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PHASE I ENHANCED VAPOR RECOVERY SYSTEM
INSTALLATION
AND
MAINTENANCE MANUAL
November 14, 2007
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iii
iv
OPW Fueling Components
Installation and Maintenance Manual
Phase 1 Enhanced Vapor Recovery Systems
For Executive Order VR102
v
vi
Table of Contents
Section 1: 1-2100 Series Spill Containment Buckets
Section 2: 700L Series Secondary Contained Spill Bucket
1
6
Section 4:
Retrofit & Upgrades, 6521XAR
Section 5:
Multi-Port
Section 6:
POMECO Multi-Port – Maintenance
Section 7:
1DK-2100
Section 8:
61SO-EVR
Section 9:
71SO-EVR
Section 10: 6111-1400 Protector 74
Section 11: 61JSK Jack Screw and FSA-400 Face Seal Adaptor
Section 12: 61SALP Fill Swivel and 61VSA Vapor Swivel Adaptors
79
86
Reference Tables:
Torque
Maintenance Activity Chart for EVR Products
CARB Test Procedure and Field Inspection
101
103
110 vii
viii
Section 1
OPW 1-2100 Series Thread-On Grade Level
Spill Containers
1
OPW Installation and Maintenance Instructions
OPW 1-2100 Series Thread-On Grade Level Spill Containers
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-2100 Spill Container is pre-assembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
In California it is prohibit to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-2100 Series
Thread-On spill containers models equipped with a drain plug.
1-2100 Series Performance
Specifications:
This Spill Container drain valve has been manufactured and tested to the following California specifications: Leak Rate to be less than or equal to
0.17 CFH @ 2.0 " W.C.
Torques Specification:
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ftlbs maximum.
4" Nipple, 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Drain Valve clamps, 5/16-18 UN thread, 11.5 ft-lbs minimum to 13.5 ft-lbs maximum.
2
OPW NO. 1-2100 SERIES GRADE
LEVEL SPILL CONTAINER
INSTALLATION INSTRUCTIONS:
Step1.
Per California SB-989, all metal must be protected from direct contact with the elements. Coat stainless steel band clamps with the following approved coatings. OPW SL-1100, 3M Underseal 08883 or
Polyguard Mastic CA-9. Only the threaded hardware needs to be coated in the field.
Lbs. max. (4” NPT)
Step 7: (See Figure 2)
Apply pipe dope to nipple and install. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound. Use only factory made nipples.
Nipples must be cut square and deburred. Torque to 125 ft-lbs min. to 250 ft-lbs max. (4” NPT).
Torque value is based on rotation at the center of pipe. For standard cover models install adaptor and dust cap. For sealable cover (1SC) models, install a standard 4" pipe cap to support adjustment system.
Step 2: (See Figure 1 & 2)
Set riser pipe. "L" is the distance between the top of
(Adaptor and dust cap must be installed in sealable cover (SC) models after concrete has dried. the riser pipe and finish grade.
Note: The “L” dimensions below factors in a
from the bottom of the threaded portion of the base
1” slope to grade.
Model Series “L” Dimension
Note: Nipple length is determined by measuring to the bottom of the cover. Then subtract 2” for clearance, height of adaptor and height of cap.
Range of nipple lengths that can be used in all of the
1-2100, 5 Gal. (Comp. Base) L=15 5/8" (40cm)
1-2100E, 7.5 Gal.(Comp. Base) L=19 5/8" (50cm)
OPW spill containers: 4” minimum to 14” maximum.
1-2115, 15 Gal. (Comp. Base) L=19 5/8" (50cm)
Finish Grade
1-2100C, 5 Gal.(Cast Iron Base) L=14 1/2"
(37cm)
1-2100EC, 7.5 Gal.(Cast Iron Base) L=18 1/2"
(47cm)
1-2115C, 15 Gal. (Cast Iron Base) L=18 1/2"
(47cm)
Note:
If using OPW FSA-400, add 3-1/4” to Dimension “L”.
If using OPW FSA-400-S, add 1-3/4 to Dimension
“L”.
NOTE: FSA-400-S will only work with Cast Iron
Base.
Step 3:
Deburr and thoroughly clean riser pipe. Apply pipe dope to riser threads. Pipe dope to be a non-
Figure1
Finish Grade
Slope 1” min.
hardening, gasoline resistant pipe thread seal compound.
Step 4:
Install OPW FSA-400 Face Seal Adapter onto riser using the OPW 61SA-TOOL. Torque to 125 ft-lbs min. to 250 ft-lbs max.( 4” NPT). Apply pipe dope to
FSA-400. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound.
Step 5:
Install spill container by rotating the mounting ring until hand tight.
NOTE: Do not attempt to completely tighten the container by using the mounting ring
Step 6:
Finish tightening the spill container with the OPW
61SA-TOOL. Torque to 125 ft-lbs min. to 250 ft.
Dust Cap
Adaptor
Nipple
Bottom of thread in base
Top of Riser Pipe
Riser Pipe
3
Figure 2
Step 8: (See Figure 3 & 4)
Install adjusting system beneath tabs on mounting ring. See Figure 3 for standard cover models. See
Figure 4 for sealable cover models. Add shims as needed and adjust with screw. (Shims must be cut to size for sealable cover models.) The height can be increased up to 1" (2.5cm).
Note: The adjustment should not be more than 1" from the initial length of the unit.
Step 9:
Upon preliminary installation perform the California
Test Procedures TP-201.1C or equivalent. Their
Test Procedures will check the seals between the drain valve, nipple and rotatable adapter. To test the spill containers base and bellows fill the container with water. A drop in the water level of
1/16” or greater after one hour means that a leak exists. To determine where the leak is, look for a steady stream of bubbles coming from one of the joints or water leaking on the outside of the bucket.
NOTE: Do not drain the water into the UST after the test is complete. Water must be disposed of per local requirements for hazardous waste. If the leak cannot be corrected the spill container should be replaced with another.
Step 10: (See Figure 2)
Before pouring concrete, place plastic over the cover and mounting ring protecting them from concrete splash. Double check that the unit is level and at proper grade height. Pour concrete per figure 2.
Ramp or dome the concrete away from the mounting ring. There should be a minimum of 1” slope to finish grade. The concrete surface should start at the bottom edge of the watershed slots and tapered down to grade level.
NOTE: Do not stand on spill container before concrete sets up.
Remove plastic from cover after concrete has dried.
Remove adjustment system. Adaptor and tight fill cap can now be installed in sealable cover models.
Re-test the spill containers for leaks as described in step 9, after the concrete has set up.
Operation and Maintenance:
Annually: Inspect and clean the interior of the spill container and drain valve screen. Remove accumulated dirt and grit. Test the drain valve using
CARB procedure TP-201.1C or TP-201.1D. If the drain valve passes testing no further maintenances required. If the drain valve fails testing, remove the valve, soak in water and use high-pressure air, if needed, to clean. Reinstall the drain valve to its proper position and test the valve with CARB procedure TP-201.1C or TP-201.1D. If problems persist, replace the drain valve with P/N 1DK-2100-
EVR (specified torque 11.5 ft-lbs min to 13.5 ft-lbs max, 5/16-18 UN thread). The sealable cover (1SC) adjustment nut is set at the factory, but due to environmental conditions it may be necessary to adjust it to either improve sealing or ease cover removal.
Important: Leave these instructions with Station
Operator.
Height
Adjustment Bolt
Shims
Cap
Adapter
Figure 3 – Standard Cover Model Height Adjustment
Shims Must
Be Cut To
Length
Height
Adjustment
Bolt
Use OPW
116-7085 or
4” Pipe Cap to Support
Adjustment
System
Nipple
Figure 4 – Sealable Cover Model height adjustment
4
I.D. Tag
Manufacture: OPW
Model: 1-Series Spill Container
Size: 5, 7.5 or 15 Gal
Composite or Cast Iron Base
Date Manufactured: MM YY
MM = Month, YY = Year
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2006 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H12295PA – 5/07
5
Section 2
700L Series Secondary Contained Spill Bucket
6
Installation and Maintenance Instructions
Direct 700L Series Secondary Contained Spill Bucket
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: This Spill Container is pre-assembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied.
Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
NOTICE: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. THERE ARE NO WARRANTIES, WHICH
EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF.
NOTE: In California it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers.
NOTE: The sealable cover (SC) adjustment nut is set at the factory, but due to environmental conditions it may be necessary to adjust it to either improve sealing or ease cover removal.
WARNING: The primary containment bucket consists
of three components cast iron ring, bellows, and bucket bottom. These parts are held together with stainless steel retaining bands. DO NOT adjust the stainless steel retaining bands securing the bellows to the containment bucket top ring or the containment bucket bottom. Adjusting the retaining bands voids any
and all warranties on this product.
WARNING: If the cover is removed, for any reason,
follow the Operation and Maintenance instruction as noted. Always inspect and replace damaged o-rings and seals and install new ones. Never reuse damaged o-rings or seals as it may result in an improper seal.
Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other then fuel prior to delivery. If water or contaminates are present, then they MUST be removed by the use of absorbent towels before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver
MUST drain any excess fuel that may have spilled into the container from their delivery hose by pulling on the drain valve until the fluid is completely gone.
Performance Specifications: This Spill Container drain valve has been manufactured and tested to the following
7
California specifications: Leak Rate at 0.17 CFH @ 2.0 "
W.C.
Tools Required:
61SA-TOOL – Torque Tool
TC-400 – Torque Cap
CHS-550 or CHS-450 – Hole Saw for 4” or 3” Entry Fitting
BFT-300 – Template for Bolted Fitting
Torque Specifications:
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
4" Nipple, 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Drain Valve clamps, 5/16-18 UN thread, 11.5 ft-lbs minimum to 13.5 ft-lbs maximum.
Mounting Ring Stud, 5/16-18 UN thread, 15 ft-lbs minimum to 20 ft-lbs maximum.
Manhole bolts, 5/16-18 UN thread, 15 ft-lbs minimum to 20 ft-lbs maximum.
Secondary Contained Spill Bucket Manhole Installation
Instructions
Mark off finish grade. (See Figure 1.)
Finish Grade
Figure 4
Cut the riser(s) from the underground tank so that both the fill and vapor risers are set below the final grade. Use the dimensions below:
Spill Container grade (L)
5 Gal. Cast Iron Base
5 Gal. Composite Base
5/8”
18½”
19
Note: Add an extra 3-1/4” when using an OPW FSA-400
Face Seal Adaptor, recommended for Composite Base.
Add an extra 1 ¾” when using the FSA-400-S Face Seal
Adaptor, recommended for Cast Iron Base. (See Figure 1.)
3. Remove Spill Container Cover, Spill
Container Mounting Ring, and Manhole Cover.
4. Slide the Fiberglass basin over the riser pipe, make sure the band clamps on the entry fitting are loose to allow for adjusting the basin over the riser. (See
Figure 2.)
8
4” Entry Fitting
Figure 5
5. Elevate the Fiberglass Basin and steel ring to grade.
6. Secure the fiberglass basin to the riser by
tightening the entry fitting band clamps.
Deburr and thoroughly clean riser pipe(s).
Apply pipe dope to riser(s). The pipe dope is to be a non-hardening, gasoline resistant, pipe thread seal compound.
Install OPW FSA-400 (Composite Base) or FSA-400S
(Cast Iron Base) Face Seal Adapter onto riser.
(Recommend Torque, 4” NPT, 125 ft-lbs min. to 250 ft-lbs max.). Apply pipe dope to FSA. The pipe dope is to be a non-hardening, gasoline resistant, pipe thread seal compound. This is optional for spill containers that are on the vapor lines. (See
Figure 3.)
Figure 6
Spill Container
FSA Face
Seal Adaptor
Thread on spill container. (See Figure 3.)
Grounding Wire Specifications:
Use a #10 coated wire TFFN or THHN from grounding.
5/16-18 threaded bolts SST (Stainless)
5/16-18 SST nuts
5/16 SST lock-washer
Grounding Wire
Grommet
Place the mounting ring over the containment buckets and rotate the mounting ring until the studs are aligned with the bucket ring holes.
(See Figure 5)
Thread nut and lock washer onto studded mounting ring. Tighten the mounting ring retaining bolts until the containment bucket o-rings make contact with the multi-port cover.
Studded
Mounting Ring
O-Ring Gasket
Grounding
Wire Hole
Figure 7
11a.) Measure the distance for the required wire from the grounding wire hole in the primary bucket base to secondary bucket grounding lug.
11b.) Attach one bolt, nut, and lock-washer with the grounding wire to the grounding wire hole in the primary base.
11c.) Attach one nut and lock-washer with the grounding wire to the grounding lug located on the inside of the secondary bucket.
11d.) Attach one nut and lock-washer with the grounding wire and grounding lug located on the outside of the secondary bucket.
11e.) Loop grounding wire to the next bucket.
Repeat steps 2-4.
11f.) Attach the last grounding wire in the series of buckets to a grounding rod.
Using the 61SA-TOOL, tighten the spill container onto the nipple with a minimum torque of 125 ft.-lbs. and a maximum torque of 250 ft.-lbs.
WARNING: Do NOT tighten the containment bucket by using the mounting ring at the top of the bucket.
Tightening the bucket using the mounting ring may lead to failure of the unit.
Assure both upper and lower entry fitting band clamps are tightly secured to the riser.
Install the steel cover, centering the riser as close as possible in the containment openings. Be very careful not to move or damage the O-Rings.
Inspect the containment bucket O-Rings and Mounting
Ring O-Rings for damage. Replace the o-ring gasket(s) if they are damaged.
Figure 5
In a crossing pattern, torque the bolts down between
15 to 20 ft.-lbs. 6 Point Ratcheting box wrench is recommended. (See Figure 6.)
Nut and
Lock Washer
Figure 6
Install the spill bucket covers.
(Optional): Install the product identification disc on the spill bucket cover and multi-port cover in the I.D. disc recess.
Cover the multi-port perimeter ring and cover with plastic to prevent concrete from settling in the drainage areas.
It is required that the perimeter ring and skirt assembly and the multi-port cover be set as an assembled unit, with the bolts engaged. Failure to engage the bolts may result in the distortion of the ring and improper fit of the ring to cover after the concrete is poured.
When pouring the concrete, hand shovel or trowel the concrete around the multi-port assembly to prevent the unit from moving or shifting, which can
9
cause alignment problems and future maintenance problems.
Note: Do not stand on the multi-port before the concrete has set up.
It is recommended that the paved contours around
POMECO covers be adequately sloped to direct water flow away from the cover and direct water runoff from adjacent areas away from POMECO covers. 1” minimum slope is recommended. (See
Figure 7.)
Figure 7
Remove the plastic after the concrete has set up.
After installation is complete, water test the multi-port fixture. The recommended water test procedures include: a) Spraying water on cover(s) for 5 to 10 minutes, using a commonly available watering device such as a lawn sprinkler. b) Standing water test, not to exceed ½” in water depth for a period of 5 to 10 minutes.
Operation and Maintenance:
Weekly: Inspect the interior of both the primary and secondary container for water or other contaminants. If water or contaminates are present, then they MUST be removed by the use of absorbent towels. Dispose of towels and debris safely and per all applicable local, state, and federal codes. Check that the cover is in good condition and properly identified. Replace the cover as necessary.
Inspect the bucket walls for cracks, bulges, or holes. If any exist, have that spill container barricaded and contact maintenance personnel immediately for repairs.
Semiannually: Follow all state and local required hydrostatic or vacuum testing on the primary bucket and secondary basin. Inspect and clean the drain valve screen.
Remove accumulated dirt and grit. If the drain valve screen becomes clogged, remove the valve, soak in water and use high-pressure air to clean. Reinstall the drain valve to its proper position and test the valve per California ARB
TP201-1C Test Procedure. If problems persist, replace the drain valve with P/N 1DK-2100-EVR (specified torque 11.5 ft-lbs min to 13.5 ft-lbs max, 5/16-18 UN thread).
Testing Spill Containers
Use California ARB TP201-1C or TP201-1D Test
Procedures: These Test Procedures will check the seals between the drain valve, nipple and rotatable adapter. To test the spill containers base and bellows fill the container with water. A drop in the water level of 1/16” or greater after one hour means that a leak exists. To determine where the leak is, look for a steady stream of bubbles coming from one of the joints or water leaking on the outside of the bucket. NOTE: Do not drain the water into the UST after the test is complete. Water must be disposed of per local requirements for hazardous waste. If the leak cannot be corrected the spill container should be replaced with another.
Important: Leave these instructions with Station Operator as per CARB Requirements
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally
Marketing Agent for POMECO by OPW, Inc.
Copyright, 2002 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n 200219 – 111407
10
Installation and Maintenance Instructions
Remote 700L Series Secondary Contained Spill Bucket
IMPORTANT: Please read these warnings and use the in material and workmanship for a period of one year from assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: This Spill Container is pre-assembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied.
Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
NOTICE: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. THERE ARE NO WARRANTIES, WHICH
EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF.
NOTE: In California it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers.
NOTE: The sealable cover (SC) adjustment nut is set at the factory, but due to environmental conditions it may be necessary to adjust it to either improve sealing or ease cover removal.
WARNING: The primary containment bucket consists
of three components cast iron ring, bellows, and bucket bottom. These parts are held together with stainless steel retaining bands. DO NOT adjust the stainless steel retaining bands securing the bellows to the containment bucket top ring or the containment bucket bottom. Adjusting the retaining bands voids any
and all warranties on this product.
WARNING: If the cover is removed, for any reason,
follow the Operation and Maintenance instruction as noted. Always inspect and replace damaged o-rings and seals and install new ones. Never reuse damaged o-rings or seals as it may result in an improper seal.
Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other then fuel prior to delivery. If water or contaminates are present, then they MUST be removed by the use of absorbent towels before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver
MUST drain any excess fuel that may have spilled into the container from their delivery hose by pulling on the drain valve until the fluid is completely gone.
Performance Specifications: This Spill Container drain valve has been manufactured and tested to the following
11
California specifications: Leak Rate at 0.17 CFH @ 2.0 "
W.C.
Tools Required:
61SA-TOOL – Torque Tool
TC-400 – Torque Cap
CHS-550 or CHS-450 – Hole Saw for 4” or 3” Entry Fitting
BFT-300 – Template for Bolted Fitting
Torque Specifications:
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
4" Nipple, 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Drain Valve clamps, 5/16-18 UN thread, 11.5 ft-lbs minimum to 13.5 ft-lbs maximum.
Mounting Ring Stud, 5/16-18 UN thread, 15 ft-lbs minimum to 20 ft-lbs maximum.
Manhole bolts, 5/16-18 UN thread, 15 ft-lbs minimum to 20 ft-lbs maximum.
Secondary Contained Spill Bucket Manhole Installation
Instructions
Mark off finish grade. (See Figure 1.)
Figure 8
Remove the four (4) bolts that secure the manhole
cover to the ring, and remove the manhole cover.
Measure length, L, and mark the distance from the center of the remote line to grade on the outside diameter of the fiberglass bucket, measuring from the top of metal ring. Follow instructions for the
bolted flange. The Maximum Length is 26 5/16” and
Minimum Length is 21 1/2”.
Deburr and thoroughly clean remote line.
Slide the Fiberglass basin over the remote line; make sure the band clamps on the entry fitting are loose to allow for adjusting the basin over the remote line. (See Figure 2).
Apply pipe dope to remote line. The pipe dope is to be a non-hardening, gasoline resistant, pipe thread seal compound.
Install elbow to remote line. Then calculate the nipple length with the equation below. (See Figure 3.)
Spill Container grade
5 Gal. Cast Iron Base
1/8”
5 Gal. Composite Base
Elbow
Standard
19 1/2”
18
Height
1/2"
Nipple Length
L – Spill Container – Elbow = Nipple Length
(Round length to closest standard length)
Deburr and thoroughly clean nipple.
Apply pipe dope to nipple. The pipe dope is to be a non-hardening, gasoline resistant, pipe thread seal compound. Thread 4” pipe 125 to 250 ft. lbs.
Align the elbow at the proper position for installation.
Secure the band clamps on the entry fitting to the required torque suggested in the installation
instructions. (See Figure 3.)
Entry Fitting
Figure 9
12
Remote
Line
Pipe
Nipple
Remote
Elbow
Remote
Line
Entry Fitting
Figure 10
Thread on spill container. (See Figure 4.)
Spill
Container
Remote
Elbow
Pipe
Nipple
Figure 11
Grounding Wire Specifications:
Use a #10 coated wire TFFN or THHN from grounding.
5/16-18 threaded bolts SST (Stainless)
5/16-18 SST nuts
5/16 SST lock-washer
Grounding Wire
Grommet
Grounding
Wire Hole
Figure 12
12a.) Measure the distance for the required wire from the grounding wire hole in the primary bucket base to secondary bucket grounding lug.
12b.) Attach one bolt, nut, and lock-washer with the grounding wire to the grounding wire hole in the primary base.
12c.) Attach one nut and lock-washer with the grounding wire to the grounding lug located on the inside of the secondary bucket.
12d.) Attach one nut and lock-washer with the grounding wire and grounding lug located on the outside of the secondary bucket.
12e.) Loop grounding wire to the next bucket.
Repeat steps 2-4.
12f.) Attach the last grounding wire in the series of buckets to a grounding rod.
Using the 61SA-TOOL, tighten the spill container onto the nipple with a minimum torque of 125 ft.-lbs. and a maximum torque of 250 ft.-lbs.
WARNING: Do NOT tighten the containment bucket by using the mounting ring at the top of the bucket.
Tightening the bucket using the mounting ring may lead to failure of the unit.
Install the steel cover, centering the riser as close as possible in the containment openings. Be very careful not to move or damage the o-rings.
Inspect the containment bucket o-rings and mounting ring o-Rings for damage. Replace the o-ring gasket(s) if they are damaged.
Place the rain tight or sealable cover mounting ring over the containment buckets and rotate the mounting ring until the studs are aligned with the bucket ring holes. (See Figure 6.)
Thread nut and lock washer onto studded mounting ring. Tighten the mounting ring retaining bolts until the containment bucket o-rings make contact with the multi-port cover.
13
Studded
Mounting
Ring
O-Ring
Gasket
POMECO covers be adequately sloped to direct water flow away from the cover and direct water runoff from adjacent areas away from POMECO covers. 1” minimum slope is recommended. (See
Figure 8.)
Figure 6
In a crossing pattern, torque the bolts down between
15 to 20 ft.-lbs. A 6 Point Ratcheting box wrench is recommended. (See Figure 7.)
Nut and
Lock Washer
Figure 7
Install the spill bucket covers.
(Optional): Install the product identification disc on the spill bucket cover and multi-port cover in the I.D. disc recess.
Cover the multi-port perimeter ring and cover with plastic to prevent concrete from settling in the drainage areas.
It is required that the perimeter ring and skirt assembly, and the multi-port cover be set as an assembled unit, with the bolts engaged. Failure to engage the bolts may result in the distortion of the ring and improper fit of the ring to cover after the concrete is poured.
When pouring the concrete, hand shovel or trowel the concrete around the multi-port assembly to prevent the unit from moving or shifting, which can cause alignment problems and future maintenance problems.
WARNING: Do not stand on the unit before the concrete has set up. Standing on the unit may result in a cracked unit, line, or tank fitting.
It is recommended that the paved contours around
Figure 8
Remove the plastic after the concrete has set up.
After installation is complete, water test the multi-port fixture. The recommended water test procedures include: c) Spraying water on cover(s) for 5 to 10 minutes, using a commonly available watering device such as a lawn sprinkler. d) Standing water test, not to exceed ½” in water depth for a period of 5 to 10 minutes.
Any water in the unit is considered a failure.
Replace the o-rings in accordance with these installation instructions and repeat test.
Operation and Maintenance:
Weekly: Inspect the interior of both the primary and secondary container for water or other contaminants. If water or contaminates are present, then they MUST be removed by the use of absorbent towels. Dispose of towels and debris safely and per all applicable local, state, and federal codes. Check that the cover is in good condition and properly identified. Replace the cover as necessary.
Inspect the bucket walls for cracks, bulges, or holes. If any exist, have that spill container barricaded and contact maintenance personnel immediately for repairs.
Semiannually: Follow all state and local required hydrostatic or vacuum testing on the primary bucket and secondary basin. Inspect and clean the drain valve screen.
Remove accumulated dirt and grit. If the drain valve screen becomes clogged, remove the valve, soak in water and use high-pressure air to clean. Reinstall the drain valve to its proper position and test the valve per California ARB
TP201-1C Test Procedure. If problems persist, replace the drain valve with P/N 1DK-2100-EVR (specified torque 11.5 ft-lbs min to 13.5 ft-lbs max, 5/16-18 UN thread).
Testing Spill Containers
Use California ARB TP201-1C or TP201-1D Test
Procedures: These Test Procedures will check the seals between the drain valve, nipple and rotatable adapter. To test the spill containers base and bellows fill the container with water. A drop in the water level of 1/16” or greater after one hour means that a leak exists. To determine
14
where the leak is, look for a steady stream of bubbles coming from one of the joints or water leaking on the outside of the bucket. NOTE: Do not drain the water into the UST after the test is complete. Water must be disposed of per local requirements for hazardous waste. If the leak cannot be corrected the spill container should be replaced with another.
Important: Leave these instructions with Station Operator as per CARB Requirements
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally
Marketing Agent for POMECO by OPW, Inc.
Copyright, 2002 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n 200242 – 111407
15
Section 3
6511-RB16 Riser Spacer
500 Series POMECO Multi-Port
Below Grade Multi-Port with Platform
16
POMECO Installation & Maintenance Instructions
6511-RB16 Riser Spacer
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The POMECO Spill Container is preassembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required.
As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
6511-RB16 Riser Spacer
Performance Specifications:
The 6511-RB16 Riser Spacer is designed to assist in the alignment of Tank risers. The 6511-RB16 bolts to Fill and Vapor risers, and a thread turnbuckle allows for adjustment.
17
6511-RB16 Riser Spacer
Installation Instructions
1. See POMECO Multi-Port Spill Container
Manhole instruction sheet MPIS-903.
2. Before completing Step 5 in the Multi-Port
Instructions, slide POMECO 6511-RB16
Riser Spacer over Fill and Vapor risers. The
Ring with two bolts should mate to the Fill
Riser, the second bolt is for grounding wire.
