FUEL TANK SWEEPER #9040PN OPERATOR S MANUAL 2012 Innovative Products of America, Incorporated. All rights reserved. This material may not be reproduced, displayed, modified or distributed without the express prior written permission of the copyright holder. For permission, contact info@ipatools.com. Innovative Products of America Incorporated 888-786-7899 www.ipatools.com 234 Tinker Street, Woodstock, NY 12498
LETTER FROM THE PRESIDENT OF IPA My name is Peter Vinci and I am the president of IPA. I would like to first thank you for your interest in IPA s product line and share my commitment to you, our products and our policies. In today s world, we have all experienced the lack of service and consideration demonstrated by many companies after you buy their products. They say whatever they can to make the sale, and then it s like pulling teeth to get any service response out of them. I know this myself first-hand and because of this, I want to be sure that your experience with IPA meets your expectations and that IPA never disappoints you with our service or customer response. To prove my commitment to you, if for any reason you are not happy with one of our products or more importantly, with the response from our customer service or any member of the IPA team for any reason, I invite you to contact me directly via my email, peter@ipatools.com or call me at 888-786-7899. Your satisfaction is more important to me than the sale itself. We will not be in business for long if we don t make you completely happy with our products and service. I want IPA to be different and to be known for its quality and service. With that said, please take a look at our product line. You will see innovative first time products that were created to help you do your job faster and better than before. I would also like to invite you to critique our products. If you can think of a better way to make them or changes that will make them better, then again, please contact me directly and I will be sure to look into it. If you have an innovation and would like some feedback, give me a call. From all of us at IPA, we thank you for taking the time to review our product line and wish you and your family the very best of everything. Peter Vinci President IPA www.ipatools.com Toll Free: 888-786-7899 Phone: 845-679-4500 Fax: 845-679-4600 2
IMPORTANT SAFETY INSTRUCTIONS IT IS IMPORTANT TO READ, UNDERSTAND AND FOLLOW ALL SAFETY MES- SAGES & INSTRUCTIONS PRINTED IN THIS MANUAL AND ON THE EQUIPMENT BEFORE OPERATING. IF SAFETY INFORMATION IS NOT HEEDED, RESULTS IN DEATH OR SERIOUS INJURY TO THE OPERATOR OR BYSTANDERS MAY OCCUR. DANGER indicates a hazardous situation, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. WARNING indicates a hazardous situation, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. CAUTION indicates a hazardous situation, if not avoided, may result in minor or major injury. The possible hazards are shown in the adjoining symbols or explained in the text. 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 Pneumatic pressures used with this equipment can cause explosive failures on damaged equipment. POTENTIAL EYE HAZARD Wear OSHA approved safety glasses. Battery acid and high air pressures create hazardous situations for eyes. POTENTIAL CHEMICAL BURN HAZARD Wear protective gloves. Battery acid is corrosive and can cause skin damage. POTENTIAL FIRE HAZARD Use caution with flammable liquids such as fuel and oil. Electrical shorts can ignite flammable liquids and wiring. Warning: For use with diesel fuel and hydraulic oils only. Do not use with gasoline. Do not use to transfer any hard contaminants such as rocks, leaves, etc. This can damage the pump and void the warranty. Warning: Do not operate with caps installed or bodily injury can result. 3
9040PN FUEL TANK SWEEPER PARTS PVC/FIBERGLASS SUCTION STICK CLEAR 1 HOSE WATER BLOCKING FILTER P/N FIL-10WB 90 DEGREE SWIVEL QUICK RELEASE FEMALE COUPLER QUICK RELEASE MALE COUPLER CANISTER FILTER 30 MICRON P/N FIL-30PT EMPTY FILTER HOUSING: USED FOR SITE GLASS (Can install optional wire mesh filter) CLEAR 1 HOSE BALL VALVE QUICK RELEASE MALE COUPLER DIAPHRAGM PUMP 30 GPM MUST READ BEFORE USE This diaphragm pump is meant for use with liquids only. DO NOT suck up leaves, gravel and other solids. Doing so will void the warranty. Manufacturer suggests the use of a screen filter on the intake side. (Reference part # 9040-TFIL) 4
