Vaporsaver 1

Installation Manual – ATEX

99-50510 09APR2009
 ATTENTION INSTALLER:

READ AND UNDERSTAND THIS IMPORTANT SAFETY

INFORMATION BEFORE BEGINNING WORK

This product is to be installed and operated near the highly combustible

environment of a gasoline storage tank and gasoline dispensing. It is essential
for your safety and the safety of others that you carefully read, understand, and
follow the warnings and instructions in this manual. Failure to do to so could
result in danger to life and property including death, serious injury, explosion, fire
or electric shock.

Failure to install this product in accordance with the instructions and warnings in
this manual as well as failure to follow the requirements of the National Electric
Code, national, state, and local codes will result in voiding warranties of this
product.

Only OPW trained and certified technicians are to install and start-up the system.
An OPW trained and certified technician shall start-up the system only after
careful inspection of the installation, and completion of the start-up check list.

It is your responsibility to install this product in accordance with the instructions

and warnings in this manual.
 Safety Symbols
The following safety symbols may be used throughout this manual to alert you to
important precautions and safety hazards that may arise during the installation and
operation of this product.

TURN POWER OFF

ELECTRICITY
Turn power off to the device
A potential shock hazard OFF
and its accessories when
exists. High voltage is
installing and servicing the
supplied to and exists in this
unit. Live power creates a
device.
potential spark hazard.

EXPLOSIVE NO POWER TOOLS

Gasoline and its vapor are Sparks from electric power
extremely explosive if tools can ignite gasoline and
ignited. its vapors.

NO PEOPLE IN THE AREA

Unauthorized people in the
FLAMMABLE
work area during installation
Gasoline and its vapors are
and service of the device
extremely flammable.
create a potential for
personal injury.

READ ALL RELATED

NO SMOKING
MANUALS
Gasoline and its vapors can
Read, understand and
be ignited by sparks and
follow all instructions,
embers of burning
warnings and requirements
cigarettes.
before you begin work.

USE SAFETY
BARRICADES
NO OPEN FLAMES Unauthorized people or
Open flames from sources vehicles in the work area
like lighters, matches, etc. create a potential for injury
can ignite gasoline and its and danger to property.
vapors. Always isolate your work
area by using safety cones,
barricades, etc.

PINCH RISK
ROTATING MACHINERY
Stay clear. Keep hands and
Stay clear. Keep hands and
tools away from rotating
tools away from rotating
machinery and moving
machinery.
parts.
 Table of Contents

1.0 Introduction................................................................................................................................... 1
1.1 Control System Description..................................................................................................... 1
1.2 Normal Operating Conditions (What the System Does) ....................................................... 1

2.0 Operation (How It Works) ............................................................................................................ 2

3.0 Component Identification ............................................................................................................ 4

3.1 User Interface ............................................................................................................................ 4
3.2 Control System.......................................................................................................................... 6

4.0 Component Location.................................................................................................................... 8

4.1 User Interface Location ............................................................................................................ 8
4.2 Control System Location ......................................................................................................... 9
4.3 Control System Mounting ...................................................................................................... 11

5.0 Control System Piping ............................................................................................................... 13

5.1 General Piping Guidelines ..................................................................................................... 13
5.2 Inlet Piping............................................................................................................................... 13
5.3 Clean Air Vent Piping ............................................................................................................. 14
5.4 Hydrocarbon Return Piping ................................................................................................... 14
5.5 Storage Tank Vapor Manifolds .............................................................................................. 18
5.6 Piping To Avoid....................................................................................................................... 22
5.7 Stage 2 Station Underground Piping .................................................................................... 25

6.0 Electrical Requirements............................................................................................................. 31

6.1 Power Requirements .............................................................................................................. 31
6.2 Control System Electrical Hook Ups..................................................................................... 32

7.0 Other Requirements ................................................................................................................... 34

7.1 Other Electrical Requirements .............................................................................................. 34
7.2 Storage Tank Overfill Devices ............................................................................................... 35
7.3 P/V Valve .................................................................................................................................. 35
7.4 Other Control System Requirements.................................................................................... 35
7.5 Auxiliary Output Relay ........................................................................................................... 35

8.0 Control System Maintenance .................................................................................................... 36

8.1 Maintenance ............................................................................................................................ 36
8.2 General Rules for Belt Tensioning ........................................................................................ 36
8.3 Component Replacement....................................................................................................... 36
8.4 Spare Parts .............................................................................................................................. 37

9.0 Glossary of Terms ...................................................................................................................... 38

TUV Certificate
Vaporsaver Interconnect Wiring Diagram
1.0 Introduction

WARNING: Only OPW trained and certified technicians are to start-up the
system. An OPW certified technician shall start-up the system only after
careful inspection of the installation, and verification and completion of the
start-up check list.

