RDR MANUAL DIESEL & GASOLINE REFUELERS & DISPENSERS

Transcription

1 Since 1924 P.D. McLAREN LIMITED RDR MANUAL DIESEL & GASOLINE REFUELERS & DISPENSERS

2 INTRODUCTION The RDR Dispenser is designed and manufactured in Canada by P.D. McLaren Limited since Built to provide the Petroleum Industry with a reliable electronic refueller for dispensing petroleum products. RDR DISPENSER SPECS High (up to 225lpm) HS series and Low Speed (up to 90lpm) LS series Commercial Refuelers: All units come standard with following: Double Skin construction with the internal frame made of satin coat steel #4 Finish Brushed Stainless Steel outer shell (Sides and top) Powder coated lower doors and bezels Heavy Duty Aluminum Swing Style Operating Handles Heavy Duty Aluminum Drip Collector Nozzle Boots Internal Piping schedule 40 welded, NPT pipe thread and/or flanged Kraus Micon 500 Electronic register with back lighted LCD displays Pulse Output Interface 1-1/2" positive displacement oscillating piston flowmeter for HS series 1 positive displacement piston flowmeter for LS series Available Options: ATC Flow Switch Programmable Pulse outputs 3 window display ($, Litres, Price Per Litre) Volume Only Display Self-Contained suction Dual Hose Dual and Single Product configurations Combination High and Low Speed Units Satellite Internal Feed and control Stainless Steel lower doors and bezels Gilbarco/ Tokheim/ MNET/ RS422 Communication Options

3 ELECTRICAL TECHNICAL DATA Electronic Computer Type Micon 1001 with Optional ATC Automatic Temperature Compensator (Tested at 25 o C unless otherwise noted) Power Consumption (Operating) 25 o C -40 o C amps max amps max Motor Control Output - Up to VAC continuous Solenoid Control Output - Up to VAC continuous Penny Pulser Output** - Solid State Switch ma Max. RS<40 ohms pulser width 7.5m sec. Volume Pulser Output** - As above except 1 pulser per.1 unit Authorize Input ma max. RIN = 2.7k ohms typical Battery Life in Power Fail Mode hours minimum ** Actual pulse output may lag actual delivery time depending on delivery rate (see pulse width specfication). If delivery rate exceeds minimum pulse width specification, pulses will be stored and will eventuallly be given. Storage rollover will occur at pulses stored. FUNCTION: Operating Temperature - 55 o C to + 50 o C DISPLAYS (LCD): Standing Temperature (1 Day) Storage Temperature (3 Days) Storage Temperature (Indefinite) R.H. 5 to 1005 non condensing - 50 o C to +70 o C R.H. 50% Maximum - 50 o C to 70 o C R.H. 25% Maximum - 40 o C to +50 o C R.H. 50% Maximum - Viewing angle +/60 nominal - Dollar volume up to per sale +.5 cents maximum - Unit volume up to per sale:.004 units metric +/-.001 units normal - Total dollar volume up to before rollover - Total unit volume up to units before rollover - Price set 0 to per unit

4 RDR Pump and Dispenser Commissioning: Customer_ Location_ Equipment Required : Micon Communicator, Micon InfoPac, PROVER (Test Measure). Multimeter. Procedure: 1. Verify all wiring is connected per wiring diagrams for the units.check handle and pulser drive shafts. 2. Ensure control power and head power are on the same phase, and from separate breakers. 3. Apply power and test the operation of all units. When starting up the units Pinch the nozzle to minimize flow until the air is purged from the supply lines and hoses. Check internals for leaks, repair Switch ON inspection switch and use a 20 litre test pail to verify the volumetrics and provide data according to the table provided below. IE: Test pail versus register versus Cardlock reading. On high speed units ie over 100 lpm, a 250 L prover is required for testing. Switch the inspection switch back OFF. Check for wiring feedback by cross testing all hoses on same pump/stp. 4. Turn over test results including cardlock receipts to owner and sign form. Provide a copy to customer and to P.D. McLaren Limited. # Model Unit # Register Volume L Test Pail L Cardlock L Signed Technician Signed Owner Company Company

5 IMPORTANT NOTE The dispenser is shipped with the battery turned off. Do not turn the battery on, until 120V is applied to terminals 1 and 2. If the battery is allowed to drain completely, it cannot be recharged and will have to be replaced. After the wiring has been completed, you must change the handle shaft actuator as follows: (A) Place the actuator shaft in the OFF position (in the OFF position no continuity will be measured between wires No. 14 and O. 15), with no power on. (B) Remove the cotter pin, which secures the couler assembly to the actuator shaft. (C) Rotate the acutator shaft 180 Degrees so that the flat side is facing up. (This will activate a micro switch which will energize the battery.)

6 P.D. McLAREN LIMITED PHONE: FAX: (604) (604) AUTHORIZATION NUMBER SERVICE REPORT CONTRACTOR: EQUIPMENT IDENTIFICATION MODEL: SERIAL NUMBER: DATE OF SERVICE: EQUIPMENT LOCATION NAME: STREET: DATE OF INSTALLATION: CITY: PROVINCE: REPORTED PROBLEM: CORRECTIVE ACTION: WARRANTY INVOICE BREAKDOWN (IF APPLICABLE) TOTAL KM S: TRAVEL, CENTS PER KLM: TOTAL $ AMOUNT: TOTAL HRS: RATE PER HR: TOTAL $ AMOUNT: CUSTOMER SIGNATURE: CUSTOMER/CONTRACTOR COMMENTS: CONTRACTOR SIGNATURE: NAME OF P.D. MCLAREN REP. CONTACTED: IMPORTANT: THIS SERVICE REPORT MUST ACCOMPANY ALL RETURNED PARTS ALSO A DUPLICATE REPORT MUST BE PRESENT WITH THE WARRANTY INVOICE.

7 ELECTRICAL

8 MOTOR CONNECTIONS Connect power supply of proper voltage and frequency to motor. For motors with a connection diagram on nameplate or decal, refer to them for proper connections. For motors with two terminal posts, connect one power line to each lead. For motors with unused speed tap leads, insulate each unused lead separately. Motors rated at 230 Volts will operate satisfactorily on 208 Volt systems. Wire Size For 115 & 230 Volt Single Phase Circuits Distance Motor To Fuse Or Meter Box -- Feet Motor 100 Ft. 200 Ft. 300 Ft. 500 Ft. HP 115V. 230V. 115V. 230V. 115V. 230V. 115V. 230V. 1/4 #14 #14 #10 #12 #8 #10 #6 #8 1/3 #12 #14 #10 #12 #6 #10 #4 #8 ½ #10 #12 #8 #10 #6 #8 #4 #6 ¾ #10 #12 #6 #10 #4 #8 #2 #6 1 #8 #10 #6 #8 #4 #6 #4 1 ½ #4 #10 #0 #8 #6 #4 2 #8 #6 #4 #2 Figure 2

9 INSTALLATION GUIDELINES

10 PIPING AND INSTALLATION INSTALLATION INSTRUCTION 1. GENERAL: Locate the pump and the tank as close together as possible. It is recommended, that the total suction lift (verticle lift plus suction line resistance) should not exceed 12 when pumping gasoline. (15 when pumping diesel fuel). If the pump is to be used with an above ground storage tank, a special solenoid valve arrangement is required on the suction side of the pump. Consult the nearest RDR Representative for details. 2. FOUNDATION: In constructing the pump island, make sure you box around the suction pipe under the pump. To provide for future servicing of the suction line and line check valve if one is located at this point. Fill this boxed in section with dry sand to keep condensation in the pump housing to a minimum. Anchor bolts should be provided and the pump firmly bolted to the pump island. We recommend a spill containment box. Example: Containment Box Models RDR CB1 or CB2. 3. SUCTION LINE (UNDER THE PUMP): (A) Use new 2 pipe and make sure it and the tank is clean. Make sure all threads are properly cut and the inside reamed to remove burrs. Use gasoline-resistant pipe compound in male threads only; pipe compound used on female threads can be squeezed in to the suction line where it can enter thepoduct stream and become lodged in the pump or meter. Install swing joints under the pump and at the tank to avoid breaks in the suction line from settling or frost heave. (B) Fiberglass pipe is preferred over steel. We recommend a flex connector be used under the pump. SEE TYPICAL LAYOUT PAGE To avoid product vaporization problems, it is important, there are no traps in the suction line. The suction line should go straight down beneath the pump to an elbow 18 below ground level and pitch down to the storage tank. The suction line should be as short as possible. Support the horizontal run of pipe on a compacted sand bed or on pea gravel for fiberglass pipe.

11 5. A suction line check valve is required for the HS-1. An angle check valve can be installed at the top of the tank or a line check valve directly under the pump. The type and location of this valve should be provided with an extractor assembly. IT IS RECOMMENDED THAT THE CHECK VALVE BE PRESSURE RELIEVED BACK TO THE TANK. 6. Before testing, remove any water in the tank through the fill opening with a pump suitable for this service. Do not use the RDR Pump to remove the water from the tank. Do not use a Submersible Pump on water either. To test the pump system, a sufficient volume of product should be put into the storage tank to ensure that the liquid level is above the bottom of the suction pipe. Operate the Pump several times, to be sure of satisfactory performance. Voltage readings should be taken while the pump is operating on bypass and while making a delivery. Any voltage drop in excess of 10% during pump operation should be considered a low voltage condition and corrective action should be taken to ensure an adequate power supply to the pump. After determining that the pump is operating satisfactorily and the system is fully primed, check the pump and piping to make sure that all connections are tight. POST INSTALLATION CHECK After rotating the actuator and checking all wiring connections the correct operation should be as follows: (SEE PAGE 4 ELECTRICAL INSTALLATION) 1) Turn on the 120 Volt head power circuit and observe that volume and dollars displays show slowly flashing zeros. 2) Enter a price described in Section C. (PAGE 25) 3) After entering a price restore the 120 Volt head power. 4) Place the pump handle in the OFF position. Turn on pump motor power and ensure that the pump motor does not run and that no product can be dispensed. 5) Place the handle switch in the ON position. The pump motor should run and/or the solenoid valve should energize. The displays should flash to all 8 s momentarily and then return to zero. 6) Dispense a convenient amount of product into a test tank and check that the head displays the proper volume and dollars amount. 7) Place the pump handle in the OFF position and ensure that the pump motor and/or solenoid shuts off. This completes the POST INSTALLATION check. If the unit does not function as described on the previous page contact your Factory or Service Representative.

12 ***NOTICE*** When this unit is used in retail trade, Weights and Measures should be notified of the installation or service of this unit. This unit is subject to inspection upon installation and at such other times as the regulations state. When electronic calibration or A.T.C. is used, the enclosure cover must be sealed by an inspector and the unit must be re-inspected, if the seal is broken. STRAINER CHECK: Check the strainer regularly, and clean when necessary. The strainer should also be checked if the pump flow rate begins to drop. PUMP VACCUM CHECK: With the pump in-operative, install a vacuum gauge on the suction side of the pum using pipe dope on the threads. Block the suction line and start the pump. If it does not, check for air leaks in the seal and gasket. Open the suction line and read the vaccum gauge with the pump primed and at operating speed. Shut off the pump and read the gauge again to determine if the vacuum remains at the maximum developed by the pump. If the vacuum falls off rapidly, an air leak exists, check to make certain that the air leak is not from vacuum gauge connection. PRIMING: Install the pump and piping as described in INSTALLATION. Make sure that the piping connections are tight and that the pump is securely mounted. Check the pump is properly lubricated. (SEE LUBRICATION in MAINTENANCE AND REPAIR). ***CAUTION*** NEVER OPERATE THIS PUMP, UNLESS THE VOLUTE (CAVITY AROUND IMPELLER) IS FILLED WITH LIQUID. THE PUMP WILL NOT PRIME WHEN DRY. EXTENDED OPERATION OF A DRY PUMP WILL DESTROY THE SEAL ASSEMBLLY.

13 FILL WITH LIQUID: A) When the pump is being put into service for the first time. B) When the pump has not been used for a considerable length of time. C) When the liquid in the volute housing has evaporated. When the volute housing is full, pump will prime and reprime as necessary. To fill the volute, remove the fill plug at the top of the volute housing and add clean liquid. Be certain to reinstall the fill plug before operating the pump. ***WARNING*** AFTER FILLING THE VOUTE HOUSING, DO NOT ATTEMPT TO OPERATE THE PUMP UNLESS THE FILL PLUG AND ALLCONNECTINGPIPING IS SECRELY INSTALLED. OTHERWISE, LIQUID IN THE PUM FORCED OUT UNDER PRESSURE, COULD CAUSE INJURY TO PERSONNEL. PRIMING PLUG MAY BE REMOTE FROM VOLUTE CHAMBER.

14 SERVICE

15 HS1 PUMP MAINTENANCE TROUBLE: POSSIBLE CAUSE: PUMP FAILS TO PRIME a) Air leak in suction line b) Lining of suction hose collapsed c) Leaking or worn seal or pump gasket d) Suction lift or discharge head too high e) Loose inlet union PROBABLE REMEDY: a) Correct leak b) Replace suction hose c) Check pump vacuum. Replace leaking or worn seal or gasket TROUBLE: POSSIBLE CAUSE: PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE a) Air leak in suction line b) Suction intake not submerged at proper level c) Lining of suction hose collapsed d) Impeller or other moving parts worn or damaged e) Impeller clogged f) Suction lift too high g) Strainer clogged h) Leaking or worn seal or pump gaskets PROBABLE REMEDY: a) Correct leak b) Check installation and correct as needed c) Check submergence chart d) Replace suction hose e) Replace worn or damaged parts f) Check that impeller is properly centered and rotates freely g) Free impeller of debris h) Reduce suction lift i) Check strainer and clean if necessary j) Check pump vaccum. Replace leaking or worn seal or pump gaskets TROUBLE: POSSIBLE CAUSE: EXCESSIVE NOISE a) Cavitation in pump b) Pumping entrained air c) Pump or drive not securely mounted d) Impeller clogged or damaged PROBABLE REMEDY: a) Reduce suction lift and/or friction losses in suction line b) Locate and eliminate source of air bubble c) Clean out debris; replace damaged parts

16 -Page 64- HS1 AND HS2 METER MAINTENANCE ERRATIC REGISTRATION Erratic registration is an indication of trouble in the system caused by air or dirt in the measuring chamber. Do not try to correct this by recalibrtion of the meter, but first check over the piping for air leaks, clean the strainer and then if the trouble has not been found, clean the meter. If this does not correct the trouble, check for faulty installation. Over-registration is an indication of air, whereas under-registration is generally caused by direct or pipe scale in the measuring chamber, or the liquid by-passing the meter in some manner. CONSISTENT OVER OR UNDER REGISTRATION When the meter registers consistently either more or less than is delivered, the calibration may be corrected. MEASURING CHAMBER TO REMOVE AND DISASSEMBLE This operation is not difficult and may be performed by an competent mechanic. No special tools are required. No trouble need be expected, if these few simple, but important directions are followed. Do not open the meter until you have checked over all other possible causes of erratic registration. 1. Prepare a clean surface on which to place the parts as they are removed. The parts are machined to close tolerances and should be handled with care. Have a replacement gasket ready before opening the meter. 2. Remove the meter cover taking care not to damage the gasket. 3. Lift the measuring chamber from the meter casing. 4. Remove the upper cylinder head by inserting a screw driver in one of the slots provided and prying it off. Be careful not to scratch or nick any part of the chamber. 5. Lift out the pisten by it s spindle. If care is taken to draw it straight, it should come out easily. Do not force it. 6. Remove the control roller and seal pin from the lower cylinder head.

17 TO REPLACE THE CHAMBER IN THE METER: Before reassembling the meter, rinse all parts in gasoline. If possible, flush out the meter body. Assemble the parts carefully, they should slide together easily without hammering or forcing. It Is essential that all contact surfaces between the upper and lower cylinder heads and the cylinder, or between the measuring chamber and it s seat in the casing, be clean and free from nicks. 1. Assemble diaphragm and seal pin in chamber if replacement was necessary. 2. Replace the seal pin. Place the control roller on it s pin and see that it will rotate freely. 3. Replace the piston and oscillate it carefully by hand, it should move easily without binding. If it sticks, do not force it, but remove and locate the cause. Do not file down the roller as this will impair the accuracy of the meter. 4. Replace the upper cylinder head and again oscillate the piston to make sure that it is free. 5. When replacing the measuring chamber in the casing, be sure that the seat is clean and free from nicks. Make sure the dowel pin in the main casing enters the slot in the bottom cylinder head properly and allows the chamber to reset on it s seat. 6. Before replacing the cover, first be sure the chamber is properly seated and inspect the gasket. Then set the arm of the gear train so that it will not come down on the piston spindle. 7. Make sure that the cover is down on it s seat before tightening the bolts. TO REPAIR LEAKING U CUP SEAL STUFFING BOX 1. Remove the register (FIGURE 25) 2. Remove the star connection(1), using a No. 8 Allen wrench. 3. Remove the stufffingbox nut (2). 4. Remove shaft seal (3). Inspect upper end of spindle to be sure its free of burrs which might damage tne new shaft seal when it is placed on the spindle. 5. Replace shaft seal with new part. Be sure expander (4) and spring (5) are in position before inerting new seal. 6. Assemble nut and tighten down all the way.

18 AIR RELEASE VALVE TROUBLES WITH THIS UNIT MAY ARISE FROM: (A) (B) (C) Collapsed ball float allowing vent to remain open. Dirty or worn valve seat. Improper position of float. TO IMPACT THIS UNIT: 1. Remove the Strainer (FIGURE 23) 2. Uncouple the vent connection. 3. Remove the cap screws on the air release cover and lift out the mechanism. 4. If the float is damaged, remove by taking out the hinge pins and replace with a new one. 5. If the valve is leaky: a) Remove the air release unit from the underside of the cover. (by unscrewing three small screws). b) Take off the sleeve with piston seal. c) Move the ball in the direction of the valve housing as far as possible and remove valve disc assembly. d) Inspect piston seal for any obvious deterioration. e) The valve disk assembly should be taken apart to inspect for dirt or defective pilot valve seat. A pair of fine nose pliers is needed for this. Replace valve if seats are defective. f) When re-assembling, make sure that the piston seal is properly positioned and that the valve disk assembly moves freely in sleeve. TO REMOVE BACK PRESSURE VALVE 1. Remove Air Release and Strainer from the line by unbolting at inlet flange and meter inlet. 2. Remove strainer sleeves and air release valve. 3. Remove drain plug. 4. Hold block of wood (1-3/4 diam.) against back pressure valve and knock valve out of housing by means of ½ diameter rod inserted through drain plug hole.

19 GENERAL METER MAINTENANCE In the maintenance of the accuracy of RDR Meters, little is necessary other than to see that the proper conditions of operaton are preserved. These conditions, once the pump has been properly installed, consist merely in guarding against foreign matter such as air, sediment and water, entering the measuring chamber. SEDIMENT The liquid passing through the measing chamber must be free of grit and other forms of sediment in order to prevent unnecessary friction and the scoring of the piston and chamber walls. Evidence of trouble from the source is under-registration of the meter. Periodic cleaning of the strainer at the inlet of the meter will help to ensure against trouble. design of this unit, particular care has been taken to make this operation as simple as possible. In the AIR Being an instrument which measures by volume, a meter will record the passage of air as well as the liquid being measured. Over-registration is the result. The air release valve is intended to prevent this condition by venting this air before it passes through the measuring chamber. WATER Incidental water will cause no damage to the meter. Trouble from this source may be expected only when water is allowed to stand in the meter for considerable periods of time. TESTING Test with 250 litres test measure. Do not base calibration on 20 litre measure.

20 -Page 71- TO LOCATE TROUBLE 1. REGISTER NOT WORKING WHEN LIQUID IS FLOWING ** Set screw loose, check flat spot on shaft. 2. LEAKAGE AT THE STUFFING BOX ** Loose stuffing box nut or worn spindle. 3. CHRONIC LEAKAGE AT THE METER MAIN CASE GASKET ** Excessive line or shock pressure. ** Broken gasket or loose bolts. 4. REDUCTION IN THE RATE OR COMPLETE STOPPAGE OF DISCHARGE ** Pump sucking air. ** Air release valve fails to close allowing the liquid to escape out the air vent ** Worn pump ** Blocked strainer due to sediment or frost ** Piston in meter stuck, caused by dirt. Check strainer and clean measuring chamber. 5. LIQUID LEAKING OUT THE AIR RELEASE VENT ** Worn, damaged or defective valve unit (refer to Red Seal Manual) 6. OVER-REGISTRATION-ERRATIC ** Air release valve jamming allowing air to pass through the meter (SEE FIGURE 26) ** Vent line from the air release valve plugged causing air to pass through the meter. ** Leaks in the suction line such as at valve stems, pump packing, or flange gaskets. ** Air pockets in closed-end piping in the suction line. ** Manifold valves only partly open causing excessive suction. ** Suction piping too small causing excessive suction. 7. UNDER-REGISTRATION-ERRATIC ** Dirt in the measuring chamber ** Badly worn control roller or diaphragm ** Main casing distorted or damaged ** Dirt under the seat of the measuring chamber at the outlet port (after cleaning) ** Leakage around the meter due to partly open valve 8. CONSISTENT OVER OR UNDER REGISTRATION ** Meter in need of calibration

21 KRAUS MICON 500 ELECTRONIC REGISTER

22 MICON 500 FAULT CODES CODE C026 C027 C028 C029 C030 C031 C032 C034 C035 C036 C037 C051 C076 C077 C078 C079 C080 C081 C082 DESCRIPTION Pulser Fault Pulser Buffer Overflow Fault Display Disconnect Fault EEProm Checksum Is Bad Excessive Reverse Counts ATC Probe Open ATC Probe Short Pulser Voltage Low One Pulse Line Missing Pulser Unrecognized No Pulser MICON 500C/H ONLY(CNG) Excess Flow Fault Pressure Transducer 1 Out of Range Pressure Transducer 2 Out of Range Ambient Temperature Probe Fault Gas Temperature Transducer Out of Range Pressure Transducers 1 and 2 Out of Tolerance Air Purge or Pressure Switch Kill Excess Fill Fault

23 Kraus Global Inc. MICON 500L ELECTRON IC REGISTER I N STALLATION I N STRU CTION M ANUAL: N ORTH AMERICAN AN D EU ROPEAN Kraus Global Inc. 25 Paquin Road Winnipeg, Manitoba CANADA R2J 3V9 THIS IS OUR GUIDE TO INSTALLING THE MICON 500LM ELECTRONIC REGISTER DESIGNED TO SIMULATE MECHANICAL REGISTERS 2002, Kraus Global Inc. Publication Number: 234AY09.INS R04 Printed in Canada

24 TABLE OF CONTENTS 1.0 IMPORTANT NOTICES PRE-INSTALLATION CHECK PHYSICAL MOUNTING CONSIDERATIONS 6 1. HANDLE SWITCH COUPLING 6 2. HANDLE SHAFT ACTUATION 9 3. ACCESSORY MOUNTING KITS CUSTOMER HARNESS LEAD ELECTRICAL CONNECTIONS IMPORTANT WARNINGS WIRING DETAIL MICON 500LN MICON 500LN WIRING DIAGRAM WIRING DETAIL MICON 500LE MICON 500LE WIRING DIAGRAM COMMUNICATION INTERFACE CONNECTIONS PULSE OUTPUT CIRCUIT DIAGRAM DUAL TWO PRODUCT DISPENSER WIRING DIAGRAM DUAL SINGLE PRODUCT DISPENSER WIRING DIAGRAM DUAL TWO PRODUCT / SINGLE PRODUCT DISPENSER WIRING DIAGRAM POST INSTALLATION CHECK MICON 500L OPERATION CONSOLE ASSESSING FOR PRICE CHANGING:MCIU READING TOTALIZERS ON A SINGLE TIER DISPENSER READING TOTALIZERS ON A SINGLE TIER DISPENSER SETTING PRICES ON A SINGLE TIER DISPENSER TWO TIER PRICE OPERATION TWO TIER OPTION INSTALLATION SETTING PRICES ON A TWO TIER DISPENSER MAKING DISCOUNT PRICE SALES ON A TWO TIER DISPENSER READING TOTALIZERS ON A TWO TIER DISPENSER ELECTRONIC AUDIT TRAILS 30 i

25 TABLE OF CONTENTS (CONT D) 7.0 ELECTRONIC CALIBRATOR ADJUSTMENT AUTOMATIC TEMPERATURE COMPENSATION PULSER ASSEMBLY REPLACMENT MICON DISPLAY FAULT CODES TROUBLE SHOOTING AND REPAIR GUIDE 39 TABLES 1. KRAUS MICON RETROFIT ADAPTOR KIT TOKHEIM MICON RETROFIT ADAPTOR KITS GASBOY MICON RETROFIT ADAPTOR KIT GILBARCO MICON RETROFIT ADAPTOR KITS WAYNE MICON RETROFIT ADAPTOR KITS ASTRO MICON RETROFIT ADAPTOR KITS BENNETT MICON RETROFIT ADAPTOR KITS SCHWELM MICON RETROFIT ADAPTOR KITS MICON 500LN (NORTH AMERICAN) WIRING DESCRIPTION MICON 500LE 230 VAC (EUROPEAN) WIRING DETAIL COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LN (NORTH AMERICAN) COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LE (EUROPEAN) MICON 500L FAULT CODES 37 ii

26 FIGURES 1. BATTERY OFF ACTUATOR SHAFT POSITION 2 2. COUPLER ASSEMBLY HANDLE OFF POSITION 3 3. INFO-PAC AND CONFIGURATION EVENT COUNTERS ON THE MICON 500L 4 4. RECEIVING DATA FROM MICON 500L 5 5. STANDARD ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION 5 6. INTRINSICALLY SAFE 2 PIN PLUG 8 7. CUSTOMER LEAD EXIT 8 8. ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION FOR CLOCKWISE ROTATION 9 9. HANDLE SHAFT ACTUATION FOR COUNTERCLOCKWISE ROTATION PRICE SETTING USING THE MICON COMMUNICATOR DISPLAY DOLLAR AND VOLUME TOTALS PRICE SETTING USING THE MICON COMMUNICATOR READING TOTALIZERS THERMAL WELL LOCATION 34 iii

27 1.0 IMPORTANT NOTICES All wiring must be installed in accordance with National and local electrical codes.! WARNING SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY. LA SUBSTITUTION DE COMPOSANTS PEUT COMPROMETTRE LA SÉCURITÉ INTRINSÈQUE.! AVERTISSEMENT! ATTENTION When this unit is used in retail trade in Canada, Measurement Canada, an agency of Industry Canada, must be notified of the installation or service of this unit. This unit is subject to inspection upon installation and at such other times as the regulations may state. When ATC TM (automatic temperature compensation) is used, a thermal well must be provided. In addition to the thermal well and probe fitting, new installations will require two BC-256 labels reading "CORRECTED TO 15 C". These labels must be attached to each faceplate of the dispenser and be visible to the customer. These labels are provided with the MICON 500L, and additional labels are available upon request. 1

28 2002 KRAUS GLOBAL INC. assumes no liability or responsibility whatsoever pertaining to the accuracy or currency of the information supplied in this manual. Installation of MICON 500L electronic pumpheads in every case is the sole responsibility of the installer performing the work. Kraus Global Inc. assumes no liability or responsibility whatsoever resulting from any type of installation, operation, or configuration, whether performed properly, improperly or in any other way. The information supplied herein is a guide only. MICON 500 is a registered trademark of Kraus Global Inc. ATC is a registered trademark of Kraus Global Inc. 2

29 2.0 PRE-INSTALLATION CHECK The MICON 500L is a computerized pumphead designed for use with liquid fuel (e.g., diesel, propane, butane) dispensers. After carefully unpacking the MICON 500L, inspect for shipping damage. Refer to the options label(s) on the MICON 500L shipping box(es) to ensure the MICON 500L is properly configured for the intended application. A preliminary electrical check should be performed as follows: 1. Observe position of the pump handle. The MICON 500L is normally shipped with the actuator shaft in the battery OFF position: flat (beveled) surface on the end of the shaft facing DOWN. Current drain will be negligible, however, if unit shipped with battery ON. FIGURE 1 BATTERY OFF ACTUATOR SHAFT POSITION battery OFF when flat (beveled) side of shaft facing DOWN 2. Battery is ON whenever flat (beveled) side of shaft is facing any direction except DOWN. Battery should be ON with flat (beveled) side of shaft facing UP when handle OFF. Prepare handle switch for a preliminary check by positioning shaft and coupler assembly in handle OFF position: a) Pull cotter pin. b) Rotate the coupler assembly to the desired OFF position. c) Rotate actuator shaft until the flat (beveled) side faces UP. d) Re-install cotter pin. The handle OFF coupler assembly will appear as in Figure 2. Coupler assembly may rest against stop pin #1 or stop pin #2, as long as flat (beveled) side of shaft faces UP when handle OFF. 3