3. Thread the hex bolts into the riser until the
6511-RB16 Riser Spacer is firmly attached to the risers.
4. Adjust turnbuckle until Spill Containers are aligned to the Multi-Port Cover.
Consult tank manufactures recommendations before repositioning risers.
WARNING
DO NOT OVERTIGHTEN RISER SPACER.
POTENTIAL RISER
P.O. Box 405003 * Cincinnati, Ohio 45240-
5003
1-800-422-2525 Domestically
513-870-3315 Internationally
Marketing Agent for POMECO by OPW,
Inc.
Copyright, 2002 - OPW Fueling
Components Inc., Cincinnati, OH
Printed in U.S.A. p/n 6511-RB16-903
18
POMECO Installation and Maintenance Instructions Multi -
Port Spill Containment Manholes
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The POMECO Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
In California it is prohibit to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-2100 Series Thread-On spill containers models equipped with drain plug P/N 1DP-
2100.
Multi-Port Performance
Specifications:
This Spill Container drain valve has been manufactured and tested to the following California specifications: Leak Rate at 0.17 CFH @ 2.0 " W.C.
Torques Specification:
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ftlbs maximum.
4" Nipple, 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Drain Valve clamps, 5/16-18 UN thread, 11.5 ft-lbs minimum to 13.5 ft-lbs maximum.
Mounting Ring Stud, 5/16-18 UN thread, 15 ft-lbs minimum to 20 ft-lbs maximum.
Manhole Cover
Spill Container
Cover
Mounting
Ring
Spill Container
Ring
19
POMECO Multi-Port Spill Container Manhole
Installation Instructions
1. Mark off finish grade. (See Figure 1.)
Finish Grade
Figure 1
2. Set multi-port manhole assembly (skirt, ring, and cover) to the final grade position. (See
Figure 2.)
Figure 2
Finish Grade
L
Note: It is strongly recommended that POMECO covers be installed with the following minimum clearances. Sheet metal skirts should have adequate clearance between the tank sump riser sidewall and or the sump top hat. A minimum of one and a half inches clearance on all sides is recommended between the POMECO skirt and the tank sump wall or the sump top hat wall. A minimum of two inches clearance is recommended between the bottom of the
POMECO skirt and the horizontal surface of the tank sump or sump top hat. These clearances are recommended to allow adequate water migration away from the sumps. Great care should be used to maintain the recommended clearances when setting the rings and pouring the concrete. (See Figure 3.)
1½ Min
3. Remove the cover and measure the distance from the top of the tanks to the final grade.
4. Cut the riser(s) from the underground tank so that both the fill and vapor risers are set below the final grade. Use the dimensions below:
Spill Container Inches below grade (L)
5 Gal. Cast Iron Base
5 Gal. Composite Base
18½”
19 5/8”
7.5 Gal. Cast Iron Base
7.5 Gal. Composite Base
22 ½”
23 5/8”
Note: Add an extra 3-1/4” when using an OPW
FSA-400 & add an extra 1 ¾” when using the
FSA-400S Face Seal Adaptor. (See Figure 2.)
(Offset add extra 6”)
5. Deburr and thoroughly clean riser pipe(s).
6. Apply pipe dope to riser(s). The pipe dope is to be a non-hardening, gasoline resistant, pipe thread seal compound.
7. Install OPW FSA-400 Face Seal Adapter onto riser. (Recommend Torque, 4” NPT,
125 ft-lbs min. to 250 ft-lbs max.). Apply pipe dope to FSA-400. The pipe dope is to be a non-hardening, gasoline resistant, pipe thread seal compound. This is optional for spill containers that are on the vapor lines.
8. Thread on spill containers
9. Using the 61SA-TOOL, tighten the spill container(s) onto the riser(s) with a minimum torque of 125 ft.-lbs. and a maximum torque of 250 ft.-lbs.
Note: Do NOT attempt to completely tighten the containment bucket by using the containment bucket mounting ring at the top of the bucket.
10. Inspect the containment bucket O-Rings and
Mounting Ring O-Rings for damage.
Replace the gasket(s) if they are damaged.
11. Install Optional Multi-Port Water Shroud
(MPWS). See separate instructions.
12. Remove Spill Container Cover and Spill
Container Mounting ring from Manhole
Cover.
13. Replace the multi-port cover, centering the riser(s) as close as possible in the containment openings. Be very careful not to move or damage the O-Rings.
14. Remove lock washers and nuts from the studded mounting ring.
Studded
Mounting Ring
15. Place the mounting ring over the containment buckets and rotate the mounting ring until the studs are aligned with the bucket ring holes.
(See Figure 4.)
O-Ring Gasket distortion of the ring and improper fit of the ring to cover after the concrete is poured.
21. When pouring the concrete, hand shovel or trowel the concrete around the multi-port assembly to prevent the unit from moving or shifting, which can cause alignment problems and future maintenance problems.
Note: Do not stand on the multi-port before the concrete has set up.
22. It is recommended that the paved contours around POMECO covers be adequately sloped to direct water flow away from the cover, and directing water runoff from adjacent areas away from POMECO covers.
(See Figure 7.)
Figure 4
16. Thread nut and lock washer onto studded mounting ring. Tighten the mounting ring retaining bolts until the containment bucket o-rings makes contact with the multi-port cover. Then, in a crossing pattern, torque the bolts down between 15 to 20 ft.-lbs. 6
Point Ratcheting box wrench is recommended (See Figure 5.)
Nut and
Lock Washer
Figure 5
17. Install the spill bucket covers.
18. (Optional): Install the product identification disc on the spill bucket cover and multi-port cover in the I.D. disc recess.
19. Cover the multi-port perimeter ring and cover with plastic to prevent concrete from settling in the drainage areas.
20. It is required that the perimeter ring and skirt assembly, and the multi-port cover be set as an assembled unit, with the bolts engaged.
Failure to engage the bolts may result in the
Figure 7
23. Remove the plastic after the concrete has set up.
24. After installation is complete, water test the multi-port fixture. The recommended water test procedures include: e) Spraying water on cover(s) for 5 to 10 minutes, using a commonly available watering device such as a lawn sprinkler. f) Standing water test, not to exceed ½” in water depth for a period of 5 to 10 minutes.
Note: The containment bucket consists of three components cast iron ring, bellows, and bucket bottom. These parts are held together with stainless steel retaining bands.
DO NOT loosen the stainless steel retaining bands securing the bellows to the containment bucket top ring or the containment bucket bottom. Loosening the retaining bands voids any and all warranties on this product.
Warning:
If the cover is removed, for any reason, follow the Service and Maintenance instruction as noted. Always inspect and replace damaged orings and install new o-rings . Never reuse damaged o-rings as it may result in an improper
seal.
21
Operation and Maintenance:
Annually: Inspect and clean the interior of the spill container and drain valve screen. Remove accumulated dirt and grit. If the drain valve screen becomes clogged, remove the valve, soak in water and use high-pressure air to clean. Reinstall the drain valve to its proper position and test the valve per the appropriate TP201-1C Test Procedure. If problems persist, replace the drain valve with P/N
1DK-2100-EVR (specified torque 11.5 ft-lbs min to
13.5 ft-lbs max, 5/16-18 UN thread). The sealable cover (1SC) adjustment nut is set at the factory, but due to environmental conditions it may be necessary to adjust it to either improve sealing or ease cover removal.
Testing Spill Containers
Use TP201-1C or TP201-1D Test Procedures. Their
Test Procedures will check the seals between the drain valve, nipple and rotatable adapter. To test the spill containers base and bellows fill the container with water. A drop in the water level of
1/16” or greater after one hour means that a leak exists. To determine where the leak is, look for a steady stream of bubbles coming from one of the joints or water leaking on the outside of the bucket.
NOTE: Do not drain the water into the UST after the test is complete. Water must be disposed of per
I.D. Tag
local requirements for hazardous waste. If the leak cannot be corrected the spill container should be replaced with another.
POMECO recommends periodic inspection of covers and seals as a part of the regularly scheduled maintenance program. If any of the seals are damage they should be replace. Only qualified, competent, well-trained technicians should perform maintenance.
Note: Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
Important: Leave these instructions with Station
Operator as per CARB Requirements
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally
Manufacture: OPW
Model: 1-Series Spill Container
Size: 5, 7.5 or 15 Gal
Composite or Cast Iron Base
Date Manufactured: MM YY
MM = Month, YY = Year
22
634TT Cap
61SALP
Adaptor
61JSK-4400
Jack Screw
FSA-400
Face Seal
Adapter
Supplemental Instructions
Fibrelite Cover or
Manhole cover
Liquid Stop Ring
Platform
Bellow Stiffener
1-2100
Spill Container
Tank Sump
To Calculate Fill and Vapor Risers
Use Fibrelite Measurement Forms
Measurements For Fibrelite
FL36 Cover Normal Remote Burial
FL36 Cover Normal Direct Burial
FL90 Cover Normal Remote Burial
FL90 Cover Normal Direct Burial
23
Drain Valve / Fill Cap Assembly
Tie Clamp
After completing the installation of the Spill Container and Fibrelite Sump attach drain valve to
634TT Fill Cap.
Step1. Remove Black Nylon Tie Clamp from instruction bag.
Step 2. Remove the Drain Valve ring from the spill container.
Step 3. Place the Black Tie Clamp through the Ring on the end of the Drain Valve chain.
Attach Tie Clamp and chain to the 634TT Fill Cap between the black link arms and the gray cap.
Step 4. Cut excess Tie Clamp from the Cap / Drain Valve assembly.
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2007 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H15324PA – 1/07
24
“X”
Distance From
String Line
To Tank
“Y”
Distance From
String Line
To Tank
FILL RISER CALCULATION
6”
String Line
To Top of
Tank
1”
Clearance
For
Spill Container
19”
Length of
OPW
Spill Container
3.25”
Length of
OPW
FSA-400
“X” - 27.5”= Length of Threaded Riser for Fill Bucket
1.75”
Thread
Allowance
VAPOR RISER CALCULATION
6”
String Line
To Top of
Tank
1”
Clearance
For
Spill Container
19”
Length of
OPW
Spill Container
6.75”
Length of
OPW 233
Extractor Cross
1.75”
Thread
Allowance
“Y” - 31”= Length of Threaded Riser for Vapor Bucket
Length of
Threaded Riser for Fill Bucket
Length of
Threaded Riser for Vapor Bucket
25
26
“X”
Distance From
String Line
To Tank
“Y”
Distance From
String Line
To Tank
6”
String Line
To Top of
Tank
FILL RISER CALCULATION
1”
Clearance
For
Spill Container
19”
Length of
OPW
Spill Container
3.25”
Length of
OPW
FSA-400
1.75”
Thread
Allowance
“X” - 27.5”= Length of Threaded Riser for Fill Bucket
6”
String Line
To Top of
Tank
VAPOR RISER CALCULATION
1”
Clearance
For
Spill Container
19”
Length of
OPW
Spill Container
6.75”
Length of
OPW 233
Extractor Cross
1.75”
Thread
Allowance
“Y” - 31”= Length of Threaded Riser for Vapor Bucket
Length of
Threaded Riser for Fill Bucket
Length of
Threaded Riser for Vapor Bucket
Section 4
Retrofit & Upgrades
6521XAR Adaptor Ring
27
Step 1: Site Information
Company:
Station Address Line 1:
Station Address Line 2:
Station #:
Survey Date:
Step 2: Dimensional Information
REPLACEMENT MULTI-PORT COVER
FIELD SURVEY FORM
(E-STYLE)
P.O. #:
Distributor:
Distributor Location:
Distributor Nubmer:
Prepared By:
Date:
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Note:
Fill buckets come w/ drain valves
Vapor buckets come w/ drain plugs
Use Y for Waste Oil Applications
If "B" + "C" is less then 16, then old style buckets are required. "B" + "C" cannot be less then 14.
10/19/2007
I
II
A B C D E
Cover
Diameter
All dimensions should be in inches.
Dimension "A" is Required only if a gauge port is selected (Standard is 10.5").
This form assumes that the spill containers are in quadrants 3 & 4 respectively.
If the spill containers are in quadrants 1 or 2 then make the dimensions negative.
****FOR OPW USE ONLY****
Sales Order Number - Line Item:
28
Step 1: General Information
Company:
Station Address Line 1:
Station Address Line 2:
Station #:
Survey Date:
Step 2: Dimensional Information
REPLACEMENT MULTI-PORT COVER
FIELD SURVEY FORM
(G-STYLE)
P.O. #:
Distributor:
Distributor Location:
Distributor Nubmer:
Prepared By:
Date:
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Note:
Fill buckets come w/ drain valves
Vapor buckets come w/ drain plugs
Use Y for Waste Oil Applications
A
Cover
Diameter
If "A" is less then 16, then old style buckets are required. "A" cannot be less then 14.
All dimensions should be in inches.
This form assumes that if a gauge port is selected then it is concentric with the main cover.
This form assumes that all spill containers are equidistant ("A") from each other.
****FOR OPW USE ONLY****
Sales Order Number - Line Item:
Multi-Port Number:
29
10/19/2007
III
IV
I
II
Step 1: Site Information
Company:
Station Address Line 1:
Station Address Line 2:
Station #:
Survey Date:
Step 2: Dimensional Information
REPLACEMENT MULTI-PORT COVER
FIELD SURVEY FORM
(L-STYLE)
P.O. #:
Distributor:
Distributor Location:
Distributor Nubmer:
Prepared By:
Date:
Is this a Fill or Vapor Bucket?
(Enter: F for Fill / V for Vapor)
Note:
Fill buckets come w/ drain valves
Vapor buckets come w/ drain plugs
Use Y for Waste Oil Applications
10/19/2007
I
A B C
Cover
Diameter
All dimensions should be in inches.
Dimension "A" is Required only if a gauge port is selected (Standard is 10.5").
This form assumes that the spill container is in quadrant 3.
If the spill container is not in quadrant 3 then make the dimensions negative accordingly.
****FOR OPW USE ONLY****
Sales Order Number - Line Item:
30
Pomeco 521 RP Retrofit Series Fill End Manhole
Cover Installation Guide
• Align bolt holes in bucket top ring with holes in port ring.
• Install new 5/16” Thread Seal beveled flat washer on hex bolt with beveled side away from bolt head. Note: Apply grease to both sides of Thread Seal washer prior to installation on bolt.
• Install 5/16” Thread Seal Series 75 Washers between washer and containment port ring.
• Apply SL-1100 to each 5/16” bolt prior to installation in containment ring.
• Tighten containment bucket ring retaining bolts in a crossing pattern, until gasket makes contact. Then torque bolts evenly in a crossing pattern to 15 to 20 ft. lbs.
• Apply an even bead of SL-1100 sealant around 5/16” bolts after final tightening.
• Loosen Roto Lock bolts to backing jamb nut, allowing Roto Lock arm to extend below bottom lip of existing outer perimeter ring or casting.
• Initially tighten each perimeter Roto Lock until snug, alternating sides in a crossing pattern, then tighten all until firm. (Recommended Maximum Torque – 40 ft-lbs. to 50 ft-lbs.). Do not over tighten.
• Note: Check to make sure all Roto Locks engaged below outer ring
or casting. Note: If cover edges appear to be elevated from the seat and movement downward was not detected as Roto Locks are tightened, Roto Locks may not have engaged the perimeter ring. It may be necessary to attempt to re-engage the Roto Lock with the
perimeter ring.
• Install correct height pipe nipple or close nipple in containment bucket, using nonhardening pipe thread sealant.
• Measure the overfill for correct length. Refer to local regulations for proper length.
• Reinstall overfill valve or drop tube following manufacturer’s recommendations.
• Inspect and reinstall OPW fill and vapor caps.
• Caulk joint around perimeter of cover and perimeter ring and Roto Lock bolts with
SL-1100 sealant.
31
Pomeco 521 RP Retrofit Series
Product Installation Guide
(10/15/04)
Servicing Existing Pomeco 521/541 Series Fill End Manhole Covers
Removal of Existing Manhole Covers
• Block off and protect work area from traffic.
• Remove any accumulation of liquid from existing containment buckets and sumps.
Note: Follow customer’s prescribed hazardous waste disposal procedures.
• Remove all bolts holding existing buckets to manhole cover.
• Loosen Roto Locks, Cam Locks or remove perimeter manhole cover bolts.
• Remove existing manhole cover.
• Thoroughly clean cover seating area on existing perimeter ring, removing old gasket, dirt and all foreign materials.
• Remove existing fill and vapor adaptors.
• Remove overfill valves or drop tubes.
• Remove existing fill and vapor containment buckets from riser pipe.
• Inspect riser pipe for signs of damage or other irregularities.
• Check distance from top of riser to top of manhole cover. This dimension should be approcimately 17 ½”.
Note: Riser length may need to be adjusted to ensure proper clearance. It is recommended that this dimension is verified prior to installation and correct length risers be available if needed.
• Apply a non-hardening pipe dope to riser threads.
• Install new Pomeco 511 containment bucket onto riser by rotating until hand tight.
DO NOT attempt to completely tighten the containment bucket by using the mounting ring at the top of the bucket.
• Tighten containment bucket to riser with a pipe wrench on lower octagon shaped area of containment bucket bottom.
Note: Maximum torque applied to the containment bucket bottom at the riser and nipple should NOT exceed 250 ft-lbs.
Note: Drain valves need not be on the same side with all buckets, however, bolt holes in the top ring of the containment bucket must be parallel.
• Clean perimeter ring gasket seating surface with 50% water – 50% bleach mix.
• Apply a bead of SL-1100 sealant to underside and topside of perimeter “T” ring at seam, before installing gasket.
• Evenly apply bead of SL-1100 sealant to gasket seating surface of outer ring.
• Install gasket in bead of caulk on seat area of steel ring. Note: Butt gasket ends closely together. Adhesive may be applied to gasket ends to ensure seal.
• Place new Pomeco Retrofit manhole cover into position, aligning ports over containment buckets. Be VERY CAREFUL not to move or damage gasket.
32
POMECO Installation Instructions
Roto Lock 6521XAR Adaptor Ring
Notice: OPW/PISCES
TM
by OPW, Inc. products must be used in compliance with applicable federal, state, provincial, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. OPW/PISCES
TM
by OPW, Inc. makes no warranty of fitness for a particular use. All illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices, materials, and specifications are subject to change at any time and models may be discontinued at any time, in either case without notice or obligation. For complete OPW warranty information, visit our website at www.opw-fc.com.
OPW STANDARD PRODUCT WARRANTY OPW/PISCES
TM
by OPW, Inc. warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW/PISCES
TM
by OPW, Inc. (ECO Systems two years from date of manufacture. ECO replacement parts one year from the date of manufacture.) Proof of purchase may be required. For any product certified to California 2001 standards*,
OPW/PISCES
TM
by OPW, Inc. warrants that products sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation, not to exceed 15 months from date of manufacture by
OPW/PISCES
OPW/PISCES
TM
TM
by OPW, Inc. As the exclusive remedy under this limited warranty,
by OPW, Inc. will at its sole discretion, repair, replace or issue credit for future orders for any product that may prove defective within the one year date of manufacture period
(repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period; complete proper warranty claim documentation required).
OPW/PISCES
TM
by OPW, Inc. further guarantees that all PISCES
TM
primary pipe is free from defects in materials and workmanship for a period of ten (10) years from the date of manufacture. Any PISCES
TM
primary pipe proven to be defective in materials or workmanship within said 10-year period will, at PISCES
TM
option, be repaired or replaced or credit will be given for future orders. PISCES
TM
will bear the reasonable labor costs associated with the repair or replacement of non-conforming PISCES
TM
primary pipe when such pipe has been used exclusively in a complete PISCES
TM
Retractable System. Any defect will be corrected promptly upon written notification to PISCES
TM
by OPW, Inc. at P.O. Box 405003 Cincinnati,
Ohio, 45240, attention Rick Jones.
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any other than service representative authorized by OPW/PISCES
TM
by OPW, Inc. or when failure is due to misuse, improper installation or maintenance. OPW/PISCES
TM
by
OPW, Inc. shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean-up, downtime, removal, installation, loss of profit, or any other cost or charges. *Products certivied to the California 2001 standards will have an OPW registration card enclosed/attached to the
33
product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, AND SPECIFICALLY THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH
EXTEND.
34
Installation Instructions
Roto Lock 6521XAR Adaptor Ring
The 6521XAR adaptor ring is designed to replace an existing bolt down manhole with a
POMECO Roto Lock hold down style manhole cover. The manhole cover perimeter ring and skirt must have a minimum of ¼” horizontal lip, or flange around the inner perimeter of the mahole perimeter ring and skirt. When the needed lip is not available, it is necessary to install a POMECO adaptor ring to the inner surface of the skirt. See following instructions.
Note:
Recommended all sites conditions pertaining to the tank sump be carefully reviewed prior to commencing work. Best safety practices should always be followed.
Use correct adaptor ring for application:
Part Number Description
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Remove existing manhole cover.
Verify the sheet metal inner skirt is flush with inner edge of the perimeter ring.
Clean inner surface of excessive foreign material as dirt and scale.
Align the top oedge of the 6521-XAR ring with the perimeter ring-seating surface.
Expand or compress the adaptor ring until sealed against the skirt.
Make sure the edge of the adaptor ring is flush with the perimeter ring sealing surface.
Make sure adaptor ring is secured in place with anchor bolts through each ring tab.
Anchor bolts are NOT included. The size may vary based on application.
Step 6:
Step 7:
Step 8:
Make and drill holes for anchor bolts. When drilling and installing bolts, it is recommended to start at one end of the ring and progressively work around the ring.
Keep adaptor ring snug against the surface.
Clean perimeter ring seating surface
Replace manhole cover perimeter gasket with new POMECO serrated gasket.
Apply an even bead of PISCES SL-1100 Sealant to perimeter ring seating
Step 9:
surface between gasket and ring seat.
Install new POMECO manhole cover.
Step 10:
Engage Roto Locks under the adaptor ring.
Note: Roto Lock arm must engage under the perimeter ring. If the bolt head is not parallel with the manhole cover, the Roto Lock is not properly engaged. Loosen the Roto Lock bolts until it will not turn. Then, retighten the Roto Lock bolts. See technical bulletin for details.
35
Technical Bulletin
POMECO Rotolock Bolt Issues
1.) To determine if the rotolock bolt is sufficiently long to pull the cover tight start by turning all rotolock bolts counterclockwise until they stop. The locknut will bottom out at this point. See Figure 1.
Turn bolts counterclockwise
Bolt in question
Figure 1
2.) Turn the bolt clockwise until either the cover pulls tight or the bolt will no longer turn.
3.) If the cover pulls tight the bolt is good and the rest of the rotolocks can be tightened. If the cover moves when pried with a screwdriver or other means the rotolock bolt will need to be replaced.
4.) Contact POMECO for replacement rotolock bolts.
5.) When new bolts are received remove the cover and take the locknut off of the bolt.
6.) Remove the old bolt and install the new bolt with all items oriented properly. See Figure
2 for assembly procedure.
36
Figure 2
37
Section 5
Multi-Port Water Shroud
Testable Multi-Port Water Shroud
38
POMECO Installation and Maintenance Instructions
Multi-Port Water Shroud (MPWS)
IMPORTANT: Please read these warnings and
use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The POMECO Spill Container is preassembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required.
As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by
OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
Multi-Port Water Shroud Performance
Specifications:
The Multi-Port Water shroud (MPWS) is optional cover designed to mate with the OPW/POMECO
Multi-Port. The MPWS isolates surface water and condensation from Tank Sumps. The Fiberglass
Shroud Cover mates to a standard tank sump top hat reducer Not included. Shroud boots isolate the spill container buckets using stainless steel band clamps, providing a tight seal between the water shroud top hat and the underside of the spill container-mounting ring.
Available in 33” or 36” Covers.
MPWS-33/36 consist of:
(1) 33” or 36” fiberglass cover with Sight Glass
(2) D02575M Boots
(2) Stainless Steel Upper Clamps
39
(2) Stainless Steel Lower Clamps
Multi-Port Water Shroud
Installation Instructions
5. See POMECO Multi-Port Spill Container
Manhole instruction sheet MPIS-903. After completing Step 10.
Optional Steps 2-4 SLPK Sealant Kit Sealant
6. Apply a bead of urethane sealant (SL-1100) into the SLPK gasket.
7. Install the gasket onto the rim of the tank sump top hat.
8. Apply a bead of urethane sealant (SL-1100) on top of the SLPK gasket.
9. Place Fiberglass cover over the buckets and onto the top hat ring. Make sure the cover is seated against the gasket
10. Band Clamp the two Shroud Boots to the fiberglass Cover. Larger diameter end of the
Shroud boot and larger clamp are used to
Small Clamp
Shroud Boot the Fiberglass cover and Shroud Boots over the
Multi-Port Spill containers until the Fiberglass cover is resting on the Top Hat Tank Sump
(See Figure 2)
12. Band Clamp top of the Shroud Boot to the Spill
Container bucket Ring on the machined surface
(See Figure 2).
13. Inspect Shroud boots for damage.
14. Complete step 12 in the Multi-Port instruction
Sheet (H15225PA).
Upper Clamp
Large Clamp
Sump Inspection Port
FRP Cover clamp to the FRP Cover (See Figure 1)
Figure 1
11. Align inspection port over gauge port and slip
40
Shroud Boot
FRP Cover
Existing Top Hat
Lower Clamp
Tank Sump
Figure 2
P.O. Box 405003 * Cincinnati, Ohio 45240-
5003
1-800-422-2525 Domestically
513-870-3315 Internationally
Marketing Agent for POMECO by OPW,
Inc.
Copyright, 2002 - OPW Fueling
Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H15226PA –05/05
POMECO Installation and Maintenance Instructions
Testable
Multi-Port Water Shroud (MPWS-TS)
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The POMECO Spill Container is preassembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
Testable Multi-Port Water Shroud
Performance Specifications:
The Testable Multi-Port Water shroud (MPWS-TS) is designed to mate with the OPW/POMECO Multi-
Port. The MPWS-TS isolates surface water and condensation from Tank Sumps. The Fiberglass
Shroud Cover mates to a 33” Max O.D. by 31-1/2”
Min I.D. tank sump top hat reducer. Not included.