Do not power up the system unless a complete start-up inspection is

completed by an OPW certified technician.

1.1 Control System Description

The OPW Vaporsaver reduces hydrocarbon emissions from a gasoline refueling facility by
controlling the storage tank pressure. Tank pressure management is achieved by releasing air
from the storage tanks, while recycling the gasoline vapor. The recycling that takes place
accomplishes three benefits. First, by returning vapor to the storage tank in a supersaturated
form, evaporative emissions are greatly reduced. Second, during the recycling process, liquid
gasoline is created and returned to the storage tank. Third, by releasing the air (and saving the
gasoline), the pressure in the storage tank is reduced, and vapor emissions to the atmosphere
due to venting or fugitive emissions become insignificant.

Pressure in the storage tank will rise due to thermal and pressure affects of the day, by the
introduction of air from filling vehicles (larger pressurization occurs with ORVR equipped
vehicles), or from Stage I deliveries.
Without the OPW Tank Pressure Management System:
• Ingested air from vehicles can evaporate the liquid product, and cause an increase in UST
pressure.
• Increased pressure from all sources will be released from the UST’s to the atmosphere
through leaks in the vapor piping, components, and P/V vents.

1.2 Normal Operating Conditions (What the System Does)

1. The Control System turns on when the UST pressure increases to approximately +0.4
mbar gage (+0.15 inches of water column) pressure.
2. It turns off in the following conditions
a. When UST pressure is reduced to approximately -2.5 mbar gage (-1.0 inches of
water column) vacuum.
b. The Control System is also designed to only operate 10 minutes continuously.
After a 10 minute run, the Control System shuts down for 2 minutes, and will start
again if tank pressure requires it. This allows the separator to drain returning
liquid product to the storage tank. As well as not allowing the Control System to
run excessively if the vapor space has significant leaks.
3. The Residue is the fresh air being released from the Control System. It is continuously
monitored for the presence of hydrocarbons to ensure it is below the allowable limit.
4. The Vaporsaver, when installed and operated as designed, is approved by TUV
(minimum 97% efficiency); it also will allow any Stage II Vapor Recovery System to meet
both the ORVR compatibility and the CARB emission requirement with the nominal A/L =
1.00 (Maximum A/L = 1.10).

1
 5. The Permeate being returned to the UST after vapor/air separation will consist of super
saturated vapor and some condensed gasoline liquid.
6. There are many variables that influence how long the Vaporsaver will operate per day at
any given site. These variables would include:
a. station dispensing volume
b. number and duration of drops
c. fuel vapor pressure
d. fuel temperature
e. barometric pressure and temperature
f. vapor tightness of the Stage I and Stage II Systems
g. storage tank ullage
7. The amount of operating time per day can vary from station to station, as well as from
day to day at the same station. A seemingly significant variation from day to day should
not be a concern. The Vaporsaver is self-monitoring; if a fault arises, an alarm will
sound.

2.0 Operation (How It Works)

As pressure in the storage tank rises, the pressure sensor monitoring the tanks will start the
Vaporsaver Control System.

1. The feed pump draws the vapor/air (saturated vapor) mixture from the storage tank.
2. The vapor/air flow is pressurized.
3. Increasing pressure within the same volume causes the vapor stream temperature to
rise.
4. The heated vapor stream passes through a heat exchanger.
5. The heat exchanger reduces the vapor stream to ambient temperature.
6. The cooling process causes liquid gasoline to condense.
7. The vapor/air mixture and liquid gasoline go to a separator.
8. The liquid gasoline is separated, removed from the vapor/air mixture, and stored for later
removal and return to the storage tank.
9. The remaining vapor/air flow proceeds to the membrane.
10. The membrane material has two sides, a pressure (feed) side, and a vacuum (permeate)
side.
11. As hydrocarbon molecules pass along the membrane pressure side, they absorb into the
membrane material.
12. Air molecules are repelled by the membrane surface on the pressure side, and continue
on until released from the Control System as clean air (residue).
13. The pressure differential between the pressure side and the vacuum side cause the
hydrocarbon molecules to be drawn through the membrane material.
14. The vacuum pump returns the supersaturated gasoline vapor (permeate) to the storage
tank where some of it will condense into liquid gasoline.
15. When the pressure in the storage tank is reduced a preset level, the Control System is
shut down and put into stand-by mode waiting for the pressure to rise again.
16. The separator valve is then opened, and the stored gasoline liquid in the separator is
released to the UST.