30 2.0 PRE-INSTALLATION CHECK (CONT D) FIGURE 2 COUPLER ASSEMBLY HANDLE OFF POSITION COTTER PIN ACTUATOR SHAFT FLAT (BEVELED) SIDE UP IS HANDLE OFF (BATTERY ON) POSITION STOP PIN #1 STOP PIN #2 COUPLER ASSEMBLY 3. The MICON 500L digital display can be manually triggered to display configuration event counter data in the dollar display, model number in the volume display, and software version number in the price display, as shown in Figure 3. To do this: Flip the handle switch rapidly ON, then OFF. The display will indicate as shown in Figure 3. The event counter in the dollar display indicates the number of times the settings have been changed with the INFO-PAC. The INFO-PAC is a hand-held, self-contained battery powered unit designed to monitor and program MICON electronic pumpheads. 4

31 2.0 PRE-INSTALLATION CHECK (CONT D) FIGURE 3 INFO-PAC AND CONFIGURATION EVENT COUNTERS ON THE MICON 500L INFO-PAC model M500L is designed to configure MICON 500L pump computer heads used to control flow of liquid fuel product from dispensers. The INFO-PAC is a transmitter and receiver. Programmable pumphead features can be set up in the INFO-PAC memory, then transmitted to MICON heads. The INFO-PAC also receives and displays features already programmed to MICON pumpheads. INFO-PAC configuration event counter in dollar display: Indicates number of times settings have been changed with the INFO-PAC. MICON model in volume display: software version number in price display MICON 500L Display 4. Figure 3 above indicates the event counter in the MICON 500L dollar display is set to 0001, which means the pumphead has been programmed once already using the INFO-PAC. To check the current configuration of your MICON 500L, use the INFO- PAC receive function, described in the INFO-PAC Programming of MICON 500L Pumpheads manual, and outlined in steps a) to d) below: The RX MICON setting on the INFO-PAC is designed to receive MICON 500L settings from pumpheads which have already been programmed. To receive information from the MICON 500L: a) Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON. 5

32 NO 2.0 PRE-INSTALLATION CHECK (CONT D) The MICON 500L display should be flashing. If display goes blank, unit is in sleep (i.e., battery save) mode. To correct this, turn handle ON and OFF. Display will start flashing. b) Turn INFO-PAC ON by pressing left arrow key. Using up or down arrow key, scroll to INFO-PAC RX MICON option. Set RX MICON on by pressing left or right pointing arrow key. c) Take INFO-PAC and go to the front display of the MICON 500L electronic pumphead. Locate optical sensor (oval hole ) at right of price display on MICON 500L. Aim INFO-PAC receiver / transmitter (located behind red tinted filter at center edge of INFO-PAC) at MICON 500L optical sensor. FIGURE 4 RECEIVING DATA FROM MICON 500L MICON 500L electronic pumphead display Aim top of INFO-PAC (red window) at optical sensor INFO-PAC Red LED (light emitting diode) to left of MICON 500L price display flashes as INFO-PAC receives data from MICON 500L. d) When INFO-PAC has received a copy of the MICON 500L setup information correctly, INFO-PAC display will show Received Micon. To view each setting, scroll with the up or down arrow key. FIGURE 5 RECEIVED MICON INFO-PAC DISPLAY 6

33 2.0 PRE-INSTALLATION CHECK (CONT D) 5. Enter a price. See section Setting Prices on a Single Tier Dispenser, for a description of the procedure. Price reading is also described in section Reading Totalizers on a Single Tier Dispenser. Setting prices and reading totalizers on two tier dispensers is described in sections 6.3.2, and Note the reading of the mechanical counter. Rotate the input shaft on the bottom of the MICON 500L in one direction until the mechanical counter has incremented by 1.00 units. On the MICON 500L the volume display should indicate units. If the gallon to litre conversion option is used with the MICON 500L, the display should indicate units. With a MICON 500L using ATC, the volume display should indicate the multiplication factor ("MF") of the ATC TM. For example, if the ATC TM has an MF of four, the display should indicate units. 7. Rotate the coupler assembly back to the original battery-off position. Flat side of actuator shaft will be facing down. If any faults are detected during this preliminary check, consult your factory or service representative. 3.0 PHYSICAL MOUNTING CONSIDERATIONS 3.1 HANDLE SWITCH COUPLING 1. The handle switch coupling on the side of the MICON 500L must be connected to the dispenser handle. In most installations, the dispenser handle can be coupled directly to the MICON 500L, without use of an adapter kit. The MICON 500L handle switch can be turned to the ON position by rotating the actuator shaft 90 degrees in either a clockwise or counterclockwise direction. The direction of rotation is dependent upon the position of the dispenser handle in relation to the coupler. To verify correct placement of the actuator, the flat (beveled) side of the shaft should be in the battery ON position when the dispenser handle is OFF. This will be flat side UP (battery actually is ON in any position except flat side DOWN). 7

34 3.1 HANDLE SWITCH COUPLING (CONT D) FIGURE 5 STANDARD ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION battery ON when flat (beveled) side of shaft facing UP ACTUATOR SHAFT COTTER PIN FLAT (BEVELED) SIDE UP IS HANDLE OFF (BATTERY ON) POSITION STOP PIN #1 STOP PIN #2 COUPLER ASSEMBLY THE COUPLER ASSEMBLY SHOWN REQUIRES A 90 DEGREE CLOCKWISE ROTATION TO TURN ON. IF COUPLER ASSEMBLY RESTS AGAINST STOP PIN #1 WHEN HANDLE OFF, ASSEMBLY WOULD REQUIRE 90 DEGREE COUNTERCLOCKWISE ROTATION TO TURN ON. IN EITHER INSTANCE, FLAT (BEVELED) END OF ACTUATOR SHAFT SNAPS TO POSITIVE OR NEGATIVE 90 DEGREE ANGLE WHEN HANDLE ON AND BATTERY ON. BATTERY IS ACTUALLY ON WHENEVER FLAT (BEVELED) SIDE OF SHAFT IS FACING ANY DIRECTION EXCEPT DOWN. 8

35 3.1 HANDLE SWITCH COUPLING (CONT D) 2. If desired, a normally open handle switch can be connected to the intrinsically safe 2 pin plug. In this case, the actuating shaft need not be connected and should be left in the handle OFF position. FIGURE 6 INTRINSICALLY SAFE 2 PIN PLUG intrinsically safe 2 pin plug located in MICON 500L tub Battery ON when flat (beveled) side of actuator shaft facing UP. 3. Customer lead exit, located on the top of the explosion-proof housing, must be connected to a suitable junction box with rigid conduit (North American only). A seal fitting must be installed between the MICON 500LN and the junction box, and must be within 18 of the MICON 500LN. FIGURE 7 CUSTOMER LEAD EXIT North America: Connect rigid conduit at customer lead exit. 4. In Canada, Measurement Canada, an agency of Industry Canada, requires that the MICON 500L have control of product flow so that the MICON 500L can stop product flow if a measurement fault is detected. Some dispensers in submersible systems incorporate a mechanically controlled valve which is not compatible with the MICON 500L installation. In such a case an electrically controlled valve would have to be installed. 9

36 2. HANDLE SHAFT ACTUATION As outlined in the explanation accompanying Figure 5, the MICON 500L handle switch may be switched ON by rotating the actuator shaft 90 degrees in either direction. As shipped from the factory, a clockwise rotation of the coupler assembly (as viewed from the coupler side) is required to switch the pumphead ON. If the installation requires a counterclockwise rotation ON, see Figure 9 and complete the following steps: to turn the head a) Turn the coupler assembly to the desired handle OFF position (i.e., against stop pin #1). b) Remove the cotter pin which secures the coupler assembly to the actuator shaft. c) Rotate the actuating shaft until the flat (beveled) surface on the end is facing upwards, and re-install the cotter pin. FIGURE 8 ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION FOR CLOCKWISE ROTATION ACTUATOR SHAFT FLAT (BEVELED) SIDE UP IS HANDLE OFF (BATTERY ON) POSITION COTTER PIN STOP PIN #2 STOP PIN #1 COUPLER ASSEMBLY ON THE COUPLER ASSEMBLY SHOWN IS RESTING AGAINST STOP PIN #1 WHEN IN HANDLE OFF (BATTERY ON) POSITION, AND REQUIRES A 90 DEGREE COUNTERCLOCKWISE ROTATION TO TURN ON. FLAT (BEVELED) END OF ACTUATOR SHAFT IS FACING UP WHEN HANDLE OFF AND SNAPS TO 90 DEGREE ANGLE WHEN HANDLE ON AND BATTERY ON. 10

37 3.2 HANDLE SHAFT ACTUATION (CONT D) FIGURE 9 HANDLE SHAFT ACTUATION FOR COUNTERCLOCKWISE ROTATION Remove cotter pin from coupler assembly after turning the assembly to the desired OFF position. Rotate actuating shaft until flat side of actuator shaft faces UP when handle OFF, then re-install cotter pin. 11

38 3.3 ACCESSORY MOUNTING KITS The installation of the MICON 500L in certain dispensers requires the use of accessory kits. Kits are available for a variety of Tokheim, Gasboy, Gilbarco, Wayne, Astro, Bennett and Schwelm dispensers. See DS Kit manuals for installation details. The DS kits available for different pump manufacturers are: TABLE 1 - KRAUS MICON RETROFIT ADAPTOR KIT DS KIT NUMBER DS 18 HLU TYPE HANDLE LINK UNIT TABLE 2 - TOKHEIM MICON RETROFIT ADAPTOR KITS DS KIT NUMBER DS 1 KIT DS 2 KIT DS 3 KIT DS 4 KIT DS 5 KIT DS 6 KIT DS 20 KIT DS 21 KIT DS 22 KIT DS 24 KIT DS 25 KIT TYPE TOKHEIM SINGLE CENTER MOUNT, ELECTRIC RESET TOKHEIM SINGLE OFFSET MOUNT, ELECTRIC RESET TOKHEIM SINGLE CENTER MOUNT, MECHANICAL RESET TOKHEIM SINGLE OFFSET MOUNT, MECHANICAL RESET TOKHEIM DUAL, ELECTRIC RESET TOKHEIM DUAL, MECHANICAL RESET RDR/TOKHEIM HS1, SINGLE CENTER MOUNT (GLASS AND LINKAGE KIT) RDR/TOKHEIM HS1 D1, SINGLE OFFSET MOUNT (GLASS AND LINKAGE KIT) RDR/TOKHEIM DUAL (LINKAGE ONLY) RDR/TOKHEIM DUAL (GLASS AND LINKAGE KIT) TOKHEIM DUAL, ELECTRIC RESET, NARROW TABLE 3 - GASBOY MICON RETROFIT ADAPTOR KIT DS KIT NUMBER DS 18 KIT DS 19 KIT TYPE GASBOY 150 AND 153 (NO PANELS) GASBOY 53 (NO PANELS) TABLE 4 - GILBARCO MICON RETROFIT ADAPTOR KITS DS KIT NUMBER DS 7 KIT DS 7L KIT DS 8 KIT DS 8L KIT DS 23 KIT TYPE GILBARCO SINGLE GILBARCO SINGLE (NO PANELS) GILBARCO DUAL GILBARCO SINGLE (NO PANELS) GILBARCO 625 (NO PANELS) TABLE 5 - WAYNE MICON RETROFIT ADAPTOR KITS DS KIT NUMBER TYPE DS 9 KIT WAYNE SINGLE CENTER MOUNT DS 10 KIT WAYNE DUAL E-732 & 33 DS 11 KIT WAYNE SINGLE OFFSET MOUNT 12

39 3.3 ACCESSORY MOUNTING KITS (CONT D) TABLE 6 - ASTRO MICON RETROFIT ADAPTOR KITS DS KIT NUMBER DS 12 KIT DS 13 KIT TYPE ASTRO UNIVERSAL DUAL (NO PANELS) ASTRO UNIVERSAL SINGLE (NO PANELS) TABLE 7 - BENNETT MICON RETROFIT ADAPTOR KITS DS KIT NUMBER DS 14 KIT DS 15 KIT DS 17 KIT TYPE BENNETT DUAL (NO PANELS) BENNETT SINGLE OFFSET MOUNT (NO PANELS) BENNETT SINGLE CENTER MOUNT (NO PANELS) TABLE 8 - SCHWELM MICON RETROFIT ADAPTOR KIT DS KIT NUMBER DS 16 KIT TYPE LTS SINGLE SCHWELM METER LPG (NO PANELS) 13

40 4.0 CUSTOMER HARNESS LEAD ELECTRICAL CONNECTIONS 4.1 IMPORTANT WARNINGS!!! IMPORTANT PLEASE READ!!!! CAUTION When performing installation or maintenance work of any kind, including servicing MICON 500L electronic pumphead main boards or using the INFO-PAC to program pumpheads, it is the responsibility of the service person performing the work to ensure: 1. All power to MICON pumphead(s) is turned OFF. 2. All supply of gas to dispenser(s) being serviced is shut OFF. 3. The customer lead exit, located on the top of the explosion-proof housing, must be properly sealed when exiting into a Division 2 area (North American only). A suitable batting material must first be used to prevent the sealing compound from entering the housing. The seal must be a minimum depth of 5/8 inches or the inside diameter of the opening, whichever is the greater. 4. All wiring must be installed in accordance with national and/or local electrical codes. 5. All unused wires must be capped or otherwise securely terminated. 6. External equipment connected to the customer harness shall not exceed or generate more than 125 VAC for all units with 120 VAC rated input or controller outputs. 7. This unit must be connected to an appropriate power source as specified by the rating nameplate. 8. Independent motor and solenoid power must not exceed the ratings specified on the rating nameplate. 9. This unit must be grounded by means of all ground wires provided. 10. The local supply ground to which this device is connected and/or any metal structure upon which this unit is mounted shall be at the same potential as the I.S. barrier ground. 14

41 4.1 IMPORTANT WARNINGS (CONT D) 11. When this unit is used in retail trade in Canada, Measurement Canada, an agency of Industry Canada, must be notified of the installation or servicing of this unit. This unit is subject to inspection upon installation and at such other times as the regulations may state. 12. When the ATC TM is used, a thermal well must be provided. In addition to the thermal well and probe fitting, new installations will require two BC-256 labels reading CORRECTED TO 15 C. These labels must be attached to each faceplate of the dispenser and be visible to the customer. These labels are supplied with the MICON 500L. Additional BC-256 labels are available upon request.! WARNING Substitution of components may impair intrinsic safety. La substitution de composants peut compromettre la sécurité intrinsèque.! AVERTISSEMENT KRAUS GLOBAL INC. ASSUMES NO RESPONSIBILITY FOR PERSONAL INJURY OR EQUIPMENT DAMAGE CAUSED BY NON-OBSERVANCE OF SAFETY WARNINGS, OR NON-COMPLIANCE WITH NATIONAL OR INTERNATIONAL LEGAL REGULATORY REQUIREMENTS. 15

42 4.2 WIRING DETAIL: MICON 500LN TABLE 9 MICON 500LN 120 VAC (NORTH AMERICAN) WIRING DESCRIPTION REFERENCE: 4.3 WIRING DIAGRAM Wire No. Wire Colour AWG# Description 1 BLACK 18 Head power hot line. If the power is interrupted on these lines, the head will go into standby and power fail modes. 2 WHITE 18 Neutral or 240 VAC line 2 for head power and main board authorize/authorize request circuit. 3A & 3B GREEN 14 Ground 1 and ground 2. Connected internally to the casting and must be connected to the service ground. 6 ORANGE 18 Solenoid control output. Used to supply power to a slow flow or cut-off solenoid under MICON control. 7 BLACK 14 Pump motor power input / Solenoid input. Connected to wire #6 and #8 when the MICON is authorized and the handle switch is ON. This circuit must be supplied through a circuit breaker and wiring adequate to power the pump motors. 8 ORANGE 14 Pump motor control output. 14 BROWN 18 Authorize input. Application of 120 VAC will authorize the MICON 500LN to dispense product. 15 GREY 18 Authorize return. When 120 VAC is applied to wire #14, and the handle switch is ON, 120 VAC will be present on this line. If 120 VAC is not present when the handle switch is turned on, the MICON 500LN applies a 2.7 Kn capacitive reactance between this line and wire #2 to serve as an authorize request load for Kraus Group Inc. self-serve equipment. Low Voltage Lines 4 YELLOW 18 Money pulser positive input. Normally connected to the pulser power supply positive line (+30 VDC Max) and provides power to money pulser line. 5 RED 18 Money pulser negative output. The MICON will source a maximum of 100 ma from the pulser positive (#4) to this line to form a pulse once for each penny of product dispensed. 18 BLUE 18 Volume pulser negative output. Provides a pulse for each specified fraction of a unit of volume (used for card/key systems). 19 WHITE/BLUE 18 Volume pulser positive input. Normally connected to the pulser power supply positive line (+30 volts maximum, DC only), and provides power to the volume pulser line. Data Communication Lines 9 PINK 18 Talk-to-pump. Connected to the appropriate terminal on the TTP terminal block of a MCIU, and carries messages from the console to the pump. 10 TAN 18 Talk-to-console. Connected to the TTC terminal block of a MCIU and carries messages from the pump to the console. 16 GREEN 18 Data channel common. Connected to the DCC terminal block of MCIU. 17 WHITE / BROWN 18 RS-422 positive receive input. 16

43 4.3 MICON 500LN WIRING DIAGRAM 17

44 4.4 WIRING DETAIL: MICON 500LE TABLE 10 - MICON 500LE 230 VAC (EUROPEAN) WIRING DESCRIPTION Wire No. YEL/GRN REFERENCE: 4.5 WIRING DIAGRAM 230 VAC Lines - (metric type shielded cable) Earth. Connected internally to the casting and must be connected to the service ground VAC head power hot line. If power is interrupted on this line, the head will go into standby and power-fail modes. 2 Neutral for head power and main board authorize/authorize request circuit. 3 Motor Output. 4 Motor/Solenoid Power 5 Solenoid Output. 6 Not Used 7 Not Used 8 Not Used 19 Authorize output. When 230 VAC is applied to wire #20 and the handle switch is on, 230 VAC will be present on this line. (3 Amp. maximum load) 20 Authorize input. Application of 230 VAC will authorize the MICON to dispense product. If 230 VAC is not present when the handle switch is turned on, the MICON applies a 14 Kn capacitive reactance between this line and wire #2 to serve as an authorize request load for Kraus Industries Self-Serve equipment. Wire No. Low Voltage Lines 9 Money pulser positive. Normally connected to the pulser power supply positive line (+30 volts maximum, DC only) and provides power to the money and volume pulser lines. 10 Money pulser negative. The MICON will source a maximum of 100 ma from the pulser common (#9) to this line to form a pulse once for each penny of product dispensed. (Used with KRAUS MONITOR and MICRO consoles.) 11 Volume pulser negative. Provides a pulse (as described above for money pulser) for each specified fraction of a unit of volume. (Used for card or key systems.) 15 Not used. 16 Not used 17 Not used 18 Not used 22 Volume pulser positive. Provides power to the volume pulser line. Wire No. Micro 2, Concept 5000 & MCIU Data Communications Lines 12 Data channel common. This line is connected to the DCC terminal block of a MCIU. 13 Talk-to-console. This line is connected to the TTC terminal block of a MCIU and carries messages from the pump to the console. 14 Talk-to-pump. This line is connected to the appropriate terminal on the TTP terminal block of a MCIU and carries messages from the console to the pump. 21 RS-422 positive input. 18

45 4.5 MICON 500LE WIRING DIAGRAM 19

46 4.6 COMMUNICATION INTERFACE CONNECTIONS Tables 12 and 13 below describe communication interface connections for the following interface options: Tokheim Interface Gilbarco Interface Tatsuno Interface RS-422 Interface RS-232 Interface Kraus MNET Interface TABLE 11 COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LN (NORTH AMERICAN) Customer Harness Wire # Tokheim Interface Gilbarco 2-Wire Interface Tatsuno Interface RS-422 Interface RS-232 Interface Kraus MNET Interface 16 DCC Not used Not used OUT + Gnd DCC 10 TTC 2-wire + + OUT - Tx TTC 9 TTD 2-wire - - IN - Rx TTP 17 Not used Not used Not used IN + Not used Not used TABLE 12 COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LE (EUROPEAN) Customer Cable Wire # Tokheim Interface Gilbarco 2-Wire Interface Tatsuno Interface RS-422 Interface RS-232 Interface Kraus MNET Interface 12 DCC Not used Not used OUT + Gnd DCC 13 TTC 2-wire + + OUT - Tx TTC 14 TTD 2-wire - - IN - Rx TTP 21 Not used Not used Not used IN + Not used Not used 20

47 4.7 PULSE OUTPUT CIRCUIT DIAGRAM 21

48 4.8 DUAL TWO PRODUCT DISPENSER WIRING DIAGRAM 22

49 4.9 DUAL SINGLE PRODUCT DISPENSER WIRING DIAGRAM 23

50 4.10 DUAL TWO PRODUCT/SINGLE PRODUCT DISPENSER WIRING DIAGRAM 24

51 1. POST INSTALLATION CHECK After completing the installation of the MICON and checking all wiring connections, correct operation should be verified as follows: 1. Enter a price, as described below (also described in section Setting Prices on a Single Tier Dispenser). a) Go to breaker box and turn OFF AC power to MICON 500L electronic pumphead being serviced. Caution: Ensure breaker box does not feed power to equipment which should remain ON. MICON display should be flashing. If display is not flashing, unit is in sleep mode. To correct this, turn handle ON and OFF. Display will start flashing. b) Take the MICON hand held communicator and go to the front display of the MICON 500L electronic pumphead display. c) Aim the communicator at the optical sensor (oval hole ) at right of price display on MICON 500L. FIGURE 10 PRICE SETTING USING THE MICON COMMUNICATOR MICON 500L electronic pumphead display Aim end of communicator at optical sensor MICON hand held communicator d) To set prices: While aiming the communicator s transmitter (located on the end of the unit) at the MICON 500L optical display sensor, press and hold the SET until the display increments to the desired number. Use the SEL key to select the next digit to be changed. Press and hold the SET key until the display increments to the desired number. 2. After entering a price, turn ON the 120 VAC (230 VAC European) MICON head power. 3. Place the dispenser handle in the OFF position. Turn ON dispenser sequencing power and ensure that no product can be dispensed. 4. If card lock equipment is being used, place the dispenser handle in the ON position. Authorize the MICON. This is normally done by inserting the appropriate card into the card terminal, then entering data (i.e., i.d. number, mileage, etc.) as required. The authorization signal received by the card terminal is sent to the MICON 500L head via input wire #14 (N. American) or #20 (European). 25

52 5.0 POST INSTALLATION CHECK (CONT D) 5. For stand alone operation, turn ON the dispenser handle. The authorization in this case is bypassed and the main board receives a direct signal. The display resets and the main flow valve is signaled by the MICON to open and commence fuel flow. 6. When resetting, displays should flash to all 8 s momentarily, go blank, then return to zero. Now the solenoid valve controlling fuel flow should energize. 7. Dispense a convenient amount of product into a test can and check that the MICON 500L displays the proper volume and dollars amount. For testing the MICON 500L with ATC TM option refer to section Place the dispenser handle in the OFF position and ensure that the pump motor and/or solenoid shuts off. This completes the post installation check. If the unit does not function as described above, contact your factory or service representative. 1. MICON 500L OPERATION 2. CONSOLE ACCESSING FOR PRICE CHANGING: MCIU The method used to set prices to MICON 500L electronic pumpheads is dependent upon the type of self serve consoles employed. If you are using Kraus Global Inc. Monitor 4 Console Systems, refer to sections Reading Totalizers and Setting Prices, for information regarding price changes and reading of totalizers.! ATTENTION If you are using a Kraus Global Inc. Micon Communication Interface Unit (MCIU), MICON 500L totalizers and prices may be accessed through the console. Refer to owner s manual for details. If it is necessary to place the station in manual mode of operation, all of the affected dispensers must be reset : 1. Place the console Emergency switch in the Emergency position and wait for all MICON 500L registers to go blank. 2. Return the Emergency switch to the normal position and place the manual switch in the manual position. The station may now be operated in the manual mode. 3. Manual mode switch switches AC power to line #14 (North American or line #20 (European: Authorize). In manual mode when emergency switch in position, AC power is removed from solenoid power line. 26

53 6.2 MICON 500L COMMUNICATOR OPERATION The hand held communicator (part # MC 200D, available as an option) allows the reading of both dollar and volume totals, and price setting READING TOTALIZERS ON A SINGLE TIER DISPENSER 1. Ensure the dispenser handle is in the OFF position, and the 120 VAC (230 VAC European) MICON head power is turned ON. 2. Aim the communicator s transmitter (located on the top of the unit) at the optical sensor located to the right of the MICON price display. e left of 3. Depress and hold the SEL key on the communicator. The red indicator to th the price display will flash as the MICON 500L receives the communicator s signal. 4. Hold the SEL key until the dollar sales total is displayed. Dollars sale total uses ten digits of the dollars and volume displays preceded by the letters d l. Refer to Figure To display volume total, depress and hold the SEL key until the display shows V l followed by the ten digit volume total. Pressing the SEL key repeatedly or holding it down will cause the display to switch back and forth between volume and dollars totals. FIGURE 11 DISPLAY DOLLAR AND VOLUME TOTALS TOTAL DOLLAR SALES DISPLAY THIS DISPLAY READS: $ TOTAL UNIT SALES DISPLAY THIS DISPLAY READS: UNITS 27

54 6.2.2 SETTING PRICES ON A SINGLE TIER DISPENSER 1. Go to breaker box and turn OFF AC power to MICON 500L electronic pumphead being serviced. Caution: Ensure breaker box does not feed power to equipment which should remain ON. MICON display should be flashing. If display is OFF, unit is in sleep mode. To correct this, turn handle ON and OFF. Display will start flashing. The dollar (top) display on the MICON 500L displays the dollar amount and Prc Take the MICON hand held communicator and go to the front display of the MICON 500L electronic pumphead. 3. Aim the communicator at the optical sensor (oval hole display on MICON 500L. ) at right of price FIGURE 12 PRICE SETTING USING THE MICON COMMUNICATOR MICON hand held communicator MICON 500L electronic pumphead display Aim end of communicator at optical sensor 4. To set prices: While aiming the communicator s transmitter (located on the end of the unit) at the MICON 500L optical display sensor, press and hold the SET key until the MICON display increments to the desired number. Use the SEL key to select the next digit to be changed. Press and hold the SET key until the display increments to the desired number. When the correct price per unit has been entered, restore head power while handle switch remains in the OFF position. 28

55 3. TWO TIER PRICE OPERATION On MICON 500L units equipped with the two tier price option it is possible to make sales at two different prices. For example, cardholders may receive a discount from the regular price while fuel is dispensed to non-cardholders at full price. The unit maintains separate totalizers for each price of sales. 1. TWO TIER OPTION INSTALLATION Two tier installation requires a connector (included with part #W392 - harness) and pricing push-button switch (part #PWP 320) or key-switch (part #Y101). To order these optional parts contact your local service representative. To install the two tier option: Connect the push button switch between the blue and orange wires on the provided connector. The push button switch can then be mounted in a 7/8 hole in the side of the dispenser. An optional key-switch is available, which can be used instead of, or together with, the push-button. Wire the key-switch and push-button in series, not parallel. 2. SETTING PRICES ON A TWO TIER DISPENSER Setting prices on a two tier dispenser is the same as on a single tier dispenser, except that pressing the DISCOUNT button will change which price is being set. 1. To set Prc 1, which is the regular price, turn OFF AC head power at the breaker box. The display should be flashing. The dollar display on the MICON 500L displays the dollar amount and Prc 1 at first. Set this price by aiming the communicator s transmitter (on top of unit) at the optical sensor (oval hole ) at right of price display on MICON 500L. Press the SEL key to select the digit to be changed, and press the SET key to increment to the desired number. 2. To set Prc 2, which is the discounted price, press the DISCOUNT button located on the side of the dispenser. The dollar display on the MICON 500L will then display the dollar amount and Prc 2 at first. Prc 2 indicates the discounted price. Set this price by aiming the communicator at the optical sensor (oval hole ) at right of price display on MICON 500L. Press the SEL key to select the digit to be changed, and press the SET key to increment to the desired number. 29

