the flow of fuel to the engine
Isolate the filter from the fuel supply if possible
Place a suitable container under the filter assembly to catch any fuel which may seep out
Grab the central bowl ring and rotate it ¼ turn anticlockwise to unscrew it
This is a bayonet ring and does not need to be rotated more than ½ a turn
If it cannot be moved by hand, gently use a rubber strap wrench to loosen the ring. Do not use a metal tool
Once the ring has been removed the bowl and element will be accessible
Carefully remove the old element from the bowl
Inset a new element, with the large o-ring edge at the bottom and the smaller proud o-ring end at the top. This element sits tightly inside the bowl
Place the bowl/element back onto the filter head, there are locating lugs to ensure it lines up
Re-attached the bowl ring and tighten it ¼ to ½ a turn. Do not over tighten
Open all isolating ball vales
Re-prime if necessary

Q1 - How often should I change the filter element?

A1 - Every 6 months

Q2 - How often should I chance the seals?

A2 - Every 3 years, or sooner if you observe wear

Q3 - What filter element types are available

A3 - 10 micron (the default), part number LKF08ELE10. 6 micron, part number LKF08ELE06. 3 micron, part number LKF08ELE03

Q4 - How long should I run the system for?

A4 -The system runs at 10 lit/min, so if you divide your fuel tank capacity (in litres), by 10, and then by 60, you get the typical running time. For a 1000 lit tank, this means 1.6 hours (1 hr 36min). You can set the system to do this automatically using the timer more.

We recommend running for a few minutes every day, rather than the entire tank in one go. Overall, your aim is to run the system to clean all the fuel every 7 days, so if you need to run for 1hr 10 min (70 mins), we recommend 10 minutes per day.

Q5 - I have fuel and power, but my system is not running.

A5 - Is the internal timer set to run, or is the system set to manual mode? If not, the unit will not run

If you carefully look inside the system, are either of the two yellow alarm LEDs illuminated? The top one indicates a need for water draining (you will see water in the fuel bowl), the other is for servicing (ie change the filter element)

Has the pump protection fuse blown? The internal 2a fuse is in place to protect the pump from mis-operation, for example if the unit has not been primed

WB Range Help

Mechanical Installation

All wall mounted systems should be firmly attached to a fixed wall or other similar secure surface. It is the installer’s responsibility to ensure the unit is securely and safely mounted in a sensible position.

You should install isolating ball valves in the pipe work before and after the unit, leaving them open at all times other than for servicing.

If the unit is mounted above the tank, or if the pipe work exits the tank top, a priming tee should be installed on the highest point of the suction line to be able to easily prime the systems delivery line. The return line should be connected to the output port and enter the tank as far away as possible from the pick-up pipe.

The system would ideally pick-up fuel from the lowest point of the tank at one end, and return it to the highest point at the opposite end. If this is not possible then we recommend placing the pick-up and return pipes as far apart as possible. The feed pipe (input to the WB unit) should be lower than the engine feed pipe in the tank.

The feed pipe to the system should be independent and separate from the feed to the engine. The return should also be independent and separate to the engines fuel return line. We recommend a minimum internal pipe diameter of 1/2” (for the 10 and 25 units) and 1” (for the 40 unit). Small diameters, long pipe runs or many bends in the pipe work will cause high frictional losses and can cause the system to run slow, or incorrectly trigger the internal monitoring systems. Likewise, high fuel lifts or fuel heads can also cause the unit to run slow.

We recommend a lightly sprung non-return valve/foot valve on the input side of the system to maintain the prime in the unit and in the input pipe work.

The pickup pipe to the unit should be either connected to the fuel tanks drain valve (i.e. the lowest point) or should be unique pipe work. If unique, the input pipe inside the tank should be resting on the tank bottom with the end cut off at 45^o. Alternatively a 90^o elbow on the end with the short end resting horizontally on the tank bottom

Electrical Installation

To avoid the risk of electric shock, make sure that the power supply is disconnected. Ensure that the power supply is at zero volts with a multi-meter before making any electrical connections. Make sure that your unit and power supply are configured for the same voltage rating. This range manual covers 12v DC, 24v DC and 220v 50hz 1ph AC models, please check to ensure you have the correct supply voltage for your model.

Incoming power is the minimum requirement to operate the machine. Inputs for once weekly timers, external run signals, external pause signals and a user input for alerts can also be connected.

The unit has been developed to be used with EN590/diesel fuel only, do not use this system with gasoline. Some fuels may have been treated with alcohol base additives; these additives will harm the unit’s seals. When using additives, be sure they are alcohol free and compatible with the unit seals.

The blue D-shaped component is a fuel conditioner; it is highly magnetic and as such should not be approached by pacemaker owners.

Do not run system dry, prime before use. Do not open the control box unless you are a qualified electrician.

The vacuum/service sensor is adjustable from 200-900mbar (cw triggers early, ccw triggers later). It has been preset to a value of 680mbar. On rare occasions, for example if the input pipe work is causing a high vacuum due to frictional losses, this vacuum switch can be adjusted up to allow the system to work for longer between service requirements.

Inputs to the system		Outputs from the system
Input 1	Daily or Once-weekly timer (daily unless connected)	Output 1	Pump run
Input 2	Internal sensor connection	Output 2	Service Lamp
Input 3	Internal sensor connection	Output 3	Drain water
Input 4	User input, active if PLC logic voltage is applied.	Output 4	Remote “healthy” output (see later section)
Input 5	Button
Input 6	Button
Input A1	External run signal, active if PLC logic voltage is applied (see later section)
Input A2	External pause signal, active if PLC logic voltage is applied (see later section)

The User Input

This input is active if the PLC logic voltage (the same power as applied to the PLC’s “+” input, typically 24v DC but please check your individual unit) is applied to input 4. This will stop the pump and signal for user interaction. As with any such service requirement, the reset button will need to be pressed before the system can be restarted. This input can be used for user supplied external components/sensors such as level sensors, flow switches, pressure switches etc. It is supplied unconnected to allow for any such adaptions by the installer or operator.

NOTE: the user input is only in operation if the pump is running. If the pump is not running the user input is disabled.

Operation

There are 3 operating modes

Manual Press the START/STOP button to run the system, press the same button again to stop it.

Remote Unit can be run via an external control system, such as a BMS or remote switch.

Timer System will start and stop automatically based on user programmable internal timer.

The system will only stop if requested to do so by the user (eg stop button, the timer completes, etc) or if the systems senses a service requirement. Clear any such service requirement either by servicing the system, changing the filter element or draining water/sludge (see servicing section), and pressing the RESET button. The system can now be restarted in manual mode, or will restart on the next timer start command.

Programming the timer mode

Ensure the RTC (real time clock) is correctly set, please refer to the servicing section for instructions. If the internal 24 volts is connected to terminal i1, a weekly timer (one run per week) is used; if not the daily timer is used.

To program the timer, press and hold the RESET button for 5 seconds, once the displayed timer reaches 5 seconds, release the button to view the programming mode screen.

The internal screen will display a day range, this can be edited by the user by pressing the SEL button next to the screen, you will now see a large black box flashing on the screen. Use the arrow keys to move this box to the day to be edited, press SEL again. You will see an underscore (a line under the day to be edited); press the up and down arrows to change the day and press OK once completed.

Repeat this process for the other day to complete your range. Next set a start and end time; use the same procedure as above (SEL for black box, highlight the value to change, SEL for underscore, up down to edit, OK to save).

Once you have set all the parameters required, press the RESET button once again to return to the main screen. Your timer is now set and will switch the unit on and off at the required times. To deactivate the timer, edit as above and select the same time for start and end.

Timer examples	Daily timer mode	Weekly timer mode (input 1 active)
SU-SU 08:00-12:00	Run every day from 8am until 12 midday	Run Sunday only 8am to 12 midday
TU-FR 21:00-10:00	Run 9pm to 10am Tuesday until Friday	Run from Tuesday 9pm until Friday 10am
WE-MO 20:00-08:00	Run 8pm to 8am Wednesday to Monday (finishing Tuesday AM)	Run from Wednesday 8pm until Monday 8am
TU-TU 01:00-01:00	The unit will never run (switch on and off at the same time)	The unit will not run (as daily timer)
TU-TU 01:01-01:00	Run every day for 23hr 59min, starting at 1am	Run all week, bar 1 minute a 1am on Tuesday
MO-TU 08:00-08:01	Run for 1 minute at 8am on Mondays and Tuesdays	Run from Monday 8am until Tuesday 8:01am

Remote control and monitoring

Remote start input: Apply PLC logic voltage to input “A1” to start the system remotely; remove this voltage to stop the system. This voltage can be taken from the systems internal logic power

Remote pause input: Apply PLC logic voltage to input “A2" to pause the system, remove this voltage to allow it to run. Voltage as per above.

Healthy output: Output Q4 is a volt free contact pair; it is closed if the system is healthy (running or not) but opens on any alert. This output pair will accept voltage from 12v to 240v AC (50 or 60hz) or 12 to 125v DC; however, it is not rated for AC3 (motor or induction) loads.