2
 VAPORSAVER 1 CONTROL SYSTEM
OPERATION SCHEMATIC
EXISTING VENT (RESIDUE)
P/V VALVE

HC

PS1 PS0 PRESSURE

PS2 RELIEF VALVE
COOLER
MEMBRANE

SEPARATOR

FEED DRAIN
PUMP VALVE
PS3
LIQUID
GASOLINE

(PERMEATE)

(FEED) MOTOR
VACUUM
PUMP

VAPOR

SUPERSATURATED VAPOR

LIQUID

NOTE: ONLY VAPOR LINES SHOWN

MD-VR020

3
3.0 Component Identification
The Vaporsaver 1 consists of two major components: The User Interface and the Control
System. The User Interface is the logic center of the system. It allows for interaction with the
system for monitoring system status information, setting initial site configuration, and accessing
recorded system history. The Control System is the active tank pressure management
component which houses the pumps, motor, monitoring sensors and the membrane.

3.1 User Interface

The User Interface incorporates the following features:
• Indicator lamps (Green - Power, Red – Alarm / Warning)
• Liquid crystal display (2 lines x 16 characters per line)
• A four button key pad
• Audible alarm indicator
• Auxiliary output alarm relay
• Port for serial communications (DB9, local or remote access)
• Operating temperature range: 0°C to 40°C (32° F to 104°F)

Power Indicator
(Green) Alarm Indicator
(Red)

Communications
Port (DB9)

Display

User Interface
Assembly

Audible Alarm
Indicator

4
 Motor Relay

PLC

Power Supply

Fuse: 500mA
slo-blow, 5mm
x 20mm

Auxiliary
Output
Relay

5
3.2 Control System
Nominal operating temperature range: -20°C to 50°C (-4° F to 120°F). Occasional and
short-term excursions beyond this nominal range are acceptable, and will not cause damage
to the unit.

Pressure
Switch Heat Exchanger
(PS0) Pressure
Switch
Fan Assembly (PS3)
Pressure
Switch
(PS1) Pressure
Switch
(PS2)

Pressure
Regulator

Hydrocarbon
Sensor

Compressor

Motor

Vacuum Pump

Drain Valve

6
 Pressure
Heat Exchanger Switch
(PS0)
Pressure Pressure
Switch
Switch
(PS2) (PS1)
Pressure
Switch
(PS3)

Compressor

Motor

Drain Valve

Vacuum Pump

7
4.0 Component Location
4.1 User Interface Location

WARNING: Installation of this product must comply with the National Electric
Code, federal, state and local codes, as well as other applicable safety codes.

WARNING

The User Interface enclosure must be installed in a non-Hazardous location.

Explosion or fire resulting in serious injury or death, or property loss or
damage could occur if the User Interface is installed in a Hazardous location.

Do not install User Interface enclosure in a combustible or explosive

atmosphere (Class IIA, Zone 0, Zone 1, or Zone 2; Class 1, Division 1 or
Division 2).

1. User Interface electrical enclosure must be installed indoors and protected from the
weather.
2. The enclosure must be installed so station personnel can hear the audible alarm.
3. There must be clear access to the enclosure so station personnel can interact with it.
4. All conduit connections must be made through the factory provided knockouts in the
bottom of the enclosure. All unused knockouts must be plugged. Use only rigid conduit.
5. There is a serial port on the side of the enclosure for downloading data to a computer
locally or via modem.
6. There are no end user serviceable parts within the User Interface enclosure.
7. The User Interface enclosure is 250 mm (10 inches) high, 200 mm (8 inches) wide, and
150 mm (6 inches) deep.

8
4.2 Control System Location

WARNING: Installation of this product must comply with all Nationally

recognized standards, federal, state and local codes, as well as all other
applicable safety codes for the country of installation.

1. A Hazardous Location is created by the Vaporsaver Control System.

2. Hazardous Location: Zone 2 within 200 mm of all sides of the equipment cabinet, and 50
mm above the cabinet.
3. The clean air Residue vent must be installed a minimum of 5 meters above grade, and
creates a Zone 1 Hazardous Location within 3 meters in all directions and Zone 2 below
the Zone 1 location down to grade.
4. The Hazardous Location shall not typically extend beyond a solid floor, wall, roof, or
other partition that has no communicating openings.
5. Vapor Processing Equipment shall be installed at least 6 meters from dispensing
devices unless approved by local authority.
6. The Vaporsaver Control System cannot be installed within a Zone 1 area created by
another device or location.
7. If the Control System is located where vehicle or pedestrian traffic has access,
measures must be taken to protect the Control System and exposed piping from
damage or vandalism.
8. Installation of vehicle bumper posts or fenced enclosures may be necessary. Use
POMECO/OPW pipe guards (POMECO SPG, 6PGU, or 6PGR series guards).