56 6.3.3 MAKING DISCOUNT PRICE SALES ON A TWO TIER DISPENSER 1. To make a discount priced sale, simply press the DISCOUNT push button, located on the side of the dispenser, before turning the dispenser handle ON. When the button is pressed, the discount price will be displayed. The next sale will proceed at the discount price. If the DISCOUNT button is pressed by mistake and you do not wish to make a discounted sale, simply press the DISCOUNT button again and the dispenser will revert back to the regular price. Pressing the DISCOUNT button while the dispenser handle is in the ON position has no effect on the dispenser. 2. When the discounted sale is completed, turn the dispenser handle to the OFF position. The regular price will again be displayed and subsequent sales will occur at the regular price. The INFO-PAC used to monitor and program the MICON 500L pumpheads has a setting intended for use when two tier (regular and discount) pricing is in effect: PRC RESTORE (price restore). When this setting is ON (default! setting), the MICON automatically reverts back to tier 1 (regular pricing) after each discounted transaction. NOTE It is possible to set PRC RESTORE OFF, in which case the price used for the current sale is retained for the next sale. Refer to INFO-PAC MICON 500L Programming Manual for details READING TOTALIZERS ON A TWO TIER DISPENSER Reading volume and dollar totals on two tier dispenser totalizers is the same as on single tier dispensers totalizers, except that pressing the DISCOUNT button will change which volume/dollar setting (regular or discount) is being read. The two tier dispenser contains two sets of totalizers: volume and dollar totals for regular priced sales; volume and dollar totals for the discount priced sales. To read the totalizers: 1. Proceed as on page 27 by ensuring the dispenser handle is in the OFF position, and the 120 VAC (230 VAC European) MICON head power is turned ON. Display should be flashing. Aim the communicator s transmitter (on top of unit) at the optical sensor (oval hole ) at right of price display on MICON 500L. Press and hold the SEL key until the dollar sales total is displayed. 30

57 6.3.4 READING TOTALIZERS ON A TWO TIER DISPENSER (CONT D) 2. Display will show d I for regular dollar totals. Press the DISCOUNT button. Display will show d I I for discount dollar totals. 3. Press the SEL key until the display shows v I (regular priced volume total) or v I I (discount priced volume total). Press the DISCOUNT button to switch back and forth between v I and v I I. 4. Press and hold the SEL to switch back and forth between dollar and volume total displays. Manually adding regular and discount volume or dollar totals will yield grand sales totals. FIGURE 13 READING TOTALIZERS press SEL key on communicator to switch between dollar and volume displays REGULAR TOTAL DOLLAR SALES DISPLAY REGULAR TOTAL VOLUME SALES DISPLAY display reads $ display reads units press DISCOUNT button on dispenser side to switch back and forth press DISCOUNT button on dispenser side to switch back and forth DISCOUNT TOTAL DOLLAR SALES DISPLAY DISCOUNT TOTAL VOLUME SALES DISPLAY display reads $ display reads units 6.4 ELECTRONIC AUDIT TRAILS The MICON 500L is equipped with electronic audit trails in the form of non-resettable event counters. This feature is facilitated in software, and meets the current requirements of Measurement Canada regulations. The top display of the MICON 500L electronic pumphead indicates the number of changes to device configuration parameters performed with the INFO- PAC, as shown in Fig

58 7.0 ELECTRONIC CALIBRATOR ADJUSTMENT The MICON 500L is equipped with an electronic calibration feature. This feature provides the MICON 500L with the capability of electronically compensating for meter errors of +/-19.99%. The required calibration error is programmed into the MICON via the INFO-PAC hand held programming device. The factory default is set for 0% calibration error. If the meter is correctly calibrated, no further adjustment is necessary. When the inspection switch (connected between P12-1 and P12-5) is turned ON, the MICON will display calibration information or ATC TM (automatic temperature compensation) information (if ATC TM is installed). The display then indicates: TOP DISPLAY CENTER DISPLAY BOTTOM DISPLAY temperature (ATC TM installed and ON) % calibration (ATC TM OFF) uncompensated vol. (same as normal volume if ATC TM is OFF or not installed) flow rate/status Until flow begins, the product compensation type will be displayed for one of the following products: GAS = GASOLINE ProP = propane desl = diesel fuel OFF = ATC turned OFF or not installed If calibration adjustment is required, follow guidelines below: 1. To receive MICON 500L settings with the INFO-PAC, follow steps as outlined below: To receive information from the MICON 500L: 1) Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON. The MICON 500L display should be flashing. If display is blank, unit is in sleep (i.e., battery save) mode. To correct this, turn handle ON and OFF. Display will start flashing. 2) Turn INFO-PAC ON by pressing left arrow key. Using up or down arrow key, scroll to INFO-PAC RX MICON option. Set RX MICON on by pressing left or right pointing arrow key. 3) Take INFO-PAC and go to the front display of the MICON 500L electronic pumphead. Locate optical sensor (oval hole ) at right of price display on MICON 500L. Aim INFO-PAC receiver / transmitter (located behind red tinted filter at centre edge of INFO-PAC) at MICON 500L optical sensor. Red LED (light emitting diode) to left of MICON 500L price display flashes as INFO-PAC receives data from MICON 500L. 4) When INFO-PAC has received a copy of the MICON 500L setup information correctly, INFO-PAC display will show Received Micon. To view each setting, scroll with the up or down arrow key. 2. If MICON 500L is equipped with ATC TM, set INFO-PAC menu option ATC off. 32

59 7.0 ELECTRONIC CALIBRATOR ADJUSTMENT (CONT D) 3. Set INFO-PAC calibration factor to C.FACTOR % (default). 4. Follow steps to transmit INFO-PAC settings to MICON 500L, outlined in the INFO-PAC MICON 500L Programming Manual and described below. To transmit information to the MICON 500L: 1. Switch OFF the head power to the MICON 500L, by removing cover of explosion-proof MICON 500L housing and removing fuse. The MICON 500L display should be flashing. This requires breaking of a Weights and Measures seal on the cover, and removal of bolts. Flip switch inside MICON 500L to enable programming mode. 2. Scroll to INFO-PAC TRANSMIT option. Set TRANSMIT on. Before transmitting settings from the INFO-PAC to the MICON 500L electronic pumphead, scroll carefully through all options displayed on the INFO-PAC, and ensure that each and every one is still on the desired setting, even if you have changed only a single setting. Whenever programming with the INFO-PAC, ALL parameters are rewritten in the MICON 500L. 3. Locate optical sensor (oval hole ) at right of price display on MICON 500L. 4. Aim INFO-PAC transmitter/receiver (located in center behind red tinted filter on edge of INFO-PAC) at MICON 500L optical sensor. Red LED to left of MICON 500L price display flashes as MICON receives data from INFO-PAC. 5. When MICON 500L has correctly received setup information, will show on MICON 500L price display. Exit programming mode by flipping switch inside MICON 500L to DOWN (Normal position). 7. Switch the head power back ON and run the MICON 500L using the new settings. 8. Replace the cover of the explosion-proof MICON 500L housing and: a) Install a suitable legal seal through the two adjacent drilled cover bolts to ensure the cover cannot be removed without breaking the seal. b) Install a suitable legal handle seal through the handle shaft, behind the cotter pin, so that the handle coupler cannot be removed from the handle shaft. 5. Place MICON 500L handle switch in ON position. Observe MICON dollars and volume displays reset to zero. 6. Dispense a known volume of product and record the reading on the volume display. 33

60 7.0 ELECTRONIC CALIBRATOR ADJUSTMENT (CONT D) 7. Use formula below to calculate percentage correction required: % Correction = Actual Volume - Register Volume X 100 Register Volume 8. Set calibration factor on INFO-PAC to the closest setting available. Example Product dispensed: Litres Register reading: Litres % Correction = ( ) X 100 = % Set INFO-PAC calibration factor to C.FACTOR 5.16%. Place the programming switch into program mode and transmit the calibration factor to the MICON with the TRANSMIT function. The dollars section of the MICON 500L display would show for the example given. 9. Repeat steps 5 and 6, to verify the calibration of the MICON 500L. 10. If ATC TM used at this installation, set ATC TM INFO-PAC menu option ATC on, and retransmit settings to MICON. 11. Replace the cover of the explosion-proof MICON 500L housing and: a) Install a suitable legal seal through the two adjacent drilled cover bolts to ensure the cover cannot be removed without breaking the seal. b) Install a suitable legal handle seal through the handle shaft, behind the cotter pin, so that the handle coupler cannot be removed from the handle shaft. A. B. 34

61 8.0 AUTOMATIC TEMPERATURE COMPENSATION The MICON 500L is optionally available with automatic temperature compensation of the product dispensed. To install the MICON 500L with the ATC TM feature, it will be necessary to install the temperature probe and a test well in the meter line.! ATTENTION It is a requirement of Measurement Canada, an agency of Industry Canada, that a thermal well be provided next to the installed temperature probe, for inspection purposes. The following guidelines should be observed when installing an inspection test well: 1. The thermal well must be positioned to retain thermally conductive fluid. The hole in the fuel line should be drilled (drill size Q) so that the well will be at an angle within 45 of vertical when the well is installed and the assembly is reconnected. 2. Install a 1/8 inch NPT test well extension fitting (Kraus part # BC 546) if needed, into the hole which was drilled into the fuel line. The inside of the 1/8 inch NPT fitting will be drilled out to accommodate the insertion of the test well (Kraus part # BC 407). Test well and probe are to be as close together as practical and the test well must be accessible to the inspector after installation. Fittings are supplied with the MICON 500L (additional fittings available upon request). The fitting should provide easy access for the insertion of a thermometer. The fitting should be placed in an appropriate location so as not to hinder reinstallation of the assembly. 3. Install the test well into the extension fitting and tighten into place. 4. Cover the test well assembly with the supplied protective plug. FIGURE 14 THERMAL WELL LOCATION TEMPERATURE PROBE THERMAL TEST WELL 35

62 8.0 AUTOMATIC TEMPERATURE COMPENSATION (CONT D)! ATTENTION If the connection is made with less than 5 threads fully engaged, it will be necessary to solder the fitting into place. Connections which are in excess of 5 full threads do not require soldering, but must make use of a thread sealing compound suitable for use with the intended fuel type. In addition to the test well and probe fitting, new installations will require two BC-256 labels ("CORRECTED TO 15 C"). These labels must be attached to each faceplate of the dispenser and be visible to the customer. Labels are provided with MICON 500L and additional labels are available upon request. The Automatic Temperature Compensator feature compensates the volume of product delivered to the equivalent volume at 15 degrees Celsius (15 o C default). In order to accurately sense the temperature of the product, the probe must be directly immersed into the product as close as possible to the meter. The following procedure should be used to verify the operation of the ATC TM : 1. Install and connect the temperature probe. 2. Turn the inspection switch to the ATC TM position. 3. Dispense a convenient volume of product into a test can and record the temperature and volume of the product in the can. 4. The volume indicated on the display of the MICON 500L is the UNCOMPENSATED volume. This volume should agree directly with the volume measured in the test can. If it does not agree, the meter is out of calibration. 5. Calculate the compensated volume in the test can using the actual volume and the temperature of the product in the test can and the appropriate correction tables. The calculated compensated volume should agree with the compensated volume shown when inspection switch in normal display position. If the values do not agree, a problem exists in the MICON or its installation. 6. Return the inspection switch to the upwards position for "normal" display position. This completes the testing of the ATC TM. If you encounter any difficulty please contact your service representative. 36

63 9.0 PULSER ASSEMBLY REPLACEMENT If troubleshooting procedures indicate a defective pulser board and / or disk then the entire base assembly should be replaced as described in steps 1 to 6, as follows:! NOTE This does not apply to remote pulsers. 1. Remove the MICON face plates. 2. Unplug the harness that enters the pulser housing. 3. Remove any other necessary hardware in order to slide the base out from under the explosion proof housing (it may be necessary to loosen the conduit coupling to lift the tub assembly). 4. Install the new base assembly. 5. Reassemble the MICON. Connect the wire harness.! NOTE Reverse polarity of the two signal lines: WHITE wire provides leading digital signal; YELLOW wire provides lagging digital signal. If polarity of pulser board is not reversed, solenoid valve will shut OFF whenever flow is detected. 6. Test the dispenser for proper operation. 37

64 10.0 MICON DISPLAY FAULT CODES Should an operational error occur while using the MICON 500L electronic register, a fault code will show in the bottom display. Fault codes are interpreted as shown in Table 13. TABLE 13 MICON 500L FAULT CODES DISPLAY CODE DESCRIPTION OF FAULT PROBABLE CAUSE RECOMMENDED ACTION TO CLEAR FAULT CONDITION CO26 PULSER FAULT Missing or disconnected pulser. CO27 CO28 CO29 CO30 CO31 CO32 PULSER BUFFER OVERFLOW FAULT DISPLAY DISCONNECT FAULT EEPROM CHECKSUM FAULT EXCESSIVE REVERSE COUNTS TEMPERATURE PROBE TEMPERATURE PROBE Input pulses coming in faster than MICON 500L rated to handle. Meter may be programmed for higher pulse per unit (ppu) number than MICON 500L rating. LCD (liquid crystal display) lost connection. Display disconnected or improperly connected. EEPROM corrupted. Pulser connected backwards. Check customer harness lead electrical connections. Ensure meter and MICON 500L flow rates are compatible. Check connections. If connections are valid, display may require replacement. Reset pumphead by turning handle switch OFF, then ON. If reset ineffective, reprogram the MICON, using the INFO-PAC. If reset and reprogramming ineffective, internal processor may require replacing. Contact your service representative. Ensure base is correct for meter direction. Probe circuit open. Check probe connections / replace probe. Probe circuit shorted. Check probe connections / replace probe. 1. Correct source of error. 2. Turn handle switch OFF, then ON. 38

65 10.0 MICON DISPLAY FAULT CODES (CONT D) FIGURE 17 - FAULT CODE DISPLAYED BY MICON 500L ELECTRONIC REGISTER Fault codes listed on previous page show in MICON 500L bottom display. 39

66 11.0 Troubleshooting and Repair Guide If, after installation, the dispenser does not operate as it is supposed to, the following tables should be consulted before calling your service representative. Troubleshooting tables have been divided alphabetically into the following categories: 1. communicator 2. display 3. (MICON) pumphead power 4. pump motor and/or solenoid valve 5. registration 1. COMMUNICATOR Problem Possible Cause Recommended Action 1.1 Unable to read totals or price setting with the communicator, Defective optical reader on the display board. Replace display board. but it functions normally with other MICON heads. Defective display wiring harness. Defective KIL 463 control board (M500L). Older communicators may not work on newer MICONS, the communicator may need to be replaced or modified. Replace harness. Contact your service representative to order new board. Contact your service representative for communicator upgrade or replacement. 1.2 Communicator exhibits poor Optical reader is in direct Shade optical reader with hand. range when attempting to set sunlight. prices or read totals on all MICON heads. Weak or dead battery in Unscrew back of communicator communicator. and replace 9 volt transistor battery. 40

67 DISPLAY Troubleshooting and Repair Guide (continued) Problem Possible Cause Recommended Action 2.1 Display blinks slowly on and off. The breaker supplying power to wire #1 has been tripped. Re-trip breaker. No head power. Blown fuse. Defective KIL 463 control board (M500L). Check 120 VAC (240 VAC European) supply to wire #1 (hot) and wire #2 (neutral). Check and replace as needed. Contact your service representative to order new board. 2.2 Displays immediately blank when 120 VAC head power is disconnected. Battery low. Defective KIL 463 control board (M500L). Handle shaft is in the wrong position. It is a 6.0 VDC rechargeable battery with a 7.0 VDC charging circuit. If battery does not recharge, contact your service representative. Contact your service representative to order new board Position handle shaft flat side up (Normal handle off position). 2.3 Segment(s) on display board are staying ON all the time or missing entirely. One display window or all three windows reading 8 s. Other display board OK. 2.4 Both display boards reading 8 s or erroneous segments being displayed. Defective display board. Defective display wiring harness. Defective display board. Defective display wiring harness. Defective KIL 463 control board (M500L). Contact your service representative to order new board. Unplug wire harness from MICON head and check connections. Unplug display boards from the MICON head one at a time and observe display to isolate defective board. Unplug wire harness from MICON head and check connections. Contact your service representative to order new board. 41

68 11.0 Troubleshooting and Repair Guide (continued) 2. DISPLAY (cont d) Problem Possible Cause Recommended Action 2.5 MICON displays will not reset to zero when pump handle ON. Product is dispensed; previous sales are added onto first. Switch S1 is not disengaging when the handle is turned OFF. The pump handle is mechanically coupled to the electronic head, and actuates two internal switches. Verify correct operation of internal microswitches #1 and #2 as described in section MICON front display LED is flashing once per second while in battery back-up mode. Low battery. These are 6 volt rechargeable batteries with a 7 volt charging circuit. Check each. 3. MICON (PUMPHEAD) POWER Problem Possible Cause Recommended Action 1.Fuse keeps blowing Blown varistor. Replace EMI filter/varistor (120V: part #V140LA10A; 240V: part #S14K275). 2.MICON keeps tripping breaker. Possible line short on wire #1 (underground). Have qualified personnel test for short; repair/replace wire as needed. 3.3 MICON shuts OFF during delivery. Error Code Authorize power loss. Isolate and replace defective part. Move pump handle from OFF to ON position to reset dispenser. Some CODE 26 problems can be solved by installing a unidirectional pulser base, providing slop in the meter coupling and in some cases, up/grading the software. Contact your service representative. Check for authorize power loss on wire #14 (NA), #20 (EU) 42

69 11.0 Troubleshooting and Repair Guide (continued) 3. MICON (PUMPHEAD) POWER (cont d) Problem Possible Cause Recommended Action 3.4 MICON shuts OFF at beginning of delivery. Reversed pulser lines. (Observe the PPU (price per unit) display in the MICON. If fault code CO30 displays, problem is excessive reverse counts, caused by backward connected pulser. Locate the 4 wire harness between the pulser and the Micon. Connect WHITE wire where YELLOW located; connect YELLOW wire where WHITE located. No pulses being generated (pulser). (Observe the PPU [price per unit] display in the MICON. If fault code CO26 displays, problem is missing or disconnected pulser.) Observe the PPU (price per unit) display in the MICON. If fault code CO27 displays, problem is pulser buffer overflow fault. Check harness lead electrical connections. Micro motion meter may be programmed for higher ppu than MICON rating. Ensure Micro- Motion meter and MICON flow rates are compatible. 43

70 INFO-PAC MICON 500L/550L Programming Manual Software Version , Kraus Group Inc. Publication Number: 206AY08.PRG R00 Printed in Canada

71 TABLE OF CONTENTS INTRODUCTION 1 KEY FUNCTIONS 1 1. Power On 2 2. Automatic Shut-Off 2 3. Service and Product Support - Canada 2 4. Set-Up Modes DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 4 Table 1 Default Settings 4 1.CONFIG 4 2. TEST 4 3.PULSER I.S IN COUNT 5 6. MULTIPLIER 5 7. CURRENCY 6 8. VOL DISP 7 9. SUPPRESS CONV NO FLOW VOL PPU VOL PW PENNY PW W/M STANDARD CLEAR ZEROS CONSOLE BAUD PUMP ID GRADE DISPLAY TIER BUTTON C. FACTOR ATC COMP. TEMP PRODUCT PRC RESTORE VOL P. QUAD STOP&START SLOW FLOW START KEY STOP KEY PRESTART CUST. PRESET P. CODE TRANSMIT RX MICON CLEAR TOTALS TX TOTALS RX TOTALS 18 IMPORTANT REMINDER Whenever programming with the INFO-PAC, all parameters are rewritten in the Micon 500/550L. Before transmitting settings from the INFO-PAC to the Micon 500/550L, electronic pump head, scroll carefully through all options displayed on the INFO-PAC, and ensure that each and every one is still on the desired setting, even if you have only changed a single setting. (i)

72 Copyright 2000, 1998 Kraus Group Inc. All rights reserved. Kraus Group Inc. assumes no liability or responsibility whatsoever pertaining to the accuracy or currency of the information supplied in this manual. Programming of MICON 500/550L electronic pumpheads in every case is the sole responsibility of the installer performing the work. Kraus Group Inc. assumes no liability or responsibility whatsoever resulting from any type of programming or installation, whether performed properly, improperly or in any other way. The information supplied herein is a guide only. 1.0 INTRODUCTION The MICON MIP500L/550L INFO-PAC is a hand-held self-contained battery powered unit designed to monitor and program MICON electronic pumpheads. INFO-PAC model MIP500L/550L is designed to configure MICON 500/550L pump computer heads used to control liquid fuel flow from gasoline, diesel, propane or butane dispensers. The INFO-PAC is a transmitter and receiver. Programmable pumphead features can be set up in the INFO-PAC memory, then transmitted to MICON heads. The INFO-PAC also receives and displays features already programmed to MICON pumpheads. Setting configuration features in the MICON using the INFO-PAC requires breaking of two Weights & Measures seals on the MICON cover and the programming wire screw. See section(s) 3.36 and KEY FUNCTIONS MICON MIP500L/550L Info-Pac This key is used to scroll upwards through the menu options. This key is used to scroll downwards through the menu options. This key is used to turn the INFO-PAC ON, and to scroll forward through the data items associated with each menu option. This key is used to scroll backward through the data items associated with each menu option. 1

73 2.1 POWER ON The INFO-PAC is powered by a 9 volt battery. ON 1. Press key to power unit ON. LCD momentarily displays INFO-PAC model and Software version number: M500L/550L V The display changes to show one of the following: CONFIG default CONFIG custom 2.2 AUTOMATIC SHUT-OFF INFO-PAC automatically shuts OFF after 30 seconds without keyboard activity. INFO-PAC shuts OFF automatically after 10 minutes when TRANSMIT, TX TOTALS, RX TOTALS or RX MICON is set to on. 2.3 SERVICE AND PRODUCT SUPPORT - CANADA Should you experience any difficulties in system operation, customer assistance is available. The procedure to receive such assistance is as follows: 1. Document the following information: 2. Call or Fax our Product Service line at: system dysfunction corrective measures taken system model number system serial number purchase order information date of installation equipment location (i.e., city, address, etc.) Company Service Number: Company Fax Number:

74 11.0 Troubleshooting and Repair Guide (continued) 4. PUMP MOTOR AND/OR SOLENOID VALVE Problem Possible Cause Recommended Action 4.1 No reset cycle, pump motor and/or solenoid valve will not turn on when handle is placed in the ON position. Previous sale is not cleared when handle is turned ON. Defective or inoperative linkage to MICON handle shaft (detent). No authorize input voltage. Replace linkage. Check for 120 VAC on wire #14 or #15. (European: Check for 240 VAC on wire #20 or #19.) Defective internal microswitch and/or authorize relay on main board inside MICON head. Contact your service representative to order new microswitch or main board. 4.2 Pump motor and/or solenoid valve will not turn on when handle is placed in the ON position. Reset sequences displaying 8 s and clearing last sale. If both pump motor and solenoid valve are not coming on, the problem could be a defective temperature probe (ATC only). No power supplying the internal triacs. Defective main board. One of the triacs in the control board (M500L: KIL 463) is burnt. Check the PPU (price per unit) display in the MICON 500L. If fault code CO31 displays, problem is disconnected temperature probe. If fault code CO32 displays, problem is short circuited temperature probe circuit. Check for 120 VAC (230 VAC European) on motor & solenoid input wire. Check output power on wire #6 (solenoid) or wire #8 (motor). European: Check output power on wire #5 (solenoid) or wire #3 (motor). Check for an open circuit on either the motor, solenoid or dead man switch. 4.3 Pump motor is always ON when the handle is in the OFF position (new installation). If the motor is controlled by the MICON, the detent could be in the wrong position. Shorted triac. Remove cotter pin and rotate detent to opposite position (Normally, handle OFF, battery on = Flat side UP.) Find cause of short & replace main control board. 44

75 11.0 Troubleshooting and Repair Guide (continued) 5. REGISTRATION Problem Possible Cause Recommended Action 5.1 Product can be dispensed but it s not registering on either the mechanical totalizer or electronic display. Inoperative drive to MICON input shaft. Stripped or loose gears on MICON base. This only occurs when direct drive meters are used (i.e., those that do not use a remote pulser). Repair drive. Replace MICON base. Broken coupling between the meter and electronic register. Replace coupling. 5.2 Product flow registering only on mechanical totalizer. Defective MICON base (pulser). Replace MICON base. 5.3 MICON registering incorrectly (new installation or board replacement only). Incorrect ATC (automatic temperature compensation) or programming of IN COUNT or MULTIPLIER setting Consult INFO-PAC MICON 500L Programming Manual (document number: 206KT00.PRG R00). 5.4 MICON is losing its price settings and totals. Low battery. It is a 6.0 VDC rechargeable battery with a 7.0 VDC charging circuit. If battery does not recharge, contact your service representative. 5.5 MICON totals are jumping or the price is changing by itself. Low battery. Defective KIL 463 control board (M500L). It is a 6.0 VDC rechargeable battery with a 7.0 VDC charging circuit. If battery does not recharge, contact your service representative. Contact your service representative to order new board.! REMINDER After correcting source of error, always turn dispenser handle switch OFF, then ON. 45

76 2.4 SET-UP MODES Scrolling through each menu option should reveal settings as shown. Pictured to the right of each menu option below are factory default data items. ON POWER ON M500L/550L V 1.0. NO FLOW off SS. TIER BUTTON off l l PRESTART off. CONFIG default S. VOL PPU 10 S l. C.FACTOR % l. CUST. PRESET off S. TEST off l. VOL PW 4.0ms S. ATC on l 2. P. CODE 0000 l. PULSER.i.s. PENNY PW 4.0MS S 2. COMP. TEMP 15ºC l e. TRANSMIT off..i.s W/M STANDARD na S e. PRODUCT gas ll. RX MICON off 2. IN COUNT 1000 e. CLEAR ZEROS off S l. PRC RESTORE on l 8. CLEAR TOTALS off e. MULTIPLIER 1 l. CONSOLE kraus S 8. VOL P. QUAD off l a. TX TOTALS off l. CURRENCY dollars 8. BAUD 9600 S a. STOP&START disab o. RX TOTALS off 8. VOL DISP a. PUMP ID. not set l o. SLOW FLOW Menuoptionsrepeat a. SUPPRESS S o. GRADE 1 l. START KEY disab o. CONV. off S. DISPLAY normal l S. STOP KEY disab 3

77 1. DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 2. CONFIG Used to set all menu options to default values. 2. TEST CONFIG default Indicates MICON 500/550L menu options are at their default values. CONFIG custom Indicates MICON 500/550L menu options have been modified from default values. Pressing either the or keys will return options to default settings. Used to put MICON 500L/550L into continuous display test mode. 3. PULSER TEST off (default) Indicates Micon 500L/550L should be in standard operating mode. Pressing either the or key will turntest mode ON. TEST on Indicates MICON 500L/550L should continuously run through display test mode until INFO-PAC is used to turn OFF test mode on the MICON. Pressing either the or key turns TEST mode OFF. Used to select pulser input source. PULSER.i.s. (default) Indicates pulser input is through the I.S. circuit external wiring. PULSER conduit Indicates pulser input is through conduit wiring. TABLE 1 - DEFAULT SETTINGS OPTION DEFAULT SETTINGS 1. CONFIG default 2. TEST off 3. PULSER.i.s. 4..I.S IN COUNT MULTIPLIER 1 7. CURRENCY dollars 8. VOL DISP SUPPRESS CONV. off 11. NO FLOW off 12. VOL PPU VOL PW 4.0ms 14. PENNY PW 4.0ms 15. W/M STANDARD na 16. CLEAR ZEROS off 17. CONSOLE kraus 18. BAUD PUMP I.D. not set 20. GRADE DISPLAY normal 22. TIER BUTTON off 23. C. FACTOR % 24. ATC on 25. COMP. TEMP. 15 o C 26. PRODUCT gas 27. PRC RESTORE on 28. VOL P. QUAD off 29. STOP&START disab 30. SLOW FLOW START KEY disab 32. STOP KEY disab 33. PRESTART off 34. CUST. PRESET off 35. P. CODE TRANSMIT off 37. RX MICON off 38. CLEAR TOTALS off 39. TX TOTALS off 40. RX TOTALS off 3.4.I.S. In the Intrinsically Safe (.I.S.) pulse input mode, two different pulser types can be used..i.s Indicates the pulser has 62.5, 125, 250, 500, 1000, etc. pulses per revolution..i.s Indicates the pulser has 64, 128, 256, 512, 1024, etc. pulses per revolution. 4