Shroud boots isolate the spill container buckets using stainless steel band clamps, providing a tight seal between the water shroud top hat and the underside of the spill container-mounting ring. A test port on the monitoring cap allows for intermittent vapor testing of the internal space of the tank sump.
Available in 33” Dia Cover.
MPWS-33TS consists of:
(1) 33” Diameter Fiberglass Cover with Entry Fitting
(2) D02868M Boot
(2) Stainless Steel Upper Clamp
(2) Stainless Steel Lower Clamp
(1) C05411M Seal
(1) 4” PVC Pipe
(1) Monitoring Cap with Test Port
(1) SL-1100 Sealant
41
Testable Multi-Port Water Shroud
Installation Instructions
1. See POMECO Multi-Port Spill Container
Manhole instruction sheet H15225PA. After completing Step 10.
2. Insert the PVC pipe and cap into the entry fitting installed into the cover to the desired height. Note: Ensure that there will be adequate clearance between the multiport cover and monitoring cap. Tighten the inside and outside entry fitting band clamps to 60 in-lbs. See Figure 1.
4. Install the seal onto the top hat. See Figure
3.
Figure 13
3. Apply approximately a ¼” bead of the supplied SL-1100 Sealant into the groove on the bottom of the C05411M seal. See Figure
2.
Figure 15
5. Connect the bottom of the shroud boots to the fiberglass cover using the large band clamps. Tighten the clamps to 60 in-lbs.
See Figure 4.
6. Apply approximately a ¼” bead of the supplied SL-1100 sealant to the top of the
C05411M Seal and lower the shroud cover assembly onto the seal and top hat. Make sure the monitoring cap location will line up with the multi-port cover gage port location.
See Figure 4.
Apply bead to top of seal
Apply bead of sealant in groove
Figure 14
42
Figure 16
7. Use the small band clamps to connect the top of the shroud boots to the machined diameter on the outside of the bucket ring.
Tighten the band clamps to 60 in-lbs. See
Figure 5.
Figure 18
Figure 17
8. Allow sealant to cure for several hours before vacuum testing.
9. Connect test equipment to the monitoring cap ¼” NPT test port. The VTA-200 and VG-
2000 or equivalent can be used for this testing.
10. Pull a vacuum of approximately 15” H
2
O on the sump and allow to stabilize.
11. Remove flow from sump and allow it to sit for 15 minutes. At this time record the initial vacuum level. Note: This reading should be at least 10” H
2
O.
12. Allow the sump to sit for an additional 30 minutes and record the final vacuum level.
13. Sump passes if the final vacuum reading does not drop more than 5” H
2
O below the initial vacuum level.
14. If sump is not tight after testing look for and repair any leaks then repeat steps 9 thru 13.
15. Complete step 12 in the Multi-Port instruction
Sheet (H15225PA). See Figure 6 for final
assembly.
P.O. Box 405003 * Cincinnati, Ohio 45240-
5003
1-800-422-2525 Domestically
513-870-3315 Internationally
Marketing Agent for POMECO by OPW,
Inc.
Copyright, 2002 - OPW Fueling
Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H15912PA –06/05
43
Section 6
POMECO Multi-Port Maintenance
44
Pomeco 500 Series
Product Service & Maintenance Guide
(Revised 11/08/04)
Servicing Existing Pomeco 500 Series Fill End Manhole Covers
Removal of Existing Manhole Covers
• Block off and protect work area from traffic.
• Remove any accumulation of liquid from existing containment buckets.
Note: Follow customer’s prescribed hazardous waste disposal procedures
• Remove all bolts holding existing buckets to manhole cover.
• Loosen Roto Locks. Rotate hex head bolts counter clockwise until Roto Lock moves freely or until hex bolt rotation is stopped by jamb nut.
• Remove Pomeco cover from sump.
• Remove Roto Locks from cover, by first removing the jamb nuts.
• Inspect Roto Locks for wear or damage. Replace any parts that may show wear or material fatigue.
• Thoroughly clean cover seating area on perimeter ring and underside of cover, removing old gasket, dirt, and all foreign material.
• Remove ALL inspection port rings and containment bucket port rings.
• Thoroughly clean containment bucket seating area on underside of cover, removing old gasket, dirt and all foreign material.
• Clean and lubricate Roto Lock Bolts.
• Install new ½” Thread Seal beveled flat washer on Roto Lock hex bolt with beveled side away from bolt head.
• Install ½” Thread Seal Series 75 washers (by Parker) between washer and cover.
Note: Apply marine grade grease to both sides of Thread Seal washer prior to installation on bolt.
• Insert Roto Lock bolt in Roto Lock bolt hole and install new bonded neoprene washer on underside of cover, between underside of cover and tension spring.
• Install Roto Lock on Roto Lock Bolt.
• Install Roto Lock stop nuts. Carefully measure and install stop nut at a height to allow Roto
Lock clearance to be rotated away from underside of seat ring lip and not so far that Roto
Locks will rotate past stop bar on underside of cover.
• Clean perimeter ring area with 90% water, 10% bleach solution.
• Apply a bead of SL1100 sealant to underside and topside of perimeter “T” ring at seam, before installing gasket.
• Evenly apply SL1100 sealant to the full width of outer ring seat surface.
• Install gasket onto seat area of steel ring. Note: Butt gasket ends closely together. (Note:
When cutting gasket, allow enough for gasket ends to overlap ¼”, then move excess
45
gasket around ring to allow the gasket ends to butt together. Use caution to avoid a gap between gasket ends.) Adhesive may be applied to gasket ends to insure seal.
• Install new 5/16” Thread Seal beveled flat washer on hex bolt with beveled side away from bolt head.
• Install 5/16” Thread Seal Series 75 washers (by Parker) between washer and containment port ring. Note: Apply grease to both side of Thread Seal washer prior to installation on bolt. Reinstall Roto Locks.
• Apply an even bead of SL1100 sealant around 5/16” bolts after final tightening.
• An even bead of SL1100 sealant may be applied to the topside of the gasket prior to reinstalling the cover on the steel ring seat.
• Replace manhole cover into position, aligning ports over containment buckets. Note: Use
caution to avoid moving or damaging new seal.
• Align bolt holes in bucket top ring with holes in the iron port ring and start bolts.
• Apply SL1100 to each 5/16” bolt prior to installation in containment ring.
• Apply anti-seize to bolt threads before installation.
• Apply liberal bead of PISCES SL1100 sealant to ring seat area.
• Reinstall ring on seat.
• Tighten containment bucket ring retaining bolts in a crossing pattern, until gasket makes contact. Then torque bolts evenly in a crossing pattern to 15 to 20 ft. lbs.
• Loosen Roto Lock bolts to backing jamb nut, allowing Roto Lock arm to extend below bottom lip of existing outer perimeter ring or casting.
• Initially tighten each perimeter Roto Lock until snug, alternating sides in a crossing pattern, then tighten all until firm. (Recommended maximum torque- 40 ft. lbs. To 50 ft. lbs.). Do not over tighten.
• NOTE: Check to make sure all Roto Locks are engaged below outer ring or casting.
Note: If cover edges appear to be elevated from the seat and movement downward was not detected as Roto Locks are tightened, Roto Locks may not have engaged the perimeter ring. It may be necessary to attempt to reengage the Roto Lock with
the perimeter ring.
• Inspect OPW 61SA swivel adapter and OPW 61VSA swivel vapor adaptor.
• Inspect OPW fill and vapor caps.
• Caulk joint around perimeter of cover and perimeter ring and Roto Lock bolts with SL1100 sealant.
• Water test cover after assembly is complete. Recommended water test procedures include: 1) Spraying water on cover or covers for 5 to 10 minutes, using a commonly available watering device such as a lawn sprinkler. 2) Standing water test, not to exceed
½” in water depth for a period of 5 to 10 minutes.
• Touch up paint damaged in cleaning process.
Warning:
When cover is removed for any reason, follow cleaning and installation instructions as noted above. Always remove existing gasket and install new gasket.
OPW does recommend periodic inspection of covers and seals as a part of the regularly scheduled maintenance program. Inspection should be performed whenever prudent periodic
46
inspection of other components in the fill and vapor recovery sumps is conducted.
Regularly scheduled inspection and maintenance programs should be a part of any service station or fueling facility operation. Only qualified, competent, well-trained technicians should perform maintenance.
Note: Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
47
Section 7
1DK-2100 Drain Valve Replacement
48
OPW Installation and
Maintenance
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: Check to make sure the unit is intact and undamaged and all parts have been supplied.
Never substitute parts for those supplied. Doing so may cause product failure and void warranty.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
The OPW 1DK is an optional drain valve replacement kit for the OPW 1 Spill containers series. It is designed to return incidental spillage of liquid back to the underground storage tank.
HOW TO INSTALL
1. Remove and discard existing drain valve and Oring.
2. Clean any dirt or debris from the sealing surface where the new drain valve will be installed.
3. Apply any common grease or light oil to the new supplied O-ring. Assemble the O-ring into the spill container base.
4. Insert the 1DK into the spill container O-ring. Be sure that the drain valve seats flush with the floor of the spill container base.
5. The pull lever of the 1DK MUST be positioned halfway between the riser pipe nipple and the spill container bellows. Rotate the drain valve until that position is attained.
6. Secure the 1DK by installing the provided retaining clips and nuts. Tighten the nuts to a torque of 11.5 ft-lbs min. to 13.5 ft-lbs max.
7. The drain valve is now installed and ready for testing.
Instructions
OPW 1DK-2100 EVR Replacement Drain
Valve
HOW TO TEST
Upon preliminary installation perform the California
Test Procedures TP-201.1C or equivalent. Their
Test Procedures will check the seals between the drain valve, nipple and rotatable adapter. To test the spill containers base and bellows fill the container with water. A drop in the water level of
1/16” or more after one hour means that a leak exists. To determine where the leak is, look for a steady stream of bubbles coming from one of the joints. NOTE: Do not drain the water into the UST after the test is complete. Water must be disposed of per local requirements for hazardous waste.
If a leak is observed in the Test Procedure, check to see that the drain valve poppet is sealing properly.
To do this, lift up the drain valve pull chain several times to actuate the poppet. This will ensure that the drain valve poppet is seating properly. If this doesn’t correct the leak remove the 1DK valve and inspect the O-ring for nicks or tears, replace if needed, also clean the sealing surfaces of the spill container base that the 1DK valve and O-ring are installed into. Reinstall 1DK valve and repeat test.
If spill container passes the Test Procedure but does not hold water then there is a leak in the bucket and will need to be replaced.
Alternative Construction
Screen Material:
Polypropylene / Stainless Steel or
Stainless Steel / Stainless Steel
Screen
O-Ring
49
1DK-2100 EVR Replacement Drain Valve Performance Specifications:
This Spill Container drain valve has been manufactured and tested to the following California specifications: Leak
Rate to be less than or equal to 0.17 CFH @ 2.0 " W.C.
Operation and Maintenance:
To open, pull drain valve chain up and hold open until liquid is drained. To close, release chain.
Annually: Inspect and clean the interior of the spill container and drain valve screen. Remove accumulated dirt and grit. Test the drain valve using CARB procedure TP-201.1C or TP-201.1D. If the drain valve passes testing no further maintenances required. If the drain valve fail testing, remove the valve, soak in water and use highpressure air, if needed, to clean. Reinstall the drain valve to its proper position and test the valve with CARB procedure TP-201.1C or TP-201.1D.
Important: Leave these instructions with Station Operator.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. OPW makes no warranty of fitness for a particular use. All illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND SPECIFICALLY
THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THERE ARE
NO WARRANTIES, WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF.
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2003– OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H11471PA – 9/03
50
Section 8
61SO-EVR Overfill Protection Valve
51
H14790PA
May 2007
OPW Installation & Ma intenance
Instruc tions
A SSEMBLY, INSTALLATION, and
M AINTENANCE INSTRUCTIONS FOR OPW
61SO VAPOR TIGHT, OVERFILL
PREVENTION VALVES.
IMPORTANT: Please read these assembly and installation instructions completely and c arefully before starting.
Vapor Tight Overfill Prevention Valves
52
GENERAL INSTRUCTIONS
The OPW 61SO Overfill Prevention Valve is designed for tight fill, gravity drop applications to help prevent accidental or intentional overfilling of underground storage tanks. It is installed in the UST drop tube in place of a standard drop tube.
The main 61SO valve closes when liquid level is at
95% of the top of the tank. A small bypass valve remains open to allow the delivery hose to drain at
3-5 gallons per minute. If the delivery truck valve is not closed after initial shut-off, the bypass valve will close and will restrict all fuel delivery.
The 61SO EVR approved models of the 61SO are designed to be installed with the following OPW products: Face Seal Adapter, Spill Container or
Multi-port, Jack Screw Kit, Rotatable Product
Adaptor, and Product Cap.
IMPORTANT
Read these assembly and installation instructions completely and carefully prior to starting. Check to make sure all parts have been provided. Use only the parts supplied; substitution of parts may cause product failure.
Failure to follow instructions may cause improper product operation or premature failure which may permit storage tank overfill. An overfilled storage tank may create hazardous conditions and/or environmental contamination.
CAUTION
Do not remove elastic band from around float until instructed to do so, as damage to valve may result.
WARNING
Failure to properly connect delivery hose and elbow, and/or disconnecting a liquid filled delivery hose or elbow will result in a hazardous spill, which may result in personal injury, property damage, fire, explosion, and water and soil pollution.
* Make sure all connections, including the hose and elbow connections, between storage tank and transport are securely coupled.
* Make sure the lip seal and/or all gaskets in the delivery elbow are properly in place to prevent spills.
* Do not operate with damaged or missing parts, which prevent tight connections.
Normal Operation: A Hose ”Kick” and reduced flow signal that the tank is full. Close transport delivery valve and drain hose into tank before disconnecting any hose fitting.
Overfilled Tank: Failure of the hose to drain after closing the delivery valve signals an overfilled tank.
Do Not Disconnect any delivery hose fitting until the liquid level in the tank has been lowered to allow the hose to drain into the tank. Attention: In the event you are splashed, remove all wetted clothing immediately. Do not go into an enclosed area and stay away from ignition sources.
IMPORTANT
Determine if the underground storage tank is equipped with a ball float vent valve, as illustrated in Figure 16. In all systems, the shutoff point of the 61SO must be reached before the ball float reduces flow to ensure proper overfill valve operation.
TOOLS NEEDED FOR INSTALLATION AND
ASSEMBLY:
1. Drill
2. A sharp 1/8" pilot drill bit
3. A sharp 5/16" drill bit
5. Hacksaw or cut-off saw, fine tooth; 24 teeth/inch
6. Fine half round file
7. Screwdriver - Phillips blade
8. ½" Wrench or socket
9. Two-part sealant (Supplied)
10. Torque Wrench
WARNING
Using electrically operated equipment near gasoline or gasoline vapors may result in fire or explosion, causing personal injury and property damage.
Check to assure the working area is free from such hazards, and always use proper precautions.
IMPORTANT: The figures in this installation and maintenance instruction may contain vapor recovery equipment (including model numbers) that is not certified by the California Air Resources Board
(CARB) for a specific Phase I Vapor Recovery
System. Please refer to Exhibit 1 of the appropriate
CARB Phase I Executive Order for a list of certified
Phase I Vapor Recovery System Equipment.
53
HOW TO LOCATE THE POSITION OF THE 61SO
AT 95% TANK CAPACITY
The length of the upper tube and the placement of the 61SO valve body determine the shut-off point.
Following the standard instructions for the OPW
61SO will provide for initial shutoff at 95%. In all cases, the upper tube length must be a minimum of
6-1/2" plus the length of the riser pipe. All length measurements are in inches.
INSTRUCTIONS
1.) Find tank capacity (in gallons) from tank calibration chart provided by tank manufacturer.
2.) Calculate 95% of capacity.
3.) Locate the 95% volume number on the tank calibration chart.
4.) Find the dipstick number (X) which corresponds to the 95% tank volume. And, find the dipstick number (Y) which corresponds to the
100%volume.
5.) Subtract the dipstick number (X) from the tank diameter (Y) to find the upper tube reference number (Z).
(Y) - (X) = (Z)
6.) Subtract 2" from (Z) to find the upper tube depth
(C).
(Z) - 2" = C
7.) Is C less than 6-1/2"?
NO Upper tube length is C plus the distance from the top of the FSA-400 Face Seal
Adaptor installed on the riser pipe to the inside, top lip of the storage (A).
Upper Tube Length = C + (A)
YES Upper tube length is 6-1/2" plus the riser pipe measurement (A).
Upper Tube Length = 6-1/2" + (A)
NOTE: You must find the actual tank capacity number that correlates to the 6-1/2” + (A) depth for the station records. This number may also be used for the purposes of calibrating an electronic tank level system.
® Registered T.M. - Owens Corning Fiberglass
Corporation
Measuring Stick
Riser Pipe with Face
Seal Adaptor
(A)
To Tank
Top (I.D.)
(B)
To Tank
Bottom
6-1/2”
EXAMPLE
1.) For an Owens-Corning Model G-3 Fiberglass®
Tank Calibration Chart:
Tank Capacity - 10,000 gal., nominal 9,403 gal.
NOTE: Use actual capacity only
2.) 95% of actual tank capacity = 0.95 x
9403 gal. = 8933 gal.
3.) The closest number which is less than 8933 gal.
Is 8910 gal. Choosing the closest number less than 95% of actual capacity ensures that the initial shutoff will occur when the tank is no more than 95% full.
4.) The calibration chart reading of 8910 gal. corresponds to a dipstick measurement of 82".
5.) Dipstick number (X) = 82"
Tank diameter (Y) = 92"
(Y) - (X) = (Z) (92 "- 82" = 10")
6.) (Z) - 2" = C
C = 8"
7.) Is 8" less than 6-1/2"?
(10" - 2" = 8")
NO Measure the distance from the top of the
Face Seal Adaptor installed on the riser pipe to the inside, top lip of the storage tank and obtain measurement (A).
Upper tube length = C + (A)
54
ASSEMBLY INSTRUCTIONS
IMPORTANT: Each of the numbered steps in the installation instructions are designed as a CHECK
LIST to insure proper installation and trouble free operation of the OPW 61SO Overfill Prevention
Valve.
Read and follow these steps carefully, checking them off as you proceed.
Figure numbers correspond to step numbers for easy reference.
STEP 1: MEASURE
Install the OPW Face Seal Adaptor and the Threadon Spill Container on the Fill Riser (Refer to the
Installation Instructions Supplied with the Spill
Container). Insert the 61SO measuring stick through the riser pipe and hook it under the inside of the tank in the lengthwise direction. Mark the measuring stick at the top of the Face Seal Adaptor threads inside the base of the spill container bucket just below the drain valve outlet window (See Figure
1 &1A). The top flange on the 61SO will rest on the
Face Seal Adaptor just below the drain valve outlet, and be locked in place between the Face Seal
Adaptor and the 4" nipple that is installed in the spill container with the Jack Screw Kit (See Figure 1A).
(For riser pipe configurations other than that shown, consult installation drawings or use other necessary means to measure Dimension “A”).
Using a tape measure, measure the distance from the top of the Face Seal Adaptor in the spill container to the bottom of the tank (Dim. “B”).
IMPORTANT: Inspect the riser pipe for any foreign material. Over spray from tank relining or any internal burrs inside of pipe must be removed prior to installation. Failure to have an unobstructed riser pipe may prevent proper installation and operation of the valve. The 61SO is designed to be installed into schedule 40 riser pipes. The 61SO cannot be installed into schedule 80 riser pipes.
STEP 2: MARK THE TUBE
Use the result from STEP 1 and HOW TO LOCATE
THE POSITION OF THE 61SO AT 95% TANK
CAPACITY to mark the upper tube. Measure the distance from the point where the upper tube and valve body meets. For “C” measurements lass than or equal to 6-1/2” see Figure 2. For “C” measurements greater than 6-1/2” use tape measure to mark the calculated upper tube length onto the upper tube.
Riser Pipe with Face
Seal Adaptor
Figure 1
4” Nipple
Measuring Stick
(A)
To Tank
Top (I.D.)
(B)
To Tank
Bottom
6-1/2”
Mark Measuring stick here for
Jack Screw installation
(Top of Face Seal)
Figure 1A
M easuring
S tick
61SO
Spill Container
Jack Screw
O-Ring Seal
Face Seal
Adaptor
Transfer M ark
From S tick to
U pper Tube
(C ut Line)
S eam
Figure 2 (For “C” less than or equal to 6-1/2 “ only)
55
STEP 3: CUT THE UPPER DROP TUBE
Carefully saw through the tube squarely, at the mark made in Step 2. Use a hacksaw with a new finetooth blade. Rotating the upper tube as the sawing progresses will minimize run out and ensure a square 90-degree cut. A piece of paper, taped square with the tube or a hose clamp can be used as guides for making a square cut.
CAUTION -DO NOT use a pipe or tubing cutter to cut the upper drop tube, this may damage the tube, causing it to be out of round thereby prohibiting assembly of the unit. coverage is completely around the tube as shown in
Fig. 5.
STEP 6: INSTALL INLET
TUBE
Install o-ring in the o-ring groove of inlet tube (DO
NOT USE GREASE).
Insert the inlet tube into the upper tube until it seats against the flange on the upper inlet tube.
Install O-Ring
In Groove
STEP 7: DRILL HOLES
Figure 6
With the inlet tube in place, carefully drill
(3) 1/8" diameter pilot holes through the drop tube and inlet tube at three locations at 120 degree intervals around the tube, 1 inch below the flange.
Using the pilot holes, drill (3) 5/16" dia. holes through the tubes. Remove the burrs from the drilling operation from the inside of the drop tube assembly with a fine half round file.
IMPORTANT: A 5/16" drill bit must be used. Do not substitute any other size drill bit.
Cut Line
Figure 3
STEP 4: FILE THE DROP TUBE
File the upper tube square and remove any burrs or rough edges. Make sure the cut is flat and square.
IMPORTANT: Carefully file a
good chamfer on the inside of the drop tube to provide a lead-in for the o-ring and inlet tube to be installed in step 6.
Caution: Failure to properly
Figure 4 apply and cure sealant may result in a failure of a pressure decay leak test.
STEP 5: APPLY SEALANT
Prepare sealant by thoroughly mixing 1/3 of each packet together until color is uniform.
Generously apply sealant to the inside diameter of the upper drop tube. Make sure
Figure 5
1”
Figure 7
STEP 8: ASSEMBLE
AND SEAL CLINCH
STUDS
Loosely assemble the three (3) clinch studs, lock washers, and nuts in holes. Do not tighten at this time. Mix up a small amount of sealant. Generously apply sealant underneath each clinch stud head, each nut, and on the outside of the tube around the holes.
Figure 8
Apply Sealant
56
STEP 9: TIGHTEN SELF-CLINCHING STUDS
Tighten clinch studs securely with a ½" wrench. Use only the self-clinching studs that are supplied with the unit. Seating torque is 11.5 ft-lbs min. to 13.5 ftlbs max. Do not over tighten.
Note: Failure to properly apply and cure the
sealant may result in a failure of a pressure
decay leak test.
STEP 10: LOWER TUBE ASSEMBLY
If a vise is used, clamp on the valve body casting only to avoid damage to the float. Mix the remaining sealant until the color is uniform. Using the mixing stick, generously apply sealant to the first 6 male
threads on the valve body as shown in figure 10.
Make sure coverage is completely around the threads, and work the sealant down into the thread profile. Quickly thread the lower tube onto the valve body. Tighten the tube securely by hand or with a strap wrench. Remove excess sealant and smooth sealant bead with water moistened mixing stick.
Important: Allow sealant (epoxy) to cure for 24 hours before installing into tank.
Apply Sealant completely around first 6 threads.
Figure 10
Note: Before installing the valve in the tank, a pressure test can be performed on the valve to check for vapor tightness. Seal off both ends of the tube with inflatable plumber’s plugs. Apply a maximum 10" W.C. (1/3 PSI) air pressure. If pressure does not hold and a leak can be located with soap solution, do not install the valve. Send the valve back to OPW for warranty evaluation.
Caution: Do not over-pressure. Excess pressure can damage the valve
STEP 11: CUT LOWER TUBE AT 45
° ANGLE
Measuring from the underside of the inlet tube flange, mark the overall length of the drop tube a distance of (B) minus 6" or as per local codes or requirements. Determine dimension (B) from the measurements taken in Step 1, Figure 1 (Top of the
Face Seal Adaptor below the drain valve outlet in the spill container to the bottom of the tank). Saw off the excess tube at a 45-degree angle and file off any sharp burrs (Refer to Figure 16). Optional: Install the OPW Tank Bottom Protector on the lower tube
(Refer to Installation instructions supplied with the
Tank Bottom Protector).
STEP 12: PREPARE FILL RISER FOR VALVE
INSERTION
IMPORTANT: Inspect the riser pipe for any foreign material. Over spray from tank relining or any internal burrs inside of pipe must be removed prior to installation. Failure to have an unobstructed riser pipe may prevent proper installation or operation of the valve. Thoroughly clean top of riser pipe.
Important: Before installing the valve, allow sealant to cure for 24 hours.
STEP 13: REMOVE ELASTIC BAND
Remove the elastic band securing the float to the valve body. The float will move into an outward position.
STEP 14: INSERT DROP
TUBE
Make sure the O-Ring gasket is under the flange of the inlet tube. Hold the float down against the valve body and slowly insert the drop tube overfill valve into the riser pipe.
Do not force valve into the riser pipe. If any obstruction or foreign matter interferes with smooth insertion of the valve, the riser pipe must be cleared.
WARNING
Failure to follow the assembly and installation instructions or use of excessive force to insert the OPW 61SO will
VOID THE WARRANTY!
Difficulty in removing the existing fill tube (if there is one)
Figure 14
means there may be an obstruction in the riser pipe. Look for burrs, deformations, excess tank lining material or other projections that may interfere with easy insertion of the OPW 61SO. The 61SO is designed for insertion into schedule 40 pipe. If schedule 80 pipe has been
57
used for the riser, the 61SO can not be installed. If seamed pipe has been used, the internal weld bead may interfere with the OPW 61SO and prevent installation. If the OPW 61SO won’t slip in easily
DON’T FORCE IT! Damage to the valve may result if excess force is used. Examine the riser pipe carefully; determine the nature of the obstruction; take appropriate steps to remove it.