9
 Hazardous Location

10
4.3 Control System Mounting

WARNING

The Control System is to be installed near locations where highly

flammable and explosive vapors and liquids may be present. Risk of
Fire, injury and Death.

You are working in an area where vehicle traffic may occur. Always
block off the work area during installation and service to protect
yourself and others.

Do not use power tools that can generate sparks if there is a risk of
flammable or explosive vapors or liquids being present.

1. The Control System can be installed directly on grade.

2. It must be permanently anchored to concrete or another solid base, and must be
installed level.
3. Minimum clearances for service access (more clearance always makes service easier).
a. Back: 0.3 meters (12 inches)
b. Top: 0.3 meters (12 inches)
c. Front: 0.3 meters (12 inches)
d. Left: 1.2 meters (48 inches)
e. Right: 0.3 meters (12 inches)
4. Do not install Control System where snow will accumulate or be placed when clearing
lots or forecourt. The above minimum clearances should be maintained at all times
during operations.
5. Do not install where irrigation or sprinkler systems can spray water up through the louver
vents.
6. If it is necessary to install a concrete pad, a 1 meter by 2 meter (3 foot by 6 foot)
reinforced pad is adequate; minimum 100 mm (4 inch) thickness. To ease and speed
installation, use a POMECO/OPW island-form (p/n 6013-SFR6W3L6 or 6013-
SFR6W3L5).

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12
5.0 Control System Piping

WARNING

The Control System is to be installed near locations where highly

flammable and explosive vapors and liquids may be present. Risk
of Fire, Injury and Death.

You are working in an area where vehicle traffic may occur. Always
block off the work area during installation and service to protect
yourself and others.

Do not use power tools that can generate sparks if there is a risk of
flammable or explosive vapors or liquids being present. Open
piping to the gasoline storage tank will be emitting dangerous,
flammable and potentially explosive vapors. Do not smoke or have
open flames in areas near open piping.

5.1 General Piping Guidelines

1. When planning the installation of a Vaporsaver, the main rule for piping is that the
Control System should pull from and return to different locations of the vapor system.
2. It is important that return piping connections are separated from the inlet piping
connections, so the permeate return vapors cannot be drawn directly back into the inlet
piping. This will maximize the vapor and fuel recovered.
3. All aboveground piping must be schedule 40 galvanized; only use pipe that is internally
and externally corrosion protected.
4. Follow local requirements for underground vapor piping with regard to secondary
containment.
5. All pipes must have slope away from the Vaporsaver Control System directed to the
storage tanks. Minimum slope: 10 mm/1 meter (0.5°, 1/8" per foot)
Recommended slope: 20 mm/1 meter (1°, 1/4" per foot)

5.2 Inlet Piping

1. The Control System inlet is typically connected to the high-grade gasoline storage tank.
2. Piping should remain a minimum of DN50 (2" NPT) from the Control System inlet
connection to the connection to the storage tank (or storage tank vents).
3. For maintenance purposes, it may be desired to install a DN50 (2”) ball valve. Ensure
that the valve has a 50mm (2”) flow opening and is approved for gasoline use. NEVER
OPERATE THE VAPORSAVER WITH THE SERVICE VALVES CLOSED; damage to
the Vaporsaver will occur. It is highly recommended that the valve handle is removed to
avoid tampering.

13
5.3 Clean Air Vent Piping
1. The clean air vent (residue) must be piped so the discharge opening is 5 meters
minimum above adjacent grade.
2. Use OPW 523AV for the clean air vent.
3. The clean air vent piping should remain a minimum of DN40 (1-1/2" NPT).
4. The vent creates a Hazardous Location.
a. Zone 1 within 3 meters in all directions of the vent opening.
b. Zone 2 below Zone 1 down to grade.
c. Follow all applicable codes.

5.4 Hydrocarbon Return Piping

1. The Control System hydrocarbon return (permeate) should be connected to the low-
grade gasoline storage tank.
2. It is important that return piping connections are separated from the inlet piping
connections, so the permeate return vapors cannot be drawn directly back into the inlet
piping.
3. The hydrocarbon return piping must slope away from Control System. This pipe will be
carrying liquid condensation from the separator, and supersaturated vapor.
Minimum slope: 10 mm/1 meter (0.5°, 1/8" per foot)
Recommended slope: 20 mm/1 meter (1°, 1/4" per foot)
4. The hydrocarbon return piping should remain DN40 (1-1/2" NPT) minimum until it returns
to the storage tank. Some special installation may allow smaller pipe to be used as long
as the internal diameter is not less than DN20 (¾ inch) and the length does not exceed 3
meters (10 feet); for longer pipe runs of DN20 consult OPW Technical Support for
installation review.
5. For maintenance purposes, it may be desired to install a DN40 (1-1/2”) or DN50 (2”) ball
valve. Ensure that the valve has a 40mm (1-1/2”) flow opening and is approved for
gasoline use. NEVER OPERATE THE VAPORSAVER WITH THE SERVICE VALVES
CLOSED; damage to the Vaporsaver will occur. It is highly recommended that the valve
handle is removed to avoid tampering.