78 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 3.5 IN COUNT Works in conjunction with MULTIPLIER settings to indicate number of pulser edges which must be counted to register 1 unit volume of fuel flow. Refers to number of edges that must be received on the two incoming pulser lines (F1 and F2) to register 1 unit of fuel flow. Indicates number of quadrature (input pulser) transitions per unit volume. This value is equal to 4 times the number of pulses on an individual pulser line. Values for this option can be scrolled through using the or keys. Values are: 3.6 MULTIPLIER Works in conjunction with IN COUNT settings to indicate volume of fuel flow equal to 1 unit Values for this option can be scrolled through using the or keys. ON Values are: MULTIPLIER 1 (default) MULTIPLIER 2 MULTIPLIER 4 MULTIPLIER 0.5 MULTIPLIER 0.25 IN COUNT IN COUNT 100 IN COUNT 10 IN COUNT (default) EXAMPLE 1 E X Y I N b r E IN COUNT 1000 MULTIPLIER 1 = 1000 PULSEREDGES / 1 UNIT OF FUEL FLOW = 1000 EDGES / UNIT.001 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) IN COUNT 1000 MULTIPLIER 2 = 1000 PULSER EDGES / 2 UNITS FUEL FLOW = 500 EDGES / UNIT.002 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) IN COUNT 1000 MULTIPLIER 4 = 1000 PULSER EDGES / 4 UNITS FUEL FLOW = 250 EDGES / UNIT.004 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) IN COUNT 1000 MULTIPLIER 0.5 = 1000 PULSER EDGES / 0.5 UNITS FUEL FLOW = 2000 EDGES / UNIT.0005 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) IN COUNT 1000 MULTIPLIER 0.25 = 1000 PULSER EDGES / 0.25 UNITS FUEL FLOW = 4000 EDGES / UNIT REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) EXAMPLE 2 IN COUNT 100 MULTIPLIER 1 = 100 PULSER EDGES / 1 UNIT FUEL FLOW = 100 EDGES / UNIT.01 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) IN COUNT 100 MULTIPLIER 2 = 100 PULSER EDGES / 2 UNITS FUEL FLOW = 50 EDGES / UNIT.02 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE) 5

79 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS money display volume display price display 3.7 CURRENCY Used to select: Type of currency sales are registered in; Number of decimal positions in money and price fields; Character displayed before total money sales in totalizer display. CURRENCY dollars (default) This setting uses 2 decimal positions in the money display field, 3 decimal positions in the price field and d in the totalizer display. CURRENCY Om,1p This setting uses 0 decimal positions in the money display field, 1 decimal position in the price field and d in the totalizer display. CURRENCY 2 dp This setting uses 2 decimal positions in the money display field, 2 decimal positions in the price field and d in the totalizer display. CURRENCY 1 dp This setting uses 1 decimal position in the money display field, 1 decimal position in the price field and d in the totalizer display. CURRENCY no dp This setting uses 0 decimal positions in the money display field, 0 decimal positions in the price field and d in the totalizer display. CURRENCY 1m,3p This setting uses 1 decimal position in the money display field, 3 decimal positions in the price field and d in the totalizer display. CURRENCY Om,2p This setting uses 0 decimal positions in the money display field, 2 decimal positions in the price field and d in the totalizer display. 6

80 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 7. CURRENCY (cont d) CURRENCY 2m,1p This setting uses 2 decimal positions in the money display field, 1 decimal position in the price field and d in the totalizer display. CURRENCY 3m,1p This setting uses 3 decimal positions in the money display field, 1 decimal position in the price field and d in the totalizer display. 8. VOL DISP The value of this option determines the number of decimal positions to be displayed in the volume unit field of the MICON 500L/550L. The MICON 500L/550L cannot be set to display a more precise reading than the incoming pulses will allow, and cannot be set to display less precisely than to the nearest unit. Values are: VOL DISP VOL DISP VOL DISP VOL DISP 3.9 SUPPRESS (default) 1.OO 1.O 1 (only available if IN COUNT setting is less than 1000) This option determines whether or not unit suppression is used, and type of unit suppression used. Values are: SUPPRESS (default) For first units of liquid fuel dispensed, MICON 500L/550L sale register display shows ZERO. For units and over, the sale amounts are displayed. SUPPRESS O.OO9 For first units of liquid fuel dispensed, MICON 500L/550L sale register display shows ZERO. For units and over, the sale amounts are displayed. (This is the maximum suppression allowed for sales registered in U.S. gallons.) SUPPRESS O.OOO MICON 500L/550L sale register display shows the sale amount. Suppression is turned OFF. 7

81 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 3.10 CONV. This option converts volume units dispensed to volume display units. For example, for fuel dispensed in U.S. gallons, the MICON 500L/550L can convert the volume measurement displayed on the register to litres, using the INFO-PAC CONV. US gal-l setting. Table 2 Conversion Settings INFO-PAC Option Fuel Dispensing Units MICON 500L/550L Register Volume Display Units CONV. OFF (default) N/A Volume dispensed not converted to litres. N/A Multiplication Factors Used for Conversion CONV. us gal-l U.S. gallons litres (metric) U.S. gallons multiplied by / = litres CONV. imp gal-l Imperial gallons litres (metric) Imperial gallons multiplied by / = litres CONV. l-us gal litres (metric) U.S. gallons Litres multiplied by / = U.S. gallons NO FLOW This option controls length of time MICON 500L/550L keeps motor and solenoid valve ON if a sale is in progress but there is no product flow being registered. Anytime during the sale (before flow starts or after flow starts), when there has been no fuel flow for the NO FLOW timer interval the motor and valves will be shut OFF and the sale terminated. No flow timer interval can be set from 15 seconds to 4 minutes, 15 seconds; in 15 second increments. (Previous model(s) permitted maximum timer value of 2 minutes.) TABLE 3 NO FLOW SETTINGS INFO-PAC SETTING NO FLOW off RESULT MICON 500L/550L will not shut down on a NO FLOW condition. INFO-PAC SETTING Before flow starts OR after 15 seconds flow starts: 30 seconds 45 seconds Pump and valves shut OFF 60 seconds 75 seconds and sale is terminated after 90 seconds NO FUEL FLOW occurs for 105 seconds the number of seconds on 120 seconds the INFO-PAC setting. 135 seconds 150 seconds 165 seconds 180 seconds 195 seconds 210 seconds 225 seconds 240 seconds 255 seconds 8

82 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 3.12 VOL PPU This option defines the number of output pulses per unit (PPU) transmitted on the Volume Out Pulse line of the MICON 500L/550L. This value cannot be more than IN COUNT value set for the MICON 500L/550L. A PPU less than 1 is not permitted by INFO-PAC. Values are: VOL PPU 1 VOL PPU 10 (default) VOL PPU 50 VOL PPU 100 VOL PPU VOL PW This option sets the width of the Volume Pulse signal. This width is defined as the "on time" length of the pulse. Setting should be compatible with equipment used. Pulse width values are: VOL PW VOL PW VOL PW VOL PW VOL PW VOL PW VOL PW VOL PW 0.5ms 1.0ms 2.0ms 4.0ms (default) 17.0ms 19.0ms 26.0ms 150.0ms 3.14 PENNY PW This option sets the width of the Penny Pulse signal. This width is defined as the "on time" length of the pulse. Setting should be compatible with equipment used. Pulse width values are: PENNY PW PENNY PW PENNY PW PENNY PW PENNY PW PENNY PW PENNY PW Choose to have either: 0.5ms 1.0ms 2.0ms 4.0ms (default) 17.0ms 19.0ms 26.0ms Penny pulser and volume pulser OR 2 channel volume pulser and no penny pulser. Note: Setting VOL P. QUAD ON disables penny pulser output, since this line is used as second line of volume pulser. (Volume out pulser becomes a two channel quadrature pulser output, disabling the penny pulser option.) 9

83 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 15. W/M STANDARD This option sets up the allowable pulser errors to meet the na (North American) or eu (European) standards. Settings are: W/M STANDARD na (default) W/M STANDARD eu 16. CLEAR ZEROS This option sets the MICON 500L/550L register to display or suppress leading zeros on the current sale display. Settings are: CLEAR ZEROS off (default) Displays leading zeros in current sale display. CLEAR ZEROS on Suppresses leading zeros in current sale display. 17. CONSOLE This option setting has no effect on the MICON 500L/550L. When the RX MICON option is used, this option will show which communications protocol is used on the serial communications lines from the MICON 500L/550L to the console. Compatible hardware interface boards, available as optional features of the MICON 500L/550L, must be installed. Communication protocols are: 18. BAUD CONSOLE kraus (default) MCIU s (MICON communication interface units) manufactured by Kraus. CONSOLE gilbarco Consoles manufactured by Gilbarco. CONSOLE tokheim Consoles manufactured by Tokheim. CONSOLE tatsuno Consoles manufactured by Leif Dige. CONSOLE W ayne Dresser Consoles manufactured by Wayne Dresser This option is used to select the Baud rate. BAUD 9600 BAUD RATE 9,600 bits/second BAUD BAUD RATE 19,200 bits/second 10

84 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 3.19 PUMP ID. This option sets the pump address used during serial data channel communications. Do not set pump address if MICON 500L/550L pump head is using Kraus MNET communications in conjunction with a MCIU or equivalent interface box. In this setup, pump address is set dynamically by the interface box. Values are: PUMP ID. not set (default) PUMP ID. 01 PUMP ID. 02 PUMP ID GRADE PUMP ID. 24 Functions for this option vary, depending on which type of console interface (i.e., Kraus, Gilbarco, Tokheim, Tatsuno) is used. Values are: GRADE 1 (default) GRADE 2 GRADE 3 For the Kraus (MNET) interface, setting GRADE to 2 disables the MICON 500L/550L s override console sales data collection feature, when the MICON 500L/550L is authorized manually. Thus, if the console stops working, the operator can flip the switch controlling the console to manual override. For the Tokheim interface, setting GRADE to 1 will transmit volume information to the console exactly as it is displayed. Setting GRADE to 2 will transmit volume information in the format , regardless of the displayed format. Gilbarco pumps have the capability of setting grades (e.g., regular or unleaded fuel) at the pump. 21. DISPLAY This option sets the way the current sale amount display on the MICON 500L/550L is to be interpreted. DISPLAY normal (default) Use this setting for computing registers. DOLLAR VOLUME PRICE 11

85 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 3.21 DISPLAY (cont d) DISPLAY bulk Display shows net volume gross volume temperature. Use this setting when both temperature compensated and uncompensated volumes are desired. Net Volume Gross Volume Temperature DISPLAY non-comp Display shows volume volume blank. Use this setting for noncomputing dispenser(s). Faceplate may cover one of the volume displays. Net Net Blank 22. TIER BUTTON This option determines if a two tier button is being used. TIER BUTTON on Two prices are allowed to be set on the MICON and a preset keypad cannot be used. TIER BUTTON off Only one price can be set on the MICON. This is required when a keypad is connected. 23. C. FACTOR This setting sets electronic calibration factor used to correct errors in the meter s registering. This calibration factor can be set from % to %. Use to scroll to each digit position. Use to change value of each digit. C.FACTOR % C.FACTOR % (default) C.FACTOR % 12

86 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 24. ATC This setting enables/disables Automatic Temperature Compensation. ATC on (default) ATC off 25. COMP. TEMP This setting sets the temperature to which the ATC feature compensate the fuel volume. If 60ºF is used, the ATC inspection mode temperature will be in Fahrenheit instead of the default Celsius. COMP. TEMP. 15ºC (default) COMP. TEMP. 60ºF COMP. TEMP. 20ºC 26. PRODUCT This setting is used to set the fuel type used for the ATC function. Each fuel type is associated with a density (see Table 4, below). TABLE 4 PRODUCT SELECTIONS INFO-PAC SETTINGS FUEL DENSITIES VCF TABLE REFERENCE PRODUCT gas (default) 730 kg/m 3 API 54B PRODUCT diesel 840 kg/m 3 API 54B PRODUCT propane 510 kg/m 3 ASTM-IP 54 PRODUCT butane 580 kg/m 3 ASTM-IP 54 PRODUCT av gas (aviation gas) 710 kg/m 3 API 54B PRODUCT jet a (jet kerosene, turbine fuel) 800 kg/m 3 API 54B PRODUCT jet b (naptha) 760 kg/m 3 API 54A 3.27 PRC RESTORE This option is used when two tier pricing is in effect. For example, a consumer who is a cardholder may receive a discount from regular sale price of liquid fuel. If PRC RESTORE is set ON, MICON 500L/550L register reverts to regular sale price (tier 1) when dispenser handle returned to OFF position. Values are: PRC RESTORE on (default) Price returns to the tier 1 price when the handle is returned to OFF position. PRC RESTORE off Price used for current sale is retained for next sale, unless explicitly changed by the user. 13

87 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS (cont d) 3.28 Vol. P. Quad VOL P. QUAD off (default) Volume out pulser is single channel, with penny pulser option. VOL P. QUAD on Volume out pulser becomes a two channel quadrature pulser output, disabling the penny pulser option. 29. STOP & START This setting enables/disables the START and STOP option. START & STOP disab (default) This setting does not allow the MICON to continue a sale after console authorization is disabled and enabled again. START & STOP enab This setting allows the MICON to continue a sale after console authorization is disabled and enabled again. 30. SLOW FLOW For PRESET SALES this option sets when the fast flow valve is closed so that only the slow flow valve is used. This option is set as the # OF VOLUME UNITS BEFORE THE PRESET AMOUNT IS REACHED. Use to scroll to each digit position. Use ON to change the value of each digit. Example: If PRESET set to 30 litres, and SLOW FLOW set to 1 litre: Fast flow valve closes at 29 litres. Last (30 th ) litre flows slowly. Note: If the VOL DISP option is changed, the SLOW FLOW option must also be adjusted, since the decimal point will be shifted. IMPORTANT REMINDER SLOW FLOW settings: SLOW FLOW SLOW FLOW (default) SLOW FLOW

88 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 31. START KEY The START KEY is reserved for future expansion. This option should remain set at: START KEY disab (default) 32. STOP KEY The STOP KEY is reserved for future expansion. This option should remain set at: STOP KEY disab (default) 33. PRESTART PRESTART on (default) The motor will turn on as soon as the pump handle is turned on. The reset cycle is extended to a total of 5 seconds. After the reset cycle, the solenoid will turn on and pulse counting will be enabled. The Micon will ignore pulses during the reset cycle to ensure meter movement and resulting pulses at start up will not be registered or displayed. This feature is used with submersible systems with leak detectors and in propane systems where vapour can be a problem. PRESTART off The motor will not turn on until after the reset cycle. 34. CUST. PRESET Reserved for custom setting. This option should remain set at: CUST. PRESET off (default) 35. P.CODE This option requires users responsible for setting fuel prices on the MICON 500L/550L to use a security code. User(s) may pick any 4 digit number as a personal identification code, to provide access to price changing. P. CODE 0000 (default) P. CODE

89 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 36. TRANSMIT This menu option is used to transmit the INFO-PAC settings to the MICON 500L/550L unit. To transmit information to the MICON 500L/550L: 1. MICON 500L: Switch OFF the head power, by removing cover of explosion-proof MICON 500L housing and removing fuse. The MICON 500L display should be flashing. This requires breaking of a Weights and Measures seal on the cover, and removal of bolts. Flip switch inside MICON 500L to enable programming mode. MICON 550L: Disconnect the program seal wire. Leave the AC power ON. If it is not convenient to remove MICON 500L cover, there is an alternative method of shutting OFF head power, and permitting 1-time programming only: 1. Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON. 2. Remove cotter pin from handle shaft on the MICON 500L, and turn handle shaft DOWN to battery OFF position. This requires breaking of a Weights and Measures seal through the handle shaft, behind the cotter pin. Leave battery OFF for 30 seconds for a completely cold start. 2. Scroll to INFO-PAC TRANSMIT option. Set TRANSMIT on. ATTENTION Before transmitting settings from the INFO-PAC to the MICON 500L/550L electronic pump head, scroll carefully through all options displayed on the INFO- PAC, and ensure that each and every one is still on the desired setting, even if you have changed only a single setting. Whenever programming with the INFO-PAC, ALL parameters are rewritten in the MICON 500L/550L. 3. Locate optical sensor (oval hole ) at right of price display on MICON 500L/550L. 4. Aim INFO-PAC transmitter/receiver (located in center behind red tinted filter on edge of INFO-PAC ) at MICON 500L/550L optical sensor. Red LED to left of MICON 500L/550L price display flashes as MICON receives data from INFO-PAC. 5. When MICON 500L/550L has correctly received setup information, will show on the MICON 500L price display. will show on the MICON 550L price display. 16

90 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 3.36 TRANSMIT (cont d) 6. Exit programming mode by flipping switch inside MICON 500L to DOWN (Normal position). Reconnect the program seal wire. This step is unnecessary if program mode was entered using alternative method in Step 1 ( preceding page). 7. Switch the head power back ON and run the MICON 500L using the new settings. 8. Replace the cover of the explosion-proof MICON 500L housing and: 37. RX MICON a) Install a suitable legal seal through the two adjacent drilled cover bolts to ensure the cover cannot be removed without breaking the seal. b) Install a suitable legal handle seal through the handle shaft, behind the cotter pin, so that the handle coupler cannot be removed from the handle shaft. On the MICON 550L, install seal wire through the 2 cover bolts and the program seal wire screw. This menu option is used for INFO-PAC to receive MICON 500L/550L settings from units which have already been programmed. To receive information from the MICON 500L/550L: (STEP 1. applies only to the MICON 500L.) 1. Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON. Alternative: Switch OFF the head power to the MICON 500L, by removing cover of explosion-proof MICON 500L housing and removing fuse. This requires breaking of a Weights and Measures seal on the cover, and removal of bolts. The MICON 500L display should be flashing. 2. Scroll to INFO-PAC RX MICON option. Set RX MICON on. 3. Locate optical sensor (oval hole ) at right of price display on MICON 500L/550L. 4. Aim INFO-PAC transmitter (located behind red tinted filter at the centre edge of INFO- PAC ) at MICON 500L/550L optical sensor. Red LED to left of MICON 500L/550L price display flashes as INFO-PAC receives data from MICON 500L/550L. 3. When INFO-PAC has received a copy of the MICON 500L/550L setup information correctly, INFO-PAC display will show Received Micon. 17

91 3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 38. CLEAR TOTALS This setting clears the total memory stored in the INFO-PAC CLEAR TOTALS off (default) The totals are retained in the INFO-PAC CLEAR TOTALS on When this setting is used, the totals in INFO-PAC memory will be erased. In order to clear totals in the MICON head, set CLEAR TOTALS to on. This sets the totals in the INFO-PAC to zero. The zero totals can be transmitted to the MICON head using the TX TOTALS function. 39. TX TOTALS TX TOTALS off (default) The INFO-PAC is not transmitting totals TX TOTALS on There are two situations where the TX TOTAL function is used: 1) Clearing totals of the MICON head to zero 2) Transmitting previously stored totals 40. RX TOTALS RX TOTALS off (default) The INFO-PAC is not receiving totals RX TOTALS on This setting receives totals from the MICON head. 18

92 OTHER COMPONENTS

93 General Purpose High Power PCBRelays Potter & Brumfifield T92 Series Two-pole 30A PCBor Panel Mount Relay n 40A, 2 forma(no) and 2 formc(co) switching capability n Designedto controlcompressorloads to 3.5 tons,110lra / 25.3FLA n Meets requirementsof UL 508 andul 873 spacings - 8mm throughair, 9.5mm over surface n Meets requirementsof VDE8mmspacing,4kV dielectric coilto- contact n Meets requirementsof UL Class Fconstruction n UL approved for 600VAC switching (1.5HP) n New screw terminal version (consult factory for availability, ratings) Typical applications HVAC,residential / commercial appliances, industrial controls. Approvals UL E58304 (Recognized and Listed); CSA LR48471; VDE Technical data of approved types on request. Contact Data Contact arrangement 2 form A (NO), 2 form C (CO) Rated voltage 277VAC Max. switching voltage 600VAC Rated current 30A NO; 3A NC Limiting continuous current 40A NO; 3A NC Limiting making current 40A NO; 3A NC Limiting breaking current 40A NO; 3A NC Contact material AgSnOInO, AgCdO Min. recommended contact load 500ma (NO)/ 100ma (NC), 12VAC Frequency of operation, with load 360hr Operate/release time max., including bounce 25/25ms Contact ratings 1) Type Load Cycles UL508 AgCdO NO NO NO NO NO 40A, 277VAC, resistive 30A, 120/277VAC, resistive 10A, 600VAC, general purpose 1HP, 120VAC 3HP, 240VAC 6x x x x10 3 1x10 3 Contact ratings 1) (continued) ARI Endurance Test (section 6.6): HVAC Definite Purpose Contactor Standard Normally Open Contacts Single Phase/Two Pole (Both poles together switching a single load) 110 LRA, 25.3 FLA, 200K operations (DC Coil) Figure 1 Single Phase Per Pole (Single load per pole) 110 LRA, 18 FLA, 200K operations (DC Coil). 60 LRA, 14 FLA, 200K operations (AC Coil). L1 L2 Figure 2 T1 L1 T1 1) Contact ratings at 25 C (unless otherwise noted) with relay properly vented. FLA, LRA ratings are compatible with 3.5 ton compressor applications. Mechanical endurance L2 T2 T2 10x10 6 ops. NO 1.5HP, 480 or 600VAC 100x10 3 Coil Data N 110LRA/25.3FLA, 240VAC (DC coil only) 100x10 3 Coil voltage range 5 to 110VDC; 12 to 240VAC O 60LRA/14FLA, 240VAC (AC coil 100x10 3 Max. coil power 1.7W; 4.0VA N only) 3A, 240VAC, pilot duty 100x10 3 O 20A, 28VDC, 100x10 3 Max. coil temperature 155 C N resistive TV10, 100x10 3 O 120VAC 100x10 3 Coil insulation system according UL Class F N 3A, 277VAC 100x10 3 O 2A, 480VAC 100x10 3 Coil versions, DC coil N 1A, 600VAC O Coil Rated Operate Release Coil Rated N coil code voltage voltage voltage resistance C power N VDC VDC VDC Ω±10% C W N C AgSnOInO AgCdO, flange mount relays code voltage 1.7 voltage voltage resistance power NO 20A, 30A, 400VAC 120/277VAC, resistive (DC coil only) 100x10 200x VAC 9 Hz VAC, Hz VAC, Hz Ω±10% 48 VA NC 3A, 400VAC 30x CO NO 20A 30A, NO 120/277VAC, / 3A NC, 400VAC resistive (AC coil only) 100x10 30x AgCdO, PC mount relays / / NO 30A, 20A, 400VAC 480VAC, resistive Catalog 100x / NC 3A, 400VAC subject and 30x10 to the product terms data 250/ of50/60 the is CO NO 30A 1.5HP, NO 120VAC, / 3A NC, 2400VAC pole making/breaking (Fig.1) 100x10 30x10 All 24figures are given 24 for coil without 18 preenergization, at ambient 2.4 temperature C. of disclaimer the Definitions and all chapters section, 1.7 NO 3HP, 240VAC, 3 phase (DC coil only) 100x ,Rev available at 1.7 Catalog product data, Definitions section, N 3HP, 480VAC, 3 phase (DC coil 100x10 tions application 11 notes and all 7255 specifications are O 2012 TycoElectronicsCorporation, only) 2HP, 600VAC, 3 phase (DC 100x subject to change. ate N ConnectivityLtd. coil company. only) Coil versions, AC coil O VDE Coil Rated Frequency Operate Release Coil Rated coil Catalog product and specification according and to IEC used only together to be with Definitions the section.

94 Max. Allowable Ambient Temp. ( C) General Purpose High Power PCBRelays Potter & Brumfifield T92 Series Two-pole 30A PCBor Panel Mount Relay (Continued) Coil Data (continued) Ambient temperature vs. coil voltage Assumptions: 1. Thermal resistance = 35 C per Watt (DC only.) 2. Still air. 3. Nominal coil resistance. 4. Max. mean coil temperature = 155 C (change of resistance method). 5. Coil temperature rise due to load = 6.3 amps. 6. Curves are based on 1.7W at 25 C (DC only.) Other Data Material compliance: EU RoHS/ELV, China RoHS, REACH, Halogen content refer to the Product Compliance Support Center at Ambient temperature DC coil AC coil Category of environmental protection IEC Vibration resistance (functional) Shock resistance (functional) Shock resistance (destructive) Terminal type Weight -55ºC to 85ºC -55ºC to 65ºC RTI - dust protected, RTII - flux proof, RTIII - wash tight 1.65mm max excursions, Hz 10g for 11msec 100g PCB-tht or quick connect 86g Resistance to soldering heat THT IEC C Packaging/unit tray/30 pcs., box/120 pcs Applied Coil Voltage (% of Rated Nominal) Insulation Data Initial dielectric strength between open contacts between contact and coil between adjacent contact Initial surge withstand voltage between contact and coil Initial insulation resistance between insulated elements Clearance/creepage between contact and coil 1500V rms 4000V rms 2000V rms 6kV 1x10 9 Ω 8mm clearance/9.5mm creepage Dimensions T92 Mounting and termination code 1 T92 Mounting and termination code 2, 3 and MAX. (52.32) 1.36 MAX. (34.54) MAX. (68.58) 1.36 MAX. (34.54) 1.21 MAX. (30.73).156 (3.96) 1.04 MAX. (26.42) MAX. (37.97).585 ±.005 (14.86 ±.13).630 ±.005 (16.00 ±.13) ±.020 (41.10 ±.51).047 TYP. (1.19).309 ±.005 (7.85 ±.13).032 TYP. (0.81) ±.010 (25.40 ±.25).250 TYP. (6.35) 2.05 MAX. (52.07) ±.005 (59.56 ±.13) TYP. (41.10 ±.51).585 ±.005 (14.86 ±.13).309 ±.005 (7.85 ±.13).090 RAD. (2.29) FOR #8 SCREW Catalog product and specification according and to IEC used only together to be section ,Rev.1112 with Definitions the 2012 TycoElectronicsCorporation, ate ConnectivityLtd. company..630 TYP. (16.00) Catalog subject and to the product terms data of the is of disclaimer the Definitions and all chapters available at section, tions Catalog product data, Definitions section, application notes and all specifications are subject to change.

95 General Purpose High Power PCBRelays Potter & Brumfifield T92 Series Two-pole 30A PCBor Panel Mount Relay (Continued) Dimensions T92 Mounting and termination code MAX. (68.58) Terminal assignment Bottom view on pins 2 form A 2 form C ±.005 (59.56 ±.13) (54.23) MAX..090 (2.29) RAD. FOR #8 SCREW 1.36 MAX. (34.54) MAX. (36.34) PCB layout Bottom view on pins MAX. (23.19) MAX. (51.05) T92 - Mounting and termination code (7.85).365 (9.27).585 (14.86) (41.10).185 (4.70).630 (16.00) (25.40).203 TYP. (5.16).052 TYP. (1.32).162 (4.12).072 TYP. (1.83) An alternate PC board layout utilizes.076 ±.003 (1.93 ±.076) diameter holes on the same center-to-center spacing shown above. Use of the rectangular holes is recommended for improved solderability. Only necessary terminals are present on single throw models. Consequently, some holes will be unnecessary for single throw models. Product code structure Typical product code T92 S 1 D Type T92 Printed circuit board / panel mount power relay T92 Enclosure P Dust protected plastic case S Wash-tight, tape sealed, plastic case (Mounting and termination code 1) Top sealed, not wash-tight, not tape sealed on bottom (Mounting and termination codes 2, 3 & 4) Contact arrangement 7 2 form A (2 NO) 11 2 form C (2 CO) Coil Input A AC voltage, 60Hz or 50/60 Hz (consult coil versions table) D DC voltage Mounting and termination 1 Printed circuit board mount; printed circuit board terminals. 2 Panel mount via flanged cover;.250 (6.35mm) x.032 (.81mm) QC terminal 3 Panel mount via flanged cover;.187 (4.75mm) x.032 (.81mm) QC terminals for coil and.250 (6.35mm) for contacts 4 Panel mount via flanged cover,.187 (4.75mm) x.020 (.51mm) QC terminals for coil and.250 (6.35mm) for contacts. 5 Panel mount via flanged cover, M4 screws w/ captive pressure plates. Requires Enclosure P and Contact arrangement 7. Contact material 2 AgCdO 4 AgSnOInO Catalog Coil voltage subject and to the product terms data of the is Coil code: please refer to coil versions table Catalog product and specification according to IEC used and to be ,Rev.1112 with only together Definitions the 2012 TycoElectronicsCorporation, section. ate ConnectivityLtd. company. of disclaimer the Definitions and all chapters available at section, tions Catalog product data, Definitions section, application notes and all specifications are subject to change. 3

96 General Purpose High Power PCBRelays Potter & Brumfifield T92 Series Two-pole 30A PCBor Panel Mount Relay (Continued) Product Code Enclosure Contacts Coil Mounting Contact Material Coil Part Number T92P7A22-24 Plastic dust cover 2 form A, 2 NO AC Panel mount + quick connect AgCdO 24 VAC T92P7A VAC T92P7A VAC T92P7A VAC T92P7A AgSnOInO 240 VAC T92P7A Panel mount + screw terminals AgCdO 120 VAC T92P7A VAC T92P7D12-12 DC PCB terminals 12 VDC T92P7D VDC T92P7D22-12 Panel mount + quick connect 12VDC T92P7D VDC T92P7D VDC T92P7D24-12 AgSnOInO 12VDC T92P7D VDC T92P7D42-24 AgCdO T92P7D52-12 Panel mount + screw terminals 12 VDC T92P7D VDC T92P11A form C, 2 CO AC PCB terminals 120 VAC T92P11A22-12 Panel mount + quick connect 12 VAC T92P11A VAC T92P11A VAC T92P11A VAC T92P11A VAC T92P11A AgSnOInO 240 VAC T92P11A AgCdO 120VAC T92P11D12-12 DC PCB terminals 12 VDC T92P11D22-12 Panel mount + quick connect T92P11D VDC T92P11D24-12 AgSnOInO 12 VDC T92P11D VDC T92S7A12-24 Wash tight 2 form A, 2 NO AC PCB terminals AgCdO 24 VAC T92S7A VAC T92S7A VAC T92S7A22-24 Top sealed Panel mount + quick connect 24 VAC T92S7A VAC T92S7A VAC T92S7D12-12 Wash tight DC PCB terminals 12 VDC T92S7D VDC T92S7D VDC T92S7D VDC T92S7D14-24 AgSnOInO 24 VDC T92S7D22-12 Top sealed Panel mount + quick connect AgCdO 12 VDC T92S7D VDC T92S7D VDC T92S7D VDC T92S11A12-24 Wash tight 2 form C, 2 CO AC PCB terminals 24 VAC T92S11A VAC T92S11A VAC T92S11A22-12 Top sealed Panel mount + quick connect 12 VAC T92S11A VAC T92S11A VAC T92S11A VAC T92S11D12-12 Wash tight DC PCB terminals 12 VDC T92S11D VDC T92S11D VDC T92S11D VDC T92S11D22-12 Top sealed Panel mount + quick connect 12 VDC T92S11D VDC Catalog product and specification according and to IEC used only together to be section ,Rev.1112 with Definitions the 2012 TycoElectronicsCorporation, ate ConnectivityLtd. company. Catalog subject and to the product terms data of the is of disclaimer the Definitions and all chapters available at section, tions Catalog product data, Definitions section, application notes and all specifications are subject to change.

