OPW 71SO-TOOLC User manual

1
71SO Overfill Prevention Valves and
71SO Testable Overfill Prevention Valves
Installation and Maintenance Instructions
IMPORTANT INFORMATION
FOLLOW ALL INSTRUCTIONS
Please read these warnings and use and assembly
instructions completely and carefully before start-
ing. Failure to do so may cause product failure, or
result in environmental contamination due to liquid
leakage into the soil, creating hazardous spill condi-
tions.
OPW Standard Product Warranty Tag: Notice: Flex-
Works by OPW, Inc., VAPORSAVER™ and all other OPW
products must be used in compliance with all applica-
ble federal, state, provincial and local laws, rules and
regulations. Product selection is the sole responsibility
of the customer and/or its agents and must be based
on physical specications and limitations, compatibil-
ity with the environment and material to be handled.
All illustrations and specications in this literature are
based on the latest production information available
at the time of publication. Prices, materials and speci-
cations are subject to change at any time, and mod-
els may be discontinued at any time, in either case,
without notice or obligation.
OPW warrants solely to its customer (the initial pur-
chaser and any subsequent purchasers within the
warranty period) that the following products sold by
OPW will be free from defects in materials and work-
manship under normal use and conditions for the pe-
riods indicated:
OPW’s exclusive obligation under this limited warran-
ty is, at its option, to repair, replace or issue credit (in
an amount not to exceed the list price for the product)
for future orders for any product that may prove de-
fective within the applicable warranty period. (Parts
repaired or replaced under warranty are subject to
prorated warranty coverage for remainder of the orig-
inal warranty period). Complete and proper warranty
claim documentation and proof of purchase required.
All warranty claims must be made in writing and deliv-
ered during the applicable warranty period to OPW at
OPW 9393 Princeton-Glendale Road Hamilton, Ohio,
USA 45011, Attention: Customer Service Manager. 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 and all required site and warran-
ty registration forms are completed and received by
OPW within 60 days of installation. This limited warran-
ty also shall not apply to any FlexWorks, VAPORSAVER™
or other OPW product: unless all piping connections are
installed with a nationally-recognized or state-
approved leak detection device in each tank and dis-
penser 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 t-
tings; unless a sump inspection log or an EPA recom-
mended/required checklist is maintained and the re-
sults are furnished to OPW upon request; and unless
OPW is notied within 24 hours of any known or sus-
pected product failure and is provided with unrestrict-
ed access to the product and the site. This limited war-
ranty 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 limita-
tion, failure to follow FlexWorks Quick Reference Manu-
al Installation Guide and all product warning labels);
abuse or misuse; violation of health or safety require-
ments; use of another manufacturer’s, or otherwise un-
PRODUCT WARRANTY PERIOD
FlexWorks Primary Pipe 10 years from date of manufacture
All Products and re-
placement parts in-
stalled in the State of
California
Certied to California CP
-201 and/or CP-206
Standards*
1 year from date of installation (proof of
purchase from certied contractors/
technicians required)
OPW warrants ongoing compliance with
the standards and specications for the
duration of the warranty period required
by the State of California; this limited war-
ranty is under the condition the equip-
ment was installed and maintained by
trained and certied contractors/
technicians unless noted in Installation
Manual.
All other Products and
replacement parts
1 year from date of manufacture**
*Products certied to California CP-201 and/or CP-206 Standards
have been factory tested and met all applicable performance stand-
ards and specications and will have an OPW registration card en-
closed/attached to the product.