14
15
16
17
5.5 Storage Tank Vapor Manifolds
1. Storage tanks must be vapor manifolded. The location of the vapor manifold will have
an impact on how the Vaporsaver feed and return can be piped.
2. A manifold too close to the Control System may cause recirculation of the permeate
return back to the Vaporsaver inlet. Therefore, if the only vapor manifold is an above
ground manifold near the Vaporsaver, the permeate should not connect to the vent
stacks, but instead should have a dedicated return to the low grade tank.
3. Some local authorities require manifolding in one location or the other; check with the
local authority having jurisdiction.
4. Above ground manifolding should be minimum 5 meters above adjacent grade; if it is
not, sufficient overfill prevention must be fitted to ensure that liquid cannot cross
contaminate tanks nor enter the Vaporsaver.
5. Vent openings must be greater than 5 meters above adjacent grade and have an
approved pressure/vacuum valve.
6. All above ground vapor piping must be schedule 40 galvanized steel, and painted to
minimize solar heat gain.
5. The vent creates a Hazardous Location.
a. Zone 1 within 3 meters in all directions of the vent opening.
b. Zone 2 below Zone 1 down to grade.
c. Follow all applicable national codes.

18
19
20
Alternate pressure/vacuum vent valve settings must be preapproved by OPW to ensure that the
Vaporsaver’s safety and performance are not compromised.

21
5.6 Piping To Avoid
1. To obtain the maximum product recovery, best performance, and longest life of the
Vaporsaver, there are several piping configurations that should be avoided.
2. Remember, the main rule for piping is that the Control System should pull from and
return to different locations of the vapor system.
3. It is important that return piping connections are separated from the inlet piping
connections, so the permeate return vapors cannot be drawn directly back into the inlet
piping.
4. Piping must be configured so that permeate return will reach the storage tank before it is
recirculated back to the Vaporsaver inlet.

The following drawings show the wrong way to install a Vaporsaver.

22
23
24
5.7 Stage 2 Station Underground Piping
1. All underground vapor piping must be a minimum of 2” NPT. Always check with local
authorities for applicable requirements; larger pipe size may be required.
2. All vapor piping must have slope for drainage to the underground storage tanks.
3. Slope minimum 10 mm per 1 meter (0.5°, 1/8" per foot); recommended 20 mm per 1
meter (1°, 1/4" per foot).
4. Always follow the requirements of the local authorities and the manufacturer of the Stage
2 vapor recovery system.

Typical Vapor Piping Layout

Notes:
• Always follow requirements of component and system manufacturers, local, state and
national authorities for installation and operation of all equipment.
• Vent piping diameters must comply with applicable codes.
• Feed piping from the Control System to the vents shall be DN50 (2” nominal ID).
• Permeate and Residue piping from the control system to the vents shall be DN40 (1-1/2”
nominal ID) minimum.

25
 Typical Vapor Piping Layout

Notes:
• Always follow requirements of component and system manufacturers, local, state and
national authorities for installation and operation of all equipment.
• Vent piping diameters must comply with applicable codes.
• Feed piping from the Control System to the vents shall be DN50 (2” nominal ID).
• Permeate and Residue piping from the control system to the vents shall be DN40 (1-1/2”
nominal ID) minimum.

26
 Typical Vapor Piping Layout

Notes:
• Always follow requirements of component and system manufacturers, local, state and
national authorities for installation and operation of all equipment.
• Vent piping diameters must comply with applicable codes.
• Feed piping from the Control System to the vents shall be DN50 (2” nominal ID).
• Permeate and Residue piping from the control system to the vents shall be DN40 (1-1/2”
nominal ID) minimum.

27
 Typical Vapor Piping Layout

Notes:
• Always follow requirements of component and system manufacturers, local, state and
national authorities for installation and operation of all equipment.
• Vent piping diameters must comply with applicable codes.
• Feed piping from the Control System to the vents shall be DN50 (2” nominal ID).
• Permeate and Residue piping from the control system to the vents shall be DN40 (1-1/2”
nominal ID) minimum.