Setting the RTC (clock)	Press SEL and OK together on the PLC to enter the clock setting screen, use the same procedure as setting the timer (see programming section). If you cannot access the clock set mode in this way, press the ESC key on its own; in the menu that appears scroll down until you see the word RTC SET, press OK to enter. Set the clock. Press ESC twice to exit, you will see the WASP home page text message.
Draining water/contaminate	Stop the system; close the ball valves before and after the unit. Place a suitable receptacle underneath the yellow handle drain tap at the bottom of the grey unit. Carefully open the small bleed valve on the top of the grey filter (in the middle of the square lid). Now open the yellow handle drain tap at the bottom, push in and rotate anti-clockwise a quarter turn; this will allow the water/contaminate to drain out. Close the yellow handle tap and bleed valve when complete. Re-prime if necessary, reopen the ball valves, press the RESET button and restart. Dispose of the waste as per your local environment agency rules.
The water alarm repeatedly triggers	If the water alarm will not reset using the reset button. Please turn the system off, wait for 10 seconds and then turn it back on again.
Changing the filter element	Stop the system, close the ball valves before and after the unit and remove the power. Use a spanner to carefully remove the 4 bolts on the top of the grey filter housing. Remove the lid, and remove the black spring cassette that sits below it in the top of the filter. You can now remove the square replaceable element from inside the filter. Install a new one, ensuring the integrated seal is pointing downwards and the small plastic handle is facing up. Reinstall the spring cassette and carefully reinstall the lid. Re-prime the filter if necessary. The lid bolts must not be tightened over 8 Nm, and typically much less is sufficient. Reopen the ball valves. You can now restart the system.
Changing the seals/gaskets	As per the changing the filter element instructions, isolate power and close the ball valves before and after the unit. Remove the grey filter lid. Place a large receptacle under the yellow handle drain tap, open the tap (push and turn) and wait until all the fuel has been drained from the system and reclose the tap. Inside the lid is the square lid seal, remove and replace carefully. Now unscrew the 4 bolts housing the circular clamp ring on the underside of the square grey filter housing. This will allow the clamp ring and bowl to be removed (the bowl may need to be teased off as the gasket between it and the housing can sometimes stick). Dry the bowl top and the underside of the square housing with appropriate media. Replace the circular bowl seal, hold the bowl vertically with the open end upwards, place the clamp ring around it so it is also at the top, now place the new circular bowl seal on the top of the bowl, it should sit inside the clamp ring. Again, ensuring all surfaces are dry and clear of fuel, place this assembly back on the underside of the square housing and carefully do up the bolts (max 8Nm, but less is advisable). Ensure you retighten the bolts in sequence, using opposite sides. This should ensure the clamp ring is square and the seal sits correctly and does not slip inside the bowl. Before you replace the lid, fully re-prime the system with the removed fuel. Replace the lid, again to a torque of 8Nm or ideally less, re-open the isolating ball valves, reapply power to the system and you are ready to restart.

How often should I run the system?	We recommend you run the system frequently enough to ensure your fuel is turned over every 2 weeks minimum. However, every week is ideal, as it ensures you catch any potential issues quickly
How often should I change the filter element?	Once every 12 months, unless the system asks for a service sooner
Fuel isn’t flowing, why?	Most likely the unit hasn’t been fully primed, but also check for blockages in the pipe work and ensure all ball valves are open. Check for air leaks in your pipe work as well
I have to change elements very often.	This might simply be your fuel is very dirty, a 10-micron filter element is roughly 1/6th the thickness of a human hair, so even tiny dirt particles could get trapped. Of course, there are other reasons too, for example, are there a lot of bends in your input pipe work, or is the lift of fuel from the tank to the unit very high? Either of these can cause the pump to work harder and hence the switch that indicates to service will trigger earlier. You can adjust that switch if this is the case, but in 99% of cases, this switch should be left as factory set
If the system is not running	Is there any power? Have the fuses blown? Has the vacuum sensor triggered too early - does it need to be adjusted?
The system says its running but the pump is not moving	Check the circuit breaker or fuse. Ensure the switch on the pump (if applicable) is set to ON (I) and not OFF (O)
Everything is working, but the flow seems slow	Is there an air leak at the inlet? Is the fuel lift too high? The pump might be worn. If installed, is the foot valve working? Piping improperly installed or dimensioned? The filter might be blocked; the vacuum switch might be adjusted too high.
The pump has worn very quickly or is getting hot	Pump has been run dry or with insufficient fuel. Is there a blockage? Have you primed the system? Is the pipe work on inlet side not appropriately dimensioned
Pump requires too much power, fuse keeps blowing	Possibly air in the pipe work. The fuel/liquid might be too viscous. There might be an electrical fault
The unit seems very noisy	There might be insufficient fuel. Air leaks in the inlet pipe? Possible air or gas on the suction side?

W-PFS Range Help

Quick start installation

Ensure the system is securely fastened to a wall or other suitable solid structure. This system should have unique pipe work, not connected to any existing fuel driven equipment other than the tank.

The input to the WASP system should feed from the bottom of the fuel tank (via a ball valve and a foot valve or non-return valve), separate to and at a level below the existing fuel tank output pipe.

The fuel polishing system’s output should ideally return to the tank at the top, opposite end to the input.

The unit can be controlled via BMS, however it is capable of self-operation and monitoring.

System must be primed before use and operation. It may also be beneficial to prime after servicing; although with a foot or non-return valve installed, priming should only be required after installation. With power applied, please ensure the system’s time and date have been correctly set.

Quick start operation

Set the clock on the home screen before progressing (press the time on the home screen to set it). A service alert may be shown after your first install. This is not an alarm, but is the system recording the setup date, simply go to the “messages” page and acknowledge it, before returning to the home page and proceeding.

With power applied to the unit, you can either run the system manually (press the MANUAL MODE) button from the home screen and then START/STOP. Alternatively, you can programme it in AUTOMATIC MODE. Here you can set a start time and duration (24 hr clock, hours and minutes).

There are also buttons to allow you to select which week of the month and which day of the week you would like the system to run. Selecting all weeks and all days will mean the system will run daily in this mode. Exit the programming screen to allow the system to run in this mode.

To enable/disable auto mode, either deselect all week or all days or use the auto mode enable/disable button; the system will therefore not start in automatic mode.

There is also an external mode - connect the system’s own 24v DC internal power to input 7 (i7) to run the unit; remove this link to stop it. Likewise, input 8 (i8) pauses the system if operated in the same way.

For the health of the fuel, storage tank and the fuel polishing system, it is recommended that a full cycle is run (3 complete tank volume cycles) once per month alternatively 1 volume cycle per week.

Quick start servicing

To ensure the efficient and optimum running of your system, we recommend you service your system every 12 months.

We also recommend you check the quality of your gaskets every 6 months and replace every 12 -36 months or at first signs of wear and tear. If the unit is installed in a corrosive or saline environment, we recommend monthly checks of all metal components and regular treatment with protective water repellent oil such as WD40 or NanoShell metal.

Separate to the regular service, the system will flag if it requires any servicing or spare parts. This is via its built in automatic monitoring system.

Mechanical Installation

If the system is wall or enclosure mounted, the unit should be securely attached to a fixed wall or other similar firm fixing position. Frame mounted systems are typically designed to be floor mounted but may also be attached to walls for additional bracing.

our unit should be mounted square and flat onto a suitable surface; otherwise distortion of the system may occur. It should be installed horizontally level and vertically upright with the water drain taps facing downwards.

It is the installer’s responsibility to ensure the unit is securely, squarely, and safely mounted in a position that is deemed safe. WASP PFS cannot accept responsibility for damage to the system or enclosure due to incorrect installation.

NOTE: This unit is not to be mounted in ATEX zones 0, 1 or 2. If in doubt, consult your facilities manager or engineer on ATEX zones.

REQUIREMENTS

Isolation ball valves before and after the polishing system in pipe work
Pipe work to and from the tank to be unique, not shared with other equipment
Input feed pipe to the fuel polishing system must be lower in the tank than the feed to the engine / generator / day tanks
All external pipework to be free from leaks, tested via pressure and vacuum
Light spring non-return valve on the input side, as close to the tank as possible (max opening pressure 0.05bar, ideally 0.03bar)
Fully prime the unit and pipe work before use
Optional sealable priming points installed into the external pipe work before and after the unit
Use minimal sharp bends in pipe work to reduce frictional losses
The unit is designed to operate as a syphon system, that means the input and output pipe work should balance each other in terms of restriction. This means keeping them sealed and not open to atmosphere.
Ensure your return pipe work to the tank is below the level of the fuel, this aids fuel flow and prevents foaming
Avoid loops in the pipe work, especially on the input site. These can trap air
The maximum lift for any fuel polishing system is 5m, however that assumes no air leaks or restrictions and that the system is primed and has an NRV fitted
The maximum output head depends on the model purchased but can be as much as 30m. However, 5m is typical.
The maximum fuel flow of your system can be impacted by fuel lifts, elbows, valves, narrow pipework and similar such external factors.