97 M203 Rev. B P.D. Oscillating Piston Flowmeters: Type 4 Petroleum Type 4 Petroleum Operating and Maintenance For Petroleum Meters

98 TABLE OF CONTENTS Installation 1 Operation 3 PresetModels 3 Printer Register Models 4 Calibration 4 Register Maintenance Preset Models with Auto Stop Valve Preset Models with Auto Stop Valve 7 Measuring Chamber Maintenance 10 Gear Train Maintenance 12 Air Release Maintenance 12 General Maintenance 14 Troubleshooting 15

99 FIGURE 1 TRUCK INSTALLATION PETROLEUM CAUTION CONTAINERS EMPLOYED TO COLLECT VAPOR OR LIQUID DISCHARGED FROM THE METER VAPOR RELEASE SHOULD BE OF SUFFICIENT SIZE TO PREVENT ANY LIQUID ESCAPE DURING NORMAL OPERATION, AND SHOULD HAVE A SUITABLE FLAME ARRESTOR VENT. ALL VENT LINES AND FITTINGS SHOULD BE OF METAL CONSTRUC- TION, AND ALL VALVES SHOULD BE DESIGNED SO THAT NORMAL VIBRATION DOES NOT CAUSE ACCIDENTAL OPENING. INSTALLATION Use pipe thread cement on the outside of male threads only. The flowmeter may be located at any convenient point on the discharge line from the pump. On Preset Models the base of the flowmeter casing is above the bottom of the valve. Do not clamp it in position without using the spacers provided or making a hole for the valve. Be sure to allow room for the removal of the strainer basket, register, and air release mechanism. (See Figure 15.) The piping on the outlet side of the flowmeter should be arranged so as to eliminate the possibility of draining the measuring chamber. All piping connected to the flowmeter must be firmly secured to prevent strain on the flowmeter casing. The use of flexible connections to the pump or tank is recommended. There must be no bypass connection around the flowmeter. Experience has shown that the valve in this line will eventually leak, work open or be accidentally left open. In order to obtain a maximum rate of delivery, the compartment outlets and the piping should be as large as practical and the number of elbows should be reduced to a minimum. Sweep elbows should be used wherever possible. Blowing The Hose: As it is impossible to blow all the liquid from the hose, the amount of liquid left in the lines on the discharge side of the flowmeter will not be the same before and after every delivery. It is therefore recommended that provision be made to keep the hose and outlet piping full of liquid at all times. For this purpose a hose nozzle with a check valve should be used. Pumping Out Underground Tanks: In making provisions for pumping out underground tanks, DO NOT provide any connection between the outlet ofthe flowmeter and the compartments or manifold. A valve in this line which is leaky or carelessly left open will allow part of the metered liquid to be diverted. Air Vent Line: The vent pipe from the air release should be 3 4 pipe or 1 2 inside diameter tubing. Care should be taken to prevent any possible obstruction to the free flow of air through this line. It should either be connected to the top of one of the compartments or run into a container of about 5 gallons capacity to collect any liquid discharged with the air. INSTALLATION Piping Page 1

100 Interlocking of Compartment or Manifold Valves If the valve of an empty compartment or auxiliary suction connection is open even slightly, while another compartment is being emptied, air drawn in through this valve will be churned up with the liquid to such an extent in the pump that some of it may be carried through the air release and cause over-registration on the flowmeter. Either the compartment or the manifold valves should be interlocked so that delivery can be made from only one compartment at a time. Compartment valves are ordinarily interlocked by means of a selector lever in the can box. Manifold valves may be of the 2-way 3-port lubricated plug type so arranged as to achieve the same purpose. Interlocking Of Compartment Or Manifold Valves FIGURE 2 MANIFOLD VALVE INTERLOCKING When Installing WARNING The connecting piping should be firmly secured to prevent strain on the flowmeter casing. Care should be taken that there is provision for expansion due to change in temperature. All piping on the inlet side of the flowmeter should be very thoroughly cleaned out. Whenever possible, place a spool in the place of the flowmeter and flush out all lines thoroughly before the flowmeter is installed. The majority of service calls on new installations would be eliminated if these directions were followed. Inlet and/or outlet are marked on flowmeter; do not install backwards. When Installing After Installing Pass sufficient liquid to clear the lines of air. Check the rate of flow. It should not exceed the rated capacity of the flowmeter. The bypass of the pump should be regulated to deliver the maximum practical rate of flow for the least amount of pressure. Pressure on the flowmeter should not exceed 125 psi. Do not try to increase the flow through undersized pipes and fittings by means of excessive pressures which will cause leaking gaskets and collapsed air release floats. Temperature of the liquid should not exceed 140 F. All flowmeters are tested and calibrated at the factory and adjustment should not be necessary. If registration appears to be in error, the flowmeter registration should be checked using a calibrated volumetric prover. The prover must be of sufficient capacity to permit a full flow delivery for at least one minute. Do not base calibration upon assumed volume of ordinary containers or dip stick measurement. If the registration is not in agreement refer to the section on Flowmeter Calibration. After Installing Cleaning The Strainer While the installation is still new, the strainer, if used, should be cleaned very frequently. After the system has been thoroughly flushed of foreign material, only periodic maintenance of the unit is recommended. Cleaning The Strainer Page 2

101 OPERATION To Operate The Flowmeter 1. Reset register to zero by turning operating knob to the rear stop. On Printer models, first insert ticket. 2. On Preset models, set the Preset wheels to the desired quantity. 3. Start pump open Auto Stop valve (if used). 4. Open hose nozzle and make delivery. 5. After completing of delivery on Printer models, stamp final reading on ticket by turning operating knob to the front stop and remove ticket. PRESET MODELS To set the Preset mechanism press the setting buttons inward until the desired quantity is noted on the Preset wheels. To Stop In Emergency Pushing the red emergency stop button will trip the valve. After it has been used either the delivery may be completed automatically as originally set by reopening the valve or the mechanism may be set for a new figure. The accuracy of delivery in either case is not affected. To Adjust Tripping Point Registers are shipped from the factory with the Preset mechanism adjusted to trip correctly at the normal rates of flow. If, due to a change in the speed of closing of the valve or for other reasons, the Preset does not trip at the correct point, the trip point may be adjusted as follows: If the valve is closing off the mark, either late (over-delivery) or early (under-delivery), adjust the two connecting link nuts to bring the trip point to the zero mark. For right-hand assembly turn the nuts to lengthen the connecting link when the trip point is early, or turn to shorten if the trip point is late. For left-hand assemblies turn in the opposite direction. Continue this procedure until the final trip is on or close to the zero mark. On double trip valves, the intermediate flow rate will be satisfactory when the final trip is adjusted, as described. Further adjustment of the trip point is possible, butis not recommended fornormal applications. The following procedure should be used only when very exact settings of the final trip are necessary. Adjust the connecting link nut as described above, and proceed as follows: Remove the trip adjusting screw located in the lower right corner of the register front housing. Insert a narrow blade ( 3 16 ) screwdriver until it engages the slotted head of the adjusting screw. One turn of this screw will change the tripping point about one-quarter of one-tenth gallon. If the Preset trips before reaching the zero mark (early), turn the adjusting screw clockwise. If the Preset trips after reaching the zero mark (late), turn counterclockwise. Do not turn the adjusting screw more than turns in either direction from the initial position or pass a point where a resistance to further turning of the screw is felt. If the trip point is not on zero after turns, return the adjusting screw to its original position and turn the connecting link nut a half turn in the appropriate direction. Then repeat the trip screw adjustment procedure. Gear shifter supplied as standard on 833 and 834 models. Optional on 831 and 832 models. CLAMP SCREW DUST BAR PRESET BUTTONS TRIP ADJUSTING SCREW COVER OPERATING KNOB EMERGENCY STOP BUTTON OPERATION To Operate the Flowmeter PRESET MODELS To Stop In Emergency To Adjust Tripping Point FIGURE 3 PRESET 800 SERIES PRINTER REGISTER Page 3

102 PRINTER REGISTER MODELS To Insert and Remove Tickets To insert a ticket be sure that the operating knob is turned forward to a stop. Then depress the dust bar and insert the ticket in the ticket slot under it, either face down bottom end first or face up top end first, as noted on the instruction plate. Turn the operating knob backward to the stop. This resets the visible wheels to zero, locks the ticket in place and prints the initial reading on the ticket. Upon completion of delivery, turn the operating knob forward to the stop. This operating prints the final reading and releases the ticket. It is now possible to remove the ticket. To Adjust Ticket Guides The Printer registers are shipped from the factory with the ticket guides adjusted for a standard (4 1 8 ) width ticket. If for any reason it is necessary to reposition the ticket, proceed as follows: 1. Remove top cover. 2. Insert a ticket into the printer. Loosen the clamp screws on the rear of the ticket guides. Move the guides to the right or left as required. Tighten clamp screws. The ticket must slide freely between the guides. If the ticket bends at the forward end of the guide, remove the guide and rebend the tail of the guide. 3. If it is necessary to raise or lower the printing, push the two stop pins to the front or rear with the end of a screwdriver. 4. Replace the top cover and reseal. To Change Setting of Letter Wheels 1. With the top plate removed, the letter wheels are visible (see Figure 4). CLAMP SCREWS STOP PINS LETTERWHEELS FIGURE 4 PRINT UNIT ADJUSTMENTS 2. By means of a screwdriver or similar tool, turn the wheels until the desired letters appear at the top where they are in position to print. To Change Position Of The Register (Non-Preset Models) Remove the register from the flowmeter. Two studs and two threaded holes will be seen on the flowmeter cover. Turn register 180 and tighten the screws in front of the register. For convenience the operating knob may be moved to the opposite side of the register. If the register is to be turned 90 transfer the studs to the two empty holes. Gear shifter standard on 833 and 834 models. Optional (extra charge) on models 831 and 832. PRINTER REGISTER MODELS To Insert and Remove Tickets To Adjust Ticket Guides To Change Setting of Letter Wheels To Change Position of the Register (Non-Preset Models) CALIBRATION Test all flowmeters with 50-gallon or larger test measures. Do not base calibration upon truck compartments. CALIBRATION Preset flowmeters should first be tested and adjusted without the Preset (set the register for more than the test quantity), then tested with the Preset. If the Preset mechanism does not trip correctly, see instructions on page 3 To Adjust the Tripping Point. Rerun the test, and then if the delivery is not correct, a service man should be called. Page 4

103 Erratic Registration Erratic registration is an indication of troublein the system caused by air ordirt in the measuring chamber. Do not try to correct this by recalibration of the flowmeter, but first check over the piping for air leaks, clean the strainer and then, if the trouble has not been found, clean the flowmeter as directed on pages 10 and 11. If this does not correct the trouble, check for faulty installation. Over-registration is an indication of air, whereas under-registration is generally caused by dirt or pipe scale in the measuring chamber, or the liquid bypassing the flowmeter in some manner. Consistent Over or Under-Registration When the flowmeter registers consistently either more or less than is delivered, the calibration may be corrected in the following manner: 1. Remove four screws holding top cover and remove cover. 2. Lift and turn the change gear shifter (see Figure 5) in the direction indicated on the top of the shifter. 3. There is a series of holes, marked A to H, in the plate into which the guide pin enters at different settings. Altering the setting by one hole changes the calibration approximately 17 cubic inches in 50 gallons. Example: Suppose the flowmeter consistently gives 34 cubic inches too much when it registers 50 gallons. After removing the cover plate move the gear shifter 2 spaces to the right (from position E to position C) to decrease the delivery about 34 cubic inches in 50 gallons. After changing the calibration always replace top cover, making sure that the sheet steel housing on the sides and back fits into the groove in the bottom edge of cover. Run a small amount of liquid through the flowmeter before testing. To prevent tampering, always reseal after calibration. Note: For broader change gear requirements, refer to form TSG-310. REGISTER MAINTENANCE Register parts are such that only minor field repairs are advisable. When a register is in need of repair or service other than that for which instruction is given here, it should be returned to an authorized Red Seal Measurement distributor for service. To Remove Register From Flowmeter Loosen the two clamp screws on lower front of the register. Lift the register off. On Preset Models the valve linkage must first be disconnected. (Remove cotter pin and washer at valve end.) CHANGE GEAR R CHANGE GEAR S (ON STD SPINDLE) FIGURE 6 CHANGE GEAR ARRANGEMENT When one register is removed and another substituted, (1) Check the number of teeth on the change gears (see Figure 6). They must be the same as the gears on the old register and on the same respective spindles. The number of teeth is stamped on each gear. To remove these gears, close the split end of the spindle with a pair of pliers and pull off the gear. After putting on a gear, spread the end of the spindle slightly. (2) Make sure the position of the Gear Shifter is the same on the new register as on the old one each hole is lettered for convenience. To Clean Register Mask GEAR SHIFTER FIGURE 5 GEAR SHIFTER ADJUSTMENTS The Register mask is made of plastic and requires special treatment.instructions for cleaning are given on next page: Erratic Registration Consistent Over or Under-Registration REGISTER MAINTENANCE To Remove Register From Flowmeter To Clean Register Mask Page 5

104 If the mask becomes soiled with grease and oil, solvents for these substances, such as kerosene or naptha, may beused to remove dirt. However, sprays that are commonly employed in cleaning glass windshields must not be used as cleaners, since they contain solvents. A water solution of nonabrasive soap is recommended for washing grease, oil, or dirt from the mask. It is then cleansed by rubbing gently with a soft cloth, in a manner similar to cleaning window glass, rinsing the plastic in clean water, and finally drying. Scouring cleanser and similar material must not be used in cleaning the mask, since they contain abrasives that scratch the surface. The use of solvents, such as acetone, ethyl acetate, benzene, and ethylene dichloride to brighten the surface is never recommended since these substances soften the surface of the plastic PRESET MODELS WITH AUTO STOP VALVE To Rotate Register When the flowmeter is assembled as a Left Hand assembly and it is desired to change it to a Right Hand assembly, or vice versa, proceed as follows: 1. Remove cotter pins (E) from valve linkage. 2. Unscrew the outside register link lock nut (P) and remove connecting rod (G). 3. Remove register link (N), rotate 1/2 turn and reassembleonto register as describedin appropriate valve adjustment instructions. 4. Loosen two clamp screws on lower front of register, lift register up and turn register Remove four handle housing assembly hex screws (C) and remove handle housing assembly from valve. 6. Remove valve handle set screw (B) and slide handle off bushing. Remove two cam retaining screws (not shown). Remove shaft seal plug (D). Disassemble valve operating shaft and valve operating cam. Reassemble valve operating shaft and install valve operating cam in the reverse direction. Reinstall two cam retaining screws andshaft seal plug. Reinstall housing assembly with valve operating cam acting on pilot rod. Secure with four hex screws (C). Reassemble valve handle (A) on knurled knob in position as shown for specific assembly. After completing the above instructions, the valve linkage must be adjusted in accordance with the procedure for the specific type valve as outlined on the following pages PRESET MODEL WITH AUTO-STOP VALVE To Rotate Register LEFT HAND ASSEMBLY RIGHT HAND ASSEMBLY M M P N A TO OPEN TO OPEN A P N O G G O E E D D B C C B FIGURE 7 VIEW LOOKING AT BACK OF REGISTER Page 6

105 To Adjust Linkage Valve Note: Before any adjustment of the Auto-Stop Valve is made, be sure that the Auto-Stop setting wheels indicate a quantity other than zero to ensure that the trip mechanism of the register is in proper position. 1. Depress the emergency stop button on the register and turn the shaft (O) clockwise (as viewed from rear of register). 2. Assemble register arm (N) on knurled knob in position as shown for specific assembly. (See Fig. 7 ). Arm should move an equal distance each side of vertical center line (M) (Angle x=x). 3. Assemble one nut (P) on connecting rod (G) and the other end of the connecting rod to the center hole in handle (A) using washers and cotter pins (E). 4. Open valve all the way. Turn shaft (O) counter clockwise to latch up mechanism. With valve held open tighten nut (P) against register arm link. Then assemble and tighten second nut at (P). 5. Depress the emergency stop button and allow the valve to close. At this point the leakage between the valve and the register must be free. If it is not, the above adjustments must be rechecked. 6. Set the register to deliver the minimum quantity and open the valve to run product through the flowmeter. 7. After the initial trip occurs the valve should close to the intermediate flow position. This rate will vary depending on product metered. If the valve closes too far, or all the way, adjust nuts (P) to provide additional rod length. 8. It is sometimes necessary to change the position of the handle. This can be done by loosening handle screw (B) and repositioning the handle as follows: if the register mechanism will not latch up, position the handle further toward the register. If the valve will not close, the handle may be positioned away from the register. Fine adjustments may be made by changing the effective length of connecting rod (G) utilizing nuts (P). Effective length of connecting rod (G) may also be variedby positioning the end of the rod in the upper or lower holes in the valve handle. 9. The Auto-Stop trip adjusting screw should be near its mid-position. To Adjust TheTripping Point The flowmeter is shipped from the factory with Auto-Stop mechanism adjusted to trip correctly at maximum rates of flow while the flowmeter is measuring a non-viscous liquid. Trip adjustment after final installation may be necessary due to differing flow rate and/or viscosity. If the Auto-Stop does not trip off at the correct mark due to a change in the speed of closing of the valve, different rates of flow, or any other reason, the adjustment is made as follows: Remove the screw located in the lower right corner of the front housing. Insert a medium-sized screwdriver into this hole until it engages the slotted head of an adjusting screw. One turn of this screw will change the tripping point about one-quarter of one graduation of the first wheel. If the Auto-Stop trips before reaching the zero mark, turn the adjusting screw in a clockwise direction. If the Auto-Stop trips after the zero mark, turn the adjusting screw in a counterclockwise direction. To Adjust Linkage Valve To Adjust The Tripping Point Preset Model With Double Trip Valve To Rotate Register When the flowmeter is assembled as a left-hand assembly and it is desired to change it to a right-hand assembly, or vice versa, proceed as follows: PRESET MODEL WITH DOUBLE TRIP VALVE To Rotate Register Page 7

106 1. Remove clevis pin (E) from valve linkage. 2. Unscrew the outside register link lock nut (P) and remove connecting rod (G) and clevis (F) as a unit. 3. Remove register link (N), rotate 1/2 turn and reassemble onto register as described in appropriate valve adjustment instructions. 4. Loosen two clamp screws on lower front of register, lift register up and turn register Remove operating shaft cap screw (C) on both sides. 6. Interchange connecting rod arm (H) and valve operating handle (A). The connecting rod arm must be assembled with notches (J and K) in specific relationship. (See item 3 of valve adjustment instructions for details regarding position of notches.) 7. Reassemble operating shaft cap screws (C). 8. Remove valve handle stop set screw (B) and screw into hole on opposite side of valve. M O N P X X G TO OPEN F E TO OPEN E F M G X X P N O RIGHT HAND ASSEMBLY DIRECTION OF FLOW A B OUTLET Y H J K C D Y J K C D H A B OUTLET DIRECTION OF FLOW LEFT HAND ASSEMBLY FIGURE 8 VIEW LOOKING AT BACK OF REGISTER After completing the above instructions, the valve linkage must be adjusted in accordance with the following procedure: Adjustment Of Auto-Stop Valve Before any adjustment of the valve is made, be sure that the Preset setting wheels indicate a quantity other than zero to insure that the trip mechanism of the register is in proper position. To Adjust Valve Linkage Page 8 1. Depress the emergency stop button on the register and turn the shaft (O) clockwise. 2. Assemble register arm (N) on knurled knob in position as shown for specific assembly. (See Fig. 8). Arm should move an equal distance each side of vertical center line (M) (Angle x = x). 3. Assemble valve arm (H) as shown for specific assembly. On the right hand assembly there must be one notch between the cast mark (K) on the valve arm and the cast mark (J) on the stop plate (J above K). On the left hand assembly these cast marks must be in line. 4. Assemble one nut (P) on connecting rod (G) and assemble clevis to the other end of the connecting rod a distance of Insert end of connecting rod through register arm link and assemble clevis (F) to valve arm (H) using upper hole. (See Figure 8). Insert clevis pin (E). 6. Open valve all the way. The opening of the valve is stopped by the set screw (B) which should project approximately 1 8 below the lug holding it. Turn shaft (O) counterclockwise to latch up mechanism. With valve held open, tighten nut (P) against register arm link. Then assemble and tighten second nut at (P). 7. Depress the emergency stop button and allow the valve to close. At this point the linkage between the valve and the register must be free. If it is not, the above adjustments must be rechecked. Adjustment of Auto- Stop Valve To Adjust Valve Linkage

107 8. Set the register to deliver the minimum quantity and open the valve to run product through the flowmeter. 9. After the initial trip occurs the valve should close to the intermediate flow position. This rate should be approximately 15 to 20 gpm. If the valve closes too far, or all the way, unscrew clevis (F) on rod (G) to hold valve open further. If the rate of flow is too fast during the intermediate position, turn the clevis onto the rod to allow the valve to close further. It should not be necessary to turn more than one turn in either direction. 10. It is sometimes necessary to change the position of set screw (B) if the clevis has been readjusted. If the register mechanism will not latch up, unscrew the set screw to allow the valve to open further. Ifthe connection rod (G) is under compression, when the valve is held all the way open, turn the set screw down to relieve the pressure on the register. 11. The Auto-Stop trip adjusting screw should be near its mid-position. If a small adjustment of this screw will not permit the register to shut off on the mark it is usually possible to correct this by a slight adjustment of the clevis (F). This will move the main valve nearer to or further away from its seat during the intermediate flow and thereby change the amount of time needed for the valve to fully close at the last trip (Also see To Adjust The Tripping Point.) NOTE: If it is difficult to obtain proper rate of flow during intermediate trip position and still have regular latch up fully. Check Auto-Stop valve to insure that it is opening all the way. Check valve by removing set screw (B) and clevis (F) from valve arm; open valve as far as possible. The distance between lug on arm and lug on stop plate must not be more than 1 4. DOUBLE TRIP MAINTENANCE To Disassemble and Assemble DoubleTrip Valve 1. Remove valve from flowmeter. 2. Remove two screws (A) holding retaining ring (B) at inlet of valve. (Caution: End plate should be held by hand when removing screws because of spring tension beneath the plate.) All internal parts of the valve can now be removed with the exception of the operating shaft mechanism. The removal of the internal parts from the valve body may be assisted by operating the valve handle as when operating the valve. 3. Disassemble piston and throttling ring assembly (items F to K). Inspect valve seats, O ring gaskets, piston ring (D), and cylinder (C) for damaged surfaces. Replace all defective parts with new parts. 4. Reassemble piston and throttling ring assembly. Apply Loctite Black Max 380 to bond the disc (G) to the piston (F), and allow 24 hours to cure before placing in service. Apply Loctite Threadlocker 242 under heads of three piston assembly screws (H). 5. Assemble pilot valve (E) on pilot valve rod (J). Place assembly into valve body. 6. Place one end of spring over pilot valve boss. FIGURE 9 VALVE ASSEMBLY 7. Place other end of spring over boss in cylinder (C) and press cylinder down over piston (F). Back of cylinders should be below flange face for proper assembly. 8. Hold cylinder in place, place O ring in body recess and attach retaining ring (B) with two screws (A). 9 Open valve as far as possible make sure that valve is not being stopped by set screw (L). DOUBLE TRIP MAINTENANCE To Disassemble and Assemble Double Trip Valve Page 9

108 To Adjust Rate of Closing Of Valve Variations in the viscosity of the liquids being measured will cause changes in the rate of closing of the valve from its full open position to its intermediate position. (Valve should reach its intermediate position with approximately 4 gallonsremaining on Preset setting wheels.) Setting of orifice plate is indicated on tag attached to valve. The rate of closing can be adjusted by changing the position of orifice plate which is readily accessible through inlet of valve. (Valve does not have to be disassembled.) (Figure 10) View of valve inlet showing position of orifice plate for gasoline and other low viscosity liquids. Note that orifice opening is completely covered. (Photo shows valve.) The normal position of orifice plate in valve to be used with gasoline or other low viscosity liquids will be set with orifice opening covered. If valve closes too slowly with this setting, turn plate counterclockwise to expose either small, medium or large hole as required. To Inspect Operating Shaft Seals of Preset Valve The following steps should be followed if it becomes necessary to disassemble the operating shafts because of leakage. Shaft seal cannot be corrected by tightening of the bearing bracket screws. In this case new O rings are usually required. (See parts list for 2 Type 1A Double Trip Preset Valve.) 1. Remove the valve handle (A), connecting rod arm (I), two stop plates (B and H), and two roll pins (C). Remove eight screws and pry off two shaft bearing brackets (D). Do not damage gaskets (G). 2. The two O ring seals (E) can be inspected for damaged surfaces. Replace any defective O rings. 3. To remove the operating shaft (J) and two shaft bearings (D), first remove the two screws in the valve operating cam (K). Inspect the shaft forscore marks and replace if necessary. New O ring seals are worthless if used with a badly scored shaft. 4. Remove retainer (F), replace O rings (G) and reinstall shaft bearings (D). 5. Reassemble the operating shaft and cam. 6. Replace rings, flat gaskets, two roll pins, two stop plates, connecting rod arm and valve handle. MEASURING CHAMBER MAINTENANCE To Remove and Disassemble FIGURE 10 VALVE ORIFICE PLATE FIGURE 11 SHAFT ASSEMBLY This operation is not difficult and may be performed by any competent mechanic. No special tools are required. No trouble need be expected, if these few simple, but important, directions are followed. Do not open the flowmeter until you have checked over all other possible causes of erratic registration. To Adjust Rate of Closing of Valve To Inspect Operating Shaft Seals of Preset Valves MEASURING CHAMBER MAINTENANCE To Remove And Disassemble Page 10

109 1. Prepare a clean surface on which to place the parts as they are removed. The parts are machined to close tolerances and should be handled with care. Have a replacement gasket ready before opening the flowmeter. 2. Loosen the two clamp screws on the lower front of the register. Lift the register off. On Preset Models the valve linkage must first be disconnected. (Remove cotter pin and washer at valve end.) 3. Remove the flowmeter cover taking care not to damage the gasket. 4. Lift the measuring chamber from the flowmeter casing. 5. Remove the upper cylinder head by inserting a screwdriver in one of the slots provided and prying it off. Be careful not to scratch or nick any part of the chamber. 6. Lift out the piston by its spindle. If care is taken to draw it straight, it should come out easily. Do not force it. 7. Remove the control roller and the diaphragm from the lower cylinder head. 8. The seal pin may be removed (for replacement only) by pulling upward, using pliers if necessary. To Clean The Measuring Chamber The parts may be most easily cleaned of scale, etc., by means of a good, coarse, stiff bristle (not wire) brush and gasoline. All foreign matter, except deeply embedded chips or heavy corrosion due to water, may be removed in this manner. Do not use abrasives, such as emery cloth or sandpaper. When the piston is badly corroded, the whole chamber should be replaced. To Clean The Measuring Chamber FIGURE 12 MEASURING CHAMBER COMPONENTS The parts of the measuring chamber which may show wear after long periods of service are the diaphragm and the control roller. These parts will not require replacement until the accuracy begins to fall off at low rates of flow. To change these parts, merely substitute the new for the old when the flowmeter has been taken down for cleaning. Experience has shown that the sliding surfaces between the chamber and piston take on a burnished finish and wear little if any. To Reassemble The Chamber In The Flowmeter Before reassembling the flowmeter, rinse all parts in gasoline. If possible, flush out the flowmeter body. Assemble the parts carefully; they should slide together easily without hammering or forcing. It is essential that all contact surfaces between the cover and chamber, or between the measuring chamber and its seat in the casing, be clean and free from nicks. To Reassemble The Chamber In The Flowmeter FIGURE 13 CHECKING THE PISTON MOVEMENT Page 11

