#9040 FUEL TANK SWEEPER™
INSTRUCTION MANUAL
• FILTERS AND REMOVES FINE
BIO-CONTAMINANTS, ALGAE, ETC.
• SWEEPING PROCESS REMOVES LARGE
CONTAMINANTS FROM OIL TANKS SUCH
AS RUST, WATER, CRUDE AND DIRT
• CIRCULATES FUEL ADDITIVES
COMPLETELY FOR OPTIMUM RESULTS
• IMPROVES OIL QUALITY AND RESTORES
CLEANLINESS
• BOOSTS OCTANE AND BOILER
PERFORMANCE
• OPTIMIZES INJECTOR NOZZLE SPRAY
PATTERN INCREASING FUEL EFFICIENCY
AND BTU OUTPUT
• REDUCES BOILER DOWN TIME 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
IT IS IMPORTANT TO READ, UNDERSTAND AND FOLLOW ALL
SAFETY MESSAGES & 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.
2
PARTS DESCRIPTION:
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 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.
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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 or similar making sure that
the vent cap is loose. (Note: Use a clean, leak free 55 Gallon drum).
3. Connect the Fiber Staff to the inlet hose via couplings being sure to
use the locking pins so the locking levers do to vibrate loose.
4. Insert the Fiber Staff 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.
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 37 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 55
gallon drums to complete the service.
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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 incorporates a 150 micron screen
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 when the oil shows
clear in the hose. You will see it turn black then when that spot is clean
it will turn red, this is the 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 1, 2 and 3 (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.
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.
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#9040-8EXT 8
Ft. Extension
Hose
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.
NOTE: There are hose caps to be used to cap off hose ends. One
hose plug has a stone filter in it. This is to be used only on the
pump outlets, not the hose itself. The purpose of the stone filter is
in case of an inadvertent pressurizing of the closed or plugged
side of the pump. Instead of allowing pressure to build up which
can be dangerous when plug is removed, the stone filter opening
discharges fuel oil alerting the user that they have the main ball
valve turned to the wrong position. The stone filter allows fuel oil
to exhaust through the filter. This can cause a mess but is
preferable to inadvertently pressurizing the wrong side of the
pump where someone could get hurt.
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.
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#9042 Fuel
Sample Stick
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.
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. 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!
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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.
TECHNICAL INFORMATION
MAX. FLUID WORKING PRESSURE 5 bar (70 psi)
MAX. AIR CONSUMPTION
(AT 5 BAR AIR PRESSURE) 700 l/min (25 SCFM)
MAX. FREE FLOW DELIVERY 120 l/min (28 GPM)
INLET AIR 3/8 ” NPT
FLUID INLET AND OUTLET 1 ” NPT Side Ports
WEIGHT 9 Kg. (20 lb)
TROUBLE SHOOTING
SYMPTOM
POSSIBLE CAUSES
SOLUTION
THE PUMP CONTINUES
OPERATING ALTHOUGH
THE OUTLET VALVE IS
CLOSED.
There is a leak at some
point of the outlet circuit.
Worn check valve balls
and/or seats.
Verify and tighten or
repair.
Replace the worn items.
THE PUMP DOES NOT
OPERATE, OR CYCLES
ONCE AND STOPS.
Air valve is stuck or dirty.
Check valve ball severely
worn and wedged in seat.
Disassemble and clean
the air valve.
Replace ball and seat.
THE PUMP OPERATES
ERRATICALLY.
Clogged suction line.
Sticky or leaking valve balls.
Diaphragm ruptured.
Verify and clean the
suction line.
Clean or replace.
Replace diaphragm.
AIR BUBBLES IN FLUID.
Suction line loose or
damaged.
Diaphragm ruptured.
Verify and tighten or
replace.
Replace diaphragm.
FLUID IN EXHAUST AIR. Diaphragm ruptured. Replace diaphragm.
THE PUMP EXHAUSTS
AIR AT STALL. Worn parts in air valve. Repair or replace.
Innovative Products of America® Incorporated
234 Tinker Street, Woodstock, NY 12498
www.ipatools.com
888-786-7899 / 845-679-4500 phone / 845-647-8500 fax
9040-Fuel Tank Sweeper-INSTRUCTIONS-v14
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