STEP 15: CHECK
INSTALLATION
Insert the drop tube all the way into the tank until the flange and gasket seat onto the top of the Face
Seal Adaptor. The float will swing out into the operating position as it passes into the tank.
Make sure that the float is aligned along the length of the tank. The length of the tank can easily be determined by locating other manholes or pump boxes that are installed around other tank fittings.
Look into the drop tube and align the deflector with the length of the tank. CAUTION: No obstruction in the tank
Figure 15
can be within 13" from the center of the riser pipe or the valve may not operate properly.
STEP 16: ALIGN VALVE
Install the OPW Jack Screw Kit and a 4" nipple to lock the valve in place. Refer to the Installation
Instructions supplied with the Jack Screw Kit. Install the Rotatable Product Adaptor (Refer to Installation
Instructions supplied with the Rotatable Product
Adaptor.) Make sure that the valve does not rotate while tightening the adaptor by observing the position of the deflector. The valve must remain
aligned along the length of the tank as in Step
15. Repeat this step as necessary to assure proper valve alignment.
Vapor Recovery
Riser
Fill Riser
Figure 16
OPW
Ball Float
6” Max.
Tube Cut per Local
Requirements
13” Minimum
Clearance for
Float
6”
Align Float Along Length of Tank
Rotatable
Product
Adapter
Spill Container
Jack Screw
Kit
61SO
Drop Tube
Face Seal
Adapter
Figure 16A
STEP 17: INSTALL WARNING
PLATE
Slide the tie wrap over the warning plate ears and position warning plate against riser pipe approximately 1" below the adaptor. Tighten the tie wrap securely. The valve is now fully installed and in operating position.
STEP 18: VALVE REMOVAL
The valve can be removed for
Figure 17
tank leak testing, inspection, etc., by removing the Rotatable Product Adaptor, the
4" nipple, and the Jack Screw Kit. Reinstall per the above instructions.
58
STEP 19: ELECTRONIC LIQUID LEVEL
MONITORING
If an electronic level monitor is installed, it must be calibrated to match the top of the 61SO valve body, which must correlate with 95% of the actual tank capacity.
PREVENTATIVE MAINTENANCE
Annually, inspect the flapper in the 61SO to see that it is open by looking down the drop tube opening.
Test the 61SO drop tube seals with CARB procedure TP-201.1D. If the drop tube seal passes testing, no further maintenance is required. If the drop tube fails testing, replace the drop tube seal with OPW P/N: H11931M for 4” Tubes. Re-test the
61SO drop tube with CARB procedure TP-201.1D.
If this does not correct the leak the 61SO needs to be replaced.
CAUTION: Do not insert any foreign object into drop tube if flapper is in the closed position. For example a tank level measuring stick. This will damage the valve and void the Warranty.
ALWAYS check flapper location before
“sticking” the tank. If flapper is in the closed position the tank is either over filled and you need to wait until the liquid level goes down or the 61SO is damaged and needs to be replaced.
61SO Performance Specifications:
This Overfill Prevention Valve has been manufactured and tested to, and met, the following
California specifications. Performance Requirement:
Leak rate to be less than or equal to 0.17 CFH @
2.0" W.C.
Torque Specification:
Self-Clinching Studs, 5/16-8 UN thread, 11.5 ft-lbs minimum to 13.5 ft-lbs maximum.
Important: Leave these installation instructions and maintenance procedures with the station operator.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND SPECIFICALLY
THE WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE DESCRIPTION
ON THE FACE HEREOF.
Manufacture: “OPW”
Model: 61SO – 4”
(4” Represents Size)
Manufacture Date:
“MFG MM YY”
MM=Month YY=Year
Product Identification
P.O. Box 405003 * Cincinnati, Ohio 45240-5002
1-800-422-2525 Domestically, 513-870-3315 Internationally www.opw-fc.com
Copyright, 2007 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H14790PA Rev. B- 5/07
59
60
Section 9
71SO-EVR Overfill Protection Valve
H15524PA
OPW Installation & Maintenance
Instructions
ASSEMBLY, INSTALLATION, and
MAINTENANCE INSTRUCTIONS FOR
OPW 71SO VAPOR TIGHT, OVERFILL
PREVENTION VALVES.
IMPORTANT: Please read these assembly and installation instructions completely and carefully before starting.
Vapor Tight Overfill Prevention Valves
61
GENERAL INSTRUCTIONS
The OPW 71SO Overfill Prevention Valve is designed for tight fill, gravity drop applications to help prevent accidental or intentional overfilling of underground storage tanks. It is installed in the UST drop tube in place of a standard drop tube.
The main 71SO valve closes when liquid level is at
95% of the top of the tank. A small bypass valve remains open to allow the delivery hose to drain at
3-5 gallons per minute. If the delivery truck valve is not closed after initial shut-off, the bypass valve will close and will restrict all fuel delivery.
The 71SO models of the 71SO are designed to be installed with the following OPW products: Face Seal
Adaptor, OPW Spill Container or Multi-port, Jack
Screw Kit, Rotatable Product Adaptor, and Product
Cap.
IMPORTANT
Read these assembly and installation instructions completely and carefully prior to starting. Check to make sure all parts have been provided. Use only the parts supplied; substitution of parts may cause product failure.
Failure to follow instructions may cause improper product operation or premature failure which may permit storage tank overfill. An overfilled storage tank may create hazardous conditions and/or environmental contamination.
CAUTION
Do not remove elastic band from around float until instructed to do so, as damage to valve may result.
WARNING
Failure to properly connect delivery hose and elbow, and/or disconnecting a liquid filled delivery hose or elbow will result in a hazardous spill, which may result in personal injury, property damage, fire, explosion, and water and soil pollution.
* Make sure all connections, including the hose and elbow connections, between storage tank and transport are securely coupled.
* Make sure the lip seal and/or all gaskets in the delivery elbow are properly in place to prevent spills.
* Do not operate with damaged or missing parts, which prevent tight connections.
Normal Operation: A Hose ”Kick” and reduced flow signal that the tank is full. Close transport delivery valve and drain hose into tank before disconnecting any hose fitting.
62
Overfilled Tank: Failure of the hose to drain after closing the delivery valve signals an overfilled tank.
Do Not Disconnect any delivery hose fitting until the liquid level in the tank has been lowered to allow the hose to drain into the tank.
WARNING
In the event you are splashed with fuel remove wet clothing immediately. Skin contact with gasoline can cause chemical burns and may result in inhalation of vapors that may be fatal. Never go inside confined areas after being splashed and never go near ignition sources.
IMPORTANT
Determine if the underground storage tank is equipped with a ball float vent valve, as illustrated in Figure 24. In all systems, the shutoff point of the 71SO must be reached before the ball float reduces flow to ensure proper overfill valve operation.
TOOLS NEEDED FOR INSTALLATION AND
ASSEMBLY:
1. 71SO-TOOL or 71SO-TOOLC (includes the following) a. Sharp 3/16” drill bit with stop b. Punch
2. Drill
3. Hammer
5. Hacksaw or cut-off saw, fine tooth; 24 teeth/inch
6. Fine half round file
7. Screwdriver - Phillips blade
8. Fine grit sandpaper / steel wool
9. Grease, black moly
11. Band clamp (3-3/4” diameter minimum)
WARNING
Using electrically operated equipment near gasoline or gasoline vapors may result in fire or explosion, causing personal injury and property damage.
Check to assure the working area is free from such hazards, and always use proper precautions.
IMPORTANT: The figures in this installation and maintenance instruction may contain vapor recovery equipment (including model numbers) that is not certified by the California Air Resources Board
(CARB) for a specific Phase I Vapor Recovery
System. Please refer to Exhibit 1 of the appropriate
CARB Phase I Executive Order for a list of certified
Phase I Vapor Recovery System Equipment.
71SO Parts Diagram
Upper O-Ring Gasket
Screws, Qty. 3
Inlet Tube
Polypak Seal
Upper Drop Tube
Valve Body
Float
Lower O-Ring
Lower Tube
63
HOW TO LOCATE THE POSITION OF THE
71SO AT 95% TANK CAPACITY
The length of the upper tube and the placement of the 71SO valve body determine the shut-off point.
Following the standard instructions for the OPW
71SO will provide for initial shutoff at 95%. In all cases, the upper tube length must be a minimum of
6-1/2" plus the length of the riser pipe. All length measurements are in inches.
INSTRUCTIONS
1.) Find tank capacity (in gallons) from tank calibration chart provided by tank manufacturer.
2.) Calculate 95% of capacity.
3.) Locate the 95% volume number on the tank calibration chart.
4.) Find the dipstick number (X) which corresponds to the 95% tank volume. And, find the dipstick number (Y) which corresponds to the
100%volume.
5.) Subtract the dipstick number (X) from the tank diameter (Y) to find the upper tube reference number (Z).
(Y) - (X) = (Z)
6.) Subtract 2" from (Z) to find the upper tube depth
(C).
(Z) - 2" = C
7.) Is C less than 6-1/2"?
NO Upper tube length is C plus the distance from the top of the Face Seal Adaptor installed on the riser pipe to the inside, top lip of the storage (A).
Upper Tube Length = C + (A)
YES Upper tube length is 6-1/2" plus the riser pipe measurement (A).
Upper Tube Length = 6-1/2" + (A)
NOTE: You must find the actual tank capacity number that correlates to the 6-1/2” + (A) depth for the station records. This number may also be used for the purposes of calibrating an electronic tank level system.
® Registered T.M. - Owens Corning Fiberglass Corporation
64
Measuring Stick
Riser Pipe with Face
Seal Adaptor
(A)
To Tank
Top (I.D.)
(B)
To Tank
Bottom
6-1/2”
Figure 1
EXAMPLE
1.) For an Owens-Corning Model G-3 Fiberglass®
Tank Calibration Chart:
Tank Capacity - 10,000 gal., nominal 9,403 gal.
NOTE: Use actual capacity only
2.) 95% of actual tank capacity = 0.95 x
9403 gal. = 8933 gal.
3.) The closest number which is less than 8933 gal.
Is 8910 gal. Choosing the closest number less than 95% of actual capacity ensures that the initial shutoff will occur when the tank is no more than 95% full.
4.) The calibration chart reading of 8910 gal. corresponds to a dipstick measurement of 82".
5.) Dipstick number (X) = 82"
Tank diameter (Y) = 92"
(Y) - (X) = (Z) (92 "- 82" = 10")
7.) (Z) - 2" = C
C = 8"
(10" - 2" = 8")
7.) Is 8" less than 6-1/2"?
NO Measure the distance from the top of the
FSA-400 Face Seal Adaptor installed on the riser pipe to the inside, top lip of the storage tank and obtain measurement (A).
Upper tube length = C + (A)
ASSEMBLY INSTRUCTIONS
IMPORTANT: Each of the numbered steps in the installation instructions are designed as a CHECK
LIST to ensure proper installation and trouble free operation of the OPW 71SO Overfill Prevention
Valve.
Read and follow these steps carefully, checking them off as you proceed.
Figure numbers correspond to step numbers for easy reference.
STEP 1: MEASURE
Install the OPW Face Seal Adaptor and the OPW
Thread-on Spill Container on the Fill Riser (Refer to the Installation Instructions Supplied with the Spill
Container). Insert the 71SO measuring stick through the riser pipe and hook it under the inside of the tank in the lengthwise direction. Mark the measuring stick at the top of the Face Seal Adaptor threads inside the base of the spill container bucket just below the drain valve outlet window (See Figure
1 &1A). The top flange on the 71SO will rest on the
Face Seal Adaptor just below the drain valve outlet, and be locked in place between the Face Seal
Adaptor and the 4" nipple that is installed in the spill container with the Jack Screw Kit (See Figure 1A).
(For riser pipe configurations other than that shown, consult installation drawings or use other necessary means to measure Dimension “A”).
Using a tape measure, measure the distance from the top of the Face Seal Adaptor in the spill container to the bottom of the tank (Dim. “B”).
IMPORTANT: Inspect the riser pipe for any foreign material. Over spray from tank relining or any internal burrs inside of pipe must be removed prior to installation. Failure to have an unobstructed riser pipe may prevent proper installation and operation of the valve. The 71SO is designed for installation into schedule 40 riser pipes. The 71SO cannot be installed into schedule 80 riser pipes.
STEP 2: MARK THE TUBE
Use the result from STEP 1 and HOW TO LOCATE
THE POSITION OF THE 71SO AT 95% TANK
CAPACITY to mark the upper tube. Measure the distance from the seam where the upper tube and valve body meet. For “C” measurements less than or equal to 6-1/2” see Figure 2. For “C” measurements greater than 6-1/2” use a tape measure to mark the calculated upper tube length onto the upper tube.
Riser Pipe with Face
Seal Adaptor
Figure 1
Mark measuring stick here for
Jack Screw installation
(Top of Face
Seal Adaptor)
Figure 1A
71SO
Measuring Stick
4” NPT
Nipple
Measuring Stick
(A)
To Tank
Top (I.D.)
(B)
To Tank
Bottom
6-1/2”
OPW Spill
Container
Jack Screw
Kit
O-Ring Seal
Face Seal
Adaptor
Transfer Mark
From Stick to
Upper Tube
(Cut Line)
Seam
Figure 2 (For “C” less than or equal to 6-1/2”
only)
65
STEP 3: CUT THE UPPER DROP TUBE
Attach the supplied band clamp to the upper tube just below the mark and ensure that it is assembled square to the tube. The clamp can be used as a guide for making a square cut. If a vise is used, clamp on the valve body casting only to avoid damage to the float and tubes (See Figure 3A).
Carefully saw through the tube squarely, at the mark made in Step 2. Use a hacksaw with a new finetooth blade. Rotating the upper tube as the sawing progresses will minimize run out and ensure a square 90-degree cut. Remove the band clamp after tube is cut.
CAUTION -DO NOT use a pipe or tubing cutter to cut the upper drop tube, this may damage the tube, causing it to be out of round thereby prohibiting assembly of the unit.
IMPORTANT: Remove all chips and shavings generated in steps 3 thru 5 out of the cut end of the tube. DO NOT remove chips and shavings by dumping thru valve body.
Band Clamp
Cut Line
Figure 3B
STEP 4: FILE THE UPPER DROP TUBE
File the upper tube square, and remove any burrs or rough edges. Make sure the cut is flat and square.
IMPORTANT: Carefully file a good chamfer on the inside edge of the drop tube to provide a lead-in for the polypak seal and inlet tube installed in step 8.
Figure 3A
Figure 4
Fine half round file
66
STEP 5: SAND THE UPPER DROP TUBE
Sand the inside of the drop tube with sandpaper and/or steel wool to remove all burrs and sharp edges. After sanding wipe down the inside of the tube with a clean rag from the top to approximately 4 inches down to remove any debris.
Caution: Failure to properly chamfer, sand, and clean the drop tube may cut the seal and result
in a failure of a pressure decay leak test. black moly grease to the polypak as shown. Make sure coverage is completely around the polypak seal.
Ensure polypak lip is up
Inlet
Tube
Polypak
Fine grit sandpaper
Figure 5
STEP 6: APPLY GREASE TO DROP TUBE
Apply black moly grease to the inside diameter of the upper drop tube. Make sure coverage is completely around the tube as shown in Figure 6.
Apply grease around polypak
Figure 7
STEP 8: INSTALL INLET TUBE
Insert the inlet tube into the upper tube until the upper tube seats against the flange on the inlet tube.
Ensure polypak is inserted evenly and stays in inlet tube groove.
Figure 6
STEP 7: APPLY GREASE TO POLYPAK SEAL
Ensure that the polypak seal is installed on the inlet tube with the lip up as shown in Figure 7. Apply
Figure 8
SEE PAGE 8 FOR INSTRUCTIONS USING THE
71SO-TOOL.
SEE PAGE 9 FOR INSTRUCTIONS USING THE
71SO-TOOLC.
67
71SO-TOOL PROCEDURE BELOW,
FOR 71SO-TOOLC, SEE PAGE 9
STEP 9A: INSERT 71SO-TOOL OVER INLET
TUBE
To install the 71SO-TOOL (sold separately) over the inlet tube, first loosen all three knobs, so the tool can pass freely over the inlet tube flange. Align the slot on the tool with the key on the inlet tube and insert the tool down. See Figure 9A.
Tool slot
Loosen all knobs
View holes
Hand tighten knobs evenly
Inlet
Tube key
Figure 9A Figure 10A
STEP 10A: TIGHTEN THE 71SO-TOOL
Use the three view holes to ensure that the tool seats out flat against the top of the inlet tube. To prevent vertical movement of the tool during drilling hand tighten all three knobs evenly the upper drop tube. See Figure 10A.
STEP 11A: PREPARE DRILL AND BIT
Confirm that the stop on the 3/16” drill bit supplied with the 71SO-TOOL is in the correct position before drilling. The stop is factory installed at a distance between 2” to 2-1/16” from the tip with the 71SO-
TOOL. If the stop is not at the correct position it must be fixed before drilling.
68
Caution: If the drill stop is not in the proper location failure of a pressure decay leak test may result.
71SO-TOOL
Tip to stop dimension must be 2 to 2-1/16 inch
Figure 11A
STEP 12A: DRILL HOLES
With the inlet tube and 71SO-TOOL in place, carefully drill a 3/16” diameter hole in the upper tube using the drill bushing in the knob as a guide. The drill stop is positioned so it will bottom out against the knob after the bit has drilled through the upper drop tube. If the stop is positioned wrong either no hole will be drilled, or a through hole could potentially be drilled through the inlet tube. If no hole is drilled return to step 11 and check the stop dimension. If a hole is drilled through the inlet tube or into the screw hole the assembly is not salvageable. Drill (2) more holes in the two remaining knobs.
Figure 12A
Drill thru upper tube only
71SO-TOOLC PROCEDURE BELOW,
FOR 71SO-TOOL, SEE PAGE 8
STEP 9B: INSERT 71SO-TOOLC OVER INLET
TUBE
To install the 71SO-TOOLC (sold separately) over the inlet tube, first loosen the thumb screw, so the tool can pass freely over the inlet tube flange. Align the slot on the tool with the key on the inlet tube and insert the tool down. See Figure 9B.
Tool Slot
Hand tighten thumb screw
Loosen thumb screw
Inlet
Tube
Key
Figure 9 Figure 10
STEP 10B: TIGHTEN THE 71SO-TOOLC
Ensure that the tool seats flat against the top of the inlet tube. To prevent vertical movement of the tool during drilling, hand tighten the thumb screw against the upper drop tube. See Figure 10B.
STEP 11B: PREPARE DRILL AND BIT
Confirm that the stop on the 3/16” drill bit supplied with the 71SO-TOOLC is in the correct position before drilling. The stop is factory installed at a distance between 1-3/16” to 1-1/4” from the tip with the 71SO-TOOLC. If the stop is not at the correct position it must be fixed before drilling.
Caution: If the drill stop is not in the proper location failure of a pressure decay leak test may result.
71SO-TOOLC
Tip to stop dimension must be 1-3/16” to 1-1/4”
Figure 11B
STEP 12B: DRILL HOLES
With the inlet tube and 71SO-TOOLC in place, carefully drill a 3/16” diameter hole in the upper tube using the hole in the 71SO-TOOLC as a guide. The drill stop is positioned so it will bottom out against the tool after the bit has drilled through the upper drop tube. If the stop is positioned wrong either no hole will be drilled, or a through hole could potentially be drilled through the inlet tube. If no hole is drilled return to step 11 and check the stop dimension. If a hole is drilled through the inlet tube or into the screw hole the assembly is not salvageable. Drill (2) more holes in the two remaining guide holes.
Figure 12B
Drill through upper tube only
69
STEP 13: DIMPLE FIRST HOLE
Remove tool. Remove any chips or burrs from the drilling operation. Place the assembly on a solid surface. Using the punch supplied with the 71SO-
TOOL and 71SO-TOOLC, align the tip of the punch with the drilled hole and dimple the upper drop tube by striking the punch with a hammer until the drop tube is formed into countersunk hole in the inlet tube. After punching, remove any chips that may have fallen into the inlet tube screw hole.
STEP 15: DIMPLE REMAINING HOLES
Remove any chips or burrs from the drilling operation. Dimple the next (2) holes as done in Step
13. Make sure the assembly is on a solid surface when punching. After punching, remove any chips that may have fallen into the inlet tube screw hole.
Align punch with drilled hole
Figure 13
STEP 14: ASSEMBLE FIRST SCREW
Ensure that the drop tube was formed into the countersunk screw hole as shown in Figure 14 if not return to step 13. Apply black moly grease to screw and tighten first screw into inlet tube with a screwdriver. Use only the taptite screws that are supplied with the unit. Seating torque is 20 in-lbs min. to 35 in-lbs max. Screw head should be flush with the drop tube. Do not over tighten.
Fig
ure 15
S TEP 16: ASSEMBLE OTHER SCREWS
Apply black moly grease to screws and tight en the other (2) screws into inlet tube with a screwdriver as done in Step 14. Use only the taptite screws that are supplied with the unit. Seating torque is 20 inlbs min. to 35 in-lbs max. Do not over tighten.
S
TEP 17: APPLY GREASE TO LOWER O-RING
AND BODY THREADS
Apply black moly grease to the lower tube o-ring and body threads as shown. Make sure coverage is completely around the o-ring. Install o-ring in gro ove just above threads.
Apply grease around o-ring
O-ring groove
Body threads
Figure 17
Figure 14
70
Ensure the drop tube is formed into countersunk hole
STEP 18: LOWER TUBE ASSEMBLY
If a vise is used, clamp on the valve body casting only to avoid damage to the float and tubes. Thread the lower tube onto the valve body until the lower tube bottoms out on valve body. Tube can be tightened by hand or with a strap wrench. If a strap wrench is used try to position it on the threaded insert portion of the lower tube to prevent damaging the tube.
Threaded insert
Figure 18
Note:
Before installing the valve in the tank, a pressure test can be performed on the valve to check for vapor tightness. Seal off both ends of the tube with inflatable plumber’s plugs. Apply a maximum 10" W.C. (1/3 PSI) air pressure. If pressure does not hold and a leak can be located with soap solution, do not install the valve. Send the valve back to OPW for warranty evaluation.
Caution:
Do not over-pressurize. Excess pressure can damage the valve.
STEP 19: CUT LOWER TUBE
Measuring from the underside of the inlet tube flange, mark the overall length of the drop tube a distance of (B) minus 6". Determine dimension (B) from the measurements taken in Step 1, Figure 1
(Top of the Face Seal Adapter below the drain valve outlet in the spill container to the bottom of the tank).
Saw off the excess tube at a 45-degree angle or per local codes or requirements and file off any sharp burrs (Refer to Figure 24). Optional: Install the OPW
Tank Bottom Protector on the lower tube (Refer to
Installation instructions supplied with the Tank
Bottom Protector).
IMPORTANT:
Remove all chips and shavings out of the cut end of the tube. DO NOT remove chips and shavings by dumping thru valve body.
STEP 20: PREPARE FILL RISER FOR VALVE
INSERTION
IMPORTANT:
Inspect the riser pipe for any foreign material. Over spray from tank relining or any internal burrs inside of pipe must be removed prior to installation. Failure to have an unobstructed riser pipe may prevent proper installation or operation of the valve. Thoroughly clean top of riser pipe.
STEP 21: REMOVE ELASTIC BAND
Remove the elastic band securing the float to the valve body. The float will move into an outward position.
STEP 22: INSERT DROP TUBE
Make sure the upper O-Ring gasket is under the flange of the inlet tube. Hold the float down against the valve body and slowly insert the drop tube overfill valve into the riser pipe. Do not force valve into the riser pipe. If any obstruction or foreign matter interferes with smooth insertion of the valve, the riser pipe must be cleared.
WARNING
Failure to follow the assembly and installation instructions or use of excessive force to insert the OPW
71SO will VOID THE
WARRANTY!
Figure 22
Difficulty in removing the existing fill tube (if there is one) means there may be an obstruction in the riser pipe. Look for burrs, deformations, excess tank lining material or other projections that may interfere with easy insertion of the OPW 71SO. The 71SO is designed for insertion into schedule 40 pipe. If schedule 80 pipe has been used for the riser, the
71SO cannot be installed. If seamed pipe has been used, the internal weld bead may interfere with the
OPW 71SO and prevent installation. If the OPW
71SO won’t slip in easily DON’T FORCE IT!
Damage to the valve may result if excess force is used. Examine the riser pipe carefully; determine the nature of the obstruction; take appropriate steps to remove it.
71
STEP 23: CHECK INSTALLATION
Insert the drop tube all the way into the tank until the flange and gasket seat onto the top of the Face Seal
Adaptor. The float will swing out into the operating position as it passes into the tank.
Vapor Recovery
Riser
Fill Riser
OPW
Ball Float
6” Max.
Tube Cut per Local
Requirements
Figure 24
6”
Align Float Along Length of Tank
14” Minimum
Clearance for
Float
Figure 23
Make sure that the float is aligned along the length of the tank. The length of the tank can easily be determined by locating other manholes or pump boxes that are installed around other tank fittings.
Look into the drop tube and align the deflector with the length of the tank.
CAUTION:
No obstruction in the tank can be within
14" from the center of the riser pipe or the valve may not operate properly (See Figure 24).
STEP 24: ALIGN VALVE
Install the OPW Jack Screw Kit and a 4" NPT nipple to lock the valve in place. Refer to the Installation
Instructions supplied with the Jack Screw Kit. Install the Rotatable Product Adaptor (Refer to Installation
Instructions supplied with the Product Adaptor.)
Make sure that the valve does not rotate while tightening the adaptor by observing the position of the deflector. The valve must remain aligned
along the length of the tank as in Step 23
.
Repeat this step as necessary to assure proper valve alignment.
72
Swivel Product
Adaptor
Figure 24A
4” NPT
Nipple
Jack Screw
Kit
STEP 25: INSTALL WARNING PLATE
Bend the three warning plate ears down then slide the tie wrap over the warning plate ears and position warning plate against riser pipe approximately 1" below the adaptor. Tighten the tie wrap securely.
The valve is now fully installed and in operating position.
Warning
Plate
Figure 25
STEP 26: VALVE REMOVAL
The valve can be removed for tank leak testing, inspection, etc., by removing the Rotatable Product
Adaptor, the 4" nipple, and the Jack Screw Kit.