110 1. Assemble diaphragm and seal pin in chamber if replacement was necessary. 2. Place the control roller on its pin and see that it will rotate freely. 3. Replace the piston and oscillate it carefully by hand; it should move easily without binding. If it sticks, do not force it, but remove and locate the cause. Do not file down the roller as this will impair the accuracy of the flowmeter. 4. Replace the upper cylinder head and again oscillate the piston to make sure that is free. 5. When replacing the measuring chamber in the casing, besure that the seat is clean and free from nicks. Make sure the dowel pin in the main casing enters the slot in the chamber bottom properly and allows the chamber to rest on its seat. 6. Before replacing the cover, first be sure the chamber is properly seated and inspect the gasket. Then set the arm of the gear train so that it will not come down on the piston spindle. 7. Make sure the cover is down on its seat before tightening the bolts. GEAR TRAIN MAINTENANCE To Repair Leaking U Cup Seal Stuffing Box Keep dirt out of register and avoid injury to gasket. Remove the register. If tightening the stuffing box nut with the fingers does not stop this leak, replace U cup shaft seal. It may also be necessary to replace U cup shaft seal and to replace the gear train. 1. Remove the register. 2. Remove the star connection (1), using a No. 8 Allen wrench. 3. Unscrew the stuffing box nut (2). 4. Remove shaft seal (3). Inspect upper end of spindle to be sure it is free of nicks or burrs which might damage the new shaft seal when it is placed on spindle. Remove the clamp nut (6); gear train assembly can be removed from underside of flowmeter cover. 5. Replace shaft seal with new part. Be sure expander (4) and spring (5) are in position before inserting new seal. 6. Assemble nut and tighten down all the way. To Replace The Gear Train 1. Remove the register (see page 5). 2. Remove the star connection (1), using a No. 8 Allen wrench. 3. Remove the flowmeter cover, with gear train assembly attached. Keep dirt out of flowmeter and avoid injury to the cover gasket. 4. Unscrew the stuffing box nut (2). 5. Remove clamp nut (6); gear train assembly can be removed from underside of flowmeter cover. AIR RELEASE MAINTENANCE General Note O Ring Gaskets 1. The groove in which the O ring is located must be free of dirt. FIGURE 14 GEAR TRAIN ASSEMBLY GEAR TRAIN MAINTENANCE To Repair Leaking U Cup Seal Stuffing Box To Replace The Gear Train AIR RELEASE MAINTENANCE General Note O Ring Gaskets Page 12

111 2. The flat face against which the O ring seats must be clean and free of nicks or dents which will allow the pressure to leak between the gasket and the metal. To Clean The Strainer Remove the strainer cover and pull out the screen. Blow the dirt off screen with compressed air and rinse in gasoline or kerosene. To Clean The Strainer FIGURE 15 AIR RELEASE COMPONENTS Air Release Valve Troubles Troubles with this unit may arise from: a) Collapsed ball float allowing vent to remain open. b) Dirty or worn valve seat. c) Improper position of float. d) Sticking back pressure valve. To Inspect Air Release Unit 1. Remove the Strainer (see Fig. 15). 2. Uncouple the Vent Connection. 3. Remove the cap screws on the air release cover and lift out the mechanism. 4. If the float is damaged, remove by taking out the hinge pins and replace with a new one. 5. If the valve is leaky, a. Remove the air release unit from the underside of the cover by unscrewing three small screws. b. Take off the sleeve with piston seal. c. Move the ball in the direction of the valve housing as far as possible and remove valve disc assembly. d. Inspect piston seal for any obvious deterioration. e. The valve disc assembly should be taken apart to inspect for dirt or defective pilot valve seat. A pair of fine nose pliers is needed for this. Replace valve if seats are defective. f. When reassembling, make sure the piston seal is properly positioned and that the valve disc assembly moves freely in sleeve. 6. To avoid possible mechanical interference, the support bracket and float linkage should appear as shown above. If this is not as shown, the framework has been bent out of shape. To adjust, bend metals back in the direction required. Air Release Valve Troubles To Inspect Air Release Unit Page 13

112 To Remove Back Pressure Valve 1. Remove Air Release and Strainer from the line by unbolting at inlet flange and flowmeter inlet. 2. Remove strainer sleeves and air release valve. 3. Remove drain plug. 4. Hold block of wood (1 3 4 diam.) against back pressure valve and knock valve out of housing by means of 1 2 diameter rod inserted through drain plug hole. GENERAL MAINTENANCE In the maintenance of the accuracy of Neptune Flowmeters, FIGURE 16 BACK PRESSURE VALVE little is necessary other than to see that the proper conditions of operation are preserved. These conditions, once the flowmeter has been properly installed, consist merely in guarding against foreign matter, such as air, sediment and water, entering the measuring chamber. The liquid passing through the measuring chamber must be free of grit and other forms of sediment in order to prevent unnecessary friction and the scoring of the piston and chamber walls. Evidence of trouble from this source is under-registration of the flowmeter. Periodic cleaning of the strainer at the inlet of the flowmeter will help to insure against this trouble. In the design of this unit, particular care has been taken to make this operation as simple as possible. See page 13. Being an instrument which measures by volume, a flowmeter will record the passage of air as well as the liquid being measured. Over-registration is the result. The air release valve is intended to prevent this condition by venting this air before it passes through the measuring chamber. Incidental water will cause no damage to the flowmeter. Trouble from this source may be expected only when water is allowed to stand in the flowmeter for considerable periods of time. When washing trucks, care should be taken to coverthe register. Water in the register will cause trouble particularly in cold weather when ice may form and cause sticking. Test with 50-gallon or larger test measures. Do not base calibration upon truck compartments or on 5-gallon measures. Instructions for calibration will be found on page 5. Preset Flowmeters should first be tested and adjusted without the Preset (set the register for more than the test quantity); then test with the Preset. If the Preset mechanism does not trip correctly see instructions on To Adjust the Tripping Point, page 3. Before a flowmeter is put in storage the measuring chamber must be flushed with a light lubricating oil to prevent condensation damage. To Remove Back Pressure Valve GENERAL MAINTENANCE Sediment Air Water Testing Storage Page 14

113 TROUBLESHOOTING 1. Register Not Working When Liquid is Flowing a) Bypass around flowmeter not shut off. b) Frozen condensation inside register. c) Register in need of repair. d) Sheared key on Change Gear caused by ice in register. 2. Leakage at the Stuffing Box Loose stuffing box nut or worn spindle. 3. Chronic Leakage at the Main Case Gasket a) Excessive line or shock pressure. b) Broken gasket or loose bolts. 4. Reduction in the Rate or Complete Stoppage of Discharge a) Pump bypass stuck open. b) Air release valve fails to close allowing the liquid to escape through air vent. c) An open valve in the piping allowing liquid to circulate around the pump. d) Worn pump. e) Blocked strainer due to sediment or frost. f) Piston in flowmeter stuck, caused by dirt. Check strainer and clean measuringchamber. 5. Over-Registration Erratic a) Leaking valve in empty compartment causing an emulsion of air and oil. b) Air release valve jamming allowing air to pass through the flowmeter c) Spring in back pressure valve broken or valve stuck open. d) Vent line from the air release valve plugged causing air to pass through the flowmeter. e) Leaks in the suction line such as at valve stems, pump packing, or flange gaskets. f) Air pockets in closed-end piping in the suction line. g) Manifold or compartment valves only partly open causing excessive suction. h) Suction piping too small causing excessive suction. 6. Under-Registration Erratic a) Dirt in the measuring chamber. b) Badly worn control roller or diaphragm. c) Main casing distorted or damaged. d) Dirt under the seat of the measuring chamber at the outlet port (after cleaning). e) Leakage around the flowmeter due to partly open valve. 7. Consistent Over- or Under-Registration Flowmeter in need of calibration. 8. Liquid Leaking Out the Air Release Vent a) Improper operation. b) Worn, damaged or defective valve unit. 9. Printing Not Clear in Cold Weather Ticket carbon not suitable for cold weather use. PRESET MODELS 10. Cut Off is Not Accurate Trip Adjustment TROUBLESHOOTING Page 15

114 1 1 4 TYPE 4 WITH 1 A/S VALVE 800 SERIES REGISTER ST D PIPE THREAD CLEARANCE FOR REMOVING STRAINER 1 NPT THREAD TAP (3) HOLES EQUALLY SPACED ON DIA B.C. 3 4 DIA. 5 CLEARANCE FOR REMOVING FLOAT DIA. (2) HOLES CLEARANCE FOR REMOVING REGISTER 1 PIPE THREAD Page 16

115 1 1 2 TYPE 4 WITH 2 A/S VALVE 800 SERIES REGISTER ST D PIPE THREAD CLEARANCE FOR REMOVING STRAINER 1 NPT THREAD TAP (3) HOLES EQUALLY SPACED ON DIA B.C. 3 4 DIA. 5 CLEARANCE FOR REMOVING FLOAT CLEARANCE FOR REMOVING REGISTER 2 PIPE THREAD Page 17

116 U.S.A./International 1310 Emerald Road Greenwood, SC Tel.: Toll-Free (800) (864) Fax: (864) Specifications subject to change without prior notification.

117 BC OM January 21, 1981 Rev. C INSTALLATION, O P E R ATION, AND MAINTENANCE MANUAL WITH PA R T S L I ST 0 SERIES PUMP MODEL 02K3- X2 1P THE GORMAN RUPP COMPANY MANSFIELD, OHIO GORMAN RUPP O F CANADA LIMITED S T. THOMAS, ONTARIO, CANADA 1981 The Gorman Rupp Company Printed in U.S.A.

118 TA B L E O F C O N T E N T S INTRODUCTION... PAGE I - 1 S A F E T Y - S ECTION A... PAGE A - 1 INSTALLATION - S ECTION B... PAGE B - 1 Pump Dimensions... PREINSTALLATION INSPECTION... POSITIONING PUMP... Lifting... Mounting... SUCTION AND DISCHARGE PIPING... Materials... Line Configuration... Connections to Pump... Gauges... SUCTION LINES... Fittings... Strainers... Sealing... Suction Lines In Sumps... Suction Line Positioning... DISCHARGE LINES... Siphoning... Valves... Bypass Lines... ELECTRICAL CONNECTIONS... PAGE B - 1 PAGE B - 2 PAGE B - 2 PAGE B - 2 PAGE B - 2 PAGE B - 2 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 3 PAGE B - 4 PAGE B - 4 PAGE B - 4 PAGE B - 4 PAGE B - 5 PAGE B - 5 O P E R ATION - S ECTION C... PAGE C - 1 PRIMING... STARTING... OPERATION... Lines With a Bypass... Lines Without a Bypass... Leakage... Liquid Temperature And Overheating... Strainer Check... Pump Vacuum Check... STOPPING... Cold Weather Preservation... PAGE C - 1 PAGE C - 1 PAGE C - 1 PAGE C - 1 PAGE C - 2 PAGE C - 2 PAGE C - 2 PAGE C - 2 PAGE C - 2 PAGE C - 3 PAGE C - 3 T ROUBLESHOOT IN G - S ECTION D... PAGE D - 1 PREVENTIVE MAINTENANCE... PAGE D - 3 PUMP MAINTENANCE AND REPAIR - S ECTION E... PAGE E - 1 PERFORMANCE CURVE... PARTS LIST: PAGE E - 1 i

119 TA B L E O F C O N T E N T S (continued) Pump Model... PUMP AND SEAL DISASSEMBLY AND REASSEMBLY... Pump Disassembly... Impeller Removal... Seal Removal and Disassembly... Seal Reassembly and Installation... Impeller Installation... Pump Reassembly... Final Pump Assembly... LUBRICATION... Seal Assembly... PAGE E - 3 PAGE E - 4 PAGE E - 4 PAGE E - 4 PAGE E - 5 PAGE E - 5 PAGE E - 6 PAGE E - 7 PAGE E - 7 PAGE E - 7 PAGE E - 7 ii

120 0 S E R I E S OM INTRODUC TION Thank You for purchasing a Gorman Rupp pump. Read this manual carefully to learn how to safely install and operate your pump. Failure to do so could result in personal injury or damage to the pump. This Installation, Operation, and Maintenance manual is designed to help you achieve the best performance and longest life from your Gorman Rupp pump. This pump is an 0 Series, enclosed impeller, selfpriming centrifugal model with straight in suction, without a suction check valve and close coupled to an explosion proof electric motor. The pump is de signed for handling clean liquids that do not con tain large entrained solids. The basic material of construction is gray iron, with bronze impeller and stainless steel impeller shaft. If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman Rupp distributor, or: The Gorman Rupp Company P.O. Box 1217 Mansfield, Ohio Phone: (419) or: Gorman Rupp of Canada Limited 70 Burwell Road St. Thomas, Ontario N5P 3R7 Phone: (519) For information or technical assistance on the mo tor, contact the motor manufacturer's local dealer or representative. This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices. The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel: Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure. Hazards or unsafe practices which CO U L D result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure. Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure. NOT E Instructions to aid in installation, operation, and maintenance or which clarify a procedure. INTRODUCTION PA G E I - 1

121 0 S E R I E S OM S A F E T Y - This information applies to 0 Series electric motor driven pumps. Refer to the manual accompanying the motor before attempting to begin operation. This manual will alert personnel to known procedures which require spe cial attention, to those which could damag e equipment, and to those which could be dangerous to personnel. How ever, this manual cannot possibly pro vide detailed instructions and precau tions for each specific application or for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner, installer and/or maintenance personnel to en sure that applications and/or mainte nance procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by s u c h applications or procedures. S EC T I O N A This pump is designed to handle petro leum products or other industrial liq uids that do not contain large entrained solids. Do not attempt to pump volatile, corrosive, or flammable materials which may damage the pump or endanger per sonnel as a result of pump failure. This pump is designed to handle petro leum products or other industrial liq uids that do not contain large entrained solids. All controls must meet industry standards and codes for use in an ex plosive atmosphere. Do not attempt to pump liquids for which the pump and/or controls have not been approved, or which may damage the pump or endan ger personnel as a result of pump fail ure. Before attempting to open or service the pump: 1. Familiarize yourself with this man ual. 2. Disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inopera tive. 3. Allow the pump to completely cool if overheated. 4. Check the temperature before opening any covers, plates, or plugs. 5. Cl ose the suction and discharge valves. 6. Vent the pump tiously. 7. Drain the pump. slowly and cau Be certain proper safety practices are followed before operating or servicing the pump. Provide adequate ventilation, prohibit smoking, wear static resistant clothing and shoes. Clean up all fuel spills immediately after occurrence. Do not install and operate a non explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with the Na tional Electric Code and all local codes. If there is a conflict between the instruc tions in the manual accompanying the unit and the National Electric Co d e or S A F ET Y PA G E A - 1

122 OM S E R I E S the applicable local code, the National or local code shall take precedence. Because this pump is designed to han dle volatile and/or flammable liquids, overheating may produce dangerous fumes. Take precautions to ensure the area surrounding the pump is ade quately ventilated. Allow the pump to cool and use extreme caution when venting the pump, or when removing covers, plates, plugs, or fittings. Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs: 1. Stop the pump immediately. 2. Ventilate the area. 3. Allow the pump to completely cool. 4. Check the temperature before opening any covers, plates, gauges, or plugs. 5. Vent the pump slowly and cau tiously. 6. Refer to instructions in this manual before restarting the pump. After the pump has been positioned, make certain that the pump and all pip ing connections are tight, properly sup ported and secure before operation. Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with g reat force. Al low the pump to cool before servicing. Do not operate the pump against a closed discharge valve for long periods of time. If operated against a closed dis charge valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode. The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to troubleshoot, test and/or service the electrical compo nents of this pump. Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards. PA G E A - 2 S A F E T Y

123 0 S E R I E S OM INSTALLATION - Review all S A F E T Y information in Section A. Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping. Most of the information pertains to a standard static lift application where the pump is posi tioned above the free level of liquid to be pumped. If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the S EC T I O N B specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve. For further assistance, contact your Gorman Rupp distributor or the Gorman Rupp Company. Pump Dimensions See Figure 1for the approximate physical dimen sions of this pump. OUTLINE DRAWING Figure 1. Pump Models 0 2 K 3 - X2 1P INSTALLATION PA G E B - 1

124 OM S E R I E S P R E I N STALLATION INSPECTION The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows: a. Inspect the pump and motor for cracks, dents, damaged threads, and other obvious damage. b. Check for and tighten loose attaching hard ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces. c. Carefully read all warnings and cautions con tained in this manual or affixed to the pump, and perform all duties indicated. Note the di rection of rotation indicated on the pump. Check that the pump shaft rotates counter clockwise when facing the impeller. The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to troubleshoot, test and/or service the electrical compo nents of this pump. POSITIONING PUMP Lifting Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity. Drain the pump and remove all customer installed equipment such as suction and discharge hoses or piping before attempting to lift existing, installed units. Only operate this pump in the direction in dicated by the arrow on the pump body and on the accompanying decal. Refer to ROTATION in O P E R ATION, Section C. d. Check levels and lubricate as necessary. Re fer to L UBRICATION in the MAINTENANCE AND R E PAIR section of this manual and per form duties as instructed. e. If the pump and motor have been stored for more than 12 months, some of the compo nents or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced to ensure maximum pump serv ice. The pump assembly can be seriously damaged if the cables or chains used to lift and move the unit are improperly wrapped around the pump. Mounting Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation. The intermediate is equipped with mounting foot holes for mounting the pump to a base. SUCTION AND D I S C H A R G E PIPING If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your Gorman Rupp distributor or the factory to deter mine the repair or updating policy. Do not put the pump into service until appropriate action has been taken. Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve and oper ating range shown on Page E 1 to be sure your overall application allows pump to operate within the safe operation range. PA G E B - 2 INSTALLATION

125 0 S E R I E S OM Materials Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended. Line Configuration Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long radius type to minimize friction loss. Connections to Pump Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings. Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose type lines are used, they should have adequate support to secure them when filled with liquid and under pressure. Gau ges Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines. Installation closer to the pump may result in erratic readings. the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created. Fittings Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets. Strainers If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself. If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump. This pump is designed to handle up to 3/8 inch (9,5 mm) diameter spherical solids. Sealing Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped. SUCTION L I N ES To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from Suction Lines In Sumps If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1 1/2 times the diame ter of the suction line. INSTALLATION PA G E B - 3

126 OM S E R I E S If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency. If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1 1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet. If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe. Suction Line P ositioning The depth of submergence of the suction line is critical to efficient pump operation. Figure 2 shows recommended minimum submergence vs. veloc ity. NOT E The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter). D I S C H A R G E L I N ES Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity phoning action causing damage to the pump could result. Siphoning Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si Valves If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line. PA G E B - 4 INSTALLATION

127 0 S E R I E S OM A check valve in the discharge line is normally rec ommended, but it is not necessary in low dis charge head applications. With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped. E L E C T R I C A L CO N N ECTIONS This pump is driven by an electric motor. Check that the electrical service available matches the motor requirements stamped on the motor name plate before connecting the motor to the incoming power. If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump. Bypass Lines The electrical power used to operate the pump is high enough to cause injury or death. Obtain the services of a qualified electrician to make all electrical con nections. If it is necessary to permit the escape of air to atmo sphere on initial priming or during the repriming cycle, install an air bypass line sized so that it will not affect the pump discharge capacity between the pump and the discharge check valve. Since this pump does not use a suction check valve, the discharge end of the bypass line must be sub merged in the liquid being pumped in order to maintain suction. NOT E The bypass line may clog frequently if the liquid contains solids and the valve remains closed. If this condition occurs, either use a larger bypass line or leave the shut off valve open during pumping. Do not install and operate a non explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with The Na tional Electric Code and all local codes. If there is a conflict between the instruc tions in the manual accompanying the unit and The National Electric Code or the applicable local code, The National or local code shall take precedence. Refer to the following motor data before making electrical connections. MODEL VOLTAGE PHASE HP Hz RPM F.L. AMPS 02K3-X2 1P 115/ /9.9 GROUNDING Because this pump is used to handle volatile or flammable liquids, the unit must be grounded by attaching a ground wire assembly to a ground rod in order to eliminate electrostatic build up by the liquid being pumped. Install the ground rod in ac cordance with the National Electrical Codes and all local codes. Be sure the fastening device makes a tight electrical connection with the rod and the pump. Inspect and test the ground wire assembly for conductivity. Replace a broken or frayed wire before resuming operation. INSTALLATION PA G E B - 5

128 0 S E R I E S OM O P E R ATION - S EC T I O N C Review all S A F E T Y information in Section A. F ollow the instructions on all tags, labels and decals attached to the pump. This pump is designed to handle petro leum products and other industrial liq uids that do not contain large entrained solids. Do not attempt to pump volatile, corrosive, or flammable liquids which may damage the pump or endanger per sonnel as a result of pump failure. Pump speed and operating conditions must be within the performance range shown on page E 1. PRIMING Install the pump and piping as described in IN S TAL LATION. Make sure that the piping connec tions are tight, and that the pump is securely mounted. Check that the pump is properly lubri cated (see L UBRICATION in MAINTENANCE AND REPAIR). This pump is self priming, but the pump should never be operated unless there is liquid in the pump casing. Never operate this pump unless there is liquid in the pump casing. The pump will not prime when dry. extended operation of a dry pump will destroy the seal assembly. O P ER ATION Add liquid to the pump casing when: 1. The pump is being put into service for the first time. 2. The pump has not been used for a consider able length of time. 3. The liquid in the pump casing has evapo rated. Once the pump casing has been filled, the pump will prime and reprime as necessary. After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connect ing piping is securely installed. Other wise, liquid in the pump forced out under pressure could cause injury to personnel. To fill the pump, remove the pump casing fill cover or fill plug in the top of the casing, and add clean liquid until the casing is filled. Replace the fill cover or fill plug before operating the pump. S TARTING Consult the operations manual furnished with the motor. O P E R ATION Lines With a Bypass Since this pump does not have a suction check valve, the discharge end of the bypass line must be submerged in order to maintain suction. Close the throttling valve in the discharge line and open the shut off valve in the bypass line so that the pump will not have to prime against the weight of the liquid in the discharge line. Start the motor. When the pump has primed and liquid is flowing steadily through the bypass line, close the bypass shut off valve and open the discharge throttling valve. PA G E C - 1

129 OM S E R I E S Lines Without a B ypass Open all valves in the discharge line and start the power source. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter operation. The pump may not prime imme diately because the suction line must first fill with liquid. If the pump fails to prime within five minutes, stop it and check the suction line for leaks. After the pump has been primed, partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely filled, adjust the throttling valve to the required flow rate. Do not operate the pump against a closed discharge throttling valve for long periods of time. If operated against a closed discharge throttling valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode. Leakage No leakage should be visible at pump mating sur faces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maxi mum pump efficiency. Liquid Temperature And Overheating The maximum liquid temperature for this pump is 160 F (71 C). Do not apply it at a higher operat ing temperature. Overheating can occur if operated with the valves in the suction or discharge lines closed. Operating against closed valves could bring the liquid to a boil, build pressure, and cause the pump to rup ture or explode. If overheating occurs, stop the pump and allow it to cool before servicing it. Refill the pump casing with cool liquid. Allow an over heated pump to com pletely cool before servicing. Do not re move plates, covers, gauges, or fittings from an over heated pump. Liquid with in the pump can reach boiling tempera tures, and vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Af ter the pump completely cools, drain the liquid from the pump by removing the casing drain plug. Use caution when re moving the plug to prevent injury to per sonnel from hot liquid. Strainer Check If a suction strainer has been shipped with the pump or installed by the user, check the strainer regularly, and clean it as necessary. The strainer should also be checked if pump flow rate begins to drop. If a vacuum suction gauge has been in stalled, monitor and record the readings regularly to detect strainer blockage. Never introduce air or steam pressure into the pump casing or piping to remove a blockage. This could result in personal injury or damage to the equipment. If backflushing is absolutely neces sary, liquid pressure must be limited to 50% of the maximum permissible operating pressure shown on the pump performance curve. Pump Vacuum Check With the pump inoperative, install a vacuum gauge in the system, using pipe dope on the threads. Block the suction line and start the pump. At oper ating speed the pump should pull a vacuum of 20 inches (508,0 mm) or more of mercury. If it does not, check for air leaks in the seal, gasket, or dis charge valve. Open the suction line, and read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. PA G E C - 2 O P ER ATION

130 0 S E R I E S OM Before checking for the source of the leak, check the point of installation of the vacuum gauge. STO P P I N G After stopping the pump, disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inoperative. Do not operate the pump against a closed discharge throttling valve for long periods of time. If operated against a closed discharge throttling valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode. Cold Weather Preservation In below freezing conditions, drain the pump to prevent damage from freezing. Also, clean out any solids by flushing with a hose. Operate the pump for approximately one minute; this will remove any remaining liquid that could freeze the pump rotat ing parts. If the pump will be idle for more than a few hours, drain the pump, and flush it thoroughly with clean liquid. Operate the pump during the draining process. O P ER ATION PA G E C - 3

131 0 S E R I E S OM TROUBLESHOOTIN G - SEC TION D Review all S A F E T Y information in Section A. Before attempting to open or service the pump: 1. Familiarize yourself with this manual. 2. Disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inopera tive. 3. Allow the pump to completely cool if overheated. 4. Check the temperature before open ing any covers, plates, or plugs. 5. Close the suction and discharge valves. 6. Vent the pump slowly and cautiously. 7. Drain the pump. TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP FAILS TO PRIME PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE Not enough liquid in casing. Air leak in suction line. Lining of suction hose collapsed. Leaking or worn seal or pump gasket. Suction lift or discharge head too high. Strainer clogged. Air leak in suction line. Lining of suction hose collapsed. Leaking or worn seal or pump gasket. Add liquid to casing. See PRIM ING. Correct leak. Replace suction hose. Check pump vacuum. Replace leaking or worn seal or gasket. Check piping installation and in stall bypass line if needed. See INSTALLATION. Check strainer and clean if neces sary. Correct leak. Replace suction hose. Check pump vacuum. Replace leaking or worn seal or gasket. TROUBLESHOOTI NG PA G E D - 1

132 OM S E R I E S TROUBLE POSSIBLE CAUSE PROBABLE REMEDY PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.) PUMP REQUIRES TOO MUCH POWER PUMP CLOGS FREQUENTLY EXCESSIVE NOISE Strainer clogged. Suction intake not submerged at proper level or sump too small. Impeller or other wearing parts worn or damaged. Impeller clogged. Suction lift or discharge head too high. Low or incorrect voltage. No voltage at line side of circuit breaker. Discharge head too low. Liquid solution too thick. Liquid solution too thick. Discharge flow too slow. Cavitation in pump. Pumping entrained air. Pump or drive not securely Check strainer and clean if neces sary. Check installation and correct sub mergence as needed. Replace worn or damaged parts. Check that impeller is properly centered and rotates freely. Free impeller of debris. Check piping installation and install bypass line if needed. See INSTAL LATION. Measure control box voltage, both when pump is running and when shut off. Check power source for blown fuse, open circuit breaker or control box, broken lead, or loose connection. Adjust discharge valve. Dilute if possible. Dilute if possible. Open discharge valve fully to in crease flow rate, and run power source at maximum governed speed. Reduce suction lift and/or friction losses in suction line. Record vac uum and pressure gauge readings and consult local representative or factory. Locate and eliminate source of air bubble. Secure mounting hardware. mounted. Impeller clogged or damaged. Clean out debris; replace dam aged parts. PA G E D - 2 TROUBLESHOOTI NG

133 0 S E R I E S OM PREVENTIVE MAINTENANCE Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble free performance and long life from your Gorman Rupp pump. For specific questions con cerning your application, contact your Gorman Rupp distributor or the Gorman Rupp Company. Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so equipped) between regularly scheduled inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time. For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently. Item Preventive Maintenance Schedule Service Interval* Daily Weekly Monthly Semi Annually General Condition (Temperature, Unusual I I I C Noises or Vibrations, Cracks, Leaks, I Loose Hardware, Etc.) I Annually Pump Performance (Gauges, Speed, Flow) I Bearing Lubrication Seal Lubrication (And Packing Adjustment, If So Equipped) I R V Belts (If So Equipped) Air Release Valve Plunger Rod (If So Equipped) Front Impeller Clearance (Wear Plate) Rear Impeller Clearance (Seal Plate) Check Valve Pressure Relief Valve (If So Equipped) Pump and Driver Alignment Shaft Deflection Bearings Bearing Housing Piping Driver Lubrication - See Mfgr's Literature Legend: I = Inspect, Clean, Adjust, Repair or Replace as Necessary C = Clean R = Replace * Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually. Adjust schedule as required for lower or higher duty cycles or extreme operating conditions. I R I C I I I I I TROUBLESHOOTI NG PA G E D - 3