SET UP INSTRUCTIONS: STEP 1 It is recommended that you visit the site 48 hours before tank sweeping to prepare the tank and assess the site condition. Using the optional IPA9041 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 (aprox.12 ). Remove the sampler and note the amount of water and crude at the bottom of the tank. It is recommend that you 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 equivalent to the tank in appropriate amounts. Using the sampler, stir the tank briskly to mix the algae cleaner into the oil. After 48 hours, the algae should be killed off and the tank is now 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 similar making sure that the vent cap is loose. (Note: Use a clean, and leak free 55 gallon drum). 3. Connect the suction stick to the inlet hose via couplings being sure to use the locking pins so the locking levers do to vibrate loose. 4. Insert the suction stick adapter all the way down to the bottom of the oil tank to be cleaned. 5. Be certain to turn the main ball valve to Sweeper direction. 6. Attach air supply line to the inlet air on the pump assembly. Do not turn on the air ball valve yet. 7. Set the air pressure to 50 PSI. Air Operating Range is from 50 PSI to 100 PSI. A setting of 50 PSI is recommended to give the operator more control of the sweeping operation. Do not turn on the air ball valve yet. NOTE: 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 the air supply and the other person doing the actual sweeping of the tank. 5
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 turn the AIR INLET ball valve to the ON position. This begins to actuate the pump assembly and suction through the Fiber Staff adapter. IN THE EVENT OF AN EMERGENCY FIRST CLOSE AIR BALL VALVE TO STOP THE PUMP. 2. Keep the adapter at the bottom of the tank and slowly sweep back and forth collecting all contaminants from the bottom of the tank only. NOTE: The pump can move up to 30 gallons per minute (GPM) at 100 PSI and fill up a 55 gallon drum in a very little time. Watch carefully and be sure not to place more than 50 gallons into the drum. This allows room for fuel expansion. Depending upon the amount of contaminates in the oil tank, you may require two or more 55 gallon drums to complete the service. 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, it would be best to run the cleaning through the lower filter housing without the screen. The Sweeper function can incorporate an optional wire mesh filter which can capture the majority of the rust and large contaminates. However, the screen openings can still be clogged up quickly causing an implosion of the screen and a reduction of the flow. The Tank Sweeper operator should move the Fiber Staff back and forth across the bottom of the tank moving the stick. You will see the oil turn black, then when that spot is clean, it will turn red. This is an indication to move the staff to another spot on the bottom of the tank. Repeat this sweeping function until only clean fuel is removed. It may be necessary to use two 55 gallon drums depending upon the amount of contaminates found. NOTE: Be mindful of the 55 gallon drum level and be sure not to over-fill. Have your Emergency Spill Kit ready and available in case of a spill. Leave sufficient air space for expansion. After the sweeping is complete, remember to lower the tank to a level position by removing the jack. Remove the outlet hose from the 55 gallon drum and install all vent or port caps and seal drum completely for transport. FILTERING AND BLENDING THE FUEL: A great feature for the Sweeper is the ability to return the contaminated fuel clean and filtered to the same or new oil tank. To do this, allow the 55 gallon drum with the fuel that came from the sweeping to sit and settle for 24 hours. 1. Turn the main Ball Valve to the Filter Selection and you can complete the fuel restoration. Observe all instruction on page 3, 4 and 5 (up to Tank Sweeping section.) 2. Install the outlet hose in the tank you want to transfer the cleaned fuel into. 3. Insert the Fiber Staff on the Filter intake side into the top of the 55 gallon drum allowing it to just contact the fuel at the top of the drum. 6