Reinstall per the above instructions.
STEP 27: ELECTRONIC LIQUID LEVEL
MONITORING
If an electronic level monitor is installed, it must be calibrated to match the top of the 71SO valve body, which must correlate with 95% of the actual tank capacity.
Manufacturer: “OPW”
Model: “71SO-4”
(4” represents size)
Manufacture Date:
“MFG MMYY”
MM=Month YY=Year
Figure 26 – Product Identification
73
PREVENTATIVE MAINTENANCE
Annually, inspect the flapper in the 71SO to see that it is open by looking down the drop tube opening.
Test the 71SO drop tube seals with CARB procedure TP-201.1D. If the drop tube seal passes testing, no further maintenance is required. If the drop tube fails testing, replace the drop tube seal with OPW P/N: H11931M for 4” Tubes. Re-test the
71SO drop tube with CARB procedure TP-201.1D.
The lower tube o-ring seal OPW P/N: H14840M can also be replaced. If this does not correct the leak the 71SO needs to be replaced.
CAUTION: Do not insert any foreign object into drop tube if flapper is in the closed position. For example a tank level measuring stick. This will damage the valve and void the Warranty.
ALWAYS check flapper location before
“sticking” the tank. If flapper is in the closed position the tank is either over filled and you need to wait until the liquid level goes down or the 71SO is damaged and needs to be replaced.
71SO Performance Specifications:
This Overfill Prevention Valve has been manufactured and tested to, and met, the following
California specifications. Performance Requirement:
Leak rate to be less than or equal to 0.17 CFH @
2.0" W.C.
Torque Specification:
Taptite Screws, #10-24 thread cutting, 20 in-lbs minimum to 35 in-lbs maximum.
Important: Leave these installation instructions and maintenance procedures with the station operator.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required.
As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by
OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
P.O. Box 405003 * Cincinnati, Ohio 45240-5002
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2007 - OPW Fueling Components Inc.,
Cincinnati, OH
Printed in U.S.A. p/n H15524PA – Rev. F 9/07
74
Section 10
6111-1400 Tank Bottom Protector
75
POMECO Installation and Maintenance
Instructions 6111-1400 Tank Bott om Protector
IMPORTANT:
Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT:
The POMECO Tank Bottom Protector is pre-assembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER:
Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required.
As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by
OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
Tank Bottom Protector:
The POMECO Tank Bottom Protector is designed to protect the Underground Storage Tank from damage due to the tank measuring stick being dropped into the tank to measure the fluid level.
76
POMECO Tank Bottom
Installation Instruction
1. Check the distance from the bottom of the fill tube to the bottom of the tank. Verify that this distance is in conformance with manufacturer’s recommendations and Local
Codes. Remove the drop tube from the tank.
2. Using a # 11 Drill (0.191") - Drill a hole into the fill tube about 1/2" above and 1” to 1
1/16 over from point “A” (see figures 1 and
2). Keep in mind that the POMECO Tank
Bottom Protector must rest on the bottom of the tank.
Protector and line up the # 11 hole in the sliding rod guide with the corresponding hole just drilled in the drop tube. Make sure that point “A” is clear for future measurements of the drop tube’s length.
(See figure 2)
Protector with the pop rivet supplied. Drill two more # 11 holes into the drop tube and sliding rod guide at the same time. Install supplied pop rivets into new holes.
5. Check to ensure that the POMECO Tank
Bottom Protector slides up and down without binding.
6. Reinstall fill tube into the tank.
*Check local codes and regulation for proper dimension
Figure 19
#11 DRILL
#11 DRILL
Figure 20
POP RIVET
1” TO 1 1/16”
FROM POINT “A”
CLEAR
ROD GUIDE
TUBE
77
78
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Marketing Agent for POMECO by OPW, Inc.
Copyright, 2002 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H14977PA – 09/02
Section 11
61JSK Jack Screw
And
FSA-400 Face Seal Adaptor
79
OPW Installation and Maintenance Instructions
OPW 61JSK-4410 and 61JSK-44CB Jack Screw Kit
IMPORTANT:
Please read these warnings and assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT:
Check to make sure the product is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied.
Doing so may cause product failure.
WARNING-DANGER:
Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required.
As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by
OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
61JSK Performance
Specifications:
This OPW Jack Screw Kit is designed to lock an
OPW 61SO Series Overfill Valve or 61T Drop Tube into an OPW 1-2100 (or Multi-Port 500) Series Spill
Container Base below the outlet of the drain valve.
Torque Specification:
5/16-18 Screw, 3.5 ft-lbs (42 in-lbs) minimum to 5.0 ft-lbs (60 in-lbs) maximum.
4" Nipple, 125 ft-lbs minimum to 250 ft-lbs maximum.
4” NPT Thread, 125 ft-lbs minimum to 250 ft-lbs maximum.
80
IMPORTANT:
The figures in this installation and maintenance instruction may contain vapor recovery equipment (including model numbers) that is not certified by the California Air Resources Board (CARB) for a specific Phase I Vapor Recovery System. Please refer to
Exhibit 1 of the appropriate CARB Phase I Executive
Order for a list of certified Phase I Vapor Recovery System
Equipment.
OPW 61JSK-4410 JACK SCREW KIT FOR
COMPOSITE BASE SPILL CONTAINERS
INSTALLATION INSTRUCTIONS:
Figure numbers correspond to step numbers for easy reference.
Step 1
Remove any old or dried pipe dope and metal burrs from top of riser pipe. Apply a gasoline resistant pipe dope on the threads of an OPW FSA-400 Face
Seal Adapter and install onto the riser pipe. Torque to 125 ft-lbs min. to 250 ft-lbs max using the OPW
61SA-TOOL.
Step 2:
Install the OPW 1-2100 or POMECO 500 Series
Spill Container in accordance with the OPW
Installation Instructions supplied with the product.
Step 3:
(See Figure 3 & 3A)
Assemble and Install the OPW Drop Tube in accordance with the OPW Installation Instructions supplied with the product.
Step 4:
(See Figure 4)
Insert the Jack Screw Lower Cage completely into the spill container base on top of the drop tube flange with the screw pockets facing up.
Step 5:
(See Figure 5)
Assemble screws into upper plate with the step facing up. Adjust the screws so that the top plate will be located just below the bottom of the threads in the spill container base when the assembly is inserted into the spill container.
Drop Tube
Top Flange
Figure 3
1-2100 Series
Spill Container
Vapor Tight
Drop Tube
O-Ring
Seal
OPW 1-2100 Series
Spill Container Base.
FSA-400
Face Seal
Adapter
Riser.
Pipe
Figure 3a
81
Composite
Base
61JSK-4410
Lower Cage -
Pockets Up
Screws in
Pockets
Figure 4
Step 6:
(See Figure 5)
Install the Jack Screw Assembly into the spill container base. Make sure the bottoms of the three screws are seated in the pockets on the Jack Screw
Lower Cage. Apply the supplied thread locker to the threads above the top plate on all three screws on the Jack Screw Top Assembly.
Step 7:
Apply a gasoline resistant pipe dope on the threads of a 4" nipple. Install the 4" nipple into the spill container and tighten securely. (Recommended torque, 4"NPT, 125 ft-lbs min. to 250 ft-lbs max.)
Note: The top plate should not be in contact with the nipple at this point. If the nipple hits the top plate while being tightened lower the top plate on the Jack
Screw below the threads on the spill container.
Step 8:
(See Figure 8)
Using a ¼ inch Allen socket, alternately and evenly tighten the three (3) screws on the Jack Screw
Assembly until the top plate contacts the bottom of the 4" nipple. Check to make sure the step in the top plate is centered in the nipple. Tighten the three
(3) screws evenly and securely with a torque of 3.5 ft-lbs min. to 5.0 ft-lbs max to ensure that the drop tube flange is sealed securely to the Face Seal
Adapter.
Step 9:
(See figure 9)
Assembly of the Jack Screw Kit is now complete.
Proceed to installation of the OPW 61SALP-EVR
Rotatable Product Adaptor and OPW 634TT Cap in accordance with the OPW Installation Instructions supplied with the product.
82
Figure 5
Composite
Base
Drop
Tube
Flange
Figure 8
4” Nipple
Top Plate
Lower Cage
O-Ring Seal
Position Top
Plate Below
Threads with
Step Facing Up
Thread Lock -
3 Places
OPW 61JSK-44CB JACK SCREW KIT FOR CAST
IRON BASE SPILL CONTAINERS
INSTALLATION INSTRUCTIONS:
Figure numbers correspond to step numbers for easy reference.
Step 1
Remove any old or dried pipe dope and metal burrs from top of riser pipe. Apply a gasoline resistant pipe dope on the threads of an OPW FSA-400 or
FSA-400-S Face Seal Adapter and install onto the riser pipe. Torque to 125 ft-lbs min. to 250 ft-lbs max using the OPW 61SA-TOOL.
Note: Only the cast iron base will work with the FSA-
400-S (Short Face Seal Adapter).
Step 2:
Install the OPW 1-2100 or POMECO 500 Series
Spill Container in accordance with the OPW
Installation Instructions supplied with the product.
Step 3:
(See Figure 3 & 3A)
Assemble and Install the OPW Drop Tube in accordance with the OPW Installation Instructions supplied with the product.
Step 4:
(See Figure 4)
Insert the Jack Screw Lower Plate (plate without threads) completely into the spill container base on top of the drop tube flange with the screw pockets facing up.
Step 5:
(See Figure 5)
Assemble screws into upper plate with the step facing up. Adjust the screws so that the top plate will be located just below the bottom of the threads in the spill container base when the assembly is inserted into the spill container.
Drop Tube
Top Flange
OPW 1-2100 Series
Spill Container Base.
1-2100 Series
Spill Container
Vapor Tight
Drop Tube
Figure 3a
O-Ring
Seal
Cast Iron
Base
FSA-400
Face Seal
Adapter
Figure 3
Figure 4
Riser.
Pipe
61JSK-44CB
Lower Plate -
Pockets Up
83
Step 6:
(See Figure 5)
Install the Jack Screw Assembly into the spill container base. Make sure the bottoms of the three screws are seated in the pockets on the Jack Screw
Lower Plate. Apply the supplied thread locker to the threads above the top plate on all three screws on the Jack Screw Top Assembly.
Step 7:
Apply a gasoline resistant pipe dope on the threads of a 4" nipple. Install the 4" nipple into the spill container and tighten securely. (Recommended torque, 4"NPT, 125 ft-lbs min. to 250 ft-lbs max.)
Note: The top plate should not be in contact with the nipple at this point. If the nipple hits the top plate while being tightened lower the top plate on the Jack
Screw below the threads on the spill container.
Step 8:
(See Figure 8)
Using a ¼ inch Allen socket, alternately and evenly tighten the three (3) screws on the Jack Screw
Assembly until the top plate contacts the bottom of the 4" nipple. Check to make sure the step in the top plate is centered in the nipple. Tighten the three
(3) screws evenly and securely with a torque of 3.5 ft-lbs min. to 5.0 ft-lbs max to ensure that the drop tube flange is sealed securely to the Face Seal
Adapter.
Step 9:
(See figure 9)
Assembly of the Jack Screw Kit is now complete.
Proceed to installation of the OPW 61SALP-EVR
Rotatable Product Adaptor and OPW 634TT Cap in accordance with the OPW Installation Instructions supplied with the product.
Operation and Maintenance:
If a leak develops at the drop tube, re-torque the (3) screws on the Jack Screw. (Torque value: 3.5 ft-lbs min. to 5.0 ft-lbs max.) If this does not correct the leak, check for burrs, clean the sealing surface on the FSA-400 and replace the o-ring on the drop tube.
NOTE: Loctite 242, thread locker, must be reapplied each time the screws are adjusted.
Important: Leave these instructions with Station
Operator.
Screws in
Pockets
Figure 5
Cast Iron
Base
Drop
Tube
Flange
Figure 8
4” Nipple
Position Top
Plate Below
Threads with
Step Facing Up.
Thread Lock -
3 Places
Top Plate
Lower Plate
O-Ring Seal
84
61SALP
Rotatable
Product
Adapter
61SALP
Rotatable
Product
Adapter
61JSK-4410
Jack Screw Kit
1-2100 Series
Spill Container with Composite
Base
FSA-400 Face
Seal Adapter
61JSK-44CB
Jack Screw Kit
61SO or 61T
Drop Tube
1-2100 Series
Spill Container with Cast Iron
Base
FSA-400 or
FSA-400-S
Face Seal Adapter
61SO or 61T
Drop Tube
Figure 9 Composite Base
Alternative Construction
Identification
This Surface
Manufacture: “OPW”
Model: “61JSK”
Manufactured Date:
“MFG MM DD YY”
Figure 9 Cast Iron Base
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2007 - OPW Fueling Components Inc.,
Cincinnati, OH
Printed in U.S.A. p/n H15289PA – 5/07
61JSK-4410
Composite Base
61JSK-44CB
Cast Iron Base
85
86
Section 12
61SALP Fill Swivel Adaptor and
61VSA Vapor Swivel Adaptor
OPW Installation and Maintenance Instructions
OPW 61SALP EVR (Low Profile) Rotatable Product Adaptors
IMPORTANT:
Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT:
Check to make sure the unit is intact and undamaged and all parts have been supplied.
Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER:
Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by
OPW (ECO products two years from date of manufacture.) Proof of purchase may be required.
As the exclusive remedy under this limited warranty,
OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.)
This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by
OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
61SALP Performance Specifications:
This Rotatable Adaptor has been manufactured and tested to the following California Specifications:
Rotatable 360°, Static Torque maximum 108 inchlbs.
Preventative Maintenance:
Annually, inspect the adaptor for large dents, cracks or deformation. Replace if necessary. The rotation mechanism is not field serviceable.
Replacement Parts:
Nipple sealing gasket OPW P/N: H09039M.
Torque Specification:
Adapter, 4" NPSM, 90 ft-lbs minimum to 110 ft-lbs maximum.
Important: Leave these Installation
Instructions with the Station Operator.
87
61SALP EVR Rotatable Product Adaptor
INSTALLATION INSTRUCTIONS
2” Minimum Clearance between spill container cover and dust cap.
1.0” Minimum Slope
Product Dust Cap
OPW Spill Container with Drain Valve
61SALP Swivel
Product Adaptor
Note: Use only a factory made nipple. Nipple must be cut square and deburred to
Note: This is a typical installation for the
Product OPW 61SALP. Installation may vary for your application.
provide a suitable sealing surface. (Option: Use OPW
FSA-400 with nipple)
Step 1
The riser nipple in the spill container must be cut square and deburred. See drawing note for the correct distance between the top of the nipple and finished grade. (Optional: Use a OPW FSA-400 Face Seal Adapter with nipple.
Add 3-1/4” to distance from top of nipple to finish grade).
Step 2 (Optional)
Apply pipe dope to the nipple. Pipe dope to be non-hardening, gasoline resistant pipe thread seal compound.
Step 3
Tighten the Rotatable Adaptor onto the nipple with a torque of 90 ft-lbs min. to 110 ft-lbs max this will be enough torque to seat and seal the gasket. Use an OPW 61SA-TOOL to install rotatable adaptor.
P.O. Box 405003 * Cincinnati, Ohio 45240-
5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Product ID: “61SALP”
Manufacture “OPW”
Date Manufactured: “MFG MMYY”
MM= Month, YY=Year
Copyright, 2007 - OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H12712PA rev.B- 5/07
88
OPW Installation and Maintenance Instructions
OPW 61VSA EVR Poppetted Rotatable Vapor Recovery Adaptor
IMPORTANT:
Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT:
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER:
Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Stand ard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
61VSA Performance Specifications
:
This Rotatable Adaptor has been manufactured and tested to the following California specifications:
Rotatable 360°, Static torque of 108 inch-lbs.
Preventative Maintenance:
Annually, inspect the adaptor for large dents, cracks or deformation. Replace if necessary. The rotation mechanism is not field serviceable.
Check the vapor poppet for damage and ensure that the poppet seats evenly with the adaptor. Clean out any foreign objects from the vapor poppet’s seal and seal surface if necessary. Test the poppet seal by applying a soap solution to the poppet while the underground storage tank is under a positive gauge pressure of at least 2.00 inches W.C and inspect for the presence of bubbles. If the facility continuously operates under vacuum, a bag test may be used by sealing a clear plastic bag to the adaptor’s sides.
If no bubbles appear at the poppet under positive pressure or the bag test shows no signs of the bag collapsing, no further maintenance is required. If bubbles appeared around the poppet seal or the bag collapsed, replace the poppet components and retest
Replacement Parts:
Nipple sealing gasket OPW P/N: H09039M.
Vapor Poppet Kit OPW P/N: 61VSA-Kit
Torque Specification:
Adaptor, 4" NPSM, 90 ft-lbs minimum to 110 ft-lbs maximum.
Patent # 5,664,951
Important: Leave these Installation Instructions with the Station Operator.
89
OPW 61VSA EVR Series Poppetted Rotatable Vapor Adaptor
INSTALLATION INSTRUCTIONS
2” Minimum Clearance between spill container cover and dust
1.0” Minimum Slope
OPW Spill
Container with
Drain Plug
Note: This is a typical installation for the OPW 61VSA. Installation may vary for your application.
Vapor Dust Cap
61VSA Vapor
Swivel Adaptor
Note: Use only a factory made nipple. Nipple must be cut square and deburred to provide a suitable sealing surface. (Option: Use FSA-
400 with nipple)
Step 1
The riser nipple in the spill container must be cut square and deburred. See drawing note for the correct distance between the top of the nipple and finished grade. (Optional: Use an OPW FSA-400 Face Seal Adaptor with nipple. Add 3-1/4” to distance from top of nipple to finish grade).
Step 2 (Optional)
Apply pipe dope to the nipple. Pipe dope to be non-hardening, gasoline resistant pipe thread seal compound.
Step 3
Tighten the Rotatable Adaptor onto the nipple with a torque of 90 ft-lbs min. to 110 ft-lbs max, this will be enough torque to seat and seal the gasket. Use a 61SA-TOOL to install rotatable adaptor.
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Manufacture: “OPW”
Date Manufactured: “MFG MMYY”
MM= Month, YY=Year
Product ID: “61VSA”
Copyright, 2007- OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H14656PA-Rev.B 5/07
90
Section 13
623V Pressure Vacuum Vent
91
OPW Installation and Maintenance Instructions
OPW 623V Pressure / Vacuum Vent Valve
IMPORTANT:
Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT:
The OPW 623V Pressure / Vacuum vent is pre-assembled for your convenience and ease of installation. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied.
Doing so may cause product failure.
WARNING-DANGER:
Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the vent pipe capped, so the vapors cannot escape into the environment.
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations. Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
623V Series Performance
Specifications:
This Pressure / Vacuum vent has been manufactured and tested to the following specifications: Pressure leak rate not to exceed
0.05 CFH at 2” W.C. Vacuum leak rate not to exceed 0.21 CFH at -4” W.C. The cracking pressure to be 3” W.C. +/- 0.5 and cracking vacuum to be -8”
W.C. +/- 2.0. Tested using CARB Test Procedure
TP-201.1E or applicable Phase I Executive Order.
Torque Specification:
Vent Assembly 2” NPT, 35 ft-lbs minimum to 55 ftlbs maximum.
92
OPW 623V Pressure / Vacuum Vent Valve
INSTALLATION INSTRUCTIONS:
Step 1:
Deburr and thoroughly clean vent pipe. Apply pipe dope to vent pipe threads. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound.
Step 2:
(See Figure 1)
Screw the vent assembly onto the vent pipe and torque to 35 ft.-lbs minimum to 55 ft-lbs maximum. Use the flats on the pipe adaptor only, Do not wrench on the composite valve
assembly.
NOTE: NEVER PAINT OR COVER THE VENT
Figure 2
Vent
Assembly
PUSH
Vent Top
Pipe Dope
Upper
Screen
Valve
Body
Vent Pipe
Figure 1
Operation and Maintenance:
Annual maintenance is required to keep the vent operating satisfactorily. Remove and inspect filter screens – clean or replace as necessary.
Upper Screen Maintenance
1. Remove vent top by depressing tabs as indicated in Fig. 2, and lift top upward.
Screen will slip up and out of valve.
2. Clean or replace filter screen (P/N
H14895M) as necessary and reinstall Fig. 3.
3. Reinstall vent top by reinserting into the body. Be sure the tabs are inside the valve body, and then rotate top until the tabs snap into place
Pipe
Adaptor
Figure 3
Lower Screen Maintenance
Note: Do not remove the pipe adaptor from the vent pipe to service the lower filter screen.
1. Remove valve assembly from the pipe adaptor. Grip assembly at the flats just
93
above the pipe adaptor and unscrew.
(Fig. 4) Wrench C05102M can be used for this purpose.
2. Lift the filter screen out and clean or replace (P/N C05086M) as necessary.
3. Reinstall filter screen in the pipe adaptor
(see Fig. 4 for orientation).
4. Reinstall valve assembly on pipe adaptor and tighten until it stops. Do not wrench valve assembly except with P/N
C05102M
Important: Leave these instructions with
Station Operator.
Valve
Body
Lower
Screen
Pipe
Adaptor
Manufacture Date “MM / YY”
MM = Month, YY = Year
Product Identification
Figure 4
P.O. Box 405003 * Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2006 - OPW
Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H14898PA –Rev A 09/06
94
Section 14
Installation Tools
95
OPW Installation Instructions
61SA-TOOL Multipurpose Installation Tool
IMPORTANT: Please read all warnings and follow the installation instructions completely and carefully.
Failure to do so will void all warranties and may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
WARNING - DANGER: Using electrically- operated equipment near gasoline or gasoline vapors may result in fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
WARNING: Proper operation is dependent on proper installation and regular maintenance. The following instructions are provided to assist you in properly installing rotating product adaptors and spill container.
Failure to follow these instructions may cause failure to the system, resulting in a hazardous condition.
Handle
Hex for
Torque
Wrench
61SA, 61SALP,
61VSA & FSA
Screw “A”
Screw “B” X 2
Rotatable
Adaptor
Socket
HOW TO USE 61SA-TOOL TO INSTALL A 61SA,
61VSA, 61SALP, AND FSA-400
1.) Slide the rotatable adaptor socket of the assembled tool onto the appropriate lugs of the necessary product. See Figure 1.
2.) Rotate the tool clockwise to tighten the product to the riser pipe.
3.)
Remove handle by removing screw “A” and use the 7/8” hex to attach torque wrench and tighten to specified torque per each products instruction sheet.
CAUTION: DO NOT over torque product.
Doing so may cause failure to the system resulting in a hazardous condition.
HOW TO USE 61SA-TOOL TO INSTALL a #1
SERIES SPILL CONTAINER BASE
1.) Remove the rotatable adaptor socket from the base bar by taking out screw “B”. The finished assembly should be as seen in
Figure 2.
2.) Slide the 61SA-TOOL onto the spill container base inside the appropriate slots.
3.) Rotate the tool clockwise to tighten the product to the riser pipe at the given torque values per the products instruction sheet.
(Optional)
PHIL-TITE
Figure 21
Figure 22
96
4.) Use the TC-400 torque cap and 61SA-TOOL for installing
4” nipples and risers (See figure 3).
5.) Use lubricate (molly grease) on the threads of the TC-400.
6.) Thread TC-400 onto the 4” Riser or Nipple.
7.) Slide the 61SA-TOOL, using the appropriate slots onto the TC-400.
8.) Rotate the tool clockwise to tighten the product to the riser pipe.
Make sure recommended torque values are applied (See installation instruction).
Figure 3
Notice:
OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance.
OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND SPECIFICALLY
THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THERE ARE
NO WARRANTIES, WHICH EXTEND BEYOND THE DESCRIPTION OF THE FACE HEREOF.
P.O. Box 405003 * Cincinnati, Ohio 45240-5002
1-800-422-2525 Domestically
1-513-870-3315 Internationally www.opw-fc.com
Copyright, 2002 – OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n H14991PA 5/05
97
98
Appendix
EVR Product Registration Card
OPW Standard Product Warranty
Reference Tables
EVR Installation Check List
CARB Test Protocol and Field Inspection
99
OPW-FC STANDARD PRODUCT WARRANTIES
NOTICE: FlexWorks by OPW, Inc., VAPORSAVER™ and all other OPW products must be used in compliance with all applicable federal, state, provincial and local laws, rules and regulations. Product selection must be based on physical specifications and limitations, compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices, materials and specifications are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
OPW warrants solely to its customer that the following products sold by OPW will be free from defects in materials and workmanship under normal use and conditions for the periods indicated:
Product
FlexWorks Primary Pipe 10 years from date of manufacture
All Products Certified to California 2001 Standards* 1 year from date of manufacture or from date of installation registration (not to exceed 15 months from
All other Products date of manufacture)
1 year from date of manufacture
* Products certified to California 2001 Standards will have an OPW registration card enclosed/attached to the product.
OPW’s exclusive obligation under this limited warranty is, at its option, to repair, replace or issue credit (in an amount not to exceed the list price for any defective product) for future orders for any product that may prove defective within the applicable warranty period (repairs or replacements are subject to prorated warranty coverage for remainder of the original warranty period). Complete and proper warranty claim documentation and proof of purchase required. All warranty claims must be made in writing and delivered during the applicable warranty period to OPW at P.O. Box 405003, Cincinnati, Ohio 45240, Attention: Richard P. Jones. No products may be returned to OPW without its prior written authority.