28
 Typical Vapor Piping Layout

Notes:
• Always follow requirements of component and system manufacturers, local, state and
national authorities for installation and operation of all equipment.
• Vent piping diameters must comply with applicable codes.
• Feed piping from the Control System to the vents shall be DN50 (2” nominal ID).
• Permeate and Residue piping from the control system to the vents shall be DN40 (1-1/2”
nominal ID) minimum.

29
 Typical Vapor Piping Layout

Notes:
• Always follow requirements of component and system manufacturers, local, state and
national authorities for installation and operation of all equipment.
• Vent piping diameters must comply with applicable codes.
• Feed piping from the Control System to the vents shall be DN50 (2” nominal ID).
• Permeate and Residue piping from the control system to the vents shall be DN40 (1-1/2”
nominal ID) minimum.

30
6.0 Electrical Requirements

WARNING

This system uses lethal voltages and operates in areas

where flammable vapors and liquids may be present.

Serious injury or death from electrical shock, fire, or

OFF
explosion may result if the power is on during installation.

Turn power off, lockout and tag power to the unit while
installing the system.

Read and understand all instructions in this manual and all

applicable requirements of the National Electric Code,
federal, state and local codes, as well as other applicable
safety codes.

6.1 Power Requirements

1. Vaporsaver System
User Interface:
100-240 VAC, 50/60 Hz
1-Phase
0.5 amp
Control System Motor:
380-415 VAC, 50 Hz / 440-480 VAC, 60 Hz
3-phase (See Special Note for 3-phase motors in Section 6.2)
1.8 kW (2.4 hp) at 50 Hz
Motor Contactor:
Coil: 220-230 VAC, 50 Hz / 230-240 VAC, 60 Hz; 1-phase
Contact Rating: 400 VAC, 3-phase, 4 kW; 480 VAC, 3-Phase, 5 hp
2. A circuit disconnect devise is not included with the Vaporsaver System. A readily
accessible three or four pole disconnect device must be incorporated in the installation
wiring for the motor.
3. There are no end user serviceable parts in the Vaporsaver System.
4. The User Interface has internal fuse: 500 mA (slow-blow), 250 V, 5mm x 20mm. The
fuse is to only be replaced by qualified and certified technicians.
5. An electrical service (breaker) of 15 amp should be used; always follow applicable
national regulations and codes regarding sizing of motor circuit breaker. Verify required
over-current protection ampacity with requirements for load and conductor ampacity
ratings and with the national and local authority having jurisdiction.
6. This product shall be installed in accordance with all applicable national and local
regulations for electrical equipment at gasoline dispensing facilities.
7. Equipment connected to this device must not use, store or generate more than 250 V
rms or dc with respect to ground.
8. The Vaporsaver 1 main power should be controlled by the facility’s main Emergency
Shut-Off system.

31
6.2 Control System Electrical Hook Ups
1. System Breaker shall be sized for power load based on requirements.
2. Wiring between the User Interface and the Control System shall be as follows.
a. All wiring to be gasoline and oil resistant with 600 V insulation.
b. Wiring for the 24 VDC control signals shall be minimum 1.0 mm2 (18 AWG).
c. Two ground wires shall be run from the Control System junction box to the load
center ground; one is for equipment ground, and the second is for a dedicated
Intrinsically Safe Barrier ground. Both ground wires must be minimum 3.3 mm2
(12 AWG). Proper grounding for the Intrinsically Safe Barrier is crucial for safe
operation of the Barriers.
d. Both the motor power wiring and the signal wiring can be routed in the same
conduit provided all wiring is only gasoline and oil resistant wiring with 600 V
insulation.
e. Wiring for motor shall be minimum 3.3 mm2 (12 AWG); sizing must comply with
requirements for motor load and wiring distance. Larger gage wire may be
necessary based on conductor length and voltage supplied by load center.
f. SPECIAL NOTE FOR 3-PHASE MOTORS: ensure that motor rotation is correct
the first time the unit is powered. If the motor rotation is incorrect exchange any
two of the 3-phase conductors. If reverse rotation is noted, immediately power
off the unit and correct wiring. Reverse rotation can cause internal damage to
the pumps.

32
Conductor Length and Size Guide

Maximum conductor length is the total length of the conductor from the load center through
the User Interface to the motor.