Installation pipe minimum diameter recommendations

W-PFS-008/010/014 ¾” (19mm)

W-PFS-026/040 1” (25mm)

W-PFS-060 1 ½” (to 38mm)

W-PFS-120 1 ½” - 2" (38mm-50mm)

W-PFS-240 2" + (50mm +)

Typical Installations

The diagram below shows a typical installation whereby the feed from the bottom of the tank to the fuel polishing system, (1) is at the bottom, side of the fuel tank.

However, if pipework from the tank to the system is to be installed from the top of the tank (below-left), the tank end of the input pipe should either be resting on the bottom of the tank with a cut off at 45 degrees or a 90-degree elbow with an open end can be used.

Environmental note

If your system is to be installed and operated in corrosive environments, for example near to the coast, or in extreme weather conditions, we recommend regular checking and treatment of all metal parts. Although stainless steel and treated steel have been used in the construction of your system, water and corrosive elements can cause contamination which may in some circumstances damage the surface of the system.

To avoid this, we recommend regular periodic inspection of the system, for example a monthly check; although the frequency may need to be altered depending on the environment experienced. We also recommend protecting all metal surfaces with a suitable degreaser or water repellent protective oil such as WD40 or NanoShell metal, regular repeated treatment may be required to maintain the pristine condition your unit was supplied in.

Electrical Installation

The units with the part number suffix 220vac are powered by 220-240v 50Hz 1ph AC.

The units with the part number suffix 110vac are powered by 100-115v 60Hz 1ph AC.

Units with the part number suffix 24vdc are powered by 24v DC

Each unit is supplied with a flying lead for mains power connection.

This flying lead should be connected to a user-installed isolating fused spur, using standard EU wiring as follows:

AC power

Live (hot) - Brown

Neutral - Blue

Earth - Yellow/Green

DC Power

Positive - Brown

0v - Blue

The systems can run autonomously with just the power connection. However, should you require it, the following BMS/Remote connections can also be made.

BMS output connections

NOTE: if the Modbus option is used, please refer to your manual.

Q2 is a user definable output which can be set to represent any of the internal status messages, e.g. paused, running, service due, etc.

Q3 is a dedicated healthy/ready signal (closed = healthy/ready, open = active service requirement or system paused)

Q4 is a dedicated Error signal (closed = alarm state, open = healthy)

Q5-Q8 These four BMS outputs are used to produce a data word, giving 16 different status messages. These outputs are volt free contact pairs and are to be read together. In other words, all 4 must be connected to accurately read this BMS output.

BMS inputs connections

I7 External run (BMS run signal). Connect the system’s internal 24v DC connection to input 7 (i7)

I8 External pause (BMS pause signal). Connect the system’s internal 24v DC connection to input 8 (i8)

User inputs

Your system is equipped with a number of inputs, each has its own function in monitoring of the system. However, input 1 is designated as a “user input”, meaning it allows the installer/operator to attach a sensor of their own choice. This in turn means your W-PFS unit can monitor external equipment.

This external sensor should be able to switch 24v DC
The PLC will only read 24v DC inputs
The PLC should be fed with the 24v DC supply from the W-PFS unit
If external 24 DC units are to be used, the 0v supply must be common to the W-PFS unit
If the flow switch add-on has been selected, this input will be used

The user input also has a time delay function built into it. It is only monitored when the pump is running, and even then, there is a delay timer (set via the user page).

This input will not trigger an alarm if the pump is not running.

The input will not trigger an alarm if the input duration is shorter than the user delay time.

Priming any pumped system is the most important part

Priming method 1

Install your feed pipework only (tank to polishing system input), via your non-return valve and isolating valve; do not connect your output yet. Close all air bleed and water drain valves, leave the internal service valve open. Open the isolation valve on the pipe work input side.

Use either a manual or automatic priming pump to draw all the air out of the input pipe work and system; fuel will then replace the air. Once fuel appears at the system’s output, stop your priming pump, and close your input side isolating ball valve.

You can now connect your output pipe work. Once complete, open both isolating ball valves before starting your system.

Priming method 2

If a priming tee has been installed at the highest point on the input side of the system, then an alternative priming method is to close the output isolating ball valve and leave the input isolating ball valve open.

Now pour fuel into the priming tee. With the correct setup, this should start to fill the system with fuel, as well as the input pipe work. Open the air-bleed valve on the top of the blue coalescing filter, when fuel emerges, close it again, but keep filling up at the priming tee until all the air has been removed.

Note

Regardless of the method chosen, we recommend before starting your system that the isolating ball valves before and after your system are closed, and the internal service valve is closed as well. Then, carefully open the lid of both the grey and blue filter; both should be full of fuel, as shown above. If they are not completely full, please top them up at this point. Re-attach the lid, reopen the central service valve, and then reopen the isolating ball valves before trying the system.

A loud noise from within the system, or a rapid increase in temperature at the pump head are indications of a lack of fuel flow. In either case, please stop the system immediately to avoid damage, and repeat the priming procedure. If you have the optional flow sensor attached, the system will tell you. If you do not have the optional sensor, please refer to the “User area and password system” section of this manual to found out how to setup the system to achieve basic fuel flow sensing.

Priming after servicing

We always recommend full priming of the unit after servicing, even though some systems have safe priming capabilities.

When the system contains air and the filters and input pipe work are not completely full of fuel, the filters will need to be bled of air and system primed. The system does not automatically purge air, so it is the engineer’s responsibility to do so as described in later sections.

The W-PFS has been developed to be used with Diesel/Biodiesel/HVO fuels only. DO NOT USE WITH PETROL (GASOLINE).
Some fuels may have been treated with alcohol base additives. These additives may harm the unit’s seals.
When using additives, be sure they are alcohol free and compatible with the unit’s gaskets.
The blue D-shaped component is a fuel conditioner. It is highly magnetic and as such should not be approached by people with pacemakers. Your care and attention is required.

Setup

Do not run system dry, always fully prime the unit and pipe work before running
Unit should be fitted with a non-return valve to maintain prime, but the system still requires priming before use
Do not open the control box unless you are a qualified electrician.
Always isolate from power supply completely before opening control box.
The vacuum/service sensor is adjustable from 200-900mbar (cw triggers early, ccw triggers later). We recommend 680mbar which is pre-set in the factory.

The W-PFS has two ‘water in fuel’ (WIF) sensors (one on each filter), two pressure transducers on the blue filter and a vacuum switch with a black rubber cover on it attached between the centrifugal filter and the pump. This vacuum switch dictates when the centrifugal filter requires servicing but may also trigger if there is a blockage on the input line.

The Vacuum/service sensor is adjustable from 200-900mbar by carefully removing the rubber cover and rotating the adjustment screw; this is situated on the rear of the sensor between the two spade connectors. We recommend a setting of 680mbar, which is about halfway through the adjustment range. On rare occasions, for example if the input pipe work is causing a high vacuum due to frictional losses, this vacuum switch can be adjusted up to allow the system to work for longer between service requirements.

Stopping/Pausing the machine

In normal operation, the system is started in one of three ways, via the automatic timer, by pressing the manual start button, or via activating the BMS run input. The machine stops either when the timer expires, the stop button is pressed or the BMS run input is taken away.

However, there is also a pause input (input 8) which can be used either by the operator or by some of the WASP add-ons. This overrides the run demand of the system and stops the unit from pumping fuel. This can be connected to the W-PFS internal 24v DC supply to pause the system, removing that input will allow the system to run again (assuming there is still a demand to).

This input can be used to pause the machine’s operation if the operator wishes the system to stop running temporarily, for example if they have other equipment which they wish to run without the polishing system in operation, or if an external alarm occurs which means all equipment must be stopped.

For major external emergencies, we recommend fully isolating the incoming power supply to the system, this will immediately stop the machine.

Vacuum switch adjustment

The vacuum switch can be adjusted to allow the system to work for longer between service requirements.

How to adjust the vacuum switch

Locate the vacuum switch between the pump and grey filter.
Remove the black rubber boot.
To lower the sensing point (i.e. the system will trigger at a lower vacuum), rotate the screw clockwise.
To raise the sensing point, rotate the screw anti-clockwise.

It is the installer’s responsibility to check all vacuum and pressure switches and set them to an appropriate level to trigger alerts on the system. This is most practical when fuel is flowing through the system.

Water in fuel sensors

Each filter stage has a water-in-fuel sensing point. The grey filter removes free water content from the fuel, the blue unit removes emulsified water from the fuel. When the separated water level reaches the sensing points, it is deemed high enough to require draining. The machine will stop at this point and signal an engineer for the service work to be carried out.

The Internal Service Ball Valve

The internal service ball valve, which is located to the left of the grey filter, is essential to restrict flow of fuel during servicing of the fuel polishing system.

It is important to following any instructions relating to closing and opening the internal

service ball valve before commencing any servicing works.

In the image opposite, you can see the black line is vertical (in line with the flow of fuel). This indicates the valve is open and is therefore in its normal position for all operating modes (except for servicing).

Screen Operation

The touch screen control system allows for simple operation of the unit. The main screen has access to all important functions; however for most operators the three round buttons in the centre of the main screen are all that are typically required. These are manual mode, automatic mode (for programming when to start/stop) and the system status.