134 0 S E R I E S OM PUMP MAINTENANCE AND REPAIR - SEC TION E M AINTENANCE AND R E PAIR O F T H E WEARING PA R T S O F T H E PUMP WILL MAINTAIN P E A K O P ER ATING PERFORM AN C E. S TANDARD P E R F O R M A N C E FOR PUMP M O D ELS 0 2 K 3 - X2 1P Based on 70 F (21 C) clear water (corrected to.80 specific gravity) at sea level with minimum suc tion lift. Since pump installations are seldom identi cal, your performance may be different due to such factors as viscosity, specific gravity, elevation, tem perature, and impeller trim. If your pump serial number is followed by an N, your pump is NOT a standard production model. Contact the Gorman Rupp Company to verify per formance or part numbers. Pump speed and operating condition points must be within the continuous per formance range shown on the curve. MAINTENANCE & REPAIR PA G E E - 1

135 OM S E R I E S S ECTION DRAWING Figure 1. Pump Models 02K3- X 2 1P PA G E E - 2 MAINTENANCE & REPAIR

136 0 S E R I E S OM PA R T S L I ST Pump Models 02K3- X 2 1P (From S/N Up) If your pump serial number is followed by an N, your pump is NOT a standard production model. Contact the Gorman Rupp Company to verify part numbers. ITEM PART MAT'L u NO. PART NAME NUMBER CODE QTY 1 PUMP CASING See Note Below 2 IMPELLER MECHANICAL SEAL u 4 FILL PLUG ASSY RD HD MACH SCREW X RD HD MACH SCREW X CASING GASKET 2958GB u 8 STUD C HEX NUT D INTERMEDIATE BRACKET 6367C STUD C HEX NUT D LOCK WASHER J PHASE MOTOR M REDUCER COUPLING AE PIPE NIPPLE THA CONDUIT BOX IMPELLER ADJUSTING SHIM SET u 19 CASING DRAIN PLUG P VANE PLATE u 21 PIPE PLUG P IMPELLER JAM NUT AT07S NAME PLATE DRIVE SCREW BM# VANE PLATE O RING S NOT SHOWN: G R DECAL WARNING DECAL ROTATION DECAL INSTRUCTION TAG SUCTION STICKER PRIMING STICKER DISCHARGE STICKER GR FF 2613M AG 6588AH 6588BJ u INDICATES PARTS RECOMMENDED FOR STOCK INCLUDED WITH REPAIR PUMP CASING ASSY MAINTENANCE & REPAIR PA G E E - 3

137 OM S E R I E S PUMP AND S E A L D I SA S S E M B LY AND R E A S S E M B LY Review all S A F E T Y information in Section A. Follow the instructions on all tags, label and decals attached to the pump. This pump requires little service due to its rugged, minimum maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional view (see Figure 1) and the accompa nying parts list. This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices. Before attempting to service the pump, disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inoperative. Close all valves in the suction and discharge lines. For motor disassembly and repair, consult the liter ature supplied with the motor, or contact your local motor representative. 3. Allow the pump to completely cool if overheated. 4. Check the temperature before opening any covers, plates, or plugs. 5. Close the suction and discharge valves. 6. Vent the pump slowly and cau tiously. 7. Drain the pump. Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. Be certain proper safety practices are followed before operating or servicing the pump. Provide adequate ventilation, prohibit smoking, wear static resistant clothing and shoes. Clean up all fuel spills immediately after occurrence. Pump Disassembly Before attempting to service the pump, remove the pump casing drain plug (19) and drain the pump. Clean and reinstall the drain plug. To service the impeller (2), seal assembly (3), or va ne plate (20), the pump housing (1) must be sepa rated from the intermediate (10). Before attempting to open or service the pump: 1. Familiarize yourself with this man ual. 2. Disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inopera tive. Remove the suction and discharge lines. Remove the nuts (9) and use a suitable hoist and sling to separate the pump casing and gasket (7) from the intermediate. Remove the vane plate O ring (25). Use lifting and moving equipment in good repair and with adequate capacity to prevent injuries to personnel or dam age to equipment. Suction and dis PA G E E - 4 MAINTENANCE & REPAIR

138 0 S E R I E S OM charge hoses and piping must be re moved from the pump before lifting. Impeller Removal For access to the impeller (2), disengage the screws (5 and 6) and remove the vane plate (20). Immobilize the impeller by inserting a bar between the impeller vanes, being careful not to damage the vanes. Disengage the impeller nut (22). Immobilize the motor shaft by inserting a large flat head screwdriver into the slot in the end of the shaft in the front end of the motor. Unscrew the impeller from the shaft. Use caution when removing the impeller; tension on the seal spring will be released as the impeller is removed. Remove the impeller adjusting shims (18). Tie and tag the shims or measure and record their thick ness for ease of reassembly. Seal Removal and Disassembly Remove the spring retainer and spring. Apply oil to the shaft and work it up under the rubber bellows. Slide the rotating portion of the seal off the shaft. Remove the hardware (12 and 13) securing the in termediate (10) to the motor (14). Slide the inter mediate off the shaft and use a suitably sized dowel to press the seal stationary element and seat out of the intermediate from the back side. Seal Reassembly and Installation Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent. Most cleaning solvents are toxic and flammable. Us e them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers. The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emer gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly. Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non oil based solvent and a clean, lint free tissue. Wipe lightly in a concentric pattern to avoid scratching the faces. Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. If any components are worn, replace the com plete seal; never mix old and new seal parts. If a replacement seal is being used, remove it from the container and inspect the precision finished faces to ensure that they are free of any foreign matter. To ease installation of the seal, lubricate the bel lows with water or a very small amount of light lu bricating oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows (see Figure 2). MAINTENANCE & REPAIR PA G E E - 5

139 OM S E R I E S S P R I N G RETAINER S E A L PLATE I M P ELLER IMPELLER SHIMS S TATIONARY ELEMEN T IMPELLER S H A F T B E L LOWS SPRING RETAINER DRIVE BAND ROTATING ELEMEN T S TATIONARY SEA T Figure 2. This seal is not designed for operation at temperatures above 160 F (71 C). Do not use at higher operating temperatures. Seal Assembly Subassemble the rotating element into the retainer and bellows. Lubricate the I.D. of the bellows with water and slide this subassembly onto the shaft until the polished faces contact. Install the seal spring and spring retainer. Impeller Installation Lay the intermediate (10) on a flat surface with the impeller side facing up. Subassemble the station ary element into the stationary seat and use even pressure to press this subassembly into the inter mediate until it seats squarely against the shoulder bore. Carefully slide the assembled intermediate and stationary portion of the seal over the motor shaft. Secure the intermediate to the motor with the hard ware (12 and 13). Inspect the impeller and replace it if cracked or badly worn. For maximum pump efficiency, the impeller should be centered within the vane plate scroll. To verify the impeller positioning, measure the vane plate and impeller as shown in Figure 3. Use these measurements to calculate the required im peller location (dimension E). Add or remove im peller adjusting shims (18) until dimension E is ob tained. PA G E E - 6 MAINTENANCE & REPAIR

140 0 S E R I E S OM C D D 2 A B 2 B E Step 1 Step 2 Step 3 A + B - C + D 2 2 = E Figure 3. Centering Impeller Within Vane Plate Scroll Install the correct thickness of impeller shims (18) and screw the impeller onto the shaft until fully seated. Apply Loctite Threadlocker No. 242 or equivalent compound to the impeller shaft threads. Immobi lize the motor shaft by inserting a large flat head screwdriver into the slot in the end of the shaft in the front end of the motor. Secure the impeller with the impeller jam nut (22). Torque the nut to 15 ft. lbs. (180 in lbs. or 2,07 m. kg.). Pump Reassembly Install the vane plate O ring (25) onto the vane plate shoulder. Install the casing gasket (7). Ease the pump casing over the vane plate. Be careful not to damage the O ring. Secure the casing to the intermediate bracket with the nuts (9). Final Pump Assembly Install the suction and discharge lines and open all valves. Make certain that all piping connections are tight, properly supported and secure. Clean all of the old adhesive from the vane plate and its mating surface on the intermediate. Apply a thin film of 3M Gasket Adhesive No. 847 or equiv alent compound to the vane plate and secure the vane plate to the intermediate bracket using the machine screws (5 and 6). Fill the pump casing with clean liquid. Reinstall the fill plug (4) and tighten it. Refer to O P ER ATION, Section C, before putting the pump back into service. LUBRICATION NOT E After the vane plate has been installed, check for free shaft rotation. Correct any scraping binding before further reassembly. Seal Assembly The seal assembly is lubricated by the medium be ing pumped and no additional lubrication is re quired. MAINTENANCE & REPAIR PA G E E - 7

141 Bennett Pump Company SB-100 Meters Operation, Service & Parts Manual Only Trained Personnel May Work on This Equipment For more information, please contact: Jim Biesecker, Component Sales 1218 E. Pontaluna Road Spring Lake, Michigan USA Tel: (USA) Tel: (International) Tel: (Sales) Fax: Read this Book For new books, visit out web page at: For Part Pricing, please visit the parts pricing section under the Literature Tab on our website Rev A Bennett 1218 E. Pontaluna Road, Spring Lake, MI USA ~ Outside USA sales@bennettpump.com ~

142 Table of Contents Introduction 3 Technical Specifications 3 Dimensions & Mounting 4 Theory of Operation 5 General Description 6 Features & Construction 6 Basic Concept 7 Accuracy & Calibration 8 Troubleshooting & Repair 9 Parts List Rev A

143 Introduction The SB-100 meter is the standard product for Bennett Dispensers. It can drive mechanical and electronic computers at any flow used in a basic gasoline dispenser. The SB-100 meter is a precision device built to maintain.3% accuracy for flow rates from 1.5 GPM (5 LPM) to 26 GPM (100 LPM). The SB-100 is a volumetric meter employing four pistons with seals and associated chambers. During the first year of use, the SB-100 meter's calibration should be checked upon installation, after 90 days and after 180 days in order to insure accurate measurement. After the break-in period, semi-annual calibration checks are all that is required. It is a compact, lightweight unit built with the following main objectives: Excellent accuracy over a wide range of flows Approvals: USA - Weights & Measures, Underwriters Laboratories Canada - Weights & Measures, CSA Europe - OIML (International Organization for Legal Metrology) as a component in an approved system Very good durability of performance and life up to 2 million gallons (7,500,000 liters) under laboratory conditions Flexible mounting capability for layout in the dispenser: several product outlet positions Minimal numbers of internal components to assemble or repair Concept takes care of potential requirements for a meter: Adaptable to temperature compensation system Electronic calibration available Compatible with alternate fuels with up to 15% additives. Models available for higher fuel blends, contact factory for details. The positive displacement meter uses the general principle of four horizontal, single effect pistons equipped with "cup seals" moving in stainless steel sleeved cylinders and driving a vertical crankshaft. The crankshaft also of stainless steel is fitted with stainless steel connecting rod rollers and self lubricated bearings throughout for minimum friction and maximum corrosion resistance. The patented SB-100 meter, patent number , is compatible with the Bennett T-75 Pumping Unit and is used in all of our electronic and mechanical dispensers sold worldwide and offers advanced features. At Bennett we consider the meter the key to accurate product measurement and the fundamental source of information for the marketer s inventory systems. The SB-100 is designed to provide years of accurate and reliable service starting with the first liter! Technical Specifications Volume per Revolution 0.5 liter gallon Outlet Shaft Diameter 10 mm in. Rotation Direction of Outlet Shaft (Top View Clockwise External Dimensions Horizontal 200x220 mm 197 mm 7.87x8.66 in in. Vertical (Including Drive) Cylinder Diameter 72.4 mm 2.85 in. Crankshaft Eccentricity mm in. Stroke (Pistons 1 & 4) Adjustable Between And Rev A mm mm in in. Minimum Mechanical Adjusting Device Increment 0.05% 0.05% Working Pressure 3.5 Bars 50 PSI Flow Rate Capacity Within +/- 0.3% Accuracy Minimum Flow Maximum Flow (Objective) 5 lpm 100 lpm 1.3 gpm 26.4 gpm

144 Dimensions & Mounting 7.75 in. (197 mm) 7.75 in. (197 mm) WEIGHT: 4.7 kg (10 lbs) Electronic Calibration Mechanical Calibration Top View - Electronic Top View -Mechanical Side View - Mechanical Bottom View - Electronic Bottom View - Mechanical Back View Mechanical or Electronic Front/Side View - Electronic Rev A Front View -Mechanical

145 Theory of Operation The meter body (1) is cast aluminum with a gasketed flange at the base for rigid mounting with other components using four to six screws. The cylinder covers (2,3) are also cast aluminum with an O-ring seal and each is secured to the body by four screws. The calibrator cover (3) has a threaded shaft extending through it that limits the piston stroke to effect calibration. The shaft is sealed with an O-ring (NOTE: Electronic calibration meters do not have the calibrator cover (3). Fastened to the top of the meter body is a cast aluminum collector housing (4), which can be assembled in several outlet positions. An O- ring and four screws make the seal and connection. Extending through the top of the collector is the output of the crankshaft which is sealed against leakage by a lip seal (5) held in place by a retainer (6) and three screws. (Refer to Figure for numbers in parenthesis). Mechanical Meter Shown. PRODUCT OUTLET PRODUCT INLET Rev A

146 Features and Constructions The meter is a positive displacement, four piston device featuring a rotary distributor valve and "cup seal" pistons. Because of these features the meter shows superior accuracy and repeatability by eliminating internal product slippage. The composition of the "cup seal" piston is such as to provide long life and low calibration drift. The SB-100 Meter features improved linearity allowing the calibration to remain within tolerance from 1.3 gpm (5 Ipm) flow rate to 27 gpm (100 Ipm). Mechanical Calibration has been simplified by placing the calibration dial wheel on the piston cover face, out where it is easily accessible. The minimum mechanical adjustment is 0.05%. calibration Currently the standard SB-100 Meter is compatible with methanol/gasoline mixtures to 15% methanol. The SB-100 can be manufactured of materials which are compatible with M85 and 100% methanol. The SB-100 is fully compatible with MTBE (methyl tertiary butyl ether) additives to 15% concentrations. The SB-100 weighs only 10 pounds (4.7 kg) making service, installation and handling very easy. The SB-100 Meter is the result of seven years of product development Rev A

147 Basic Concept The liquid to be measured enters the bottom part of the meter body (1) and pressure seals the rotating distributor (2) down on its mating surface through a diaphragm (3) and a countervalve (3). The pressure differential on the two sides of pistons 1 and 2 pulls the connecting rods (4) and makes the crankshaft (5) turn clockwise (top view). The crankshaft drives the distributor which changes the distribution of liquid; piston 2 and 3 become active, then 3 and 4 and finally 4 and 1 before the cycle starts again. Each cylinder is closed with cover (6), one of them being fitted with a calibrating device (7 mechanical only) that allows adjustment of the stroke of the corresponding piston to get the exact value of the volume per revolution dispensed by the meter. The crankshaft and connecting rods are supported by self lubricating bearings to minimize the wear and make the moving parts run smoothly. The crankshaft may drive a mechanical computer or an electronic pulser that can be fixed directly to the collector (8) which forms the upper part of the meter Rev A

148 Tenths of 1% Deviation Accuracy & Calibration The accompanying Meter Accuracy Curve is typical of the SB-100; 0.3% accuracy from 1.3 gpm (5 lpm) to 27 gpm (100 lpm). Calibration is achieved by adjustment of the dial and screw assembly on the cover attached to cylinder No. 1. A clockwise adjustment decreases delivery while counterclockwise increases delivery. Total adjustment is +/- 15 cubic inches (+/- 240 ml) in minimum increments of 0.05%. Once the meter is adjusted to zero, a pin is inserted through the dial and into the cover and wire sealed through a cross drilled hole in the pin. See Figure Based on metering gasoline with an approximate viscosity of 30 SSU Flow Rate (gpm) Typical Meter Accuracy Curve Figure Rev A

149 Troubleshooting & Repair Problem Cause Solution 1. Over delivery and out of tolerance difference between fast and slow delivery. A. Dirty or gummed pistons and/ or piston chambers. B. Damage or worn piston seals. A. Remove cylinder covers. Remove screw holding piston to connecting rod. Using vise grips, secure the center hub of the piston and pull straight out. Clean piston seal and piston chamber using mineral spirits. Reassembly in reverse order. B. Replace all Pistons. Use piston repair kit KR Leakage at the output shaft. A. Top lip seal is damaged. A. Replace top lip seal s 3. Large over delivery amount. A. Damaged distributor and/or diaphragm. A. Use distributor/diaphragm kit KR Figure Rev A

150 SB100 Mechanical Meter Rev A

151 SB100 Electronic Meter Rev A

152 SB100 Meter Parts List Item Part Number Description Comment 1 N/A Lead Seal Wire Please Call for details 2 N/A Universal Link Please Call for details 3 H Half Coupling Unthreaded See Kit List 4 H Half Coupling Threaded 5 H Screw 6 A Screw, Flat Head M X 8 mm 7 N Shaft Seal Retainer S Shaft Seal 9 A Screw, Hex Head M6-1.0 X 20 mm 9 N Screw, Hex Head M6-1.0 X 20 mm with Seal Hole 10 A O-Ring, Square Section 11 N Collector Cover High Alcohol Collector Cover 12 A O-Ring, Square Section 13 N Gasket Spring 15 A Screw, Fil Head M4-0.7 X 10 mm Stainless Steel 16 N Inner Diaphragm Retainer Diaphragm 18 N Gasket 19 N Counter Valve Counter Valve Assembly 21 N Outer Diaphragm Retainer 22 A Screw, Pan Head M5-0.8 X 12 mm Collector Cover Assembly High Alcohol Collector Cover Assembly 24 N Drive Pin 25 N Distributor 26 A Retaining Ring 27 A Washer Crankshaft Support Meter Body Assembly High Alcohol Meter Body Assembly 29 N Roller & Bearing Assembly 30 A Washer 31 A Lock Nut 32 N Crank Shaft Assembly Gallons 32 N Crank Shaft Assembly Liters Pin Cylinder Cover Gallons Pin Cylinder Cover Liters Pin Cylinder Cover High Alcohol Gallons Pin Cylinder Cover High Alcohol Liters 33 N Cylinder Cover (Non Pin) 34 A O-Ring, Square Section 35 N Piston Screw, Hex Head With Nylon Patch (also use with High Alcohol) 36 N Piston Assembly High Alcohol Piston Assembly 38 N Connecting Rod 39 A Retaining Ring 40 N Calibrating Cover High Alcohol Calibrating Cover O-Ring 42 N Calibrating Dial & Screw Assembly 43 N Seal Pin 44 N Calibration Cover Assembly Calibration Cover Assembly High Alcohol Gasket, Meter Inlet Not Shown 46 N902401S Valve Plate Not Shown 47 A Screw, Valve Plate Not Shown 48 A DU Bearing, Meter Body Not Shown, for meters built since N DU Bearing and Retainer, Meter Body Not Shown, for meters built before Rev A

153 Kit List Part Number Description Comment Kit, SB100, V'Plate/C'Valve Replacement Includes 1 each of items 8, 10, 12, 13, 14, 20, 25 & 46 KR Kit, SB-100 Piston Retail, 4 Per Includes 4 of items 34, 35, & 36, 1 each of 10 & Kit, SB-100 Piston Retail, Alcohol Meters Includes 4 of items 34, 35, & 36, 1 each of 10 & Kit, Crankshaft Bearing Replacement Includes 2 of item 29, 1 ea. of 10, 31 & Kit, Lower Hydraulic Gallon SB-100 Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & Kit Lower Hydraulic Gallon SB-100 Alcohol Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & Kit Lower Hydraulic Liter SB-100 Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & Kit Lower Hydraulic Liter SB-100 Alcohol Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & 48 KR Kit, SB-100 Diaphragm/Distributor Includes 4 of item 15, 1 ea. of 8, 10, 12, 13, 14, 17, 25 & Kit, SB-100 Meter Coupling Includes items 3, 4 & Kit, Tools for Du Bearing Replacement Field Du Bearing Install/Removal Tool Kit, Meter Gallon Pin Covers M-Calibration Includes 3 of items 33 & 34, 2 ea. of 29, 1 ea. of 10, 8, 38, 48, Kit, Meter Gallon Pin Covers E-Calibration Includes 4 of items 33 & 34, 2 ea. of 29, 38, 1 ea. of 10, 8, 45, Kit, Meter Liter Pin Covers M-Calibration Includes 3 of items 33 & 34, 2 ea. of 29, 1 ea. of 10, 8, 38, 48, Kit, Meter Liter Pin Covers E-Calibration Includes 4 of items 33 & 34, 2 ea. of 29, 38, 1 ea. of 10, 8, 45, 48 These two kits are for SB100 meters built since 1995 KR Kit, SB-100 Meter, Crankshaft, Gallons Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 48 KR Kit, SB-100 Meter, Crankshaft, Liters Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 48 These two kits are for SB100 meters built before 1995 KR Kit, SB-100 Meter, Crankshaft, Gallons Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 49 KR Kit, SB-100 Meter, Crankshaft, Liters Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & Rev A

154 Rev A Bennett 1218 E. Pontaluna Road, Spring Lake, MI USA ~ Outside USA sales@bennettpump.com ~

155 Bennett Pump Company T-75 Hydraulic Pumping Units Operation, Service & Parts Manual Only Trained Personnel May Work on This Equipment For more information, please contact: Jim Biesecker, Component Sales 1218 E. Pontaluna Road Spring Lake, Michigan USA Tel: (USA) Tel: (International) Tel: (Tech Support - USA) Tel: (Sales) Fax: techhelp@bennettpump.com sales@bennettpump.com jbiesecker@bennettpump.com Read this Book For new books, visit out web page at: For Part Pricing, please visit the parts pricing section under the Literature Tab on our website Rev D 02/21/11 Bennett 1218 E. Pontaluna Road, Spring Lake, MI USA ~ Outside USA sales@bennettpump.com ~

156 Table of Contents Introduction 4 Specification Sheet 5 Technical Specifications 6 Pump Curve U.S. Market 7 Pump Curve European Market 8 Overall Dimensions 9 Theory of Operations 11 Hydraulic Schematics & Principle 13 How to Correct Problems on Pumping Units 15 Parts List 18 Appendices A. European Approval 22 B. European Approval 25 C. Dimensions and Mounting 29 D. Installation Piping for Type 75 Pump Dispenser Rev D 02/21/11

157 Introduction The Type 75 pumping unit is the standard product produced by Bennett Pump Company. many countries and has proven its ability to work properly even in the toughest conditions. It is used in It is a compact, lightweight unit built with the following functions: Filtering Pumping Air elimination By-Pass (adjustable as an option) Outlet Control Valve The same unit is used to achieve the two standard flows of 13 gpm (3m 3 /h) or 22 gpm (5m 3 /h). feature is achieved by: This U.S. Market 60Hz power: Using two sizes of pump chamber initially assembled into the housing. The 13 gpm pump requires a 250 Watt 1/3 hp motor, the 22 gpm pump uses a 560 Watt 3/4 hp motor. Europeon Market 50Hz power: Running the 22 gpm pump at different speeds, just by changing the pump pulley This unit uses a rotary vane pump with carbon blades that produces very good suction (power) even when the pump is dry (at start). The rotor is supported at each end by self lubricated insert bearings that are field replaceable. Air elimination is achieved within extreme standards through a patented fully static device using a vortex effect. Filtration is achieved with three different filter means (10 micron cloth filter, 35 micron pleated paper filter and 70 micron Nylon strainer), according to the conditions of use. The T-75 Pumping Unit is fully compatible with the SB-100 Meter. For further information, please contact the Bennett Technical Service Department at Rev D 02/21/11

158 Specification Sheet Standard Fuels (up to 15% alcohol) or Alcohol Fuels (E85 typical) Standard Flow (13 GPM) or High Flow (22 GPM) Ultra High (50 psi), High Pressure (45 psi), Normal Pressure (35 psi) or Low Pressure (25 psi) By-Pass Valve Spring (nominal pressures w/adjustable bypass screwed in) Adjustable or Non-Adjustable By-Pass Valve Settings Low Pressure (4.3 psi) or Standard Pressure (6 psi) Control Valve Spring Meter Outlet Flange or Tube Style Outlet W/Tube outlet - offer a Motor Mount Option on Atmospheric Cover 100 or 70 Micron Metal Strainer Basket or 35 Micron Paper Element Filter with or without Fabric Integral Inlet check valve Rev D 02/21/11

159 Technical Specifications U.S. Market Maximum Flow (gpm) Noise Level (db) Bypass Pressure (psi) Motor Power (hp) 1/3 3/4 Minimum Dry Suction (in. Hg) Minimum Wet Suction (in. Hg) Air Elimination According to OIML, CEE Regulation Micron Filter (µ) 10,35,70 according to conditions of use Pump Curve See Figure 1 See Figure 2 Technical Specifications European Market Maximum Flow (m 3 /h) 3 5 Minimum Flow (m 3 /h) Noise Level (db) Bypass Pressure (b) 1.8 (Adjustable ) 2.0 (Adjustable ) Motor Power (Kw) Minimum Dry Suction (mb Hg) 450 Minimum Wet Suction (mb Hg) 700 Air Elimination According to OIML, CEE Regulation Micron Filter (µ) 10,35,70 according to conditions of use Pump Curve See Figure 3 Approval Documents (See Appendices Ministère de I Industrie et du Commerce - FRANCE # (July 1, 1985) # (Dec. 31, 1987) Rev D 02/21/11

160 Pump Pressure (psi) Pump Pressure (psi) Pump Curves U.S. Market Pump Speed 700 rpm Test Conditions: Tested on Stoddard Solvent * 30 SSU Viscosity * 0.78 Specific Gravity inches Hg operating vacuum 3. Fixed bypass cover Flow Rate (gpm) T-75 Pump (1/3 hp) Performance U.S. Market Figure Pump Speed 700 rpm Test Conditions: 1. Tested on Stoddard Solvent * 30 SSU Viscosity * 0.78 Specific Gravity inches Hg operating vacuum 3. Fixed bypass cover Flow Rate (gpm) T-75 Pump (3/4 hp) Performance U.S. Market Figure Rev D 02/21/11

161 Pump Pressure (bars) Pump Curves European Market Note: Adjustable bypass can vary pump pressures from posted curve values by +/- 20 % from 0 to 80% of fast flow Pump Speed 700 rpm 0.55 Kw motor Pump Speed 450 rpm 0.37 Kw motor Tes t Conditions: 1. Tested on Stoddard Solvent * 30 SSU Viscosity * 0.78 Specific Gravity mb Hg operating vacuum Flow Rate (lpm) T-75 Pump Performance European Market Pa g e 15 Figure Rev D 02/21/11

162 Overall Dimensions T75 with Meter Outlet Top View 2.69 Back View Side View Front View 0: :[40mm] Bottom View Rev D 02/21/11

163 Overall Dimensions T75 with Tube Outlet Top View 2.69 Back View Side View Front View 0: :[40mm] Bottom View Rev D 02/21/11

164 Theory of Operation Detailed Description Figure Rev D 02/21/11

165 Theory of Operation The pump assembly has the following main components: (See Figure 7 for numbers in parenthesis.) a body (1) of cast aluminum The inlet is designed to accept a triangular inlet flange with a 3-hole bolt pattern. a cover (2) outlet flanged for direct meter mounting tubular outlet for remote meter mounting (as shown on page 6) a filter (3) in the horizontal position. The filter cover includes a pipe plug to drain the pump. An optional inlet checkvalve (19) is available to hold product in the suction line when the pump is turned off. This is an environmentally friendly device that maintains a vacuum in the line preventing fuel from leaking through a loose joint into the ground. a rotating pump (4) with radial carbon blades Throwout rings (5) maintain contact of the blades to the stator. The stator (6) is made of cast iron and is tightly fitted in the pump body. The rotor (7) is made of cast iron with a chrome plated shaft. Self lubricated bearings (21) prevent seizure when tank is pumped dry. The cover (8), also of cast iron, encapsulates the rotor and the stator. an air elimination assembly (9), a patented fully static device, uses a vortex effect. The insert (10) starts spinning the fluid. The foam and the air pass through the tube (11) and evacuated through the orifice (12). a drain line eliminator (13) or atmospheric chamber of 1.2 gallon (4.5 liter) capacity. The float valve assembly (14) provides for the recovery of liquid from the chamber, while air is evacuated through the vent tube (15). A non return float (20) seals the atmospheric chamber when the pump is turned off to prevent flooding and spilling out onto the driveway. a bypass valve (16) limiting the maximum working pressure. its cover includes a device to adjust the bypass pressure (optional in USA) a control valve assembly (17) assures that all downstream hydraulic components are filled with liquid. This valve has a relief valve (18) to relieve excess pressure. NOTE: A diaphragm operated preset valve is available as an option Rev D 02/21/11