2
authorized, substances or components; soil or other
surface or subsurface conditions; or re, ood, 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 negli-
gence, strict liability or any other claim, including, with-
out limitation, for special, incidental, consequential or
exemplary damages or for the cost of labor, freight, ex-
cavation, clean-up, downtime, removal, reinstallation,
loss of prot, 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 war-
ranty is not assignable.
** Date of manufacture on this product is located on
the at area of the valve body, under oat.
GENERAL INSTRUCTIONS
The OPW 71SO Overll Prevention Valve is designed for
tight ll, gravity drop applications to help prevent acci-
dental or intentional overlling 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 reaches the
initial shut o point. 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-o, the bypass valve will close and will re-
strict all fuel delivery to ensure that the top of the tank
is not wetted per EPA requirements.
The 71SO models of the 71SO are designed to be in-
stalled 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 com-
pletely 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 fail-
ure.
Failure to follow instructions may cause improper prod-
uct operation or premature failure which may permit
storage tank overll. An overlled storage tank may
create hazardous conditions and/or environmental con-
tamination.
CAUTION
Do not remove elastic band from around oat until
instructed to do so, as damage to valve may result.
WARNING
Failure to properly connect delivery hose and el-
bow, and/or disconnecting a liquid lled delivery
hose or elbow will result in a hazardous spill, which
may result in personal injury, property damage, re,
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 deliv-
ery 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 ow
signal that the tank is full. Close transport delivery
valve and drain hose into tank before disconnecting
any hose tting.
Overlled Tank: Failure of the hose to drain after clos-
ing the delivery valve signals an overlled tank. Do Not
Disconnect any delivery hose tting until the liquid lev-
el 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 inhala-
tion of vapors that may be fatal. Never go inside
conned areas after being splashed and never go
near ignition sources.
IMPORTANT
Determine if the underground storage tank is equipped
with a ball oat vent valve, as illustrated in Figure 24. In
all systems, the shut-o point of the 71SO must be
reached before the ball oat reduces ow to ensure
proper overll valve operation.
TOOLS NEEDED FOR INSTALLATION AND ASSEM-
BLY:
1. 71SO-TOOL or 71SO-TOOLC or
71SO-TOOLCT (includes the following)
 Sharp 3/16” drill bit with stop
 Punch
NOTE: Testable 71SO models ending with a “T” re-
quire the 71SO-TOOLCT or modied 71SO-TOOL or
71SO-TOOLC

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Alternate Components - Testable Versions
Note: all components are the same except the
socket adaptor & cable assembly, rivet, testable
inlet tube, and ferrule.
Rivet
Ferrule
Testable Inlet
Tube
Socket Adaptor & Cable
Assembly
2. Drill
3. Hammer
4. Tape measure
5. Hacksaw or cut-o saw, ne tooth; 24 teeth/inch
6. Fine half round le
7. Screwdriver - Phillips blade
8. Fine grit sandpaper / steel wool
9. Grease, black moly
10. Torque Wrench
11. Band clamp (3-3/4” diameter minimum)
12. TESTABLE MODELS ONLY: rivet tool for 1/8” man-
drel, crimping tool / pliers, wire cutter / scissors,
pipe dope, 1/4” square drive extension or 3/8”
square drive extension with 3/8” to 1/4” socket
adapter.
WARNING
Using electrically operated equipment near gasoline
or gasoline vapors may result in re 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 gures in this installation and
maintenance instruction may contain vapor recovery
equipment (including model numbers) that is not certi-
ed by the California Air Resources Board (CARB) for a
specic Phase I Vapor Recovery System. Please refer to
Exhibit 1 of the appropriate CARB Phase I Executive Or-
der for a list of certied Phase I Vapor Recovery System
Equipment.
Valve Body
Lower Tube
71SO Parts Diagram
Upper O-Ring Gasket
Screws, Qty 3
Inlet Tube
Polypak Seal
Upper Drop Tube
Float
Lower O-Ring