There are also four small buttons around the edge of the main screen which access the information messages screen, the trend screen, the set-language screen and the set time/date.

The HOME button (house logo at the bottom left of each screen) will take you back to the starting page.

Note

Before first operation please set the date and time.

Set the Date and Time

To do so, press the clock (top left corner of the home screen) and a pop-up window will appear to allow you to make any necessary adjustments.

The system has a battery backup for all data (programming, language, time/date etc); it is rechargeable and needs power applied for 20 days to be fully charged (ie the system needs to be switched on for 20 days). After the unit has been charged, the unit can be left without power for one month before it needs to be charged again. This only applies if the room temperature where the unit is kept does not exceed 25^OC.

Touch Screen LED

The touch screen itself has a small LED to the top left-hand corner. This is used as a separate visual indication as to the machine’s status.

LED colour	LED flash mode	Machine Status
Blue	Steady/On	Machine is healthy and stopped
Blue	Flashing	Machine is healthy and running
Red	Flashing	Machine has stopped with a service message or is paused
Pink	Flashing	Service is due, machine can still be operated

Automatic Screen and Timer Programming

Please ensure you have set the time and date on the main page before proceeding. See previous page for instruction

The programming screen utilises buttons to set the days and weeks to run, plus a start time and duration.

1). Select days to run

First use the buttons for the days of the week (top left) to select which days you would like the system to run. In the above example, Monday to Friday have been selected, Saturday and Sunday have not. Press the day to either select or deselect it; the machine will only run on selected days/weeks.

2). Select weeks to run

Next using the numbered buttons (1-5) top right to choose the weeks of the month to run on. If all are selected, the system will run on every week. In the above example, 1, 3, 4 and 5 are selected, week 2 is not.

3). Choose a start time

Press the start time and a new window pops up. This allows you to enter a start time (24hr clock, 00:00 to 23:59). If an invalid time has been selected, the system will automatically default to the nearest valid time.

In this example, we have asked the system to switch on at 09:00 (9am).

4). Choose a run time duration

Next press the duration time, a new window will pop-up. This allows you to select the duration the system will run for. This can be any duration from 00 hrs 01 mins to 99 hrs 59 mins.

5). Enable or disable the mode

So far, in this example, we have set the system to run Monday to Friday, the 1^st, 3^rd, 4^th and 5^th week of every month, starting at 9am and running for 8 hours (i.e. stopping at 5pm). However, the system will only run in automatic mode if we enable the mode. Press the enable or disable button to suit your requirements

The on screen (?) button brings up a help screen which also gives additional assistance.

Once you have completed your setup, press the HOME button to return to the main screen.

Each installation may require a different calculation as to how long you will need to run your system for. However, the following guide should help you to get a good basic setup. Periodic monitoring of the system’s performance, along with 6 monthly fuel sampling, will allow you to adjust your setup should you feel your fuel quality needs to be better managed.

We recommend ensuring your fuel is cleaned every 1 to 2 weeks. That means ensuring your system is running for sufficient time to clean your fuel in that period. A basic calculation can be achieved using the following factors.

How large is your fuel tank (in litres)?
What speed does your fuel polishing system run at?

For example, a 25,000 lit fuel tank and a W-PFS-026, which runs at 26 lit/min would use this basic calculation (assuming there are no large lift/head considerations).

To calculate your run time, in hours*

A = Size of fuel tank / System flow rate

A / 60 + 20%= run time

((2500/26)/60)+3.2 = 19.2 hours

*assumes minimal fuel lift/head and minimal 90 degree pipe work bends and other restrictions which may cause a system to slow down. If your system has a limited maximum flow due to external factors, please adjust your cleaning times to match.

In the above example, we have a time of 19.2 hour; approximately 9 hours, 15 minutes.

We want to run the system for that duration, over a 1 week period, so if we divide that time by 7 (days) we could work out a regular run time for daily use. 19.2/7=2.75 hours (2 hours 45 mins).

In other words, in this basic example, if we set our system to run every day, and every week for 2 hours 45 minutes, we would achieve the basic desired setup.

Grey Filter Service

Note

Before any servicing work is carried out, please ensure the system is isolated from the fuel supply (close any ball valves). The internal valve should be closed for this service but must be reopened before the unit is restarted

You will need:

Spanner
Gloves
Replacement element
Gasket set for grey filter
Flat head screwdriver (If gasket replacement is required)

Turn off the power supply to your machine – talk to your internal representative if required.
Close any ball valves to isolate the system from the fuel supply. Talk to your internal representative if required.
Locate the internal service ball valve between the centrifugal pre filter and the pump. Turn the valve from the open to the closed position.
Unscrew the 4 lid screws using the spanner and alternate between the screws as there will be pressure from the internal spring cassette.
Remove grey filter lid and inspect black lid gasket and if a replacement is required, replace as per instructions from Step 6. If not replacing gasket, skip to step 9.
Remove Gasket from the grey filter lid using a flat head screwdriver to prise it out.
Clean any residue from the filter lid where the gasket was.
Install the new gasket, ensuring it is sitting correctly in the given area.
Remove spring cassette.
Remove old element using the handle*.
Fit the new element using the handle at the top.
Install the spring cassette.
Replace grey lid on to the filter unit and tighten 4 bolts (6-8nm max) **onto filter lid.
Open internal service ball valve.
Re-open any ball valves isolating the system from the fuel supply.
Turn back on the power supply to your machine
Acknowledge any messages relating to the service items you have just completed.
Run the machine as and when required

Note

If dirt has clogged the filter element, a vacuum will develop above the filter element, the system will detect this and send an appropriate “service filter” message. When element has been replaced, clear this message by going in to messages, highlight the message and acknowledge.

If message does not clear you may need to bleed air from the filters and prime the system and clean the Fuel Conditioner unit as per instructions in your WASP Manual.

*Dispose of fuel and used elements in accordance with local environment rules.

**The filter lid tightening torque is a maximum of 8 Nm. Do not over tighten, as this can damage the filter body and or filter lid.

Notes on bleeding air from primary grey filter

As this component is on the vacuum side of the pump, it cannot be bled when the pump is running. If you try to open the top air bleed valve at this point, more air would enter the system, so we do not recommend it. However, air can be bled with the pump off, open the valve as per the “Back-flushing the Primary Filter” instructions.

Grey Filter Draining Water and Back Flushing

Note

Both the grey and blue filters will isolate water collected from fuel. They each have sensors which trigger an alert when they reach a certain level and require the water to be drained. This can however be done regularly before the alert is triggered to avoid the machine stopping.

You will need:

Flathead screwdriver
Gloves
Suitable bowl to collect water

Turn off the power supply to your machine – talk to your internal representative if required.
Close any ball valves to isolate the system from the fuel supply. Talk to your internal representative if required.
Locate the internal service ball valve between the centrifugal pre filter and the pump. Turn the valve from the open to the closed position.
Place a suitable container under the drain tap to collect the water
Open the air bleed valve/screw located on the top of the grey filter by turning clockwise
Open drain tap to release the water by pushing down the tap and twisting anti clockwise.
When the water has drained, close the drain tap by turning clockwise in to a horizontal position
Dispose of the water from the container*.
Close air bleed valve on the lid.
Open internal service ball valve
Re-open any ball valves isolating the system from the fuel supply.
Turn back on the power supply to your machine.
Acknowledge any messages – Go to Messages, highlight the message and acknowledge. Please note if the message does not clear you may need to bleed air from the filters and prime the system.
Run the machine as and when required

Note

If your system is not running correctly after emptying fuel, you may need to prime your WASP System. If required, please follow instructions earlier in this manual or contact WASP on 01923 606 600.

*Dispose of fuel, water and used elements in accordance with local environment rules.

Blue Filter Service

Note

The blue filter has a lid gasket to ensure a fuel tight seal at the lid and bowl connection. They should be replaced every 12-36 months and inspected regularly to check for deterioration and replaced as and when required.

You will need:

Spanner
Gloves
Replacement blue filter element
Gasket set for blue filter
Flat head screwdriver (If gasket replacement is required)

Turn off the power supply to your machine – talk to your internal representative if required.
Close any ball valves to isolate the system from the fuel supply. Talk to your internal representative if required.
Locate the internal service ball valve between the centrifugal pre filter and the pump. Turn the valve from the open to the closed position.
Open the blue filter by removing the dome nuts on the top of the blue filter and remove the lid.
Inspect the blue filter gasket and if replacing follow from instruction 6. If gasket does not need replacing, skip to step 9.
If replacing the gasket, Remove Gasket from the blue filter lid using a flat head screwdriver to prise it out.
Clean any residue from the filter lid where the gasket was.
Install the new gasket, ensuring it is sitting correctly in the given area.
Remove the large single internal dome nut that holds the 2-stage element in place
Remove the used element*
Install the new element by inserting down through open enclosure and filter tops.
Ensure it is firmly fitted and secure with the large dome nut.
Replace the filter lid and secure the dome nuts
Open internal service ball valve.
Re-open any ball valves isolating the system from the fuel supply.
Turn back on the power supply to your machine.
Acknowledge any messages – Go to Messages, highlight the message and Acknowledge. Please note if the message does not clear you may need to bleed air from the filters and prime the system.
Run the machine as and when required.

