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5) Dipstkk number(X)=82' Tank diameter (Y) = 92' (Y) -(X)=(2) (92'-82'=10') (Z)=10' 6) (2)-2'=C 00'-2'=8') C=8' 7) Is 8' less than 6-1/2'7 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 ob- tain measurement (A). Upper tube length = C + (A) Fortestable models only, ending In *T-. Upper Tube Length . C +(A) -1.112' ASSEMBLY INSTRUCTIONS IMPORTANT: Each of the numbered steps In the Instal- lation instructions are designed as a CHECK LIST to en- sure proper Installation and trouble free operation of the DPW 71 SO 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 DPW Face Seal Adaptor and the DPW Thread - on Spill Container on the FIII Riser (Refer to the Installa- tion Instructions Supplied with the Spill Container). In- sert a tape measure through the riser pipe and hook it under the inside of the tank in the lengthwise direction. Measure the distance from the top ofthe Face Seal Adaptor threads Inside the base of the spill container bucketfust below the draln valve outlet window to the Inside, top lip of the storage tank (Dim. 'A) (See Figure 1 &1A). The top flange on the 71 SO will rest on the Face Seal Adaptor lust 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 l A). (For riser pipe configu- rations other than that shown, consult Installation drawings or use other necessary means to measure Di- menslon'A'). Using a tape measure, measure the distance from the 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. 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 black moly grease to the polypak as shown. Make sure cover- age Is completely around the polypak seal. Ensure polypak lip Is up \ WO Tub rl I Rry Appy green around pdypek Figure? STEPS: INSTALL INLET TUBE Insert the inlet tube Into the upper tube until the upper tube seatsagainst the flange on the Inlet tube. Ensure polypak is Inserted evenly and stays In inlet tube groove. 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 ma- terial. Over spray from tank relining or any internal burn Inside of pipe must be removed prior to Installa- tion. Failure to have an unobstructed riser pipe may prevent proper Installation and operation of the valve. The 71 SO Is designed for Installation Into schedule 40 riser pipes. The 71 SO 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 7ISO AT 9S%TANK CAPACITY to mark the upper tube. Measure the distance from the seam where the upper tube and valve body meet. Use a tape measure to mark the calculated upper tube length onto the upper tube. See Figure 2. Figure 1 Ir NPT 12'wlde Tap*--- R as Pip. with the 71 SO -TOOL is In the correct position before able valves wan Faro NI S. A.F. ToTank lel Jack Screw Topll.D.I TO Tank before drilling. Hol m for JatkSaew blebbn 9 O-Rng Seal Figure 1 Figure IA 3 Figures NOTE: Testable inlet tube must have cable port in line with float. Testable inlet tube bottoms out on stop, it does not bottom out on inlet flange. SeeFig- e AA • Cable port must be in line with float Figure 9A Testable Models Only SEE PAGE 8 FOR INSTRUCTIONS USING THE 71So- TOOL. SEE PAGE 9 FOR INSTRUCTIONS USING THE 71 SO- TOOL4 SEE PAGE 10 FOR INSTRUCTIONS USING THE 71SO- ir � e Nostable 7150 modeh ending with a -'require the 77SO-TOOLCT.,.aMred 7150 -TOOL ar ?ISO- TOOLC Tape measure Mark Upper Tube (Cut Una) Seam Figure 2 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 mak- ing a square cut. If a vise Is used, clamp on the valve body casting only to avoid damage to the float and tubes (See Figura 3A). Carefully saw through the tube squarely, at the mark made In Step 2. Use a hacksaw with a new fine-tooth blade. Rotating the upper tube as the sawing progresses will minimize run out and en- sure a square Wdegree 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 rig— Figure 3B 71 SO -TOOL PROCEDURE BELOW FOR 71 SO-TOOLC, SEE PAGE FOR 71 SO-TOOLCT, SEE PAGE 10 Nae: 71 SO -TOOL can only be used withtestable overfill valves if modified as shown below. A 2" wide slot must he added to accommodate cast lua. IMPORTANT: Remove all chips and shavings generated In steps 3 thru 5 out of the curt end ofthe tube. DO NOT remove chips and shavings by dumping thru valve body. STEP 4: FILE THE UPPER DROP TUBE File the upper tube square, and remove any buns or rough edges. Make sure the cut is flat and square. IMPORTANT. Carefully file a good chamfer on the In- side edge of the drop tube to provide a lead -In for the polypak seal and Inlet tube Installed In Step S. Figure4 STEP 5: SAND THE UPPER DROP TUBE Sand the Inside ofthe drop tube with sandpaper and/or steel wool to re move all burrs and sharp edges. After sanding wipe down the Inside ofthe 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. .