Fuel Tank Sweeper #9049 OPERATOR S MANUAL Innovative Products of America Incorporated 888-786-7899 www.ipatools.com 234 Tinker Street, Woodstock, NY 12498
DO NOT USE WITH GASOLINE! Transfers, filters and removes fine biocontaminants, algae, etc. Sweeping process removes contaminants such as rust, water, crude and dirt from oil tanks. Circulates fuel additives completely for optimum results. Improves fuel quality and restores cleanliness. Boosts octane performance. Optimizes injector nozzle spray pattern, increasing fuel efficiency and BTU output. Reduces downtime and service interruptions. Extends oil tank life by removing water and contaminants. Eliminates costly tank corrosion which can lead to tank leakage and liability. 1
IMPORTANT SAFETY INSTRUCTIONS This manual contains safety and operating instructions for the #9049 Series. Refer to this manual for information on safe operation. Read, understand and follow all safety messages and instructions printed in this manual and on the equipment before operating. An icon, when present, gives a graphical description of the potential hazard. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury to the operator or bystanders. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to the operator or bystanders. CAUTION indicates a hazardous situation which, if not avoided, may result in minor or major injury. POTENTIAL BURN HAZARD: sparks from electrical shorts can ignite flammable liquids such as fuel or oil. Heat from electrical overloads can cause fire hazards. POTENTIAL EXPLOSIVE AIR HAZARD: airborne fuel vapors can be volatile and ignite. POTENTIAL EYE HAZARD: wear OSHA approved safety glasses high air pressures create hazardous situations for eyes. POTENTIAL CHEMICAL BURN HAZARD: wear protective gloves. fuel and fuel oils can be corrosive. POTENTIAL FIRE HAZARD: use caution with flammable liquids such as fuel and oil. Electrical shorts can ignite flammable liquids and wiring. 2
PARTS DESCRIPTION 3
TRANSFER PUMP SPECIFICATIONS 115 VOLT/AC 60HZ 1/3HP 6.5 AMPS 30 MINUTE DUTY CYCLE NOTE: A Duty Cycle is the time specified for the motor to run continuously. An auto shut down and cool down time will engage. DO NOT USE WITH GASOLINE! Do not dry run or dead head this pump assembly. Do not use with water or water contaminated fluids. Do not use with gasoline or alcohol, as a static charge is possible and an explosion could occur. Do not use in hazardous locations. To obtain the best flow rate of 18GPM, remove filter from the housing and install a 1 fuel hose on the intake and the discharge port. STEP 1 SET UP INSTRUCTIONS It is recommended that you visit the site 48 hours before tank sweeping to prepare the tank and assess the site condition. Using the IPA9049 sampling tool, insert the sampler all the way down to the bottom of the tank to be cleaned. Draw the piston shaft up enough to get a good sample of the fuel (approx. 12 ). Remove the sampler and note the amount of water and crude at the bottom of the tank. Transfer the sample into a glass jar and allow the various contaminants to settle and separate for 24 hours. This will give you an idea of the fuel condition inside the tank and the amount and type of the contaminated fuel. STEP 2 Add an algae bio-cleaner or an equivalent to the tank in appropriate amounts. Using the sampler, stir the tank briskly to mix the algae 4
cleaner into the oil. After 48 hours, the algae should be killed off and the tank is ready for sweeping. If convenient and safe, you may use a small jack to elevate the tank a few degrees on one side to allow the majority of contaminates to collect on one end of the tank. This is the end you will choose to sweep. TANK SWEEPING SET UP 1. Set up your Tank Sweeper near the tank to be cleaned, allowing enough room for the inlet hose to reach the tank. 2. Install the outlet hose to a 55 gallon drum or filter back into the tank being cleaned. (Note: use a clean and leak-free 55 gallon drum.) 3. Connect the flex staff to the inlet hose via couplings, making sure to use the locking pins so the locking levers do not vibrate loose. 4. Insert the flex staff adapter all the way down to the bottom of the oil tank to be cleaned. 5. Connect the AC pump to a 120 power outlet, making sure it is a grounded outlet. NOTE# 1: The use of the inlet filter is important to protect the pump from the contaminants. If the inlet filter is not used and heavy dirt is drawn through, the pump may be damaged and the warranty will be voided. NOTE# 2: When ready to sweep the tank, be sure to check all connections for leaks and be prepared to shut down the sweeper in the event of a leak. Have your Emergency Spill Kit available and in reach. It is best to have this operation performed by two people - one operating and one standing by to help in the event of a spill. TANK SWEEPING 1. Once all safety precautions have been complied with and you are certain of good and proper connections with the outlet hose firmly in the holding drum or tank, plug the AC pump into a grounded 12- Volt AC socket. When ready, turn on the pump via the switch. This begins to actuate the pump assembly and the suction through the Intake flex staff adapter. The intake and discharge flex staffs can be cut to accommodate your custom needs. 5