Maximum Conductor Length (1-Phase)

Voltage 208 208 230 230
% Voltage Drop 3% 5% 3% 5%

AWG mm2 Feet (meters)

12 3.3 91(28) 151 (46) 100 (30) 167 (51)
10 5.3 144 (44) 240 (73) 159 (48) 265 (81)
8 8.4 229 (70) 382 (116) 254 (77) 423 (129)

Maximum Conductor Length (3-Phase)

Voltage 200 200 230 230 400 460
% Voltage Drop 3% 5% 3% 5% 3% 3%

AWG mm2 Feet (meters)

14 2.1 506 (154) 671 (205)
12 3.3 139 (42) 231 (70) 178 (54) 297 (91) 805 (245) 1068 (331)
10 5.3 220 (67) 365 (111) 283 (86) 471 (144) 1279 (390) 1697 (517)
8 8.4 351 (107) 585 (178) 450 (137) 751 (229) 2037 (620) 2702 (824)

Notes:
• These tables are based on 140% of nameplate ratings, if national or local authority
will allow voltage drop conductor length calculations based on load ampacity rating of
125% of motor nameplate, multiply the maximum length in the table by 1.12 to get
the new maximum conductor length.
• For 3-phase voltages over 380 volts, 2.1 mm2 (14 AWG) can be used if:
o local electrical regulations allow for it to be used in motor applications and for
the motor ratings stated on the motor name plate, and
o the voltage at the motor and the running amps of the motor are within the
limits stated on the motor nameplate, and
o motor starting difficulties are not present.

THESE TABLES ARE ONLY TO BE USED AS A REFERENCE.

ALWAYS VERIFY AND FOLLOW NATIONAL AND LOCAL ELECTRICAL REGULATIONS.

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7.0 Other Requirements
7.1 Other Electrical Requirements
1. Hazardous Location Seal-offs are generally required for a conduit run leaving a Zone 1
or Zone 2 location to a non-Hazardous Location. Install as required by national and local
regulations, codes and authority having jurisdiction.
2. Wiring shall be sized as specified by nationally recognized regulations for the load and
conductor length from the load center to the motor.
3. The Control System is supplied with a knock-out for recommended field conduit
termination. This knock-out is supplied with a weather tight plug. If an alternate location
to terminate the field conduit in the Control System electrical enclosure is chosen, the
following must be followed.
a. Do not remove the factory knock-out weather tight plug.
b. A field knock-out must never be installed in Control System electrical enclosure
into the Intrinsically Safe zone.

DO NOT TERMINATE FIELD CONDUIT

INTO THE CONTROL SYSTEM
ELECTRICAL ENCLOSURE INTRINSICALLY CONTROL SYSTEM
SAFE ZONE. ELECTRICAL ENCLOSURE

FACTORY PROVIDED
KNOCK-OUT RECOMMENDED
FOR FIELD CONDUIT
TERMINATION ON LEFT
SIDE OF ENCLOSURE.
INTRINSICALLY SAFE.
DO NOT INSTALL FIELD
CONDUIT TERMINATION
IN THIS LOCATION
(SHOWN AS HATCH)

IM-VR122

34
7.2 Storage Tank Overfill Devices
Storage tank over fill prevention devices must be used to ensure that in the event of an
overfill liquid gasoline does not enter the Control System. Damage may occur, and may
result in a hazardous condition.

7.3 P/V Valve

1. Required minimum one per site
2. Use valve approved by CARB, UL, or other nationally approved agency.
3. Typical pressure setting: +3 inwc +/- ½ inwc (7.5 mbar gage +/- 1.25 mbar gage).
4. Typical vacuum setting: -8 inwc +/- 2 inwc (-20 mbar gage +/- 5 mbar gage).
5. Some jurisdictions may allow alternate pressure or vacuum settings. Do not install
pressure/vacuum valves with cracking pressures greater than +/- 70 mbar gage.
6. Pressure/vacuum vent valve settings other than +3 inwc/-8 inwc must be preapproved by
OPW to ensure that the Vaporsaver’s safety and performance are not compromised

7.4 Other Control System Requirements

1. The Vaporsaver should not be used with any flexible vapor or vent piping as there is a
risk of liquid blockage of the vapor and vent piping.
2. The Vaporsaver requires that entire vapor system (piping, tanks, valves, dispensers…)
be kept vapor tight and able to pass a Pressure Decay Test (CARB TP201.3 or
equivalent) (always follow local authority requirements).
3. During a Pressure Decay Test, the Vaporsaver must be powered off.
4. To ensure proper operation of all vapor recovery components and systems (including the
Vaporsaver), installations must be able to pass vapor piping blockage tests for all
underground vapor and vent piping (CARB TP201.4 or equivalent).
5. The Vaporsaver has no impact on the Stage II vapor recovery system, or on the ability of
the site to pass A/L testing (CARB TP201.5 or equivalent).