*Dispose of fuel, water and used elements in accordance with local environment rules.

Blue Filter Draining Water

Note

The purpose of the filter is to clean fuel and remove contaminates including water. Therefore, you should regularly drain your blue filter of water to avoid reaching the point where the level is too high and the system stops. We recommend you drain the blue filter during a service. However, when the water reaches a certain level the internal sensor will trigger the “Drain water in blue filter” message and machine will stop.

You will need:

Spanner
Gloves
Suitable container

Turn off the power supply to your machine – talk to your internal representative if required.
Close any ball valves to isolate the system from the fuel supply. Talk to your internal representative if required.
Locate the internal service ball valve between the centrifugal pre filter and the pump.
Turn the valve from the open to the closed position.
Open the air bleed valve on the top of the blue filter by pulling the trigger on the handle towards you and rotating the handle anti clockwise.
Place a suitable container under the drain tap and release the water* by pushing in the yellow drain tap and then turning anti clockwise.
Once the water has finished draining and fuel starts, close the drain tap and then the air valve.
Open internal service ball valve
Re-open any ball valves to reinstall the system from the fuel supply.
Turn back on the power supply to your machine.
Acknowledge any messages - Go to Messages, highlight the message and Acknowledge. Please note if the message does not clear you may need to bleed air from the filters and prime the system.

*Dispose of fuel, water and used elements in accordance with local environment rules.

Status Messages

No output pressure (S1201)

This function is a way to detect fuel flow through the machine if no flow switch has been fitted. It’s a function which must be ordered before the machine is supplied and therefore is not a standard operation. This message is triggered if the machine detects a complete lack of output pressure, 10 seconds after the pump starts.

If this message is triggered, the most likely cause is a lack of fuel. This means there may be an air leak in the pipe work, the machine has not been primed, or there is a separate reason the fuel cannot flow. It’s also possible the on-board pump has been locally switched off (there is an on-off (I/O) switch on the rear of some pumps. This must be left in the on (I) position at all times).

Service is due (S1301)

As per our recommendation throughout this manual, this machine must be serviced every 12 months. This means the two filter elements in both the grey and blue filters must be changed. Please refer to the previous sections for full instructions on how to do this.

If this message is displayed, 12 months have passed since the last full service. Once it appears, a flashing light can be seen on the touch screen (see separate section for explanation), and a BMS communication message is sent. However, the machine can still be operated as normal.

Change the filter elements as listed in the previous section and acknowledge the messages afterwards to ensure correct operation. Failure to do so may end up with your machine not performing correctly.

Not enough flow (X0301)

If you requested the optional external flow switch when your machine was ordered, this message would be shown if it did not detect fuel flowing after a pre-set “debounce” time of 10 seconds. This switch is not monitored unless the machine is pumping fuel (in its “running” state).

If this message is triggered, the most likely cause is a lack of fuel. This means there may be an air leak in the pipe work, the machine has not been primed, or there is a separate reason the fuel cannot flow. It’s also possible the on-board pump has been locally switched off (there is an on-off (I/O) switch on the rear of some pumps. This must be left in the on (I) position at all times).

The flow switch option is also a suitable method for ensuring all ball valves are correctly opened/there are no blockages in the fuel lines. If any such blockages are present, the lack of fuel flow will be quickly picked up by the flow meter alert.

External leak switch triggered (X0401)

Inside enclosure units, there is a small white float switch (see section on enclosures). This detects a presence of liquid inside the enclosure and will trigger a message when a significant amount has amassed. This will stop the pump from running and alert the user (and BMS). The user should then investigate the cause of the leak; for example, has a drain tap been left open, if the system is outside was the door left open during a rain storm, etc.

Input restriction (X0501)

On manifold units, an additional vacuum sensing system is installed to ensure the user does not manually close all valves. If so, and if the system has been started, this message will be displayed, and the pump will stop. As the pump creates the vacuum, this sensing system can only operate if there is fuel inside the pipes. The pump will not generate sufficient vacuum if there is air or a possible pipe work leak.

The user needs to investigate the cause of the restriction, ensure all valves are open, and even check the pipe work to make sure there are no potential restrictions or blockages which the pump cannot overcome. Remove the obstruction and acknowledge the message before restarting.

If this alert is occurring on a freshly installed machine, it may be the input pipe work is causing the restriction on its own. If so, please refer to the separate previous section relating to vacuum switch adjustment.

Communication lost to IO module (X0001)

If the central control system has been interfered with (e.g. wires disconnected, large EMC/RI locally, electrical noise from external source), the internal communications between the screen and the sensors can be lost. To counteract this and to make sure it is recorded, this software revision includes a status message which is logged by the system. There is no need to acknowledge this message, simply reconnect the removed wire to proceed. Normal machine operation will continue once reconnected and the internal communications have been re-established.

General Alert (X1501)

A general alert message is a “catch all” message. This allows the system to automatically stop the pump should any unexpected condition arise which is not covered by the messages previously listed. Should this be displayed, please use the “further information” button on the messages screen for more data.Messages and Codes

The following messages are available across the range of W-PFS machines, although some may be more relevant to your individual setup. For example, some messages relate to optional extras (e.g. Absolute Polishing ® Element).

In addition to the message text, and the update available on the status screen when any message is active, each message has a dedicated code associated to it.

Code Reading

The prefix “S” relates to a standard service requirement, such as draining water. These are not errors but are more an indication the machine is operating correctly and has removed contamination from your fuel. For example, a ‘filter full’ message means your system has removed a significant amount of foreign matter and requires a back flush of the element or a replacement element.

The prefix “X” relates to messages which either require additional external hardware or indicate an external influence on the machine. For example, the ‘communication lost’ message suggests the internal communication of the system has been interrupted by a high frequency electrical noise or a component being disconnected.

Message Code	Message Text	Machine Status (BMS)	Section in this manual to refer to
S0601	Drain water from grey filter	6	Grey Filter - Draining water
S0701	Grey filter full	7	Grey filter service
S0702	Grey filter full*	7	Grey filter service
S0801	Drain water from blue filter	8	Blue Filter - Draining water
S0901	Blue filter full	9	Blue Filter Servicing
S1001	Output pressure high	10	See WASP Product Manual
S1201	No output pressure, is there flow?	12	See WASP Product Manual
S1301	Service is due. Change both filters	13	Service filters
X0301	Not enough flow	3	Prime the system, check for leaks in pipe work
X0401	External leak switch triggered	4	Contact WASP PFS
X0501	Input restriction	5	Contact WASP PFS
X0001	Communication lost to IO module	0	Contact WASP PFS
X1501	General alert	15	Contact WASP PFS

*messages S0701 and S0702 refer to the same service requirement, but are sensed in different ways

This list is not exhaustive, and other messages may be added to the above list. Other machine status numbers do exist; please refer to the BMS section of your product manual for more information.

Frequently Asked Questions

Before contacting WASP, there are several topics (listed below) which can assist you in rectifying any query you may have.

The system is not running	· Is there any / sufficient power? · Have the fuses blown? · Are any messages shown? · Does the status or message screen display further information? · Has the switch on the pump been moved from I to O?
The system says it is running but the pump is not running	· Check the circuit breaker or fuse · Has the system been running dry? If so, the pump’s protection fuel may have tripped · Has the pump been switched off via it’s I/O switch
The pump is running but there is no or little fuel flowing / The pump is very hot	· It is vital to never run the system dry, please stop the pump immediately · Has the system been primed? · Are all valves open or is the pipe blocked? · The fuel lift might be too high. · Are there restrictions in the pipe work? · Is there an air leak? · Is the non-return valve stuck or hard to open?
Everything is working, but the flow seems slow	· Is there an air leak at the inlet? · Is the fuel lift too high? · If installed, is the foot valve working? · Piping improperly installed or dimensioned (i.e., too narrow)? · The filter might be blocked; the vacuum switch might be adjusted too high.
My grey filter is filling up very quickly	· That means the unit is working well and it is extracting the contamination · Try the back-flush procedure to gain extra life from your filter element · Consider using a “clean-up” element in the blue filter
My blue filter is filling up very quickly	· That means the unit is working well and it is extracting tiny contamination · If the grey filter is not filling up, this means you have lots of fine sediment in your fuel · Try using a 12 micron “clean-up” element in the blue filter to remove contaminate
The pump has worn very quickly	· Pump has been run dry or with insufficient fuel · Plumbing on inlet side not appropriately dimensioned
Pump requires too much power/ circuit breaker keeps tripping	· It might be air in plumbing lines · The fuel/liquid might be too viscous
The unit seems very noisy or hot	· The most likely cause is a pump running dry · Has the system been primed or has it lost the prime? · There might be insufficient fuel or fuel starvation · Air leaks in the inlet pipe? · Possible air on the suction side, this loses prime and means the pump runs dry · Is the non-return valve on your pipe work opening?
Will my unit rust?	· It shouldn’t as it is made from stainless steel, polymer, aluminium, and treated steel. However, in some conditions you may experience surface contamination build-up (for example saline environments) regular treatment of all metal surfaces with WD40 or a similar water repellent protective substance will maintain your unit’s appearance.