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IMPORTANT: The instructions below for the 71SO
Overll Prevention Valve are written for the initial
stage shuto at 95%, but can be adjusted to shuto
at any desired tank capacity. Please contact the Au-
thority Having Jurisdiction (AHJ) and review local,
state, and national codes to determine the regulato-
ry requirements governing shut-o capacity in your
region, as well as take into account other considera-
tions such as extreme tank tilt. In all cases, the up-
per tube must protrude into the tank at least 6 1/2”
to ensure that the valve can shut o ow into the
tank completely before the top of the tank is wetted
as per EPA requirements.
HOW TO LOCATE THE POSITION OF THE 71SO AT
95% TANK CAPACITY
(Shut-o points can be adjusted to any capacity to
comply with AHJ Requirements)
The length of the upper tube and the placement of the
71SO valve body determine the shut-o point. Follow-
ing the standard instructions for the OPW 71SO will pro-
vide for initial shuto 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 calibra-
tion chart.
4) Find the dipstick number (X) which corresponds to
the 95% tank volume. And, nd the dipstick num-
ber (Y) which corresponds to the 100% volume.
5) Subtract the dipstick number (X) from the tank di-
ameter (Y) to nd the upper tube reference number
(Z).
(Y) - (X) = (Z)
6) Subtract 2" from (Z) to nd 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
tank (A).
Upper Tube Length = C + (A)
For testable models only, ending in “T”:
Upper Tube Length = C + (A) – 1-1/2”
YES Upper tube length is 6-1/2” plus the riser pipe
measurement (A).
Upper Tube Length = 6-1/2” + (A)
For testable models only, ending in “T”:
Upper Tube Length = 6-1/2” + (A) - 1-1/2”
NOTE: You must nd the actual tank capacity num-
ber 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.
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
shuto will occur when the tank is no more than
95% full.
4) The calibration chart reading of 8910 gal. corre-
sponds to a dipstick measurement of 82”.

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5) Dipstick number (X) = 82”
Tank diameter (Y) = 92”
(Y) - (X) = (Z) (92” - 82” = 10”)
(Z) = 10”
6) (Z) - 2” = C (10” - 2” = 8”)
C=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 ob-
tain measurement (A).
Upper tube length = C + (A)
For testable models only, ending in “T”: Upper Tube
Length = C + (A) - 1-1/2”
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 OPW 71SO Overll Prevention Valve.
Read and follow these steps carefully, checking them
o 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 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 of the Face Seal
Adaptor threads inside the base of the spill container
bucket just below the drain valve outlet window to the
inside, top lip of the storage tank (Dim. “A”) (See Figure
1 &1A).
The top ange 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 congu-
rations other than that shown, consult installation
drawings or use other necessary means to measure Di-
mension “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 ma-
terial. Over spray from tank relining or any internal
burrs 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 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. Use
a tape measure to mark the calculated upper tube
length onto the upper tube. See Figure 2.
Figure 1
Figure 1A

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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 oat and
tubes (See Figure 3A). Carefully saw through the tube
squarely, at the mark made in Step 2. Use a hacksaw
with a new ne-tooth blade. Rotating the upper tube
as the sawing progresses will minimize run out and en-
sure 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.
STEP 4: FILE THE UPPER DROP TUBE
File the upper tube square, and remove any burrs or
rough edges. Make sure the cut is at and square.
IMPORTANT: Carefully le 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 8.
Figure 4
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.
Figure 5
Seam
Tape measure
Mark Upper Tube
(Cut Line)
Figure 2
Figure 3A
Figure 3B

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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.
Figure 7
STEP 8: INSTALL INLET TUBE
Insert the inlet tube into the upper tube until the upper
tube seats against the ange on the inlet tube. Ensure
polypak is inserted evenly and stays in inlet tube
groove.
SEE PAGE 8 FOR INSTRUCTIONS USING THE 71SO-
TOOL.
SEE PAGE 9 FOR INSTRUCTIONS USING THE 71SO-
TOOLC.
SEE PAGE 10 FOR INSTRUCTIONS USING THE 71SO-
TOOLCT.
Note: testable 71SO models ending with a “T” require the
71SO-TOOLCT or modied 71SO-TOOL or 71SO- TOOLC
Figure 8
NOTE: Testable inlet tube must have cable port in
line with oat. Testable inlet tube bottoms out on
stop, it does not bottom out on inlet ange. See Fig-
ure 8A
Figure 8A
Testable Models Only
Cable port must be in
line with oat

