Tank Indicator Installation Model: VSTI-A020, Stainless Reverse Read System Guide Cables No Guide Cables 1 August 4, 2011
Assembly Instructions: (Shown with a 2 board, 12 ft kit) ITEM NO. PART NUMBER DESCRIPTION QTY. 1 1000072-72 STAFF GUAGE BOARD 2 2 7000414 WEIGHTED FLOAT 1 3 7000478 CABLE TENSION ASSEMBLY 2 4 1000077 COUPLING BRACKET 1 5 7000019 SHEAVE HOUSING 2 6 1000010 1" X 3" THREADED PIPE NIPPLE 3 7 1000006 1" UNION 3 8 1000067 1" X 24" THREAD PIPE NIPPLE 3 9 7000018 TARGET 1 10 7000412 FLOAT CABLE 1 11 7000006 WIRE ROPE CLAMP 3 12 1000068 TANK BRACKET 3 13 1000089 STAFF GAUGE CLOSURE BRACKET 1 14 1000084 RULER BRACKET 1 15 1000083 TANK BRACKET EXTENSION 3 16 1000787-05-16 5/16" HEX HEAD BOLT 14 17 1000794-05 5/16" HEX NUT 14 18 1000793-05 5/16" LOCK WASHER 14 19 1000791-05 5/16" FLAT WASHER 28 20 1000720-01 WEIGHTED PLATE 1 21 1000420 FLOAT GUIDE CABLE 1 2 August 4, 2011
There are different ways to assemble & mount the Staff Gauge Boards onto the tank. The method chosen largely depends on these factors: a. The height of the tank b. The equipment available c. Whether or not you are able to mount the Tank Brackets directly to the tank STEP A - Assemble Staff Gauge Boards 1. Each Staff Gauge Board comes with a mounted decal set displaying height values; Lay the boards on a flat surface in the correct order/orientation. 2. Install each bracket assembly using a Tank Bracket, Tank Bracket Extension, (4) Hex Head Bolts, (8) Flat Washers, (4) Lock Washers, and (4) Hex Nuts. Note: The Tank Brackets can point up or down, depending on installation needs. 3 August 4, 2011
3. Configure and install the top bracket assembly using the following parts: Tank Bracket, Tank Bracket Extension, Ruler Bracket, and Coupling Bracket, with (6) Hex Head Bolts, (12) Flat Washers, (6) Lock Washers & (6) Hex Nuts. Note: The pipe socket on the Coupling Bracket must point up to receive the Reeving Assembly. 4 August 4, 2011
4. Trim the bottom of the Staff Gauge Board as necessary to fit the height of the tank. Note: The Staff Gauge Closure Bracket is only required when the Staff Gauge Board needs trimming. 5. When attaching the Staff Gauge Closure Bracket, saw the Staff Gauge Board to length (as necessary), then drill an 11/32 hole through the Staff Gauge Board. Use a Hex Head Bolt, Lock Washer, and Hex Nut to secure the Staff Gauge Closure Bracket to the bottom of the Staff Gauge Board. STEP B - Mount the Staff Gauge Boards 2 Ways 1. Field conditions permitting, mount the Tank Brackets directly to the tank. Then mount each individual Staff Gauge Board to each bracket assembly One bracket, then one Staff Gauge Board, next bracket, etc. 2. If unable to mount brackets directly to the tank, the Staff Gauge Board can be mounted to a support channel first. This channel is supplied by the customer, and should be at least 5 wide and as tall as the tank, in order to sufficiently support the Staff Gauge Board assembly. Once all components of the Staff Gauge Board assembly have been mounted to the channel, the entire assembly can be raised and mounted onto the tank as a unit. Note: For tall tanks, this may be done in sections to prevent bowing. 5 August 4, 2011
3. Attach the Wire Rope Clamp to the Target. 4. Slide the Target with attached Wire Rope Clamp onto the Staff Gauge Board. 5. Temporarily tape or tie the Target to the Staff Gauge Board so that it will not fall when the Staff Gauge Board is lifted vertically into position. Note: No cable installation is needed at this time. STEP C - Reeving Assembly 1. Using the two Sheave Housings, assemble the 1 x 24 Threaded Pipe Nipple, 1 Unions, and 1 x 3 Threaded Pipe Nipples as shown below. 6 August 4, 2011
1 x 24 Threaded Pipe Nipple 1000010 Sheave Housing 7000019 1 x 3 Threaded Pipe Nipple 1000010 1 Union 1000006 Reeving Assembly Note: Positioning of the Reeving Assembly is important because it is used to determine the exact point of penetration for the 1 NPT Coupling, where the Reeving Assembly meets the roof of the tank. The Staff Gauge Board is mounted to the outside of the tank wall, and the Reeving Assembly directs the Float Cable from the Staff Gauge Board over and through the roof of the tank. 2. One end of the Reeving Assembly is attached to the Coupling Bracket. The other end connects to the customer-provided 1 NPT Coupling, located on the roof of the tank. 3. Placement of the Reeving Assembly should mark exactly where the cable meets the tank. It can be adjusted when necessary by adding or removing length to the 1 NPT nipples. 4. Disassemble the Reeving Assembly to seal all its pipe joints. 5. Reassemble the Reeving Assembly onto the tank. 6. The two Cable Tension Assemblies can now be installed at the roof of the tank. The Float Guide Cable will be installed in a later step. Note: The customer is encouraged to use all safety precautions, devices, and procedures when working in elevated locations. 7 August 4, 2011