2. Keep the flex staff adapter at the bottom of the tank and slowly sweep back and forth collecting all contaminants from the bottom of the tank. 3. The Tank Sweeper will remove the bottom contents of the tank where the majority of fuel contaminants exist, i.e., water, crude, algae and rust. If a badly contaminated tank is expected, you must run the cleaning through the filter housing with the filter installed. The Tank Sweeper operator should move the flex staff back and forth across the bottom of the tank moving the stick when the oil is clear in the filter housing. You will see it turn black. Then when that spot is clean, it will turn red. You should now move the staff to another spot at the bottom of the tank. Repeat this sweeping function until only clean fuel is removed. FILTERING AND BLENDING THE FUEL A great feature of the Sweeper is its ability to return the contaminated fuel clean and filtered to the same or a new oil tank. 1. Install the outlet hose in the tank into which you want to transfer the cleaned fuel. NOTE: Observe above warnings. 2. Insert flex staff into one hole at the top of the tank and insert the outlet hose into another hole at the top of the tank. NOTE # 1: Depending upon what contaminants are present when using the hose and how well it is cleaned afterwards determines how long the filter housing remains clear. NOTE# 2: After transferring or filtering the fuel, drain both the intake and the discharge hoses. Cleaning of the hoses after use is necessary to maintain its longevity. When ready, allow the hoses to gravity drain. Once the hoses have been drained, hang them away from the sun over a pail or a bucket to catch any additional residue. SAMPLE STICK (OPTIONAL) #9042 The Sample Stick is designed to remove a small sample of fuel oil 6
from the bottom of a fuel tank so the operator can see what contaminants are present. TO OPERATE: 1. Insert the Sample Stick through one of the cap openings at the top of the tank all the way until it contacts the bottom of the tank. 2. Slowly withdraw the piston via the handle until the desired amount of fuel is drawn into the sample stick. 3. Remove the Sample Stick from the tank keeping an oil absorbent towel ready. Allow the sample stick to drip drain into the towel. 4. Have a suitable container made of glass or material that will not be affected by the fuel oil, ready for the sample fuel oil. 5. Slowly withdraw the piston until it is removed completely from the sample tube. Place the piston on a towel to drip drain. 6. Pour the remaining contents of the sample tube into the sample jar. 7. Once the sample is in the jar, let it sit for 24 hours to separate the contents. The water will settle to the very bottom with rust, then algae, and then the crude. The clear oil will be on top. This should be a real time view of what is happening at the bottom of the oil tank. 8. Once the sample has been taken, you must replace the piston in the sample stick tube. Because of the one way valve at the bottom of the foot valve, there will be a pressure block as you attempt to replace the piston. You need to break the suction seal by unscrewing the foot valve two turns counter clockwise. This allows the air to escape and the piston to be replaced. Once the piston reaches the bottom of the tube, you must retighten the foot valve. Be certain not to over-tighten the O-ring. A snug torque of the foot valve halves is all that is needed. Cleaning of the Sample Stick after use is necessary to maintain its clear appearance. When ready, allow the Sample Stick to gravitydrain the oil. Once the stick has been drained, a solution of warm soapy water should be used to flush the stick a few times until clean. NOTE: The tube of the Sample Stick is made of a clear acrylic material. The Sample Stick should not be used for gasoline, ONLY OIL! #9042 Fuel Sample Stick 7
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9049 Fuel Tank Sweeper One Year Limited Warranty Innovative Products of America Incorporated has established a Limited One Year Warranty Policy for the 9049 Fuel Tank Sweeper, not including any wearable parts, i.e. batteries, etc. 1 Year Limited Warranty/Return or Replace Policy: These products are covered for 1 year from date of original user purchase under the stipulations of the Standard Warranty. The product, the Fuel Tank Sweeper, is warranted to be free from defects in workmanship or materials. If there is a problem due to workmanship or material defect, Innovative Products of America Incorporated will repair or replace the product within three working days after receipt by the IPA Repair Service Center. In the event it is determined that the product has been tampered with, or altered in any way, the warranty is void and all claims against the product will not be honored. The Warranty Repair/Return procedures require that proof of purchase must be established (by either warranty card from the seller or by point of purchase receipt/invoice) and that the manufacturer will make every attempt to return ship the product within three business days from receipt of the returned product, freight prepaid. If it has been determined that the tool has been damaged due to misuse, Innovative Products of America Incorporated will repair the tool at a cost we deem reasonable and these charges will be the responsibility of the user. We truly want you to be happy with our products so if you have any questions, call us toll-free at 888-786-7899. Innovative Products of America Incorporated 234 Tinker Street, Woodstock, NY 12498 www.ipatools.com 888-786-7899 9049-Fuel Tank Sweeper-INSTRUCTIONS- 03 9