8
71SO-TOOL PROCEDURE BELOW,
FOR 71SO-TOOLC, SEE PAGE 9
FOR 71SO-TOOLCT, SEE PAGE 10
Note: 71SO-TOOL can only be used with testable
overll valves if modied as shown below. A 2”
wide slot must be added to accommodate cast lug.
71SO-TOOL Modications for Testable Inlet
STEP 9A: INSERT 71SO-TOOL OVER INLET TUBE
To install the 71SO-TOOL (sold separately) over the inlet
tube, rst loosen all three knobs, so the tool can pass
freely over the inlet tube ange. Align the slot on the
tool with the key on the inlet tube and insert the tool
down. See Figure 9A.
STEP 10A: TIGHTEN THE 71SO-TOOL
Use the three view holes to ensure that the tool seats
out at 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 11A: PREPARE DRILL AND BIT
Conrm 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 be-
tween 2” to 2-1/16” from the tip with the 71SO-TOOL. If
the stop is not at the correct position it must be xed
before drilling.
CAUTION: If the drill stop is not in the proper loca-
tion failure of a pressure decay leak test may result.
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 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 11A 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.
Add 2” wide
slot to use with
testable valves
Figure 9A Figure 10A
Figure 12A
Tip to stop dimension must be
2” to 2-1/16”.
Figure 11A

9
71SO-TOOLC PROCEDURE BELOW,
FOR 71SO-TOOL, SEE PAGE 8
FOR 71SO-TOOLCT, SEE PAGE 10
Note: 71SO-TOOLC can only be used with testable
overll valves if modied as shown below.
STEP 9B: INSERT 71SO-TOOLC OVER INLET TUBE
To install the 71SO-TOOLC (sold separately) over the
inlet tube, rst loosen the thumb screw, so the tool can
pass freely over the inlet tube ange. Align the slot on
the tool with the key on the inlet tube and insert the
tool down. See Figure 9B.
STEP 10B: TIGHTEN THE 71SO-TOOLC
Ensure that the tool seats at against the top of the inlet
tube. To prevent vertical movement of the tool during
drilling, hand tighten the thumb screw against the up-
per drop tube. See Figure 10B.
STEP 11B: PREPARE DRILL AND BIT
Conrm 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 be-
tween 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 xed before drilling.
CAUTION: If the drill stop is not in the proper loca-
tion failure of a pressure decay leak test may result.
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 po-
sitioned 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 11B 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.
Add a 10-24 UNC thread or similar
to all three legs of the 71SO-
TOOLC in the area shown. Use set
screws to secure tool to upper
tube.
71SO-TOOLC Modications for Testable Inlet
Figure 11B
Figure 12B

10
71SO-TOOLCT PROCEDURE BELOW,
FOR 71SO-TOOL, SEE PAGE 8
FOR 71SO-TOOLC, SEE PAGE 9
STEP 9C: INSERT 71SO-TOOLCT OVER INLET TUBE
To install the 71SO-TOOLCT (sold separately) over the
inlet tube, rst loosen the thumb screws, so the tool can
pass freely over the inlet tube ange. Align the slot on
the tool with the key on the inlet tube and insert the
tool down. See Figure 9C .
STEP 10C: TIGHTEN THE 71SO-TOOLCT
Ensure that the tool seats at against the top of the inlet
tube. To prevent vertical movement of the tool during
drilling, hand tighten the thumb screws against the up-
per drop tube. See Figure 10C.
STEP 11C: PREPARE DRILL AND BIT
Conrm that the stop on the 3/16” drill bit supplied
with the 71SO-TOOLCT is in the correct position before
drilling. The stop is factory installed at a distance be-
tween 1-3/16” to 1-1/4” from the tip with the 71SO-
TOOLCT. If the stop is not at the correct position it must
be xed before drilling.
CAUTION: If the drill stop is not in the proper loca-
tion failure of a pressure decay leak test may result.
STEP 12C: DRILL HOLES
With the inlet tube and 71SO-TOOLCT in place, carefully
drill a 3/16” diameter hole in the upper tube using the
hole in the 71SO-TOOLCT 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 11C
and check the stop dimension. If a hole is drilled
through the inlet tube or into the screw hole the assem-
bly is not salvageable. Drill (2) more holes in the two
remaining guide holes.
Tool Slot
Loosen
thumb
screws
Inlet
Tube
Key
Hand tighten
thumb screws
Figure 9C Figure 10C
Figure 11C
Figure 12C