Pipe may need to be cut & threaded to adjust for field conditions Partial tank shown 1 NPT Coupling (Customer Provided) (2) Cable Tension Assemblies 7000478 Float Guide Cable (optional) 1000420 Staff Gauge Board 1000072 3/16 Float Cable 7000002 STEP D - Feeding the Float cable 1. Remove the covers of the Sheave Housing to aid in feeding the Float Cable through. 2. Attach the Float Cable to the Weighted Float. 3. Feed the Float Cable: The taped end of the Float Cable comes up from the Weighted Float, then feeds up and through the Reeving Assembly, down to the Target, outside the tank. 4. Make sure the Float Cable is running on the pulleys in the Sheave Housing before placing the covers back on. 5. Temporarily attach the Float Cable to the Wire Rope Clamp on the Target using two set screws. Note: You will later need to calibrate the length of the Float Cable by positioning the Target outside of the tank, to the same height as the liquid inside the tank. 8 August 4, 2011
Reeving Assembly Remove covers to aid feeding Float Cable 7000412 34-1/4 Float Cable 7000412 12 Feed Float Cable (7000412) up & through Reeving Assembly 9 August 4, 2011
Tank top installation view: Reeving Assembly Partial tank shown 34-1/4 Distance dependent upon field conditions (3) 1 NPT Couplings (Customer Provided) 14.82 (2) Cable Tension Assemblies 7000478 12 Staff Gauge Board Float Guide Cables 1000420 10 August 4, 2011
STEP E - Weighted Plate at the bottom of the tank Note: Only used when Float Guide Cables are required 1. The Weighted Plate should be secured to the tank floor while the tank is empty. This can be done by welding, or using the two mounting holes provided. The eyes in the plate should line up with the Cable Tension Assembly on top of the tank. These eyes are 12 apart and are positioned in line with the Weighted Float. A plumb-bob may be used for accurate locating. Note: If the tank currently has liquid inside, the Weighted Plate and Float Guide Cable assemblies can be lowered into the tank. 11 August 4, 2011
Connector swaged onto 3/16 Float Cable 7000002 Weighted Float 7000414 Float Weights Float Guide Cable 1000420 2. Feed the Float Guide Cables through the Weighted Float; One Float Guide Cable should feed through the hole on each side of the Weighted Float. 12 August 4, 2011
3/16 Float Cable 7000002 Set Screws Wire Rope Clamp 7000006 Target 7000018 STEP F - Calibrate Target 1. Finally, adjust the Target to the height of the Weighted Float. This is done by loosening the two set screws, and pulling the Float Cable through until the Target represents the correct height of the Weighted Float inside the tank. 2. Tighten the screws and check for smooth operation by pulling down on the Target. 3. Cut off the excess Float Cable. 13 August 4, 2011
Weighted Float 7000414 Float Guide Cable 1000420 Weighted Plate 1000720-01 STEP G.a Tension Guide Cables on an Empty Tank 1. Pull up on the Float Guide Cable to provide tension. The Weighted Plate should be affixed to the tank floor, so you will not be able to lift if off the tank floor. 2. Compress the conical spring and locking collar 3/8 to ½ ; Mark the cable at the top of the locking collar. Tighten the locking collar using the two set screws. (Be careful not to overtighten as this will damage the Float Guide Cable). 3. Install the 3 Threaded Pipe Nipple back onto the base of the Cable Tension Assembly. 4. Cut the excess Float Guide Cables at the top of the 3 Threaded Pipe Nipple. 5. Replace the pipe caps using a sealant that is strong enough to retain the cap, but allowing you to remove it later to adjust tension as required. 14 August 4, 2011
STEP G.b Tension Guide Cables on a Live Tank 1. Pull up on the Float Guide Cable until you feel the Weighted Plate being lifted off the tank floor. 2. Using a marker; mark the cable at the top of the locking collar. 3. Tighten the locking collar to the cable 3/8 to 1/2 down from the mark using the two set screws. (Be careful not to over-tighten as this will damage the Float Guide Cable). 4. Lower the conical spring, locking collar and Float Guide Cable down into the base. This should tension the Float Guide Cables without lifting the Weighted Plate off the bottom of the tank. 5. Install the 3 Threaded Pipe Nipple back onto the base of the Cable Tension Assembly. 6. Cut the excess Float Guide Cables at the top of the 3 Threaded Pipe Nipple. 7. Replace the pipe caps using a sealant that is strong enough to retain the cap, but allowing you to remove it later to adjust tension as required. 15 August 4, 2011
STEP H - Tension the Float Guide Cables 1. Tension the Float Guide Cable at the top of the tank using the Cable Tension Assembly. 2. Remove the cap from the Cable Tension Assembly and the 3 Threaded Pipe Nipple. 3. Slide the Float Guide Cable through the customer-provided 1 NPT Coupling. 4. Feed each Float Guide Cable through the base of each Cable Tension Assembly. 5. Loosen the 2 set screws on the locking collar to feed the Float Guide Cable through the conical spring & locking collar. CONGRATULATIONS, YOU ARE NOW DONE INSTALLING A TROUBLE FREE TANK LEVEL INDICATOR FROM VERSA-STEEL INC.! 16 August 4, 2011
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