W-HL Range Help

Quick start installation

Ensure the system is securely fastened to a wall or other suitable solid structure. This system should have unique pipe work, not connected to any existing fuel driven equipment other than the tank.

The input to the WASP system should feed from the bottom of the fuel tank (via a ball valve and a foot valve or non-return valve), separate to and at a level below the existing fuel tank output pipe.

The fuel polishing system’s output should ideally return to the tank at the top, opposite end to the input.

The unit can be controlled via BMS, however it is capable of self-operation and monitoring.

System should be primed before use and operation. It may also be beneficial to prime after servicing; although with a foot or non-return valve installed, priming should only be required after installation. With power applied, please ensure the system’s time and date have been correctly set.

Quick start operation

Set the clock on the home screen before progressing (press the time on the home screen to set it). A service alert may be shown after your first install. This is not an alarm, but is the system recording the setup date, simply go to the “messages” page and acknowledge it, before returning to the home page and proceeding.

With power applied to the unit, you can either run the system manually (press the MANUAL MODE) button from the home screen and then START/STOP. Alternatively, you can programme it in AUTOMATIC MODE. Here you can set a start time and duration (24 hr clock, hours and minutes).

There are also buttons to allow you to select which week of the month and which day of the week you would like the system to run. Selecting all weeks and all days will mean the system will run daily in this mode. Exit the programming screen to allow the system to run in this mode.

To enable/disable auto mode, either deselect all week or all days or use the auto mode enable/disable button; the system will therefore not start in automatic mode.

There is also an external mode - connect the system’s own 24v DC internal power to input 7 (i7) to run the unit; remove this link to stop it. Likewise, input 8 (i8) pauses the system if operated in the same way.

For the health of the fuel, storage tank and the fuel polishing system, it is recommended that a full cycle is run (3 complete tank volume cycles) once per month alternatively 1 volume cycle per week.

Quick start servicing

To ensure the efficient and optimum running of your system, we recommend you service your system every 12 months. See later sections for details.

We also recommend you check the quality of your gaskets every 6 months and replace every 12 -36 months or at first signs of wear and tear. If the unit is installed in a corrosive or saline environment, we recommend monthly checks of all metal components and regular treatment with protective water repellent oil such as WD40 or NanoShell metal.

Separate to the regular service, the system will flag if it requires any servicing or spare parts. This is via its built in automatic monitoring system

Mechanical Installation

If the system is wall or enclosure mounted, the unit should be securely attached to a fixed wall or other similar firm fixing position. Frame mounted systems are typically designed to be floor mounted but may also be attached to walls for additional bracing.

our unit should be mounted square and flat onto a suitable surface; otherwise distortion of the system may occur. It should be installed horizontally level and vertically upright with the water drain taps facing downwards.

It is the installer’s responsibility to ensure the unit is securely, squarely, and safely mounted in a position that is deemed safe. WASP PFS cannot accept responsibility for damage to the system or enclosure due to incorrect installation.

NOTE: This unit is not to be mounted in ATEX zones 0, 1 or 2. If in doubt, consult your facilities manager or engineer on ATEX zones.

REQUIREMENTS

Isolation ball valves before and after the polishing system in pipe work
Pipe work to and from the tank to be unique, not shared with other equipment
Input feed pipe to the fuel polishing system must be lower in the tank than the feed to the engine / generator / day tanks
All external pipework to be free from leaks, tested via pressure and vacuum
Light spring non-return valve on the input side, as close to the tank as possible (max opening pressure 0.05bar, ideally 0.03bar)
Fully prime the unit and pipe work before use
Optional sealable priming points installed into the external pipe work before and after the unit
Use minimal sharp bends in pipe work to reduce frictional losses
The unit is designed to operate as a syphon system, that means the input and output pipe work should balance each other in terms of restriction. This means keeping them sealed and not open to atmosphere.
Ensure your return pipe work to the tank is below the level of the fuel, this aids fuel flow and prevents foaming
Avoid loops in the pipe work, especially on the input site. These can trap air
The maximum lift for any fuel polishing system is 5m, however that assumes no air leaks or restrictions and that the system is primed and has an NRV fitted
The maximum output head depends on the model purchased but can be as much as 30m. However, 5m is typical.
The maximum fuel flow of your system can be impacted by fuel lifts, elbows, valves, narrow pipework and similar such external factors.

Installation pipe minimum diameter recommendations

W-HL060 1 ½” (to 38mm)

W-HL-120 1 ½” - 2" (38mm-50mm)

Typical Installations

The diagram below shows a typical installation whereby the feed from the bottom of the tank to the fuel polishing system, (1) is at the bottom, side of the fuel tank.

However, if pipework from the tank to the system is to be installed from the top of the tank (below-left), the tank end of the input pipe should either be resting on the bottom of the tank with a cut off at 45 degrees or a 90-degree elbow with an open end can be used.

Environmental note

If your system is to be installed and operated in corrosive environments, for example near to the coast, or in extreme weather conditions, we recommend regular checking and treatment of all metal parts. Although stainless steel and treated steel have been used in the construction of your system, water and corrosive elements can cause contamination which may in some circumstances damage the surface of the system.

To avoid this, we recommend regular periodic inspection of the system, for example a monthly check; although the frequency may need to be altered depending on the environment experienced. We also recommend protecting all metal surfaces with a suitable degreaser or water repellent protective oil such as WD40 or NanoShell metal, regular repeated treatment may be required to maintain the pristine condition your unit was supplied in.

Electrical Installation

The units with the part number suffix 220vac are powered by 220-240v 50Hz 1ph AC.

The units with the part number suffix 110vac are powered by 100-115v 60Hz 1ph AC.

Each unit is supplied with a flying lead for mains power connection. This flying lead should be connected to a user-installed isolating fused spur, using standard EU wiring as follows:

AC power

Live (hot) - Brown

Neutral - Blue

Earth - Yellow/Green

The systems can run autonomously with just the power connection. However, should you require it, the following BMS/Remote connections can also be made.

BMS output connections

NOTE: if the Modbus option is used, please refer to your manual.

Q2 is a user definable output which can be set to represent any of the internal status messages, e.g. paused, running, service due, etc.

Q3 is a dedicated healthy/ready signal (closed = healthy/ready, open = active service requirement or system paused)

Q4 is a dedicated Error signal (closed = alarm state, open = healthy)

Q5-Q8 These four BMS outputs are used to produce a data word, giving 16 different status messages. These outputs are volt free contact pairs and are to be read together. In other words, all 4 must be connected to accurately read this BMS output.

BMS inputs connections

I7 External run (BMS run signal). Connect the system’s internal 24v DC connection to input 7 (i7)

I8 External pause (BMS pause signal). Connect the system’s internal 24v DC connection to input 8 (i8)

User inputs

Your system is equipped with a number of inputs, each has its own function in monitoring of the system. However, input 1 is designated as a “user input”, meaning it allows the installer/operator to attach a sensor of their own choice. This in turn means your W-PFS unit can monitor external equipment.

This external sensor should be able to switch 24v DC
The PLC will only read 24v DC inputs
The PLC should be fed with the 24v DC supply from the W-PFS unit
If external 24 DC units are to be used, the 0v supply must be common to the W-PFS unit
If the flow switch add-on has been selected, this input will be used

The user input also has a time delay function built into it. It is only monitored when the pump is running, and even then, there is a delay timer (set via the user page).

This input will not trigger an alarm if the pump is not running.

The input will not trigger an alarm if the input duration is shorter than the user delay time.

Priming any pumped system is the most important part of setup but may be needed after servicing as well.

Why prime?

Whilst most pumps are not self-priming if they are continually rated, the pump in the W-HL can self-prime to 5m. That said it is ALWAYS best to prime a pump, regardless of its setup and capabilities you remove stress and increase pump life by priming it first. To ensure this does not happen it is therefore recommended to fully fill your W-HL unit and input pipe work with fuel; the head of fuel in the tall blue filters will then keep the pump head primed, assuming it is not drained.

If your system is above the fuel tank, it is vital to install a non-return valve on the input side of the system as well as fully priming the input pipe work.

Our recommended priming method for new installs

When installing your fuel polishing system, we recommend the feed to the system’s input is from the lowest point of your tank, below and separate to the feed from your tank to your engine.

We also recommend a non-return valve is fitted to the feed into the polishing system, as close to the tank as possible. If it can be inside the tank at the pipe end, even better.

The non-return valve must be diesel compatible and have an opening/cracking pressure of 0.03bar or less. Do not use gas NRVs.

Priming method 1

Install your feed pipework only (tank to polishing system input), via your non-return valve and isolating valve; do not connect your output yet. Close all air bleed and water drain valves, leave the internal service valve open. Open the isolation valve on the pipe work input side.

Use either a manual or automatic priming pump to draw all the air out of the input pipe work and system; fuel will then replace the air. Once fuel appears at the system’s output, stop your priming pump, and close your input side isolating ball valve.

You can now connect your output pipe work. Once complete, open both isolating ball valves before starting your system.