*ear.dsere Figure 5 STEP 10A: TIGHTEN THE 71 SO -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 to the upper drop tube. See Figure 10A. Ir NPT 12'wlde Confirm thatthe stop on the 3/16'drill bit supplied Nipple with the 71 SO -TOOL is In the correct position before able valves drilling. The stop 1,factory Installed atadistance be- SNI container tween 2' to 2-1/16' from the tip with the 71 SO -TOOL. If Jack Screw Messunsbh before drilling. KA for JatkSaew blebbn 9 O-Rng Seal (TapdF.m S*el Adaptor/ —S-1 7150 Mads Figure IA 3 Figures NOTE: Testable inlet tube must have cable port in line with float. Testable inlet tube bottoms out on stop, it does not bottom out on inlet flange. SeeFig- e AA • Cable port must be in line with float Figure 9A Testable Models Only SEE PAGE 8 FOR INSTRUCTIONS USING THE 71So- TOOL. SEE PAGE 9 FOR INSTRUCTIONS USING THE 71 SO- TOOL4 SEE PAGE 10 FOR INSTRUCTIONS USING THE 71SO- ir � e Nostable 7150 modeh ending with a -'require the 77SO-TOOLCT.,.aMred 7150 -TOOL ar ?ISO- TOOLC Tape measure Mark Upper Tube (Cut Una) Seam Figure 2 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 mak- ing a square cut. If a vise Is used, clamp on the valve body casting only to avoid damage to the float and tubes (See Figura 3A). Carefully saw through the tube squarely, at the mark made In Step 2. Use a hacksaw with a new fine-tooth blade. Rotating the upper tube as the sawing progresses will minimize run out and en- sure a square Wdegree 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 rig— Figure 3B 71 SO -TOOL PROCEDURE BELOW FOR 71 SO-TOOLC, SEE PAGE FOR 71 SO-TOOLCT, SEE PAGE 10 Nae: 71 SO -TOOL can only be used withtestable overfill valves if modified as shown below. A 2" wide slot must he added to accommodate cast lua. IMPORTANT: Remove all chips and shavings generated In steps 3 thru 5 out of the curt end ofthe tube. DO NOT remove chips and shavings by dumping thru valve body. STEP 4: FILE THE UPPER DROP TUBE File the upper tube square, and remove any buns or rough edges. Make sure the cut is flat and square. IMPORTANT. Carefully file a good chamfer on the In- side edge of the drop tube to provide a lead -In for the polypak seal and Inlet tube Installed In Step S. Figure4 STEP 5: SAND THE UPPER DROP TUBE Sand the Inside ofthe drop tube with sandpaper and/or steel wool to re move all burrs and sharp edges. After sanding wipe down the Inside ofthe 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. .*ear.dsere Figure 5 STEP 10A: TIGHTEN THE 71 SO -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 to the upper drop tube. See Figure 10A. STEP 9A: INSERT 71SO-TOOL OVER INLET TUBE To Install the 7150 -TOOL (sold separately) over the Inlet tube, first loosen all three knobs, so the tool can pass Keely 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. Todabl leo 41 Held boas vlewholes tOh- knobs O O Ns Tube Iwy Figure 9A Figure 1OA CAUTION: If the drill stop Is not in the proper loca- tion failure of a pressure decay leak test may result 71�4 Tip to stop dimension must be 2'to 2-1/16'. Figure 11A STEP I2A: DRILLHOLES With the inlet tube and 71 SO -TOOL in place, carefully drilla 3/16" diameter hole In the upper tube using the drill bushing In the knob as a guide. The drill stop Is po- sitioned 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 I IA 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. O Figur 124 STEPPREPARE DRILL AND BIT 12'wlde Confirm thatthe stop on the 3/16'drill bit supplied to use with with the 71 SO -TOOL is In the correct position before able valves drilling. The stop 1,factory Installed atadistance be- tween 2' to 2-1/16' from the tip with the 71 SO -TOOL. If the stop is not at the correct position it must be fixed before drilling. STEP 9A: INSERT 71SO-TOOL OVER INLET TUBE To Install the 7150 -TOOL (sold separately) over the Inlet tube, first loosen all three knobs, so the tool can pass Keely 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. Todabl leo 41 Held boas vlewholes tOh- knobs O O Ns Tube Iwy Figure 9A Figure 1OA CAUTION: If the drill stop Is not in the proper loca- tion failure of a pressure decay leak test may result 71�4 Tip to stop dimension must be 2'to 2-1/16'. Figure 11A STEP I2A: DRILLHOLES With the inlet tube and 71 SO -TOOL in place, carefully drilla 3/16" diameter hole In the upper tube using the drill bushing In the knob as a guide. The drill stop Is po- sitioned 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 I IA 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. O Figur 124