NOTE: 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 the air supply and the other person doing the actual sweeping of the tank. 4. When in the filtering mode and turning the air valve to the ON position, slowly lower the fiber staff into the 55 Gallon drum following the fuel level watching the clear hose for signs of black contamination. The contaminates will be settled in the last few inches of the drum so when you get close to the bottom and as soon as you see the color of the fuel change to dark, lift up the fiber staff and stop the transfer operation. Dispose of the bottom of the tank with the contaminated fuel properly. IF YOU WISH TO BLEND FUEL ADDITIVES OR FILTER THE OIL IN THE TANK: 1. While observing all safety precautions, turn the Sweeper to the Filter selection via Main Ball Valve. 2. Insert Fiber 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: 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 the air supply and the other person doing the actual sweeping of the tank. 3. Turn the air valve on and allow the fuel to circulate through the filters and back into the tank. At this point you can turn the pressure up to maximum or 100 PSI to achieve a 37GMP rate. With this rate, you can move 275 gallons of fuel oil through the sweeper in several minutes. If there is a noticeable decrease in the fuel flow rate, the problem may be clogged filters. If this is the case, replace filter cartridges as necessary. OPTIONAL ACCESSORIES: 8 FT. EXTENSION HOSE #9040-8EXT 1. To connect the 8ft. Extension Hose between the Sweeper and the hose that you want to extend, take the male quick disconnect of the 8ft. extension hose and put it into the desired female port of the Sweeper. 2. Take the female end of the 8 ft. extension hose and attach it to the male end of the hose you are extending. 3. To couple the male and female quick disconnects together, put the male quick disconnect into the female quick disconnect. 4. Pull the levers on the side of the female end all the way down towards itself tight against the side. Be sure to insert the cotter pins through the hole to lock the levers in place. NOTE: During the pump operation, excessive vibration has a tendency to vibrate loose the coupling locking handles. Be certain to use the locking cotter pins. 7
5. To maintain the clear appearance of the hose after use, it is good practice to gravity drain all fluid from the hose. Then using warm soapy water, flush until clean and air drain and dry afterwards. NOTE: Depending upon what contaminates are present when using the hose and how well it is cleaned afterwards determines how long the hose remains clear. The hose is warranted to be free from manufacturer s defects for one year. Digital Flow Meter 9040-FLOM T-Filter for large particles 9040-TFIL SAMPLE STICK #9042 The Sample stick is designed to remove a small sample of fuel oil from the bottom of a fuel tank so the operator can see what contaminates exist. 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, and then algae, 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. 8
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 gravity drain 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! OPTIONAL FILTERS 25 MICRON LARGE HYDRAULIC FILTER #FIL00003B 16 MICRON LARGE HYDRAULIC FILTER #FIL00003C SMALL WIRE MESH FILTER #FIL-300M NOTE: One extra filter each of the large 30 MICRON FILTER FIL-30PT and SMALL 10 MICRON WATER BLOCKER FIL-10WB are included. Addtional quantities avaiable from IPA. AIR-OPERATED DIAPHRAGM PUMP DESCRIPTION 1:1 ratio air-operated diaphragm pump with aluminum body and Buna N diaphragms. Recommended for transferring oil or evacuating waste oil. 9
10
NOTES 11
Limited One Year Warranty FUEL TANK SWEEPER #9040PN Innovative Products of America Incorporated has established a Limited One Year Warranty Policy for the Fleet Tank Sweeper. One Year Limited Warranty/Return or Replace Policy: The product is covered for one year from the date of original user purchase under the stipulations of the Standard Warranty. The product is warranted to be free from defects in workmanship or material. If there is a problem due to workmanship or material defect, Innovative Products of America Incorporated will repair or replace the product within 24 working hours after it is received 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 the proof of purchase must be established (either by warranty card from the seller or by point of purchase receipt/invoice) and the manufacturer makes every attempt to return ship the product within three business days from the 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 888-786-7899 / 845-679-4500 www.ipatools.com 2012 Innovative Products of America, Incorporated. All rights reserved. This material may not be reproduced, displayed, modified or distributed without the express prior written permission of the copyright holder. For permission, contact info@ipatools.com. 009040PN-MANUAL-IPA