Priming method 2

If a priming tee has been installed at the highest point on the input side of the system, then an alternative priming method is to close the output isolating ball valve and leave the input isolating ball valve open.

Now pour fuel into the priming tee. With the correct setup, this should start to fill the system with fuel, as well as the input pipe work. Open the air-bleed valve on the top of the blue coalescing filter, when fuel emerges, close it again, but keep filling up at the priming tee until all the air has been removed.

Regardless of the method chosen, we recommend before starting your system that the isolating ball valves before and after your system are closed. Then, carefully open the lid of both blue filters; both should be full of fuel, as shown above. If they are not completely full, please top them up at this point. Re-attach the lids, and then reopen the isolating ball valves before trying the system.

A loud noise from within the system, or a rapid increase in temperature at the pump head are indications of a lack of fuel flow. In either case, please stop the system immediately to avoid damage, and repeat the priming procedure. If you have the optional flow sensor attached, the system will tell you. If you do not have the optional sensor, please refer to the “User area and password system” section of this manual to found out how to setup the system to achieve basic fuel flow sensing.

If you require further information on priming, or to discuss your individual set up; please contact WASP PFS Technical Support on 01923 606 600 or email info@wasp-pfs.com.

Priming after servicing

We always recommend full priming of the unit after servicing, even though some systems have safe priming capabilities.

When the system contains air and the filters and input pipe work are not completely full of fuel, the filters will need to be bled of air and system primed. The system does not automatically purge air, so it is the engineer’s responsibility to do so.

The W-HL has been developed to be used with Diesel/Biodiesel/HVO fuels only. DO NOT USE WITH PETROL (GASOLINE).
Some fuels may have been treated with alcohol base additives. These additives may harm the unit’s seals.
When using additives, be sure they are alcohol free and compatible with the unit’s gaskets.
The black square-shaped component is a fuel conditioner. It is highly magnetic and as such should not be approached by people with pacemakers. Your care and attention is required.

Setup

Do not run system dry, always fully prime the unit and pipe work before running
Unit should be fitted with a non-return valve to maintain prime, but the system still requires priming before use
Do not open the control box unless you are a qualified electrician.
Always isolate from power supply completely before opening control box.
The vacuum/service sensor is adjustable from 200-900mbar (cw triggers early, ccw triggers later). We recommend 680mbar which is pre-set in the factory.

The W-HL has two ‘water in fuel’ (WIF) sensors (one on each filter), four pressure transducers (2 on each blue filter).

Stopping/Pausing the machine

In normal operation, the system is started in one of three ways, via the automatic timer, by pressing the manual start button, or via activating the BMS run input. The machine stops either when the timer expires, the stop button is pressed or the BMS run input is taken away.

However, there is also a pause input (input 8) which can be used either by the operator or by some of the WASP add-ons. This overrides the run demand of the system and stops the unit from pumping fuel. This can be connected to the W-HL internal 24v DC supply to pause the system, removing that input will allow the system to run again (assuming there is still a demand to).

This input can be used to pause the machine’s operation if the operator wishes the system to stop running temporarily, for example if they have other equipment which they wish to run without the polishing system in operation, or if an external alarm occurs which means all equipment must be stopped.

For major external emergencies, we recommend fully isolating the incoming power supply to the system, this will immediately stop the machine.

Water in fuel sensors

Each filter stage has a water-in-fuel sensing point. The first filter removes free water content from the fuel, the second removes emulsified water from the fuel. When the separated water level reaches the sensing points, it is deemed high enough to require draining. The machine will stop at this point and signal an engineer for the service work to be carried out.

Screen Operation

The touch screen control system allows for simple operation of the unit. The main screen has access to all important functions; however for most operators the three round buttons in the centre of the main screen are all that are typically required. These are manual mode, automatic mode (for programming when to start/stop) and the system status.

There are also small buttons around the edge of the main screen which access the information messages screen, the trend screen, the set-language screen and the set time/date.

The HOME button (house logo at the bottom left of each screen) will take you back to the starting page.

Note

Before first operation please set the date and time.

Set the Date and Time

To do so, press the clock (top left corner of the home screen) and a pop-up window will appear to allow you to make any necessary adjustments.

The system has a battery backup for all data (programming, language, time/date etc); it is rechargeable and needs power applied for 20 days to be fully charged (ie the system needs to be switched on for 20 days). After the unit has been charged, the unit can be left without power for one month before it needs to be charged again. This only applies if the room temperature where the unit is kept does not exceed 25^OC.

Touch Screen LED

The touch screen itself has a small LED to the top left-hand corner. This is used as a separate visual indication as to the machine’s status.

LED colour	LED flash mode	Machine Status
Blue	Steady/On	Machine is healthy and stopped
Blue	Flashing	Machine is healthy and running
Red	Flashing	Machine has stopped with a service message or is paused
Pink	Flashing	Service is due, machine can still be operated

Automatic Screen and Timer Programming

Please ensure you have set the time and date on the main page before proceeding. See previous page for instruction

The programming screen utilises buttons to set the days and weeks to run, plus a start time and duration.

1). Select days to run

First use the buttons for the days of the week (top left) to select which days you would like the system to run. In the above example, Monday to Friday have been selected, Saturday and Sunday have not. Press the day to either select or deselect it; the machine will only run on selected days/weeks.

2). Select weeks to run

Next using the numbered buttons (1-5) top right to choose the weeks of the month to run on. If all are selected, the system will run on every week. In the above example, 1, 3, 4 and 5 are selected, week 2 is not.

3). Choose a start time

Press the start time and a new window pops up. This allows you to enter a start time (24hr clock, 00:00 to 23:59). If an invalid time has been selected, the system will automatically default to the nearest valid time.

In this example, we have asked the system to switch on at 09:00 (9am).

4). Choose a run time duration

Next press the duration time, a new window will pop-up. This allows you to select the duration the system will run for. This can be any duration from 00 hrs 01 mins to 99 hrs 59 mins.

5). Enable or disable the mode

So far, in this example, we have set the system to run Monday to Friday, the 1^st, 3^rd, 4^th and 5^th week of every month, starting at 9am and running for 8 hours (i.e. stopping at 5pm). However, the system will only run in automatic mode if we enable the mode. Press the enable or disable button to suit your requirements

The on screen (?) button brings up a help screen which also gives additional assistance.

Once you have completed your setup, press the HOME button to return to the main screen.

Each installation may require a different calculation as to how long you will need to run your system for. However, the following guide should help you to get a good basic setup. Periodic monitoring of the system’s performance, along with 6 monthly fuel sampling, will allow you to adjust your setup should you feel your fuel quality needs to be better managed.

We recommend ensuring your fuel is cleaned every 1 to 2 weeks. That means ensuring your system is running for sufficient time to clean your fuel in that period. A basic calculation can be achieved using the following factors.

How large is your fuel tank (in litres)?
What speed does your fuel polishing system run at?

For example, a 25,000 lit fuel tank and a W-PFS-026, which runs at 26 lit/min would use this basic calculation (assuming there are no large lift/head considerations).

To calculate your run time, in hours*

A = Size of fuel tank / System flow rate

A / 60 + 20%= run time

((2500/26)/60)+3.2 = 19.2 hours

*assumes minimal fuel lift/head and minimal 90 degree pipe work bends and other restrictions which may cause a system to slow down. If your system has a limited maximum flow due to external factors, please adjust your cleaning times to match.

In the above example, we have a time of 19.2 hour; approximately 9 hours, 15 minutes.

We want to run the system for that duration, over a 1 week period, so if we divide that time by 7 (days) we could work out a regular run time for daily use. 19.2/7=2.75 hours (2 hours 45 mins).

In other words, in this basic example, if we set our system to run every day, and every week for 2 hours 45 minutes, we would achieve the basic desired setup.

Blue Filter Service

Note

The right hand blue filter has the 12 micron "clean-up" element in it, the left hand blue filter has the 2 micron final clean element in it.

The blue filter has a lid gasket to ensure a fuel tight seal at the lid and bowl connection. They should be replaced every 12-36 months and inspected regularly to check for deterioration and replaced as and when required.

You will need:

Spanner
Gloves
Replacement blue filter element
Gasket set for blue filter
Flat head screwdriver (If gasket replacement is required)

Turn off the power supply to your machine – talk to your internal representative if required.
Close any ball valves to isolate the system from the fuel supply. Talk to your internal representative if required.
Locate the internal service ball valve between the centrifugal pre filter and the pump. Turn the valve from the open to the closed position.
Open the blue filter by removing the dome nuts on the top of the blue filter and remove the lid.
Inspect the blue filter gasket and if replacing follow from instruction 6. If gasket does not need replacing, skip to step 9.
If replacing the gasket, Remove Gasket from the blue filter lid using a flat head screwdriver to prise it out.
Clean any residue from the filter lid where the gasket was.
Install the new gasket, ensuring it is sitting correctly in the given area.
Remove the large single internal dome nut that holds the 2-stage element in place
Remove the used element*
Install the new element by inserting down through open enclosure and filter tops.
Ensure it is firmly fitted and secure with the large dome nut.
Replace the filter lid and secure the dome nuts
Open internal service ball valve.
Re-open any ball valves isolating the system from the fuel supply.
Turn back on the power supply to your machine.
Acknowledge any messages – Go to Messages, highlight the message and Acknowledge. Please note if the message does not clear you may need to bleed air from the filters and prime the system.
Run the machine as and when required.