This limited warranty shall not apply to any FlexWorks or VAPORSAVER™ product unless it is installed by an
OPW attested installer. This limited warranty also shall not apply to any FlexWorks, VAPORSAVER™ or other
OPW product: unless all required site and warranty registration forms are completed and received by OPW within
60 days of installation; unless all piping connections are installed with a nationally-recognized or state-approved leak detection device in each tank and dispenser sump (which are not for storage and from which all discharge hydrocarbons must be removed, and the systems completely cleaned, within 24 hours); unless testable sumps utilize FlexWorks pipe and access fittings; unless a sump inspection log or an EPA recommended/required checklist is maintained and the results are furnished to OPW upon request; and unless OPW is notified within 24 hours of any known or suspected product failure and is provided with unrestricted access to the product and the site. This limited warranty also shall not apply to any product which has been altered in any way, which has been repaired by anyone other than a service representative authorized by OPW, or when failure or defect is due to: improper installation or maintenance (including, without limitation, failure to follow FlexWorks Quick Reference
Manual Installation Guide and all product warning labels); abuse or misuse; violation of health or safety requirements; use of another manufacturer’s, or otherwise unauthorized, substances or components; soil or other surface or subsurface conditions; or fire, flood, storm, lightning, earthquake, accident or any other conditions, events or circumstances beyond OPW’s control.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND ALL
OTHER WARRANTIES INCLUDING, WITHOUT LIMITATION, THE WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY EXCLUDED. OPW shall have no other liability whatsoever, whether based on breach of contract, negligence, gross negligence, strict liability or any other claim, including, without limitation, for special, incidental, consequential or exemplary damages or for the cost of labor, freight, excavation, clean-up, downtime, removal, reinstallation, loss of profit, or any other cost or charges. No person or entity is authorized to assume on behalf of OPW any liability beyond this limited warranty. This limited warranty is not assignable.
CUSTOMER SERVICE DEPARTMENT
North America Toll Free - TELEPHONE: (800) 422-2525 or FAX (800) 421-3297
E-mail: [email protected] www.opw-fc.com
100
EVR Phase I Components
Installation Torque Specifications
Component
(Oct. 19, 2007)
Torque Specification
All 4" NPT pipe. See note 1.
FSA-400, FSA-400-S. See note 1.
Spill containment bucket. See note 1.
Spill bucket cover perimeter bolts/nuts.
Drain valve retaining bolts/nuts.
61SO Inlet Adaptor
71SO Inlet Adaptor
Jack Screw Assembly
61JSK-4400 (Old Style)
61JSK-4410
61JSK-44CB
61VSA Swivel Adaptor
61SALP Low Profile Swivel Fill Adaptor
623V Pressure Vacuum Vent base
3" NPT
2" NPT
Foot Pounds (Inch Pounds)
125 to 250 ft-lb
125 to 250 ft-lb
125 to 250 ft-lb
15 to 20 ft-lb
11-1/2 to 13-1/2 ft-lb
11-1/2 to 13-1/2 ft-lb
(20 to 35 in-lb)
3 to 4-1/2 ft-lb (36 to 56 in-lb)
3-1/2 to 5 ft-lb (42 to 60 in-lb)
3-1/2 to 5 ft-lb (42 to 60 in-lb)
90 to 110 ft-lb
90 to 110 ft-lb
35 to 55 ft-lb
125 to 200 ft-lb
100 to 150 ft-lb
Notes: 1. All 4" NPT thread are to be torqued progressively lower from the tank up.
101
OPW EVR Phase I
Spill Bucket Installation “L” Dimension
Reference Chart
(October 22, 2007)
The following are “L” dimensions for riser installation heights referenced in OPW’s 2100 Series
Installation Instructions and POMECO’s 500 Series Multi-Port Installation Instructions.
Note: If using OPW FSA-400, add 3-1/4” to Dimension “L.” If using OPW FSA-400-S, add 1-
3/4” to Dimension “L.” NOTE: FSA-400-S will only work with Cast Iron Base.
NOTE: FSA-400 is required on fill risers and tank probe risers in areas governed by ARB
Phase I Enhanced Vapor Recovery regulations.
The height of all Spill Containers, except Below Grade Applications, can be adjusted ±1 inch. Below Grade Applications can only be adjusted ±1/2 inch.
“L” Dimension
Bucket Style
POMECO 700 Series
POMECO 700 Series
POMECO 500 Series
POMECO 500 Series
OPW 2100C Series
OPW 2100 Series
Below Grade Application
21-1/2” N/A
* “L” Dimension is from underside of structural platform to top of fill riser.
102
OPW Installation, Operation, and Maintenance Manual
Summary of Guidelines for Maintenance Activities Required of the OPW Phase I Vapor
Recovery System
1
Interval
Component
Pressure/Vacuum Vent Valve
OPW 623V
Husky 4885
Spill Containers and Drain
Valves
OPW/POMECO “All Models”
Dust Caps
OPW “All Models”
Product Adaptor
OPW 61SALP
Annual and after each delivery
Annual
Annual
Annual
Annual
Maintenance To Be Performed
Upper Screen
1. Remove vent top by depressing tabs on side of valve. Screen will slip up and out of valve.
2. Clean or replace filter screen as necessary and reinstall.
3. Reinstall vent top by reinserting into the body.
Be sure the tabs are inside the valve body and then rotate top until the tabs snap into place.
Lower Screen
1. Remove valve assembly from pipe adaptor
2. Lift the filter screen out and clean or replace as necessary.
3. Reinstall filter screen in the pipe adaptor.
4. Reinstall valve assembly on pipe adaptor and tighten until it stops.
1. Remove screws that hold top cover on.
2. Remove any debris that might be sitting inside the lower cover.
3. Check the drain holes in the lower cover for blockage.
4. Do not remove the two (2) screens.
5. Reinstall the top cover and retaining screws.
6. Tighten the screws firmly.
After each delivery, the operator must remove any standing fuel from the container. Annually, clean the interior of the container and drain valve.
Annually, remove accumulated dirt and grit. If the drain valve becomes clogged, remove the valve, soak in water, and use high-pressure air to clean.
If valve is removed, reinstall to its proper position and perform CARB TP-201.1C or TP-201.1D
Visually inspect the seal in cap and replace if damaged or missing.
Visually inspect the adaptor for large dents, cracks, or deformations.
1
These maintenance requirements shall not circumvent use of the manufacturer’s installation and maintenance instructions. Maintenance contractors or owner/operators shall refer to the manufacturers complete installation and maintenance instructions found herein for the OPW Phase I System to ensure
that all maintenance and torque requirements are met.
103
OPW Installation, Operation, and Maintenance Manual
Summary of Guidelines for Maintenance Activities Required of the OPW Phase I Vapor
Recovery System
1
Component
Vapor Adaptor
OPW 61VSA
Jack Screw Kit
OPW 61JSK-4410
OPW 61JSK-44CB
OPW 61JSK-4400-EVR
Face Seal Adaptor
OPW FSA-400
OPW FSA-400-S
Drop Tubes
OPW 61T
Interval
Annual
Annual
None
Annual
Maintenance To Be Performed
Visually inspect the adaptor for large dents, cracks, or deformations. Check the vapor poppet for damage and ensure that the poppet seats evenly with the adaptor. Clean out any foreign objects from the vapor poppet’s seal and seal surface if necessary. Test the poppet seal by applying a soap solution to the poppet while the underground storage tank is under a positive gauge pressure of at least 2.00 inches W.C and inspect for the presence of bubbles. If the facility continuously operates under vacuum, a bag test may be used by sealing a clear plastic bag to the adaptor’s sides. If no bubbles appear at the poppet under positive pressure or the bag test shows no signs of the bag collapsing, no further maintenance is required. If bubbles appeared around the poppet seal or the bag collapsed, replace the poppet components and re-test.
Visually inspect the Jack Screw for proper alignment and installation.
No maintenance is required for this product.
Visually inspect Drop Tube to see if it is installed and ensure that the bottom of tube is within 6 inches of the bottom of tank. Test the drop tube seal with ARB procedure TP-201.1C or TP-201.1D as applicable. If the drop tube seal passes testing, no further maintenance is required. If the drop tube seal fails testing, replace the drop tube seal with
OPW P/N: H11931M for 4” Tubes. Re-test the drop tube seal with ARB procedure TP-201.1C or
TP-201.1D as applicable.
1
These maintenance requirements shall not circumvent use of the manufacturer’s installation and maintenance instructions. Maintenance contractors or owner/operators shall refer to the manufacturers complete installation and maintenance instructions found herein for the OPW Phase I System to ensure
that all maintenance and torque requirements are met.
104
OPW Installation, Operation, and Maintenance Manual
Summary of Guidelines for Maintenance Activities Required of the OPW Phase I Vapor
Recovery System
1
Component
Drop Tube Overfill
Prevention
OPW 61SO
OPW 71SO
Tank Bottom Protector
OPW/POMECO 6111-1400
Tank Gauge Port
Components
OPW 62M
Morrison Brothers 305
Ever-Tite 4097
Veeder-Root 312020-952
Interval
Annual
Annual
None
Annual
Maintenance To Be Performed
Inspect the flapper in the 61SO to see that it is open by looking down the drop tube opening. Test the 61SO drop tube seals with ARB procedure TP-
201.1D. If the drop tube passes testing, no further maintenance is required. If the drop tube fails testing, replace the drop tube seal with OPW P/N:
H11931M for 4” Tubes. Re-test the 61SO drop tube with ARB procedure TP-201.1D. If this does not correct the leak, the 61SO needs to be replaced.
Inspect the flapper in the 71SO to see that it is open by looking down the drop tube opening. Test the 71SO drop tube seals with ARB procedure TP-
201.1D. If the drop tube passes testing, no further maintenance is required. If the drop tube fails testing, replace the drop tube seal with OPW P/N:
H11931M for 4” Tubes. Re-test the 71SO drop tube with ARB procedure TP-201.1D. If this does not correct the leak, the 71SO needs to be replaced.
No maintenance is required for this product.
Visually inspect cap to see that it is not missing any seals and is installed properly.
1
These maintenance requirements shall not circumvent use of the manufacturer’s installation and maintenance instructions. Maintenance contractors or owner/operators shall refer to the manufacturers complete installation and maintenance instructions found herein for the OPW Phase I System to ensure that all maintenance and torque requirements are met.
105
OPW
EVR Phase I Equipment
Installation Check List
(Revised 08/25/04)
Site Identification Information
Site Address:
________________________________________________________________
________________________________________________________________
________________________________________________________________
Installing Company:
_____________________________________________________
Technician’s Name (Print Clearly):
_____________________________________________________
Technician’s Signature:
_____________________________________________________
Date of installation: ____________________________________
106
OPW
EVR Phase I Equipment
Installation Check List
(Revised 08/25/04)
Components Installed
OPW 500 Series EVR Fill Spill Containment Bucket
OPW 500 Series EVR Vapor Spill Containment Bucket
OPW 2100 Series EVR Fill Spill Containment Bucket
OPW 2100 Series EVR Vapor Spill Containment Bucket
Yes __
Yes __
Yes __
Yes __
No__
No__
No__
No__
OPW FSA-400, or FSA-400-S Threaded Riser Adaptor (Face Seal Adaptor)
On Fill Riser (Required) Yes ___ No ___
On Tank Probe Riser (Required)
On Vapor Riser (Optional)
Yes ___
Yes ___
No ___
No ___
OPW 61SO 400 EVR Series Overfill Prevention Valve
OPW 71SO 400 EVR Series Overfill Prevention Valve
Yes ___
Yes ___
No ___
No ___
OPW 61JSK Jack Screw Assembly
61JSK-4410 (Use with composite base spill bucket) Yes ___
61JSK-44CB (Use with cast iron base spill bucket) Yes ___
OPW 61VSA Vapor Swivel Adaptor
OPW 61SALP Fill Swivel Adaptor
OPW 634TT Top Seal EVR Fill Cap
OPW 1711T Top Seal EVR Vapor Cap
OPW 634LPC Low Profile Top Seal EVR Fill Cap
OPW 1711LPC Low Profile Top Seal EVR Vapor Cap
OPW 623 Pressure Vacuum Vent
Yes ___
Yes ___
Yes ___
Yes ___
Yes ___
Yes ___
Yes ___
No ___
No ___
No ___
No ___
No ___
No ___
No ___
No ___
No ___
OPW 53VML Ball Float Vent Valve
OPW 30MV Ball Float Vent Valve
Yes ___
Yes ___
No ___
No ___
________________________________________________________________________
Installation acknowledgment
Installed OPW FSA-400 (-S) Threaded Riser Adaptor (Face Seal Adaptor) on fill riser and tightened to ___________ ft. lb.
Thread sealant compound used_______________________
Installed OPW FSA-400 (-S) Threaded Riser Adaptor (Face Seal Adaptor) on tank probe riser and tightened to ___________ ft. lb.
Thread sealant compound used_______________________
Optional:
107
Installed OPW FSA-400 (-S) Threaded Riser Adaptor (Face Seal Adaptor) on vapor riser and tightened to ___________ ft. lb.
Thread sealant compound used_______________________
Installed OPW 2100 Series ____ or 500 Series ___ Fill spill containment bucket onto FSA-400 attached to fill riser and tightened to ___________ ft. lb.
Thread sealant compound used_______________________
Installed OPW 2100 Series ____ or 500 Series ____ vapor spill containment bucket onto vapor riser and tightened to ___________ ft. lb.
Thread sealant compound used_______________________
Assembled 61SO-400C-EVR Series overfill prevention valve
Used supplied
Applied epoxy: To upper 1” inside of top tube; under cinch head bolts and lock washers; on threads of valve body at lower tube connection.
Allowed epoxy to cure for 24 hours before exposure to fuel or vapor
Installed OPW 61SO 400C-EVR Series overfill prevention valve into fill spill containment
Assembled 71SO-400C-EVR Series overfill prevention valve
Used 71SO-TOOLC
Installed 71SO-400C-EVR Series overfill prevention valve into fill spill containment bucket.
Alternative to 61SO:
Installed OPW 61T Straight Drop Tube into fill spill containment bucket.
Installed OPW 61JSK Jack Screw assembly on top of 61SO 400C-EVR Series overfill prevention valve or on top of 61T Series Straight Drop Tube.
Yes
Screws tightened to ______________ ft. lb.
Installed faced off 4” NPT pipe nipple in fill spill containment bucket and tightened nipple to
________ ft. lb.
Thread sealant compound used __________________________
Tool used to install nipple ______________________________
Installed faced off 4” NPT pipe nipple in vapor spill containment bucket and tightened nipple to
________ ft. lb.
Thread sealant compound used __________________________
Tool used to install nipple ______________________________
Installed OPW 61 SALP Fill Swivel Adaptor onto faced off 4” NPT pipe nipple in fill spill containment bucket and tightened fill adaptor to ________ ft. lb.
Thread sealant compound used __________________________
Tool used to install nipple ______________________________
108
Installed OPW 61 VSA Vapor Swivel Adaptor onto faced off 4” NPT pipe nipple in vapor spill containment bucket and tightened vapor adaptor to ________ ft. lb.
Thread sealant compound used __________________________
Tool used to install nipple ______________________________
OPW 61 SA-Tool used to install OPW components Yes ___ No ___
109
Vapor Recovery Test Procedure
TP-201.1B
Static Torque of Rotatable Phase I Adaptors
Adopted: July 3, 2002
Amended: October 8, 2003
110
California Environmental Protection Agency
Air Resources Board
Vapor Recovery Test Procedure
TP-201.1B
Static Torque of Rotatable Phase I Adaptors
Definitions common to all certification and test procedures are in:
D-200 Definitions for Vapor Recovery Procedures
For the purpose of this procedure, the term "CARB" refers to the California Air Resources Board, and the term
"Executive Officer" refers to the CARB Executive Officer, or his or her authorized representative or designate.
1. PURPOSE AND APPLICABILITY
The purpose of this procedure is to quantify the amount of static torque required to start the movement of a rotatable Phase I adaptor and to ensure 360-degree rotation. This procedure determines compliance with the performance specifications set forth in Section 3 of CP-201
Vapor Recovery Certification Procedure.
2. PRINCIPLE AND SUMMARY OF TEST PROCEDURE
A compatible dust cap is installed on a rotatable Phase I adaptor. A Torque Test Tool is installed on the dust cap. A socket wrench is installed on the Torque Test Tool and 360degree rotation is verified. Following the rotation test, a torque wrench is installed on the
Torque Test Tool and three static torque measurements are taken. If the resulting, average static torque is less than, or equal to, the maximum allowable value specified in
Certification Procedure 201 (CP-201), the adaptor is verified to be in compliance.
3. BIASES AND INTERFERENCES
3.1
Missing or defective gaskets in the dust cap may bias the results towards compliance as a dust cap may slip on the rotatable adaptor prior to the adaptor rotating. This bias is eliminated by ensuring that the dust cap seal is securely in place and does not show signs of excessive wear or damage.
3.2
Gasoline or other lubricants on the sealing surface of the rotatable adaptor or the dust cap seal can cause the dust cap to slip and may bias the results towards compliance. This bias is eliminated by ensuring that the sealing surface of the rotatable adaptor and dust cap is clean, dry and free of lubricants.
111
4. SENSITIVITY, RANGE, AND PRECISION
4.1
Torque Wrench. The maximum full-scale range shall be 250 pound-inches with minimum accuracy of 3.0 percent full-scale and minimum readability of 5 pound-inch increments. The torque wrench shall incorporate a mechanism, such as a tell-tale needle that identifies the maximum applied torque during each measurement.
5. EQUIPMENT
5.1
Torque Wrench. Use a Snap-On
®
Model TER12FUA Torque Wrench, or equivalent, to measure the static torque of the rotatable adaptor.
5.2
Static Torque Test Assembly. Use a compatible dust cap and rotatable adaptor Torque Test
Tool, Phil-Tite
®
Part Number 6004, or equivalent. A depiction of a Torque Test Tool is shown in Figure 1. An example of a Static Torque Test Assembly is shown in Figure 2.
5.3
Socket wrench and socket extension. Use a
3
/
8
inch or ½ inch socket wrench, adaptors and socket extension (if needed) to verify 360-degree rotation or to conduct static torque testing.
The socket extension shall not exceed 12 inches in length.
Figure 1
Phil-Tite
®
Torque Test Tool
112
Figure 2
Static Torque Test Assembly
Torque Test Tool
Dust Cap
Rotatable Adapter
Torque Test Assembly
6. PRE-TEST
6.1
Remove the lids of the Phase I spill containers. Visually determine that the adaptors are of the rotatable design.
6.2
Inspect the dust caps to ensure that the caps and that the gaskets are intact and do not show signs of excessive wear or damage.
6.3
Inspect the rotatable adaptors. If the adaptors are wet or covered with a lubricant, wipe the adaptors clean to ensure maximum friction between the dust cap and the adaptor seal surface.
7. TEST
7.1
7.2
7.3
Install the dust cap on the Phase I rotatable adaptor.
Install the Torque Test Tool on the dust cap as shown in Figure 2.
Verification of rotation, conducted prior to the Static Torque Test. Place a socket wrench with socket extension (if required) into the Torque Test Tool, or equivalent. Rotate the
113
adaptor a minimum of 360 degrees. Do not continue with static torque measurements if the adaptor does not rotate 360 degrees. Record the result on the data sheet where provided.
7.4
Install the Torque Wrench into the Torque Test Tool. If the spill container is too deep to allow connection of the Torque Wrench, use a compatible socket extension to reach into the bucket to the Torque Test Tool. The socket extension shall not exceed 12 inches in length.
7.5
Place one hand on top of the Torque Wrench, directly above the center of the Torque
Test Tool to keep the wrench level while applying pressure. Gently apply an even, steady pressure just until the adaptor begins to rotate. Record the maximum applied static torque value shown on the torque wrench and proceed to 7.6.
7.6
After the first measurement, slowly rotate the adaptor one third of full rotation (120 degrees) from the point that the first measurement was taken. Using the same technique described in 7.5, measure and record the second torque measurement.
7.7
Following the first two measurements, slowly rotate the adaptor another, one third of full rotation (120 degrees) from the second measurement location. Using the same technique as described in 7.5, measure and record the third torque measurement. Rotating the adaptor in one-third increments ensures that the average static torque is representative of the entire adaptor rotation.
8. POST-TEST
8.1
Remove the Torque Test Assembly and replace the appropriate lids on each of the spill containers. Store all test equipment in a protected location to prevent damage to the equipment.
9.
CALCULATING RESULTS
9.1
Calculate the arithmetic average of the three tests for each adaptor tested and record the value on the data sheet where provided.
10.1 Report the results of the static torque measurements on the data sheet where provided.
Alternate data sheets may be used provided they include the same parameters identified on Form 1.
11. ALTERNATE
11.1
This procedure shall be conducted as specified. Modifications to this test procedure shall not be used to determine compliance unless prior written approval has been obtained from the
Executive Officer, pursuant to Section 14 of Certification Procedure CP-201.
114
Form 1
Static Torque of Rotatable Phase I Adaptors
Test Company:
Test Date:
Conducted By
Facility Name:
:
Facility Address: City:
Measurement Units:
(circle one):
pound-inches pound-feet
Vapor Adaptor 1 Vapor Adaptor 2 Vapor Adaptor 3 Vapor Adaptor 4
Brand: Brand: Brand: Brand:
Model: Model: Model: Model:
Grade: Grade: Grade: Grade:
Torque 1:
Torque 2:
Torque 3:
Average:
Torque 1:
Torque 2:
Torque 3:
Average:
Torque 1:
Torque 2:
Torque 3:
Average:
Torque 1:
Torque 2:
Torque 3:
Average:
360 Rotation: Yes / No 360 Rotation: Yes / No 360 Rotation: Yes / No 360 Rotation: Yes / No
Product Adaptor 1 Product Adaptor 2 Product Adaptor 3 Product Adaptor 4
Brand: Brand: Brand: Brand:
Model: Model: Model: Model:
Grade: Grade: Grade: Grade:
Torque 1:
Torque 2:
Torque 3:
Average:
Torque 1:
Torque 2:
Torque 3:
Average:
Torque 1:
Torque 2:
Torque 3:
Average:
Torque 1:
Torque 2:
Torque 3:
Average:
360 Rotation: Yes / No 360 Rotation: Yes / No 360 Rotation: Yes / No 360 Rotation: Yes / No
Comments:
115
• 9393 Princeton-Glendale Road • Cincinnati, Ohio 45011 • Tel: (800) 422-2525 • Fax: (800) 421-3297 •
• www.opw-fc.com •
EVRTM-11/07
116
OPW Stage I EVR
Addendum
OPW 1-3100 Series Spill Container Page 2
OPW Installation and Maintenance Instructions
OPW 1-3100 Series Thread-On Double Wall Grade Level Spill Containers
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100 Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
In some states it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-3100 Series Thread-On spill container models equipped with a drain plug.
WARNING: If the snowplow ring is removed, for any reason, follow the Operation and Maintenance instruction as noted. Replace o-rings and seals and install new ones.
Never reuse damaged o-rings or seals as it may result in an improper seal. Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other than fuel prior to delivery. If water or contaminates are present, then they MUST be removed before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver MUST drain any excess fuel that may have spilled into the container from their delivery hose.
1-3100 Series Performance Specifications:
This Spill Container drain valve has been manufactured and tested to the following specifications: Leak Rate to be less than or equal to 0.17 CFH @ 2.0 " W.C.
Torque Specification:
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
4" Nipple: 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Note: All 4” NPT threads are to be torqued progressively lower from the tank up.
Drain Valve clamps: 5/16-18 UN thread, 11.5 ft-lbs minimum to 13.5 ft-lbs maximum.
Ring and Nipple Adaptor Bolts: 3/8-16 UN, 20 ft-lbs minimum to 25 ft-lbs maximum.
Tools Recommended:
1-3100-TOOL
– Torque Installation Tool
DW-VAC-TEST
– Vacuum Test Equipment
(or 202310 Test Adaptor)
OPW 1-3100 Series Spill Container Page 3
OPW NO. 1-3100 SERIES GRADE LEVEL SPILL
CONTAINER INSTALLATION INSTRUCTIONS:
Step 1: (See Figures 1 & 2)
Determine riser pipe height. "L" is the distance between the top of the riser pipe and finish grade.
Note: The spill container height (from riser to grade) is L+ 1”.
Model Series
“L” Dimension
1-3100, 5 Gal. (Cast Iron Base) L=15 5/8" (40cm)
Step 2:
De-burr and thoroughly clean riser pipe. Apply pipe dope to riser threads. Pipe dope to be a nonhardening, gasoline resistant pipe thread seal compound.
Step 3:
Install gravel guard on riser pipe. Leave band clamp loose.
Note: Ground riser pipe to nearest grounding rod.
Step 4:
Install spill container by rotating the mounting ring until hand tight.
Note: Do NOT attempt to completely tighten the container using the mounting ring. Doing so may cause the unit to fail.
Step 5: (See Figure 2)
Finish tightening the spill container secondary base using the wrenching boss or with the 1-3100-TOOL.
Torque to 125 ft-lbs min. to 250 ftlbs max (4” NPT).
1-3100-TOOL can be used to set final torque (see 1-
3100-TOOL instructions).
Step 6: (See Figures 2 & 3)
Remove Nipple Adaptor from spill container. Apply pipe dope to nipple and install in Nipple Adaptor.
Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound. Use only factory made nipples. Torque nipple to 125 ft-lbs min. to 250 ft-lbs max. (4” NPT). 1-3100-TOOL can be used to set final torque. Torque value is based on rotation at the center of pipe. For standard covers install rotatable adaptor and dust cap per manufacturers’ instructions.
For sealable cover (1SC) models, install a standard
4" pipe cap to support adjustment system. (Adaptor and dust cap must be installed in sealable cover (SC) models after concrete has dried. Install drop tube, overfill prevention valve and/or loose jack screw assembly if used (61JSK-
44CB) per manufacturers’ instructions. Reinstall the Nipple Adaptor in spill container. Torque Nipple Adaptor bolts to 20 ft-lbs minimum to 25 ft-lbs maximum.
Note: Nipple length is determined by measuring from the bottom of the threaded portion of the base to the bottom of the cover. Then subtract 2” minimum for clearance, height of adaptor and height of cap.
Range of nipple lengths that can be used in all of the
OPW spill containers: 4” minimum to 9” maximum.
See Figure 6.
OPW 1-3100 Series Spill Container
Figure 1
Finish Grade
Slope 1” Min.
Snowplow Ring
Mounting Ring
Dust Cap
Rotatable Adaptor
Nipple
Nipple Adaptor
Top of Riser Pipe
Gravel Guard
Grounding Lug
Wrenching Boss
Band Clamp
Riser Pipe
L
Figure 2
Clamp Nipple to Prevent Rotation When Tightening
Figure 3
Finish Grade
Nipple
Nipple Adaptor
1-3100-TOOL
Page 4
Step 7: (See Figure 4 & 8)
If necessary, the height of the spill container can be adjusted by ±1" (2.5cm). If it is necessary to increase height, install adjusting system (sold separately, part number 203931) beneath tabs on mounting ring. See
Figure 4 for standard cover models and Figure 8 for sealable cover models. Add shims as needed and adjust with screw (shims must be cut to size for sealable cover models).