7.5 Auxiliary Output Relay

1. The User Interface is equipped with an Auxiliary Output Relay for external monitoring of
the Vaporsaver system. It is located on the main terminal block.
2. When the Vaporsaver is powered and operating normally, the Aux Relay is energized
(green LED on Aux Relay is lit). When the Vaporsaver is either powered off, or is in
Alarm, the Aux Relay is de-energized.
3. Aux Relay contact rating: 240V, 6A with 4000V isolation.

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8.0 Control System Maintenance
The OPW Vaporsaver is designed to require very little scheduled maintenance. The following
table is a general guide of what is required.

8.1 Maintenance
1. Every 36 months, the Hydrocarbon Sensor must be returned to OPW for calibration.
2. Every 12 months, check all belts for wear and proper tension. Only replace belts with
same size and type as originally installed. See Section 8.2 for belt tension guidelines.
3. Every 12 months, check Control System operating pressure and vacuum readings.
4. Every 12 months, check overall System, piping and fittings should be visually checked
for leaks or other wear issues.
5. Every 12 months check total run time (TRT). If approaching or greater than the
maximum hours stated in Section 8.3 replace pumps. Verify records to ensure pumps
have not already been changed.

8.2 General Rules for Belt Tensioning

1. On units equipped with self adjusting idlers, set the tension so the idler arm arrow is
between 15-20 degrees on the idler body reference scale.
2. Ideal belt tension is the lowest tension at which the belt will not slip under peak
conditions.
3. Tension the belt when slipping.
4. Over tensioning shortens pump, bearing and belt life.
5. Keep belts free from foreign material that may cause slippage.
6. Never apply belt dressing, as this will damage the belt and cause early failure.
7. Only replace belts with OPW specified belt size and type.
8. Over tensioning belts places extra load on the motor. An overly tight belt can add
several amps to the motor loading.
9. IMPORTANT: After changing or adjusting belts, always measure the motor full load
amperage; it must be less than the full load rating of the motor.

8.3 Component Replacement

The User Interface has a totalizer (TRT: total run time since first installed) that is part of the
continuous scrolling screens. This totalizer shall be used for the following
maintenance/replacement items:
a. It is recommended that the compressor pump be replaced at approximately
8,000 hours of operation, and is required to be replaced before 8,500 hours of
operation.
b. It is recommended that the Vacuum pump be replaced at approximately 10,000
hours of operation, and is required to be replaced before 12,000 hours of
operation.
c. The Membrane Module may need to be replaced at approximately 15,000 hours
of operation.

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8.4 Spare Parts
14-55000: Membrane module replacement o-ring kit
14-40200: Membrane module replacement assembly (with o-rings)
14-41267: Compressor (ATEX)
14-41268: Vacuum Pump (ATEX)
14-44002: Hydrocarbon sensor
14-44300: Belt, compressor
14-44400: Belt, vacuum pump
14-41034: Motor (ATEX, 50 Hz)
14-41033: Motor (ATEX, 60 Hz)
14-48231: Pressure switch (PS0)
14-48230: Pressure switch (PS1)
14-41121: Pressure switch (PS2)
14-42700: Pressure switch (PS3)
14-40010: Drain valve
14-40015: Fan assembly
14-40300: PLC
14-40350: Display
14-40400: Power supply
14-40401: I.S. Barrier (1 channel)
14-40402: I.S. Barrier (2 channel)
14-40406: I.S. Power supply
14-41225: Pressure regulator

Contact OPW Fueling Components Customer Service or Technical Support for other available
spare parts kits.

37
9.0 Glossary of Terms
A/L Air to liquid ratio. With any vapor recovery
system A/L relates to the volume of air (or
vapor) returned by the vapor recovery system
(usually measured in Cubic Ft.) divided by the
volume of liquid dispensed (7.481 Gallons
U.S. = 1 Cubic Ft.).

CARB California Air Resource Board.

Control System The enclosure that houses the membrane,

motor, pumps and associated hardware that
mounts to the vapor space of the UST to
control tank pressure. (See Section 3.2)

Feed Vapor flow which the Vaporsaver pulls from

the storage tank, pressurizes, partially
condenses and enters the membrane.

ORVR Onboard Refueling Vapor Recovery refers to

vehicles equipped with their own vapor
recovery system.

Permeate Supersaturated vapor flow from the

Vaporsaver returned to the storage tank.

Residue Clean air exhaust from the Vaporsaver.

User Interface The User Interface is the control panel for the
Vaporsaver system. It contains the display and
visual and audible indicators that allow
personnel to observe the operational
information of the Vaporsaver. It also allows
end-users to set time/date and acknowledge
alarms. (See Section 3.1)

UST Underground Storage Tank

Voltage Drop The amount of voltage lost due to any

components specific resistance. All
components in an electrical circuit have an
inherent voltage loss. (See Section 6.0)

38