*Dispose of fuel, water and used elements in accordance with local environment rules.

Blue Filter Draining Water

Note

The purpose of the filter is to clean fuel and remove contaminates including water. Therefore, you should regularly drain your blue filter of water to avoid reaching the point where the level is too high and the system stops. We recommend you drain the blue filter during a service. However, when the water reaches a certain level the internal sensor will trigger the “Drain water in blue filter” message and machine will stop.

You will need:

Spanner
Gloves
Suitable container

Turn off the power supply to your machine – talk to your internal representative if required.
Close any ball valves to isolate the system from the fuel supply. Talk to your internal representative if required.
Locate the internal service ball valve between the centrifugal pre filter and the pump.
Turn the valve from the open to the closed position.
Open the air bleed valve on the top of the blue filter by pulling the trigger on the handle towards you and rotating the handle anti clockwise.
Place a suitable container under the drain tap and release the water* by pushing in the yellow drain tap and then turning anti clockwise.
Once the water has finished draining and fuel starts, close the drain tap and then the air valve.
Open internal service ball valve
Re-open any ball valves to reinstall the system from the fuel supply.
Turn back on the power supply to your machine.
Acknowledge any messages - Go to Messages, highlight the message and Acknowledge. Please note if the message does not clear you may need to bleed air from the filters and prime the system.

*Dispose of fuel, water and used elements in accordance with local environment rules.

Status Messages

No output pressure (S1201)

This function is a way to detect fuel flow through the machine if no flow switch has been fitted. It’s a function which must be ordered before the machine is supplied and therefore is not a standard operation. This message is triggered if the machine detects a complete lack of output pressure, 10 seconds after the pump starts.

If this message is triggered, the most likely cause is a lack of fuel. This means there may be an air leak in the pipe work, the machine has not been primed, or there is a separate reason the fuel cannot flow. It’s also possible the on-board pump has been locally switched off (there is an on-off (I/O) switch on the rear of some pumps. This must be left in the on (I) position at all times).

Service is due (S1301)

As per our recommendation throughout this manual, this machine must be serviced every 12 months. This means the two filter elements in both the grey and blue filters must be changed. Please refer to the previous sections for full instructions on how to do this.

If this message is displayed, 12 months have passed since the last full service. Once it appears, a flashing light can be seen on the touch screen (see separate section for explanation), and a BMS communication message is sent. However, the machine can still be operated as normal.

Change the filter elements as listed in the previous section and acknowledge the messages afterwards to ensure correct operation. Failure to do so may end up with your machine not performing correctly.

Not enough flow (X0301)

If you requested the optional external flow switch when your machine was ordered, this message would be shown if it did not detect fuel flowing after a pre-set “debounce” time of 10 seconds. This switch is not monitored unless the machine is pumping fuel (in its “running” state).

If this message is triggered, the most likely cause is a lack of fuel. This means there may be an air leak in the pipe work, the machine has not been primed, or there is a separate reason the fuel cannot flow. It’s also possible the on-board pump has been locally switched off (there is an on-off (I/O) switch on the rear of some pumps. This must be left in the on (I) position at all times).

The flow switch option is also a suitable method for ensuring all ball valves are correctly opened/there are no blockages in the fuel lines. If any such blockages are present, the lack of fuel flow will be quickly picked up by the flow meter alert.

External leak switch triggered (X0401)

Inside enclosure units, there is a small white float switch (see section on enclosures). This detects a presence of liquid inside the enclosure and will trigger a message when a significant amount has amassed. This will stop the pump from running and alert the user (and BMS). The user should then investigate the cause of the leak; for example, has a drain tap been left open, if the system is outside was the door left open during a rain storm, etc.

Input restriction (X0501)

On manifold units, an additional vacuum sensing system is installed to ensure the user does not manually close all valves. If so, and if the system has been started, this message will be displayed, and the pump will stop. As the pump creates the vacuum, this sensing system can only operate if there is fuel inside the pipes. The pump will not generate sufficient vacuum if there is air or a possible pipe work leak.

The user needs to investigate the cause of the restriction, ensure all valves are open, and even check the pipe work to make sure there are no potential restrictions or blockages which the pump cannot overcome. Remove the obstruction and acknowledge the message before restarting.

If this alert is occurring on a freshly installed machine, it may be the input pipe work is causing the restriction on its own. If so, please refer to the separate previous section relating to vacuum switch adjustment.

Communication lost to IO module (X0001)

If the central control system has been interfered with (e.g. wires disconnected, large EMC/RI locally, electrical noise from external source), the internal communications between the screen and the sensors can be lost. To counteract this and to make sure it is recorded, this software revision includes a status message which is logged by the system. There is no need to acknowledge this message, simply reconnect the removed wire to proceed. Normal machine operation will continue once reconnected and the internal communications have been re-established.

General Alert (X1501)

A general alert message is a “catch all” message. This allows the system to automatically stop the pump should any unexpected condition arise which is not covered by the messages previously listed. Should this be displayed, please use the “further information” button on the messages screen for more data.Messages and Codes

The following messages are available across the range of W-PFS machines, although some may be more relevant to your individual setup. For example, some messages relate to optional extras (e.g. Absolute Polishing ® Element).

In addition to the message text, and the update available on the status screen when any message is active, each message has a dedicated code associated to it.

Code Reading

The prefix “S” relates to a standard service requirement, such as draining water. These are not errors but are more an indication the machine is operating correctly and has removed contamination from your fuel. For example, a ‘filter full’ message means your system has removed a significant amount of foreign matter and requires a back flush of the element or a replacement element.

The prefix “X” relates to messages which either require additional external hardware or indicate an external influence on the machine. For example, the ‘communication lost’ message suggests the internal communication of the system has been interrupted by a high frequency electrical noise or a component being disconnected.

Message Code	Message Text	Machine Status (BMS)	Section in this manual to refer to
S0601	Drain water from right blue filter	6	Draining water
S0701	Right blue filter full	7	Blue filter Servicing
S0801	Drain water from left blue filter	8	Draining water
S0901	Left blue filter full	9	Blue Filter Servicing
S1001	Output pressure high	10	See WASP Product Manual
S1201	No output pressure, is there flow?	12	See WASP Product Manual
S1301	Service is due. Change both filters	13	Service filters
X0301	Not enough flow	3	Prime the system, check for leaks in pipe work
X0401	External leak switch triggered	4	Contact WASP PFS
X0501	Input restriction	5	Contact WASP PFS
X0001	Communication lost to IO module	0	Contact WASP PFS
X1501	General alert	15	Contact WASP PFS

*messages S0701 and S0702 refer to the same service requirement, but are sensed in different ways

This list is not exhaustive, and other messages may be added to the above list. Other machine status numbers do exist; please refer to the BMS section of your product manual for more information.

Frequently Asked Questions

Before contacting WASP, there are several topics (listed below) which can assist you in rectifying any query you may have.

The system is not running	· Is there any / sufficient power? · Have the fuses blown? · Are any messages shown? · Does the status or message screen display further information? · Has the switch on the pump been moved from I to O?
The system says it is running but the pump is not running	· Check the circuit breaker or fuse · Has the system been running dry? If so the pump’s protection fuel may have tripped · Has the pump been switched off via it’s I/O switch
The pump is running but there is no or little fuel flowing	· It is vital to never run the system dry, please stop the pump immediately · Has the system been primed? · Are all valves open or Is the pipe blocked? · The fuel lift might be too high. · Are there restrictions in the pipe work? · Is there an air leak? · Is the non-return valve stuck or hard to open?
Everything is working, but the flow seems slow	· Is there an air leak at the inlet? · Is the fuel lift too high? · If installed, is the foot valve working? · Piping improperly installed or dimensioned (i.e. too narrow)? · The filter might be blocked; the vacuum switch might be adjusted too high.
My blue filter is filling up very quickly	· That means the unit is working well and it is extracting tiny contamination · If the first blue filter is not filling up, this means you have lots of fine sediment in your fuel, all such contamination has to be extracted
The pump has worn very quickly	· Pump has been run dry or with insufficient fuel · Plumbing on inlet side not appropriately dimensioned
Pump requires too much power/ circuit breaker keeps tripping	· It might be air in plumbing lines · The fuel/liquid might be too viscous
The unit seems very noisy or hot	· The most likely cause is a pump running dry · Has the system been primed or has it lost the prime? · There might be insufficient fuel or fuel starvation · Air leaks in the inlet pipe? · Possible air on the suction side, this loses prime and means the pump runs dry · Is the non-return valve on your pipe work opening?
Will my unit rust?	· It shouldn’t as it is made from stainless steel, polymer, aluminium, and treated steel. However, in some conditions you may experience surface contamination build-up (for example saline environments) regular treatment of all metal surfaces with WD40 or a similar water repellent protective substance will maintain your unit’s appearance.

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