Note: The adjustment should not be more than 1" from the initial length of the unit.
Step 8:
Where applicable, upon preliminary installation perform the CARB Test Procedure TP-201.1C or equivalent. This Test Procedure will check the seals between the drain valve, nipple, bases, and rotatable adapter.
Note: Follow all state and local required testing on the primary and secondary buckets.
Step 9: (See Figure 7)
Verify torque on mounting ring bolts. Torque to be 20 ft-lbs minimum to 25 ft-lbs maximum.
Using OPW DW-VAC-TEST (or 202310 Test
Adaptor), perform a vacuum test on the spill container. An initial vacuum of 15” of water should be attained and the spill container must retain a vacuum of at least 12” of water after 5 minutes. (See
DW-VAC-TEST Instructions.)
Step 10: (See Figure 2)
Install gravel guard at final height as shown in Figure
2 and tighten band clamp to 30 in-lbs. Where applicable, per California SB-989, all metal must be protected from direct contact with the elements. Coat stainless steel band clamp with the following approved coatings: OPW SL-1100, 3M Underseal
08883 or Polyguard Mastic CA-9.
Step 11: (See Figures 2 & 5)
Before pouring concrete, place plastic over the cover and Mounting Ring protecting them from concrete splash and tighten the clamp on the gravel guard mounted on the riser pipe. Double check that the unit is level and at proper grade height. Pour concrete per Figure 5. Ramp or dome the concrete away from the mounting ring. There should be a minimum of 1” slope to finish grade.
Note: Do not stand on spill container before concrete sets up.
Remove plastic from cover after concrete has dried.
Remove adjustment system. Re-test the spill containers for leaks as described in step 9, after the concrete has set up.
Operation and Maintenance:
After each fuel delivery, the operator must remove any standing fuel from the container. Fuel can be removed by actuating the drain valve or with a gasoline absorbing disposable towel. If access to drop tube or overfill valve is required remove Nipple
Adaptor from primary bucket.
Weekly: Perform a visual inspection of the interior of
OPW 1-3100 Series Spill Container the primary containment bucket for water or other contaminants and check the secondary containment bucket by checking the gauge in the base of the spill container. If water or other contaminants are found they must be disposed of with disposable towels.
Dispose of towels safely and per all applicable local, state and federal codes. Check that cover is in good condition and properly identified. Replace cover and seal as necessary. Inspect the bucket walls for cracks, bulges or holes. If any exist, have that spill container barricaded and contact maintenance personnel immediately for repairs.
Semiannually: Follow all state and local required hydrostatic or vacuum testing on the primary and secondary buckets. Inspect and clean the interior of the spill container and drain valve screen. Remove accumulated dirt and grit. Where applicable, test the drain valve using CARB procedure TP-201.1C or TP-
201.1D. If the drain valve passes testing no further maintenances required. If the drain valve fails testing, remove the valve, soak in water and use highpressure air, if needed, to clean. Reinstall the drain valve to its proper position and where applicable, test the valve with CARB procedure TP-201.1C or TP-
201.1D. If problems persist, replace the drain valve with P/N 1DK-2100-EVR (specified torque 11.5 ft-lbs min to 13.5 ft-lbs max, 5/16-18 UN thread). The sealable cover (1SC) adjustment nut is set at the factory, but due to environmental conditions it may be necessary to adjust it to either improve sealing or ease cover removal.
Important: Leave these instructions with Station
Operator.
Height Adjustment Bolt
Adaptor
Figure 4
Shims
Page 5
2” Min Clearance
C
B
A
Height Adjustment Bolt
Length of Nipple = Dimension A
– Dimension B – Dimension C – 2” Min
Figure 6
ID Tag
Mounting Ring Bolts
22-
1/8”
Ref
Nipple
Use OPW
116-7085 or
4” Pipe Cap to
Support
Adjustment
System
Figure 8
Shims
Must be
Cut to
Length
Manufacturer: OPW
Model: 1-Series Double Wall
Spill Container
Size: 5 Gallon
Cast Iron Base
Date Manufactured: MMYY
MM = Month, YY = Year
9393 Princeton-Glendale Rd.
Hamilton, Ohio 45011
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2009
OPW Fueling Components Inc.
Cincinnati, OH
Printed in U.S.A. p/n 202181
– Rev E - 07/09
OPW 1-3100 Series Spill Container
Figure 7
Page 6
OPW 1-3100 Series Spill Container Page 7
OPW 1-3100 Series Spill Container Page 8
OPW Installation and Maintenance Instructions
OPW 1-3122 and 1-3132 Series Thread-On Double Wall Grade Level Spill
Containers with Electronic Sensor Access Port
IMPORTANT: Please read these warnings and follow the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100 Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage or death. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. THERE ARE NO WARRANTIES, WHICH
EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF.
In some states it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-3100 Series Thread-On spill container models equipped with a drain plug.
WARNING: If the snowplow ring is removed, for any reason, follow the Operation and Maintenance instruction as noted. Replace o-rings and seals and install new ones.
Never reuse damaged o-rings or seals as it may result in an improper seal. Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other than fuel prior to delivery. If water or contaminates are present, then they MUST be removed before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver MUST drain any excess fuel that may have spilled into the container from their delivery hose.
1-3122 & 1-3132 Series Performance
Specifications:
Torque Specification:
Ring Bolts: 3/8-16 UN, 20 ft-lbs minimum to 25 ft-lbs maximum.
Plug in Secondary Base, 1-
1/2” NPT, 100 to 130 ft-lbs.
Tools Recommended
1-3100-TOOL
– Torque Installation Tool
9/16”, 7/8”, and 1-7/16” hex socket
Torque wrench
Large slotted screwdriver
Note: No bucket disassembly is required to install this product.
The 1-3122 series of products is compatible with sensors that are 1-
1/2” in diameter or less and 4” or less in height. Sensors that are known to meet these dimensions are OPW FMS 30-3221-1A,
OPW FMS 30-3221-1B, VR 794390-420, & VR
794390-460. The grommet supplied with the sensor must have third party approval. The 1-
3132 series of products is supplied with an OPW
FMS 30-3221-1A sensor.
OPW 1-3100 Series Spill Container Page 9
10-1/2”
Sensor
1” Min
Clearance
Conduit
(customer
Supplied)
Sensor
Adaptor
Adaptor
O-Ring
Primary
Bucket
Secondary
Bucket
Grommet
(supplied with sensor)
1-
1/2” Plug
Seal off
(customer
Supplied)
Top View into Guard
Figure 1
OPW 1-3100 Series Spill Container Page 10
1-3100 SERIES ELECTRONIC SENSOR
INSTALLATION INSTRUCTIONS
(Only applies to 1-3122 & 1-3132 models)
For 1-3132 models skip to Step 6.
Step 1: (See Figure 2)
Before installing spill container onto riser pipe remove 1-
1/2” Plug from secondary base using a 1-
7/16” wrench. Check the sensor that is going to be installed to ensure that it works properly.
Step 2: (See Figure 2)
Remove 3/8” Plug from 1-1/2” Plug. The 1-1/2” plug comes with the capability to handle 1/2” NPT or 3/8”
NPT threads, the included bushing can be removed if 1/2” NPT threads are needed. Install grommet with pipe dope into plug and tighten per manufacturer’s instructions. Pipe dope to be a nonhardening, gasoline resistant pipe thread seal compound. Pass sensor wiring thru grommet
(supplied with sensor) and plug. At least 4 feet of wire should be between the sensor and the grommet, tighten grommet per manufacturer’s instructions (Note: All joints must be vacuum tight).
3/8” NPT
1/2” NPT
1-
7/16”
Hex
1-
1/2” NPT
Figure 2
Step 3: (See Figures 1 & 3)
Using the two supplied ty-raps wrap a loop in the wire that is 10-
1/2” from the bottom of the sensor to the top of the loop as shown in Figure 1. Trim tyraps after attaching. Ensure enough wire is available for sensor to reach grade for future testing.
A service loop should be left in the secondary bucket in case sensor replacement is ever required in the future.
Step 4: (See Figures 1 & 3)
Remove white sensor adaptor from primary bucket.
Pass sensor and wire thru hole in the bottom of the secondary base and fish up thru the hole in the primary base that the sensor adaptor was removed from. Install 1-
1/2” Plug back into bottom of secondary base with pipe dope being careful not to
OPW 1-3100 Series Spill Container twist sensor wire when tightening. Torque plug to
100 to 130 ft-lbs (Note: a 1-
7/16” crow’s foot wrench can be used).. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound.
Ensure sensor wire is not twisted after plug installation.
Step 5: (See Figure 1)
From this point on in the installation the bucket should be kept in a vertical position as shown in
Figure 1. Feed excess wire into secondary bucket.
Align sensor with the hole in the primary base where the sensor adaptor will be installed as shown in
Figure 1. Ensure sensor is as flat as possible on bottom of secondary base. Inspect o-ring on sensor adaptor replace if it is not in good condition. Thread sensor adaptor back into primary bucket until o-ring is no longer visible (approximately 6 turns), do not overtighten.
Step 6:
Drill hole in guard to allow conduit to pass thru.
Pass conduit (customer supplied) thru guard. Attach conduit to seal off (customer supplied). Seal off should be positioned approximately 23” to 23-1/2” from the top of the bucket to the centerline of the seal off and should be positioned so as to not interfere with the secondary base during installation.
Step 7:
Thread bucket onto riser pipe per installation instructions for 1-3100 Series (p/n 202181) as shown in Steps 1-5. Be careful not to damage sensor wiring during installation of bucket onto riser pipe.
Step 8: (See Figures 1 & 3)
Attach sensor wiring to conduit as shown in Figures
1 & 3. Ensure adequate clearance (1” or more) is left between secondary base and seal off (customer supplied) to allow for bellows movement. Ensure no obstructions are directly below the plug in the secondary base to enable removal of the plug in the future. Use SL-1100 or equivalent to seal around conduit where hole was drilled in guard to prevent backfill from entering. Complete sensor wiring per sensor manufacturer’s instructions and all applicable codes and regulations. Ensure sensor is working properly.
Step 9:
Complete bucket installation per installation instructions for 1-3100 Series (p/n 202181) as shown in Steps 6-11.
Sensor can be tested as required by removing the sensor adaptor and pulling the sensor to grade. The sensor can be tested by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm. Reinstall sensor as in step 5.
Page 11
Figure 3
9393 Princeton-Glendale Rd, Hamilton, Ohio 45011
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2009, OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A., p/n 202574
– Rev D. - 11/09
OPW 1-3100 Series Spill Container Page 12
OPW 1-3100 Series Spill Container Page 13
OPW 1-3100 Series Spill Container Page 14
OPW 1-3100 Series Spill Container Page 15
OPW 1-3100 Series Spill Container Page 16
OPW Installation and Maintenance Instructions
OPW 1-3100 Series Primary and Secondary Bucket Replacement Instructions
IMPORTANT: Please read these warnings and follow the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100 Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage or death. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
In some states it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-3100 Series Thread-On spill container models equipped with a drain plug.
WARNING: If the snowplow ring is removed, for any reason, follow the Operation and Maintenance instruction as noted. Replace o-rings and seals and install new ones.
Never reuse damaged o-rings or seals as it may result in an improper seal. Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other than fuel prior to delivery. If water or contaminates are present, then they MUST be removed before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver MUST drain any excess fuel that may have spilled into the container from their delivery hose.
Replacement Kit (p/n 203172) Contents:
Seal
Set Screws
Base O-Ring
201689
203171
201692
Qty. 2
Qty. 8
Qty. 1
Adaptor O-Ring
Gage O-Ring
Torque Specifications:
201972
202013
Qty. 1
Qty. 1
Ring Bolts: 3/8-16 UN, 20 ft-lbs minimum to 25 ft-lbs maximum.
Primary Bucket to Secondary Bucket: 40 ft-lbs minimum to 100 ft-lbs maximum.
Secondary Bucket to Riser Pipe: 125 ft-lbs min to
250 ft-lbs max. Note:
All 4” NPT threads are to be torqued progressively lower from the tank up.
Tools Recommended:
1-3100-TOOL
– Torque Installation Tool
9/16” hex socket
Torque wrench
DW-VAC-TEST
– Vacuum Test Equipment
(or 202310 Test Adaptor)
OPW 1-3100 Series Spill Container Page 17
1-3100 SERIES PRIMARY AND SECONDARY
BUCKET REPLACEMENT INSTRUCTIONS
NOTE: These instructions only apply when a primary or secondary bucket requires removal. Standard installation does not require
disassembly of buckets.
Step 1:
Remove nipple adaptor, jack screw kit, and drop tube or overfill prevention valve from spill container.
Step 2: (See Figure 1)
Remove white plastic adaptor from the primary bucket. On models (1-3112 series) with a mechanical float gage removing the adaptor will also remove the float gage. On models with a sensor (1-
3122 & 1-3132 series) push the sensor and wiring down into the interstitial space.
Step 3:
Disconnect drain valve split ring from tab on snowplow ring. Remove eight bolts (9/16 hex) from snowplow ring. Remove snowplow ring and discard seal. Set ring, lock washers, and bolts aside. Note:
Seal must be replaced before installing new bucket.
Step 4: (See Figure 2)
Remove primary bucket using 1-3100-TOOL as shown in tool instruction sheet 202395 (ensure large slot on tool is aligned with drain valve). When removing primary bucket ensure that only the primary bucket is rotating. A visual check by viewing into the hole in the primary base or into the middle of the base can confirm that only the primary bucket is rotating.
If initial installation was installed to the proper torques the secondary bucket will not rotate.
If secondary bucket is rotating on a sensor style
(1-3122 & 1-3132 series) spill container the
sensor wiring will be damaged if disassembled.
Do not continue disassembling unless prepared to replace all sensor components including sensor, wiring, and seal off.
If secondary bucket is rotating on a float gage style
(1-3112 series) disassembly can continue as long as the proper tools are available to disassemble the buckets after removal from the riser pipe. To disassemble this model after removing from the riser pipe secure boss on the secondary base with a vise or pipe wrench and remove primary bucket with 1-
3100-TOOL.
Note: If replacing only the primary bucket, skip to step 9.
OPW 1-3100 Series Spill Container
Figure 1
Figure 2
Figure 3
Page 18
White
Plastic
Adaptor
1-3112 Series Secondary Bucket Only
(Float Gauge Models)
Step 6: (See Figure 3)
Remove secondary bucket using 1-3100-TOOL as shown in instruction sheet 202395. Note: Seal must be replaced before installing new bucket.
Step 7: (See Figure 3)
Install new secondary bucket using 1-3100-TOOL to torque the secondary bucket to 125 ft-lbs min to 250 ft-lbs max. Align bolt holes in secondary bucket to holes in the ring. Proceed to step 9.
1-3122 Series Secondary Bucket Only
Replacement Kit (p/n 202943) Required
(Customer Supplied Sensor Model)
Tools Recommended:
¾” & 7/8” hex sockets (for OPW 30-3221-1A sensor)
Magnetic Pickup Tool
Magnetic Object (must fit thru 9/16” diameter hole)
Step 1-3122 #1: (See Figure 1-3122 #1)
If sensor style (1-3122 series) a 202943 Wire Splice
Kit will need be needed to replace the secondary bucket. Ensure that the sensor is functional if not it will need to be replaced. Test the sensor by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm.
Step 1-3122 #2: (See Figure 4)
Cut the sensor wire approximately 2 feet away from the plug in the secondary base. Loosen the dome nut on the top of the grommet in the 1-
1/2” plug
(recommended tool is ¾” crowfoot wrench for OPW
30-3221-
1A sensor). Remove the grommet (7/8” hex on OPW 30-3221-1A sensor) from the 1-
1/2” plug and slide the grommet off of the wire. Attach a magnetic object capable of fitting th ru a 9/16” diameter hole to the end of the wire that runs thru the secondary base. Pass the object and wire thru the 1-
1/2” Plug in the secondary base.
3/8” NPT
1/2” NPT
1-
7/16”
Hex
1-
1/2” NPT
Figure 1-3122 #1
OPW 1-3100 Series Spill Container
Step 1-3122 #3: (See Figure 3)
Remove secondary bucket using 1-3100-TOOL as shown in instruction sheet 202395. Note: Seal must be replaced before installing new bucket. A new seal is included with the bucket replacement kit.
Step 1-3122 #4: (See Figure 3 & 1-3122 #2)
Note the location of the wire and magnetic object in the gravel guard then install new secondary bucket using 1-3100-TOOL to torque the secondary bucket to 125 ft-lbs min to 250 ft-lbs max. Using a magnetic pickup tool pull the magnetic object and wire back thru the plug and secondary base into the interstitial space. Align bolt holes in secondary bucket to holes in the ring. Install new seal.
Pull wire back thru plug
Figure 1-3122 #2
Step 1-3122 #5:
Apply pipe dope to threads of grommet, pass wire thru grommet, and reinstall the grommet in the 1-
1/2” plug, tig hten per manufacturer’s instructions.
Tighten dome nut on grommet per manufacturer’s instructions (Note: All joints must be vacuum tight).
Step 1-3122 #6:
Before reconnecting sensor wire, verify that the factory installed loop in the sensor wire is 10-1/
2” tall from the bottom of the sensor to the top of the loop.
The 202943 Wire Splice Kit is required in order to reconnect the wires.
Note: Splice is to be installed no closer than 2 feet from the sensor loop.
Note: At least 4 feet of wire should be between the sensor and the grommet.
Step 1-3122 #7: (See Figure 1-3122 #3)
Remove the end caps from the splice kit barrel.
Cut the tip off of one of the cones on each of the end caps so that the end cap will fit snugly around the sensor wiring.
Page 19
End
Cap
End
Cap
Barrel
Sleeve
Figure 1-3122 #2
Step 1-3122 #8: (See Figure 1-3122 #4)
Insert the sensor wire from the secondary base through the hole in one of the end caps and the wire attached to the sensor through the hole in the other end cap and slide the end caps out of the way.
Slide barrel and sleeve onto the sensor wire and slide out of the way as shown in Figure 1-3122 #4.
Sensor wire from secondary base
Wire from sensor
Figure 1-3122 #4
Step 1-3122 #9:
Using the included wire nuts, join the wires per the sensor manufacturer’s instructions. Using the included split bolt, securely fasten the two wire ends together.
Step 1-3122 #10:
Center the barrel and sleeve over the splice and slide end caps onto the barrel.
Step 1-3122 #11:
Warm the included compound to at least 60° F (15°
C). As shown in the compound mixing instructions, break the center barrier in compound bag by grasping the sides of the bag and rolling thumbs through the barrier. Thoroughly mix the compound, being sure to strip the compound from the corners while mixing.
Step 1-3122 #12:
Cut one corner off of bag and pour the compound through the opening in the barrel until completely full.
OPW 1-3100 Series Spill Container
Step 1-3122 #13:
Close the barrel by centering the sleeve over the hole in the barrel and rotating the sleeve around the barrel until the hole is completely covered
Step 1-3122 #14:
Test the sensor by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm. If sensor functions properly proceed to step 9.
1-3132 Series Secondary Bucket Only
Replacement Kit (p/n 202943) Required
(Customer Supplied Sensor Model)
Tools Recommended:
1-
1/4” Crowfoot Flare Nut 12 Point Wrench
Magnetic Pickup Tool
Magnetic Object (must fit thru 1-
3/4” diameter hole)
Step 1-3132 #1:
If sensor style (1-3132 series) a 202943 Wire Splice
Kit will need be needed to replace the secondary bucket. Ensure that the sensor is functional if not it will need to be replaced. Test the sensor by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm.
Step 1-3132 #2:
Remove the 1-
1/2” plug from the secondary bucket using a 1-
1/4” crowfoot flare nut 12 point wrench on the hex of the plug. Pull plug into secondary bucket and cut sensor wire at least six inches below plug.
Step 1-3132 #3:
Remove secondary bucket using 1-3100-TOOL as shown in instruction sheet 202395. Note: Seal must be replaced before installing new bucket. A new seal is included with the bucket replacement kit.
Step 1-3132 #4:
Inspect sensor wiring and ensure wire was not damaged when plug was removed (damaged wiring must be replaced). Attach a magnetic object capable of fitting thru a 1-
3/4” diameter hole to the end of the sensor wire that is in the gravel guard.
Step 1-3132 #5:
Check the number of turns required by hand to install the sensor plug back into the secondary base as this information will be needed in step 1-3132 #17
(should be about 5 to 7 turns). Remove the sensor plug from the secondary base.
Step 1-3132 #6:
Ensure grommet is tight. Check both dome nut on wire and thread into plug.
Page 20
Step 1-3132 #7: (See Figure 3 & 1-3132 #1)
Note the location of the wire and magnetic object in the gravel guard then install new secondary bucket using 1-3100-TOOL to torque the secondary bucket to 125 ft-lbs min to 250 ft-lbs max. Using a magnetic pickup tool pull the magnetic object and wire back thru the secondary base into the interstitial space.
Align bolt holes in secondary bucket to holes in the ring. Install new seal.
Figure 1-3132 #2
Step 1-3132 #9: (See Figure 1-3132 #2)
Insert the sensor wire coming through the secondary base in one of the end caps and the wire attached to the plug through the hole in the other end cap and slide the end caps out of the way. Slide barrel and sleeve onto the sensor wire and slide out of the way as shown in Figure 1-3132 #3.
Sensor wire from secondary base
Pull wire back thru secondary base
Figure 1-3132 #1
Step 1-3132 #8: (See Figure 1-3132 #2)
Reconnect wires with the 202943 Wire Splice Kit.
Remove the end caps from the splice kit barrel. Cut the tip off of one of the cones on each of the end caps so that the end cap will fit snugly around the sensor wiring.
End
Cap
End
Cap
Barrel
Sleeve
OPW 1-3100 Series Spill Container
Wire from plug
Figure 1-3132 #3
Step 1-3132 #10:
Using the included wire nuts, join the wires per the sensor ma nufacturer’s instructions. Using the included split bolt, securely fasten the two wire ends together.
Step 1-3132 #11:
Center the barrel and sleeve over the splice and slide end caps onto the barrel.
Step 1-3132 #12:
Warm the included compound to at least 60° F (15°
C). As shown in the compound mixing instructions, break the center barrier in compound bag by grasping the sides of the bag and rolling thumbs through the barrier. Thoroughly mix the compound, being sure to strip the compound from the corners while mixing.
Step 1-3132 #13:
Cut one corner off of bag and pour the compound through the opening in the barrel until completely full.
Step 1-3132 #14:
Close the barrel by centering the sleeve over the hole in the barrel and rotating the sleeve around the barrel until the hole is completely covered
Step 1-3132 #15:
Test the sensor by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm.
Step 1-3132 #16:
Wait at least 5 minutes then feed the splice kit and excess wire into the gravel guard.
Page 21
Step 1-3132 #17: (See Figure 1-3132 #4)
Apply pipe dope to threads of plug then wrap the sensor wire below the plug in a counterclockwise direction the number of turns determined in step 1-
3132 #5.
Wrap wire in
CCW direction
Figure #1-3132 #4
Step 1-3132 #18:
Install 1-
1/2” plug back into base and torque to 100 to 130 ft-lbs with 1-
1/4” crowfoot flare nut 12 point wrench.
Step 1-3132 #19:
Test the sensor by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm. If sensor functions properly proceed to step 9.
OPW 1-3100 Series Spill Container Page 22
Step 9:
(Beginning of Primary Bucket Installation)
If secondary bucket was not replaced a new o-ring must be installed on the secondary base and the secondary bucket torque should be verified (torque should be 125-250 ft lbs). Lubricate o-ring with black moly grease or equivalent.
Step 10: (See Figure 4)
Place new seal (included in kit 203172) on top of secondary bellows.
Note: New seal must be used. No sealant required.
To prevent rotation of the seal, install eight 3/8-16
UNC set screws (supplied with replacement kit) into the mounting ring. Thread the set screws in to just below the top of the seal.
Set screw
Figure 4
Step 11: (See Figure 2)
Install primary bucket using 1-3100-TOOL into secondary bucket until tight (at least 6 turns).
Recommended torque on bucket is 40 to 100 ft-lbs.
Align bolt holes in primary bucket with holes in secondary bucket.
For sensor models, lay sensor wire flat half way around secondary bucket and note location before installing primary bucket. Fish wire thru access hole in primary base and stand sensor upright. Make sure that the hole in the primary base does not align with the plug in the secondary base.
Step 12:
Raise the set screws so that they are above the top of the primary bellows.
Step 13:
Place new seal and snowplow ring back into place.
Remove one set screw at a time and replace with bolt and lock washer. Torque bolts in crossing pattern to 20 to 25 ft-lbs.
Step 14:
Attach drain valve split ring to tab on snowplow ring.
Step 15:
Replace o-ring(s) on adaptor and lubricate with black moly grease or equivalent (o-rings included in replacement kit).
Install white plastic adaptor back into the primary bucket. On models (1-3112 series) with a mechanical float gage thread in the adaptor until the float gage just touches the bottom of the secondary bucket then back off ¼ turn.
On models with a sensor (1-3122 & 1-3132 series) ensure sensor is as flat as possible on bottom of secondary base. Inspect o-ring on sensor adaptor replace if it is not in good condition. Thread sensor adaptor back into primary bucket until o-ring is no longer visible (approximately 6 turns), do not overtighten.
Step 16:
Test bucket as indicated in 202383 DW-VAC-TEST instructions or Step 9 of 202181 installation instructions. An initial vacuum of 15” of water should be attained and the spill container must retain a vacuum of at least 12” of water after 5 minutes.
Step 17:
Install nipple adaptor, jack screw kit, and drop tube or overfill prevention valve into spill container per applicable instructions.
9393 Princeton-Glendale Rd * Hamilton, Ohio 45011
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2009
OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A., p/n 203050
– 02/09
OPW 1-3100 Series Spill Container Page 23
OPW 1-3100 Series Spill Container Page 24
OPW Installation and Maintenance Instructions
OPW 1-3122 and 1-3132 Series Electronic Sensor Replacement
IMPORTANT: Please read these warnings and follow the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100 Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage or death. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
In some states it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-3100 Series Thread-On spill container models equipped with a drain plug.
WARNING: If the snowplow ring is removed, for any reason, follow the Operation and Maintenance instruction as noted. Replace o-rings and seals and install new ones.
Never reuse damaged o-rings or seals as it may result in an improper seal. Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other than fuel prior to delivery. If water or contaminates are present, then they MUST be removed before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver MUST drain any excess fuel that may have spilled into the container from their delivery hose.
1-3122 & 1-3132 Series Performance
Specifications:
Torque Specification:
Ring Bolts: 3/8-16 UN, 20 ft-lbs minimum to 25 ft-lbs maximum.
Tools Recommended
Large slotted screwdriver
DW-VAC-TEST
– Vacuum Test Equipment
(or 202310 Test Adaptor)
OPW 1-3100 Series Spill Container Page 25
10-1/2”
Sensor
1” Min
Clearance
Conduit
(customer
Supplied)
Sensor
Adaptor
Adaptor
O-Ring
Primary
Bucket
Secondary
Bucket
Grommet
(supplied with sensor)
1-
1/2” Plug
Seal off
(customer
Supplied)
Top View into Guard
Figure 1
OPW 1-3100 Series Spill Container Page 26
1-3100 SERIES ELECTRONIC SENSOR
REPLACEMENT INSTRUCTIONS
(Only applies to 1-3122 & 1-3132 models)
Step 1: (See Figures 1 & 4)
Remove the white sensor adaptor from primary bucket and pull sensor to grade. Be careful not to damage sensor.
Step 2:
Ensure that the old sensor is not functional. Test the sensor by flipping it over and checking for an alarm.
Alternate test method: Dip the sensor in a cup of water and check for an alarm.
Step 3:
Near the old sensor, cut the sensor wire. Discard the old sensor.
Step 4: (See Figure 1)
Verify that the factory installed loop in the sensor wire is 10-
1/2” tall from the bottom of the sensor to the top of the loop as shown in Figure 1. Cut new sensor wire 2 feet from the sensor loop.
Note: Splice is to be installed no closer than 2 feet from the sensor loop.
Note: At least 4 feet of wire should be between the sensor and the grommet.
Step 5: (See Figure 2)
Remove the end caps from the splice kit barrel.
Cut the tip off of one of the cones on each of the end caps so that the end cap will fit snugly around the sensor wiring.
End
Cap
End
Cap
Barrel
Sleeve
Figure 2
Step 6: (See Figure 3)
Insert the new sensor wire through the hole in one of the end caps and the existing sensor wire (coming in thru the secondary base) through the hole in the other end cap and slide the end caps out of the way.
Slide barrel and sleeve onto the sensor wire and slide out of the way as shown in Figure 3.
OPW 1-3100 Series Spill Container
Existing sensor wire
New sensor wire
Figure 3
Step 7:
Using the included wire nuts, join the wires per the sensor manufacturer’s instructions. Using the included split bolt, securely fasten the two wire ends together.
Step 8:
Center the barrel and sleeve over the splice and slide end caps onto the barrel.
Step 9:
Warm the included compound to at least 60° F (15°
C). As shown in the compound mixing instructions, break the center barrier in compound bag by grasping the sides of the bag and rolling thumbs through the barrier. Thoroughly mix the compound, being sure to strip the compound from the corners while mixing.
Step 10:
Cut one corner off of bag and pour the compound through the opening in the barrel until completely full.
Step 11:
Close the barrel by centering the sleeve over the hole in the barrel and rotating the sleeve around the barrel until the hole is completely covered
Step 12:
Test the sensor by flipping it over and checking for an alarm. Alternate test method: Dip the sensor in a cup of water and check for an alarm.
Step 13: (See Figures 1 & 4)
Wait at least 5 minutes then feed the splice kit and excess wire into the secondary bucket. Align sensor with the hole in the primary base where the sensor adaptor will be installed as shown in Figures 1 & 4.
Ensure sensor is as flat as possible on bottom of secondary base. Inspect o-ring on sensor adaptor replace if it is not in good condition. Thread sensor adaptor back into primary bucket until o-ring is no longer visible (approximately 6 turns), do not overtighten.
Step 14:
Test bucket as indicated in Step 9 of Installation
Instructions.
Page 27
Figure 4
9393 Princeton-Glendale Rd, Hamilton, Ohio 45011
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2008, OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A., p/n 202946
– 2/09
OPW 1-3100 Series Spill Container Page 28
OPW Installation and Maintenance Instructions
OPW DW-VAC-TEST Double Wall Spill Container Vacuum Test Instructions
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW DW-VAC-TEST Double Wall
Vacuum Tester is pre-assembled for your convenience and ease of use. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
OPW 1-3100 Series Spill Container
Figure 1
Page 29
OPERATION INSTRUCTIONS:
Step 1: (See Figure 2)
Attach vacuum pump to gauge assembly using the
Quick Connect Fitting.
Quick
Connect
Fitting
Step 5:
Leave the spill container undisturbed for 5 minutes while under vacuum.
Step 6:
Check vacuum gauge after 5 minutes. If gauge does not show 12 or more inches of water column, the spill container has failed the test.
Test Valve
Test Adaptor
Figure 2
Step 2: (See Figure 3)
Make sure Test Valve is clean.
Connect Test Adaptor to Test Valve on OPW 1-3100
Series Double Wall Spill Container.
Step 3: (See Figure 2)
Make sure that the ball valve on the DW-VAC-TEST is open and use the pump to increase the vacuum to
-15 inches of water column as displayed on vacuum gauge.
Step 4:
Close ball valve when -15 inches of water column is displayed on the vacuum gauge. Allow spill container to sit for 30 seconds. Refill spill container to -15 inches of water column.
Figure 3
NOTE: Keep the temperature of the unit constant during testing. Fluctuations in temperature of the unit could result in bias results.
P.O. Box 405003, Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2008 - OPW Fueling Components Inc,.Cincinnati, OH
Printed in U.S.A. p/n 202383
– 04/08
OPW 1-3100 Series Spill Container Page 30
OPW Installation and Maintenance Instructions
OPW 1-3100-TOOL Installation Torque and Removal Tool Instructions
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100-TOOL is pre-assembled for your convenience and ease of use. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied.
Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
OPERATION INSTRUCTIONS:
Removing Nipple Adaptor: (See Figure 1)
Remove three 9/16” bolts from nipple adaptor flange and remove entire adaptor assembly as one piece by pulling straight out.
Figure 1
Installing Nipple in Nipple Adaptor: (See Figure 2)
To properly torque the Nipple Adaptor and nipple, use the 1-3100-TOOL to tighten the Nipple Adaptor with the nipple secured to prevent rotation.
Figure 2
OPW 1-3100 Series Spill Container Page 31
Primary Bucket Install/Removal: (See Figure 3)
To remove primary spill bucket, first remove the eight 9/16” bolts holding the top ring in place. With the bolts holding the top ring removed, align the largest window on 1-3100-TOOL with the drain valve or drain plug. By aligning this window to the drain valve or plug, the three smaller windows will align with the three bosses on the bottom of the primary base and prevent damage to the drain valve if one is installed.
Setting Torque: (See Figure 5)
To set the torque on the primary base, secondary bases, or nipple adaptor, , remove the hand bar and vertical post on the 1-3100-TOOL by removing the bolt in the post. This exposes the 7/8” hex head to allow a torque wrench to be used. Align the tool to the respective item as described above.
Figure 3
Secondary Bucket Install/Removal: (See Figure 4)
To loosen or tighten the secondary base, align the two windows 180 degrees apart on the 1-3100-
TOOL with the two lugs on the secondary base.
Figure 4
OPW 1-3100 Series Spill Container
Figure 5
P.O. Box 405003, Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2008
OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A. p/n 202395
– 04/08
Page 32
OPW 1-3100 Series Spill Container Page 33
THE EDGE
Single Wall Spill Container
OPW Installation and Maintenance Instructions
OPW 1-3100 Series Spill Container Page 34
OPW 1-3100 Series Thread-On Single Wall Grade Level Spill Containers
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting.
Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100 Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication. Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards, OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. THERE ARE NO WARRANTIES, WHICH
EXTEND BEYOND THE DESCRIPTION ON THE FACE
HEREOF.
In some states it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-3100 Series Thread-On spill container models equipped with a drain plug.
WARNING: If the snowplow ring is removed, for any reason, follow the Operation and Maintenance instruction as noted.
Replace o-rings and seals and install new ones. Never reuse damaged o-rings or seals as it may result in an improper seal.
Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers MUST inspect the inside of the container for water or contaminants other than fuel prior to delivery. If water or contaminates are present, then they MUST be removed before proceeding.
Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver MUST drain any excess fuel that may have spilled into the container from their delivery hose.
1-3100 Series Performance Specifications:
This Spill Container drain valve has been manufactured and tested to the following specifications: Leak Rate to be less than or equal to 0.17 CFH @ 2.0 " W.C.
Torque Specification:
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
4" Nipple: 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Note: All 4” NPT threads are to be torqued progressively lower from the tank up.
Drain Valve clamps: 5/16-18 UN thread, 11.5 ft-lbs minimum to
13.5 ft-lbs maximum.
Ring Bolts: 3/8-16 UN, 20 ft-lbs minimum to 25 ft-lbs maximum.
Tools Recommended:
61SA-TOOL
– Torque Installation Tool
OPW 1-3100 Series Spill Container Page 35
OPW NO. 1-3100 SERIES GRADE LEVEL SPILL
CONTAINER INSTALLATION INSTRUCTIONS:
Step 1: (See Figures 1 & 3)
Determine riser pipe height. "L" is the distance between the top of the riser pipe and finish grade.
Note: The spill container height (from riser to grade) is L+ 1”.
Model Series
1-3101, 5 Gal, CI Base
“L” Dimension
L=13 3/4”
(35cm)
1-3101, 5 Gal. with FSA-400-S
(39cm)
L=15 1/2"
Note: The use of the FSA-400-S is recommended in order to upgrade the spill bucket to a double wall configuration in the future.
Step 2:
Install gravel guard on riser pipe. Leave band clamp loose.
Note: Ground riser pipe to nearest grounding rod.
Step 3:
De-burr and thoroughly clean riser pipe. Apply pipe dope to riser threads. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound.
Step 4:
Install OPW FSA-400-S Face Seal Adapter onto riser using the OPW 61SA-TOOL. Torque to 125 ft-lbs min. to 250 ftlbs max.( 4” NPT). Apply pipe dope to FSA-
400-S. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound.
Step 5:
Install spill container by rotating the mounting ring until hand tight.
Note: Do NOT attempt to completely tighten the container using the mounting ring. Doing so may cause the unit to fail.
Step 6: (See Figure 2)
Finish tightening the spill container base with the OPW
61SA-TOOL. Torque to 125 ft-lbs min. to 250 ft-lbs max
(4” NPT).
Step 7: (See Figure 3)
Apply pipe dope to nipple and install in base. Pipe dope to be a non-hardening, gasoline resistant pipe thread seal compound. Use only factory made nipples. Torque nipple to 125 ft-lbs min. to 250 ftlbs max. (4” NPT).
61SA-TOOL with TC-400 Cap can be used to set final torque. Torque value is based on rotation at the center of pipe. Install drop tube, overfill prevention valve and/or loose jack screw assembly if used (61JSK-44CB) per manufacturers’ instructions. For standard covers install rotatable adaptor and dust cap per manufacturers’ instructions. For sealable cover (1SC) models, install a standard 4" pipe cap to support adjustment system.
(Adaptor and dust cap must be installed in sealable cover (SC) models after concrete has dried.
OPW 1-3100 Series Spill Container
Figure 2
Finish Grade
Figure 2
Snowplow Ring
Finish Grade
Slope 1” Min.
Mounting Ring
Dust Cap
Rotatable Adaptor
Nipple
Grounding Lug
L
Top of Riser Pipe
Face Seal Adapter
Gravel Guard
Band Clamp
Riser Pipe
Figure 3
Page 36
Note: Nipple length is determined by measuring from the bottom of the threaded portion of the base to the bottom of the cover. Then subtract 2” minimum for clearance, height of adaptor and height of cap. Range of nipple lengths that can be used in all of the OPW spill containers: 4” minimum to 9” maximum. See Figure 6.
Step 8: (See Figure 4 & 8)
If necessary, the height of the spill container can be adjusted by ±1" (2.5cm). If it is necessary to increase height, install adjusting system (sold separately, part number 203931) beneath tabs on mounting ring. See
Figure 4 for standard cover models and Figure 8 for sealable cover models. Add shims as needed and adjust with screw (shims must be cut to size for sealable cover models).
Note: The adjustment should not be more than 1" from the initial length of the unit.
Step 9: (See Figure 7)
Verify torque on mounting ring bolts. Torque to be 20 ftlbs minimum to 25 ft-lbs maximum.
Step 10:
Where applicable, upon preliminary installation perform the CARB Test Procedure TP-201.1C or equivalent.
This Test Procedure will check the seals between the drain valve, nipple, and rotatable adapter. To test the spill container base and bellows fill the container with water. A drop in the water level of 1/16” or greater after one hour means that a leak exists. To determine where the leak is, look for a steady stream of bubbles coming from one of the joints or water leaking on the outside of the bucket. NOTE: Do not drain the water into the UST after the test is complete. Water must be disposed of per local requirements for hazardous waste. If the leak cannot be corrected the spill container should be replaced with another.
Note: Follow all state and local required testing on the bucket.
Step 11: (See Figure 3)
Install gravel guard at final height as shown in Figure 3 and tighten band clamp to 30 in-lbs. Where applicable, per California SB-989, all metal must be protected from direct contact with the elements. Coat stainless steel band clamp with the following approved coatings: OPW
SL-1100, 3M Underseal 08883 or Polyguard Mastic CA-
9.
Step 12: (See Figures 3 & 5)
Before pouring concrete, place plastic over the cover and Mounting Ring protecting them from concrete splash. Double check that the unit is level and at proper grade height. Pour concrete per Figure 5. Ramp or dome the concrete away from the mounting ring. There should be a minimum of 1” slope to finish grade.
Note: Do not stand on spill container before concrete sets up.
Remove plastic from cover after concrete has dried.
OPW 1-3100 Series Spill Container
Remove adjustment system. Re-test the spill containers for leaks as described in step 10, after the concrete has set up.
Operation and Maintenance:
After each fuel delivery, the operator must remove any standing fuel from the container. Fuel can be removed by actuating the drain valve or with a gasoline absorbing disposable towel.
Weekly: Perform a visual inspection of the interior of the bucket for water or other contaminants. If water or other contaminants are found they must be disposed of with disposable towels. Dispose of towels safely and per all applicable local, state and federal codes. Check that cover is in good condition and properly identified.
Replace cover and seal as necessary. Inspect the bucket walls for cracks, bulges or holes. If any exist, have that spill container barricaded and contact maintenance personnel immediately for repairs.
Semiannually: Inspect and clean the interior of the spill container and drain valve screen. Remove accumulated dirt and grit. Where applicable, test the drain valve using
CARB procedure TP-201.1C or TP-201.1D. If the drain valve passes testing no further maintenances required. If the drain valve fails testing, remove the valve, soak in water and use high-pressure air, if needed, to clean.
Reinstall the drain valve to its proper position and where applicable, test the valve with CARB procedure TP-
201.1C or TP-201.1D. If problems persist, replace the drain valve with P/N 1DK-2100-EVR (specified torque
11.5 ft-lbs min to 13.5 ft-lbs max, 5/16-18 UN thread).
The sealable cover (1SC) adjustment nut is set at the factory, but due to environmental conditions it may be necessary to adjust it to either improve sealing or ease cover removal.
Important: Leave these instructions with Station
Operator.
Height Adjustment Bolt
Cap
Adaptor
Figure 4
Slope 1” Down From Top of Mounting Ring
Finish Grade
Figure 5
Shims
Page 37
2” Min
Clearance
C
B
A
Height Adjustment Bolt
15-
7/8”
Ref
Length of Nipple = Dimension A
– Dimension B – Dimension C – 2” Min
Figure 6
ID Tag
Mounting Ring Bolts
Nipple
Use OPW
116-7085 or
4” Pipe Cap to
Support
Adjustment
System
Shims
Must be
Cut to
Length
Figure 8
Manufacturer: OPW
Model: 1-Series Single Wall
Spill Container
Size: 5 Gallon
Cast Iron Base
Date Manufactured: MMYY
MM = Month, YY = Year
9393 Princeton-Glendale Rd.
Hamilton, Ohio 45011
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2009
OPW Fueling Components Inc.
Cincinnati, OH
Printed in U.S.A. p/n 203196
– Rev D - 07/09
OPW 1-3100 Series Spill Container
Figure 7
Page 38
OPW Installation and Maintenance Instructions
OPW 1-3101 Series Single Wall Bucket Replacement Instructions
IMPORTANT: Please read these warnings and follow the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 1-3100 Spill Container is preassembled for your convenience and ease of installation.
Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied. Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage or death. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
In some states it is prohibited to use spill container drain valves on spill containers that are exclusively used for vapor return risers. Install only 1-3100 Series Thread-On spill container models equipped with a drain plug.
WARNING: If the snowplow ring is removed, for any reason, follow the Operation and Maintenance instruction as noted. Replace o-rings and seals and install new ones.
Never reuse damaged o-rings or seals as it may result in an improper seal. Only qualified, competent, well-trained technicians should perform maintenance. Common sense and good judgment should always be exercised. The contractor’s understanding of all related site conditions prior to starting the project is essential. If the contractor does not have a clear understanding of the required work and site conditions, the contractor is advised to seek clarification prior to starting any portion of the project.
NOTICE TO DELIVERY DRIVER: All delivery drivers
MUST inspect the inside of the container for water or contaminants other than fuel prior to delivery. If water or contaminates are present, then they MUST be removed before proceeding. Dispose of towels and debris safely and per all applicable local, state, and federal codes. After delivery is complete, the driver MUST drain any excess fuel that may have spilled into the container from their delivery hose.
Replacement Parts Needed:
Seal
Set Screws
201689
203171
Qty. 1
Qty. 8
Replacement Bucket 203193 Drain Valve Bucket
Or 203194 Plug Bucket
Torque Specifications:
Ring Bolts: 3/8-16 UN, 20 ft-lbs minimum to 25 ft-lbs maximum.
Spill Container 4" NPT, 125 ft-lbs minimum to 250 ftlbs maximum.
4" Nipple: 4" NPT, 125 ft-lbs minimum to 250 ft-lbs maximum.
Note: All 4” NPT threads are to be torqued progressively lower from the tank up.
Tools Recommended:
61SA-TOOL
– Torque Installation Tool
9/16” hex socket
Torque wrench
OPW 1-3100 Series Spill Container Page 39
1-3101 SERIES SINGLE WALL BUCKET
REPLACEMENT INSTRUCTIONS
NOTE: These instructions only apply when a bucket requires removal.
Standard installation does not require
disassembly of bucket.
Step 1:
Remove jack screw kit and drop tube or overfill prevention valve from spill container.
Step 2:
Disconnect drain valve split ring from tab on snowplow ring. Remove eight bolts (9/16 hex) from snowplow ring. Remove snowplow ring and discard seal. Set ring, lock washers, and bolts aside. Note:
Seal must be replaced before installing new bucket.
Step 3: (See Figure 1)
Remove bucket using 61SA-TOOL as shown in tool instruction sheet 202394 and Figure 1.
Figure 1
Step 4: (See Figure 2)
Ensure spacer is installed with ribs down.
Note: New seal must be used. No sealant required.
Step 5: (See Figure 2)
To prevent rotation of the spacer, install eight 3/8-16
UNC set screws into the mounting ring. Thread the set screws in to just below the top of the spacer.
OPW 1-3100 Series Spill Container
Set screw
Figure 2
Step 6:
Thoroughly clean riser pipe or FSA-400-S Face Seal
Adaptor. Apply pipe dope to riser pipe or
FSA-400-S Face Seal Adaptor. Pipe dope to be a non-hardening gasoline resistant pipe thread seal compound.
Step 7:
Install bucket using 61SA-TOOL onto riser pipe or
FSA-400-S. Torque to 125 ft-lbs min. to 250 ft-lbs max (4” NPT). Align bolt holes in bucket with holes in spacer and mounting ring.
Step 8:
Raise the set screws so that they are above the top of the bellows.
Step 9:
Place new seal and snowplow ring back into place.
Remove one set screw at a time and replace with bolt and lock washer. Torque bolts in crossing pattern to 20 to 25 ft-lbs.
Step 10:
Attach drain valve split ring to tab on snowplow ring.
Step 11:
Install jack screw kit and drop tube or overfill prevention valve into spill container per applicable instructions.
9393 Princeton-Glendale Rd * Hamilton, Ohio 45011
1-800-422-2525 Domestically
513-870-3315 Internationally www.opw-fc.com
Copyright, 2009
OPW Fueling Components Inc., Cincinnati, OH
Printed in U.S.A., p/n 203554
– 04/09
Page 40
OPW Installation and Maintenance Instructions
OPW 61SA-TOOL Instructions
IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
IMPORTANT: The OPW 61SA-TOOL is pre-assembled for your convenience and ease of use. Check to make sure the unit is intact and undamaged and all parts have been supplied. Never substitute parts for those supplied.
Doing so may cause product failure.
WARNING-DANGER: Using electrically operated equipment near gasoline or gasoline vapors may result in a fire or explosion, causing personal injury and property damage. Be sure that the working area is free from such hazards, and always use proper precautions.
NOTE: At all times when product is in the storage tank keep the riser pipe capped, so the vapors cannot escape into the environment.
Notice: OPW products must be used in compliance with applicable federal, state, and local laws and regulations.
Product selection should be based on physical specifications and limitations and compatibility with the environment and material to be handled. All illustrations and specifications in this literature are based on the latest production information available at the time of publication.
Prices, materials, and specification are subject to change at any time, and models may be discontinued at any time, in either case, without notice or obligation.
Standard Product Warranty
OPW warrants that products sold by it are free from
OPERATION
INSTRUCTIONS:
defects in materials and workmanship for a period of one year from the date of manufacture by OPW (ECO products two years from date of manufacture.) Proof of purchase may be required. As the exclusive remedy under this limited warranty, OPW, will at its sole discretion, repair, replace, or issue credit for future orders for any product that may prove defective within the one year date of manufacture period (repairs, replacements, or credits may be subject to prorated warranty for remainder of the original warranty period, complete proper warranty claim documentation required.) This warranty shall not apply to any product that has been altered in any way, which has been repaired by any party other than a service representative authorized by OPW, or when failure is due to misuse, or improper installation or maintenance. OPW shall have no liability whatsoever for special, incidental or consequential damages to any party, and shall have no liability for the cost of labor, freight, excavation, clean up, downtime, removal, reinstallation, loss of profit, or any other cost or charges.
For any product certified to California 2001 standards,
OPW warrants that product sold by it are free from defects in material and workmanship for a period of one year from date of manufacture or one year from date of registration of installation not to exceed 15 months from date of manufacture by OPW.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THERE ARE NO
WARRANTIES, WHICH EXTEND BEYOND THE
DESCRIPTION ON THE FACE HEREOF.
61SALP
For 61SALPs, align the two ears with the small slots in the 61SA-
TOOL.
OPW 1-3100 Series Spill Container
61SA
For 61SAs, make sure that the large window on the tool is aligned with the retaining rod hole.
61VSA
For 61VSAs, align the two ears with the small slots in the 61SA-
TOOL.
Page 41
For Philtite Adaptors, align the four ears with the wide windows on the 61SA-TOOL.
7/8” Hex
Composite Base
For Composite Bases, remove the two bolts from the cross bar to remove the swivel pipe.
Cast Iron Base
For Cast Iron Bases, remove the two bolts from the cross bar to remove the swivel pipe. Then turn over the cross bar by removing bolt from the bottom of the post.
TC-400
For TC-400s, align the four ears with the small slots on the
61SA-TOOL.
Torque Tool
To use the 61SA-TOOL to check torque, remove the post from the swivel pipe and cross bar by removing the bolt in the post. This exposes the 7/8” hex head on the guide attached to the cross bar.
FSA-400/FSA-400-S
For FSA, align the two ears with the small slots in the 61SA-
TOOL.
Philtite Adaptor
Swivel Adaptor Rotation
Torque Test
For testing the rotation torque on swivel adaptors, remove the post and handle and align the two wide windows with the latch of the lid.
P.O. Box 405003, Cincinnati, Ohio 45240-5003
1-800-422-2525 Domestically - 513-870-3315 Internationally www.opw-fc.com
Copyright, 2008
OPW Fueling Components Inc,.Cincinnati, OH
Printed in U.S.A. p/n 202394
– 05/08
OPW 1-3100 Series Spill Container Page 42
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Table of contents
- 19 Installation and Maintenance Instructions
- 19 Remote 700L Series Secondary Contained Spill Bucket
- 20 Tools Required:
- 20 Torque Specifications:
- 24 Below Grade Multi-Port with Platform
- 25 POMECO Installation & Maintenance Instructions
- 27 POMECO Installation and Maintenance Instructions Multi-Port Spill Containment Manholes
- 27 Standard Product Warranty
- 27 Torques Specification:
- 30 513-870-3315 Internationally
- 47 POMECO Installation and Maintenance Instructions Multi-Port Water Shroud (MPWS)
- 47 IMPORTANT: Please read these warnings and use the assembly instructions completely and carefully before starting. Failure to do so may cause product failure, or result in environmental contamination due to liquid leakage into the soil, creating hazardous spill conditions.
- 48 Figure 1
- 49 POMECO Installation and Maintenance Instructions Testable Multi-Port Water Shroud (MPWS-TS)
- 62 NOTE: Use actual capacity only
- 72 NOTE: Use actual capacity only
- 84 The POMECO Tank Bottom Protector is designed to protect the Underground Storage Tank from damage due to the tank measuring stick being dropped into the tank to measure the fluid level.
- 94 61SALP Fill Swivel Adaptor
- 120 Figure 1
- 120 Phil-Tite® Torque Test Tool
- 121 Figure 2
- 121 Static Torque Test Assembly
- 123 Vapor Adaptor 1
- 123 Vapor Adaptor 2
- 123 Product Adaptor 1
- 123 Product Adaptor 2