166 Hydraulic Schematics & Principle Figure 8 Figure Rev D 02/21/11

167 (See Figure 8 for numbers in parenthesis.) Hydraulic Schematics & Principle The product is drawn from the underground storage tank through the strainer screen of filter (1). The rotary van pumping unit (2) pressurizes the fluid. Product enters the centrifugal air separator assembly (3). Any air present is forced out the air tube along with a small amount of liquid into the atmospheric chamber (4). Product collected in the atmospheric chamber is returned to the pump intake across the non return float when the liquid level in the chamber lifts the float and valve assembly from its seat (5). Any air is then vented to the atmosphere through the vent tube. Air free product leaving the air separator opens the control valve (6) and is pumped to the meter. The control valve includes a built-in relief valve (7) which relieves excess pressure caused by hot weather expansion. Product passes through the meter where it is accurately measured, then through the hose and nozzle into the vehicle being fueled. Whenever the nozzle is not fully opened, some liquid is relieved into the pump intake through the bypass valve (8) Rev D 02/21/11

168 How to Correct Problems on Pumping Units Problem Cause Action 1. The motor starts but the pump does not deliver fuel. a. The fuel supply is below the suction stub in the storage tank. a. Fill the storage tank. b. The vent pipe is plugged in the storage tank. c. The strainer screen or filter assembly has an obstruction. d. The bypass valve is not seating properly due to wear or obstruction. b. Clean the vent pipe. c. Remove obstructions from the screen or filter assembly. d. Check the valve for an obstruction causing the valve to stay open, and/or replace the bypass valve. e. The v-belt is loose or broken. e. Adjust or replace the v-belt. f. There is an obstruction in the atmospheric float valve. g. The pump is out of prime. All fuel drained out of suction line due o fault line check or foot valve. f. Clean the float and valve area. Check for swelling and binding in the linkage. g. Check for a faulty foot valve in the storage tank or a faulty check valve in the suction line. h. The suction line is leaking. h. Start the pump and open the nozzle. If bursts of air are felt while holding a finger on the vent tube, the suction line is damaged. Repair or replace. i. The intake line, foot valve, angle check valve, or vertical check valve have an obstruction. j. The suction stub in the storage tank is on the bottom of the tank. k. The control valve has an obstruction. i. Connect a vacuum gauge to the 1/4 plug on the filter cover. Turn the pump on and open the nozzle. A reading of 15 or more inches of mercury with no flow indicates a complete blockage in the suction line. Clean the line or replace. j. Make sure there is a three inch clearance. k. Clean the control valve. It must slide freely in the valve cavity. l. The nozzle is not working. l. Replace the nozzle. m. *Two pumps are connected to one storage tank with one suction line. There is a faulty check valve in one of the supply lines. *Not recommended. m. Disconnect the vent tube on the idle pump. Install a short copper tube. Place the end of the copper tube in a container of liquid. If the liquid is drawn out of the container when the opposite pump is operated with an open nozzle, the line check valve is faulty. Replace the check valve Rev D 02/21/11

169 How to Correct Problems on Pumping Units Problem Cause Action 2. The pump runs, but delivery is slow. a. The fuel supply level is low. a. Fill the storage tank. b. The storage tank vent pipe is partially obstructed. c. The strainer screen is partially plugged. d. The pump bypass valve is not seated properly. b. Clean the vent pipe. c. Remove obstructions from the screen or filter assembly. d. Remove and clean the strainer screen. e. The v-belt is loose. e. Adjust the v-belt. f. The motor voltage is too low. f. Check the power supply voltage. Check for too many pieces of equipment on one electrical line. g. A blade or blades in the pump are worn or broken. h. An automatic nozzle has been installed. g. Check the blades and replace if necessary. h. Delivery speed will be reduced by 10-25%. If maximum speed is desired, replace with a manual nozzle. i. The motor is defective. i. Inspect the motor for loose connections. If no loose connections are found, the motor is defective. Repair or replace. j. There is a slow leak in the suction line. k. The suction line is obstructed or the foot valve, angle or vertical check valve is partially stuck and will not open fully. l. The pump control valve is partially stuck and will not open fully. m. The nozzle check valve is sticking. n. The hose is defective (flattened). j. Start the pump and open the nozzle. If bursts of air are felt while holding a finger on the vent tube, the suction line is damaged. Repair or replace. k. Connect a vacuum gauge to the 1/4 plug on the filter cover. Turn the pump on and open the nozzle. A reading of 11 to 13 inches of mercury indicates a partial obstruction in the suction line. Clean or replace the suction line components. l. Remove the valve and clean thoroughly. m. Clean or replace the nozzle check valve. n. Replace the hose Rev D 02/21/11

170 How to Correct Problems on Pumping Units Problem Cause Action 3. Inaccurate Delivery. a. Control valve stuck open. a. Remove 4-bolt control valve cover and free control valve. b. Vent tube from air eliminator to atmosphere plugged. b. Clear any obstructions. 4. Fuel Runs out Vent Tube When Pump is Operating. 5. The computer jumps when the pump is turned on. a. Float valve stuck in a closed position. b. Flooded suction chamber. Directional flow valve missing. a. Control valve not seated properly. b. Expansion relief Dill valve in control valve stuck open. a. Clean the float and valve area. Check for swelling and binding in the linkage. b. Storage tank level must be lower than pumping unit. Make sure 2 or more pumps are not using same suction line. a. Remove valve cover & inspect for dirt or nicks in O- ring. b. Remove and inspect for foreign matter. Pull spring loaded seat for better view. Reinstall Rev D 02/21/11

171 Type 75 Pumping Unit Rev D 02/21/11

172 Type 75 Pumping Unit Parts List Item Part Number Description Comment 1 A Bolt M X 25 mm (Use N for Seal Wire Bolt) 2 N Meter Inlet Adaptor With Tap Meter Inlet Adaptor High Alcohol 3 N Gasket, Meter Inlet Adaptor Housing, Air Valve Float Assembly Gasket Float Retainer Ring ID Tag 12 N Cover, Atmospheric Chamber Meter Mount Style Cover, Atmospheric Chamber Meter Mount Style - High Alcohol 13 N Cover, Atmospheric Chamber Pipe Outlet with Motor Mount Ears Cover, Atmospheric Chamber Pipe Outlet with Motor Mount Ears - High Alcohol Cover, Atmospheric Chamber GPU Cover, Atmospheric Chamber GPU - High Alcohol 17 N Gasket - Atmospheric Cover 18 A Bolt - Round Head M6-0.7 X 20 mm 19 N Non-Reversing Float O-Ring #O17 Also used with High Alcohol Atmospheric Float Assembly 22 N Gasket - Atmospheric Cover One Piece Air Separator Body High Alcohol One Piece Air Separator Body 24 N Gasket, Inlet Separator 25 N Gasket, Outlet Separator 26 N Insert - Air Separator Inlet Tube - Air Separator Piston OIML Only Spring End Cap 31 N Tube - Air Separator Screw - Air Test Valve Adaptor - Air Test Valve Pipe Plug 1/4-18NPT 35 N Cover, Control Valve High Alcohol Cover, Control Valve 36 N Gasket 37 E Spring Standard Delivery Pump 12 GPM J Spring Heavy Duty Delivery Pump 22 GPM Control Valve Assembly Aluminum Body Version with Hard Coat 39 A Pressure Relief Valve O-Ring #210 Also used with High Alcohol 41 N Pump Body High Alcohol Pump Body N Pump Body Side Inlet Version Pump Body Side Inlet High Alcohol 42 N Filter Insert Strainer Standard Production A Filter Paper Filter 35 Micron Strainer Special - Used with Sack N Cloth Sack 10 Micron Rev D 02/21/11

173 Type 75 Pumping Unit Parts List Item Part Number Description Comment 44 N Filter Spring 45 N Gasket 46 N Filter Cover High Alcohol Filter Cover 47 N Bypass Cover Bypass Cover Non-Adjustable High Alcohol 48 N Gasket 49 N N N Bypass Valve Bypass Valve Bypass Valve Standard - Silver Spring Low Pressure Standard - Green Spring Medium Pressure Standard - Copper Spring High Pressure O-Ring #229 Also used with High Alcohol 51 A Cap Nut 52 A Seal Ring 53 N Disc 54 N Adaptor Not Sold Separately - See Item #60 55 A Retaining Ring 56 N Check Valve Body 57 N Spring 58 N Washer 59 N Shaft 60 N KR Check Valve Assembly Check Valve Assembly With out Ring Includes Item #50 & Item #60 61 N Cap 62 N Adjustment Screw 63 A Washer 64 N Cover - Adjustable Bypass 65 A Screw M X 20 mm 66 A Lock Washer 67 A Flat Washer 68 N Pulley - Single Groove Pulley - Dual Groove 69 N Clamping Ring 70 N Gasket 71 J Rotor Cover Assembly 72 A Flat Head Screw 73 H Shaft Seal Retainer 74 A Shaft Seal (with insertion tool) Shaft Seal Kit - Includes #74 & 75 with install plug 75 A Square Seal 76 N Rotor Cover 77 N N Throw Out Ring Throw Out Ring Standard Delivery Pump Heavy Duty Pump 78 A Woodruff Key 79 A Retaining Ring 80 N *KR0420xx Rotor & Shaft Assembly *Rotor Replacement Kit Standard 6 Blade Rotor Includes #70, 74, 75, (2) 77, 80, (6) 81 xx= 01 Std Delivery 02 Heavy Duty Rotor Blade 82 N N Stator Stator Standard Delivery Pump Heavy Duty Pump KR Gasket Set for Pumping Unit Complete Set of Gaskets, Seals, and O-Rings for P/U Rev D 02/21/11

174 Appendix A BULLETIN OFFICIEL DES INSTRUMENTS DE MESURE CERTIFICAT D'APPROBATION C.E.E. DE MODELES n du 31 décembre 1987 modifiant le certificat C.E.E. n du fer juillet 1985 (f) Groupes de pompage el de dégazage SATAM modèles EPZ 75/3 et EPZ 75/5 Le présent certificat est établi en application de la directive 71/316/CEE du 26 juillet 1971, modifiée par la directive 83/575/CEE du 26 octobre 1983, relative aux dispositions communes aux instruments de mesurage et aux méthodes de contrôle métrologique, de la directive 71/319/CEE du 5 juillet 1971, relative aux coupleurs de liquides autres que l eau el de la directive 77/313/CEE du 5 avril 1977, modifiée par la directive 82/625/CEE du l'er juillet 1982, relative aux ensembles de mesurage de liquides autres que l eau. Du décret n du 4 août 1973, modifié par le décret n du 6 décembre 1984, portant application des prescriptions de la Communauté économique européenne relatives aux dispositions communes aux instruments de mesurage et aux méthodes de contrôle métrologique et du décret n du 4 août 1973 relatif a l'application des prescriptions de la Communauté économique européenne au contrôle des compteurs volumétriques de liquides autres que l eau et de leurs dispositifs complémentaires. Fabricant: SATAM Industries, 63, Avenue du General. Leclerc, B.P La Courneuve. Paris, France. Objet: Le présent certificat CEE modifie le certificat CEE n du l'er juillet 1985 (1). Caractéristiques: Les groupes de pompage et de dégazage SATAM, modèles EPZ 75/3 et EPZ 75/5, faisant l objet du présent certificat CEE différent des modèles approuvés par le certificat CEE précité par: Le remplacement sure le couvercle des groupes de pompage et de dégazage d un clapet tare par un orifice protège par une bride rivetée : cet orifice assure l'évacuation des vapeurs et des gaz de la cuve de purge dans le cas ou le tube de mise a l'atmosphère est obstrue. La modification du groupe de pompage du modèle EPZ 75/3 : il est identique a celui du modèle EPZ 75/5 mais la vitesse de rotation de l axe des palettes dans la chambre d aspiration est réduite. La pression maximale de fonctionnement, identique pour les deux modèles, est égale à 2 bar. Les autres caractéristiques, les indications complémentaires, le signe d approbation CEE, le principe de fonctionnement et le plan de scellement ne sont pas modifies. Les ensembles de mesurage routiers approuves antérieurement avec un groupe de pompage et de dégazage SATAM, modèle EPZ 75/3 ou EPZ 75/5, objet du certificat CEE n précité peuvent être équipes d un groupe de pompage et de dégazage objet du présent certificat. (1) Revue de Métrologie, juillet 1985, page 509. Revue de Métrologie, t. 65, n 12, décembre Rev D 02/21/11

175 Signe d approbation de modèle: F85 Dépôt de modèles: Appendix A BULLETIN OFFICIEL DES INSTRUMENTS DE MESURE Les plans et schémas ont été déposés au siège de la direction régionale de l industrie et de la recherche d Ile-de-France et à la sous direction de la métrologie. Validité du présent certificat CEE: Le présent certificat CEE est valable jusqu en juillet Annexe: Dessin n Pour le ministre et par délégation: Par empêchement du directeur général de l industrie: L Ingénieur général des Mines, A.C. Lacoste Revue de Métrologie, t. 65, n 12, décembre Rev D 02/21/11

176 Appendix A BULLETIN OFFICIEL DES INSTRUMENTS DE MESURE N 4858 Groupes de pompage et de dégazage SATAM EPZ 75/3 et EPZ 75/5 Vue en coupe du couvercle tube do mise a l atmosphère rivets bride couvercle sortie vers le mesureur orifice cuve de purge Revue de Métrologie, t. 65, n 12, décembre Rev D 02/21/11

177 Appendix B BULLETIN DES INSTRUMENTS DE MESURE JUILLET 1985 CERTIFICAT D'APPROBATION C.E.E. DE MODELES n du fer juillet 1985 Groupes de pompage el de dégazage SATAM modèles EPZ 75/3 et EPZ 75/5 (Précision commerciale) Le présent certificat est établi en application de la directive 71/316/CEE du 26 juillet 1971, relative aux dispositions communes aux instruments de mesurage et aux méthodes de contrôle métrologique, de la directive 71/319/CEE du 26 juillet 1971, relative aux coupleurs de liquides autres que l eau Du décret n du 4 août 1973 portant application des prescriptions de la CEE relatives aux dispositions communes aux instruments de mesurage et aux méthodes de contrôle métrologique du décret n du 4 août 1973 relatif à l'application des prescriptions de la CEE au contrôle des compteurs volumétriques de liquides autres que l eau et de leurs dispositifs complémentaires et de l arrêté du8 novembre 1973 relatif aux modales d application de certaines dispositions du décret n du 4 août 1973, de l arrêté du 20 novembre 1973 portant application du décret n di 4 aout 1973 et de l arrêté du 19 juin 1978 relatif à l'application des prescriptions de la CEE au contrôle des ensembles de mesurage à computeur columetrique destines à determines le volume des liquides outres que l eau. Fabricant: SATAM Industries, 63, Avenue du General. Leclerc, B.P La Courneuve. Paris, France. Caractéristiques: Les groupes de pompage et de dégazage SATAM, modèles EPZ 75/3 et EPZ 75/5, sont destines au mesurage de l essence, do supercarburant et du gazole. Ils sont composes des éléments suivants: Un filtre avec couvercle amovible. Une pompe rotative a six palettes radiales. Un séparateur de gaz statique a effet VORTEX. Une cuve de purge. Un clapet de bipasse. Un clapet anti-retour. Un orifice de refoulement vers le mesureur. Ces deux modèles différent par la cylindrée do la chambre d aspiration de la pompe. En outre, le modèle EPZ 75/7 comporte une bague de guidage des palettes Rev D 02/21/11

178 Appendix B BULLETIN DES INSTRUMENTS DE MESURE JUILLET 1985 Leurs caractéristiques métrologiques sont les suivantes: Indication complémentaire: Lorsque le groupe de pompage et de dégazage SATAM, modèle EPZ 75/5 est incorporé dans un ensemble de mesurage routier destiné au mesurage de gazole, un indicateur de gaz doit être dispose en amont du flexible de l ensemble. Signe d approbation de modèle: F85 Dépôt de modèles: Les plans et schémas ont été déposés au service de la métrologie. Validité du présent certificat CEE: Jusqu au ler juillet Annexe: Notice descriptive. Dessins n et 2 Modèle EPZ 75/3 EPZ 75/5 Débit maximal 3 m 3 /h 5 m 3 /h Pression maximale de fonctionnement 1.7 bar 2 bar Pression minimale de fonctionnement 0.6 bar 0.6 bar Pour le ministre et par délégation: Par empêchement du Directeur de la qualité et de la sécurité industrielles: Le Chef du service de la Métrologie, P, Bertran. 510 B Rev D 02/21/11

179 Appendix B BULLETIN DES INSTRUMENTS DE MESURE Groupe pompe dégazeur SATAM EPZ 75/3 JUILLET 1985 N o Section AA exit mousse Liquide Liquide dégaze entrance Rev D 02/21/11

180 Appendix B BULLETIN DES INSTRUMENTS DE MESURE Groupe pompe dégazeur SATAM EPZ 75/5 JUILLET 1985 N o N o Section AA exit exit Section AA mou mousse Liquide8 10 Liquide 11 dégaze 22 Liquide Liquide dégaze entrance Rev D 02/21/11

181 Appendix C Inlet & Mounting Dimensions Figure 5 - Meter Flange Outlet Option Rev D 02/21/11

182 Appendix C Inlet & Mounting Dimensions Figure 6 - Tubular Outlet/Motor Mount Option Rev D 02/21/11

183 Appendix D Installation Piping for Type 75 Pump Dispenser To obtain maximum flow rates on a self-contained pump, follow these guidelines: 1. The total length of horizontal piping between the pump and tank must be no longer than 60 feet. 2. Piping specifications: a. Use new 1-1/2 galvanized or approved non-metallic pipe for GPM pumps. Use new 2 galvanized or approved non-metallic pipe for GPM pumps. b. All horizontal piping must be buried a MINIMUM of 18 below the finishing grade. c. The pipe from the tank must slope up to the pump (approximately 1-1/2 to 2 per 10 feet). The pipe MUST be straight. The pipe must be supported continuously to prevent sagging. d. All piping must hold a 50 PSI pressure test for 10 minutes. e. To absorb ground movement from settling of the tank, front heaving of the ground pump or pump island settling, a swing joint must be used in the supply line at the tank and directly underneath the dispenser. Three additional directional changes using elbows are permitted. f. Only one pumping unit is permitted for each underground pipe. Do not use a tee to connect two pumps off one line. 3. Static lift on self contained units must not exceed 10 feet (vertical distance between product level in the storage tank and the center of the pumping unit) Rev D 02/21/11

184 WAY Pilot Operated General Service Solenoid Valves 2-4 Brass or Stainless Steel Bodies 3/8" to 2 1/2" NPT 2/2 SERIES 8210 Features Wide range of pressure ratings, sizes, and resilient materials provide long service life and low internal leakage High Flow Valves for liquid, corrosive, and air/inert gas service Industrial applications include: - Car wash - Laundry equipment - Air compressors - Industrial water control - Pumps ^ % ) Construction *Catalog Numbers 8210G127, 8210G129, 8210G132, 8210G133 have 316L Stainless Steel bodies. Electrical Valve Parts in Contact with Fluids Body Brass 304 Stainless Steel* Seals and Discs Disc-Holder Core Tube Core and Plugnut Springs NBR or PTFE Solenoid Enclosures Standard: RedHat II - Watertight, Types 1, 2, 3, 3S, 4, and 4X; RedHat - Type I. Optional: RedHat II - Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, 6P, 7, and 9; Red-Hat - Explosionproof and Watertight, Types 3, 4, 4X, 7, and 9. (To order, add prefix EF to catalog number, except Catalog Numbers 8210B057, 8210B058, and8210b059, which arenot available with Explosionproof enclosures.) SeeOptional FeaturesSection for other available options. PA 305 Stainless Steel 430F Stainless Steel 302 Stainless Steel Shading Coil Copper Silver Standar d Coil and Class of Insulatio n DC Watts Watt Rating and Power Consumption AC Watts VA Holding VA Inrush Spare Coil Part Number General Purpose Explosionproo f AC DC AC DC F F F F F F H H Standard Voltages: 24, 120, 240, 480 volts AC, 60 Hz (or 110, 220 volts AC, 50 Hz). 6, 12, 24, 120, 240 volts DC. Must be specified when ordering. Other voltages available when required. NC NO Nominal Ambient Temp. Ranges RedHat II/ RedHat RedHat II RedHat AC: 32 F to 125 F (0 C to 52 C) DC: 32 F to 104 F (0 C to 40 C) DC: 32 F to 77 F (0 C to 25 C) (104 F/40 C occasionally) 8210G227 AC: 32 F to 130 F (0 C to 54 C) DC: 32 F to 90 F (0 C to 32 C) Refer to Engineering Section for details. Approvals UL listed as indicated. CSAcertified. RedHat II meets applicable CEdirectives. Refer to Engineering Section for details. 11

185 2- WAY 2/2 SERIES Specifications (English units) Pipe Size (in) 12 Orific e Size (in) Cv Flow Facto r Operating Pressure Differential (psi) Min. Max. AC Max. DC Air- Inert Gas Water Light 300 SSU Air- Inert Gas Water NORMALLY CLOSED (Closed when de-energized), NBR or PTFE ➁ Seating Light 300 SSU Max. Fluid Temp. F AC DC Catalog Numbe r Brass Body Stainless Steel Body Watt Rating/ Class of Coil Insulation ➆ 3/8 3/8 1.5 ➀ G073 ➂ 1P 8210G036 1P 6.1/F 11.6/F ➂ 3/8 5/ G093 5D /F 11.6/F 3/8 5/ G001 6D /F 11.6/F 3/8 5/ G006 5D /F - 1/2 7/ ➀ G015 ➂ 2P 8210G037 2P 6.1/F 11.6/F ➂ 1/2 5/ G094 5D /F 11.6/F 1/2 5/ G087 7D 17.1/F 11.6/F 1/2 5/ G002 6D /F 11.6/F 1/2 5/ G007 5D /F - 1/2 3/ G227 5D /F 40.6/H 3/4 5/ G088 7D 17.1/F 11.6/F 3/4 3/ G009 9D /F 11.6/F 3/4 3/ G095 8D /F 11.6/F 3/4 3/ G003 11D /F 11.6/F 3/4 3/ B026 ➁ 10P /H 3/4 3/ G026 ➁ 40P F B054 31D D089 15D /H G054 41D 8210G089 45D 16.1/F G004 12D /F 11.6/F G027 42P /F G078 ➁ 13P /F - 1 1/4 1 1/ B055 32D /H 1 1/4 1 1/ G055 43D /F - 1 1/4 1 1/ G008 16D /F 11.6/F 1 1/2 1 1/ B056 33D /H 1 1/2 1 1/ G056 44D /F - 1 1/2 1 1/ G022 18D 8210G /F 11.6/F 2 1 3/ G100 20P 8210G /F 11.6/F 2 1/2 1 3/ G101 21P /F 11.6/F NORMALLY OPEN (Open when de-energized), NBR Seating (PA Disc-Holder, except as noted) 3/8 5/ G033 23D /F 11.6/F 3/8 5/ G011 ➇ 39D /F 11.6/F ➈ 1/2 5/ G034 23D /F 11.6/F 1/2 5/ G030 37D 10.1/F 11.6/F 1/2 5/ G012 ➇ 39D /F 11.6/F ➈ 3/4 3/ G035 25D /F 11.6/F 3/4 5/ G038 38D 10.1/F 11.6/F 3/4 3/ C013 24D /F 3/4 3/ G013 46D /F B057 ➅ 34D /F - ➉ D014 26D /F G014 47D /F - 1 1/4 1 1/ B058 ➅ 35D /F - ➉ 1 1/4 1 1/ D018 28D /F 1 1/4 1 1/ G018 48D /F - 1 1/2 1 1/ B059 ➅ 36D /F - ➉ 1 1/2 1 1/ D032 29D /F 1 1/2 1 1/ G032 49D 8210G /F / P /F 2 1 3/ G103 50P 8210G /F - 2 1/2 1 3/ P /F 2 1/2 1 3/ G104 51P /F - ➀ 5 psi on Air; 1 psi on Water. ➅ Valves not available with Explosionproof enclosures. UL listed for fire protection systems per UL429A. ➁ Valve provided with PTFE main disc. ➆ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts. Must have solenoid mounted vertical and upright. ➂ Valve includes UItem (G.E. trademark) piston. ➇ AC construction also has PA seating. ➃ Letter D denotes diaphragm construction; P denotes pistonconstruction. ➈ No disc-holder. Const. Ref. ➃ UL ➄ Listing Catalo g Numbe r Const. Ref. ➃ UL ➄ Listing AC DC

186 2- WAY 4 2/2 SERIES 8210 Specifications (Metric units) Pipe Size (in) Orific e Size (mm) Kv Flow Factor (m 3 /hr) Operating Pressure Differential (bar) Min. Max. AC Max. DC Air- Inert Gas Water Light 300 SSU Air- Inert Gas NORMALLY CLOSED (Closed when de-energized), NBR or PTFE ➁ Seating Water Light 300 SSU Max. Fluid Temp. C AC DC Catalog Numbe r Brass Body Stainless Steel Body Watt Rating/ Class of Coil Insulation ➆ 3/ ➀ G073 ➂ 1P 8210G036 1P 6.1/F 11.6/F ➂ 3/ G093 5D /F 11.6/F 3/ G001 6D /F 11.6/F 3/ G006 5D /F - 1/ ➀ G015 ➂ 2P 8210G037 2P 6.1/F 11.6/F ➂ 1/ G094 5D /F 11.6/F 1/ G087 7D 17.1/F 11.6/F 1/ G002 6D /F 11.6/F 1/ G007 5D /F - 1/ G227 5D /F 40.6H 3/ G088 7D 17.1/F 11.6/F 3/ G009 9D /F 11.6/F 3/ G095 8D /F 11.6/F 3/ G003 11D /F 11.6/F 3/ B026 ➁ 10P /H 3/ G026 ➁ 40P F B054 31D D089 15D /H G054 41D 8210G089 45D 16.1/F G004 12D /F 11.6/F G027 42P /F G078 ➁ 13P /F - 1 1/ B055 32D /H 1 1/ G055 43D /F - 1 1/ G008 16D /F 11.6/F 1 1/ B056 33D /H 1 1/ G056 44D /F - 1 1/ G022 18D 8210G /F 11.6/F G100 20P 8210G /F 11.6/F 2 1/ G101 21P /F 11.6/F NORMALLY OPEN (Open when de-energized), NBR Seating (PA Disc-Holder, except as noted) 3/ G033 23D /F 11.6/F 3/ G011 ➇ 39D /F 11.6/F ➈ 1/ G034 23D /F 11.6/F 1/ G030 37D 10.1/F 11.6/F 1/ G012 ➇ 39D /F 11.6/F ➈ 3/ G035 25D /F 11.6/F 3/ G038 38D 10.1/F 11.6/F 3/ C013 24D /F 3/ G013 46D /F B057 ➅ 34D /F - ➉ D014 26D /F G014 47D /F - 1 1/ B058 ➅ 35D /F - ➉ 1 1/ D018 28D /F 1 1/ G018 48D /F - 1 1/ B059 ➅ 36D /F - ➉ 1 1/ D032 29D /F 1 1/ G032 49D 8210G /F P /F G103 50P 8210G /F - 2 1/ P /F 2 1/ G104 51P /F - ➀ 0.3 bar on Air; 0.0 bar on Water. ➁ Valve provided with PTFE main disc. ➂ Valve includes UItem (G.E. trademark) piston. ➃ Letter D denotes diaphragm construction; P denotes pistonconstruction. Const. Ref. ➃ UL ➄ Listing Catalo g Numbe r Const. Ref. ➃ UL ➄ Listing ➅ Valves not available with Explosionproof enclosures. UL listed for fire protection systems per UL429A. ➆ On 50 hertz service, the watt ratingfor the 6.1/F solenoidis 8.1 watts. Must have solenoid mounted vertical and upright. ➇ AC construction also has PA seating. ➈ No disc-holder. AC DC 13

187 2- WAY 2/2 SERIES Dimensions: inches (mm) Const. Ref. H K L P W 1* in mm * in mm in mm * in mm in mm in mm * in mm * in 5.25 X mm 133 X * in mm in mm in mm * in 5.34 X mm 136 X in mm * in mm * in mm * in mm in mm in 5.06 X mm 129 X in mm in 6.53 X mm 166 X in 8.22 X mm 209 X in 6.53 X mm 166 X in 7.03 X mm 179 X * DC dimensions slightly larger. IMPORTANT: Valves may be mounted in any position, except as noted in specifications table [42] H P NPT BOTH ENDS L FLOW L FLOW K Const. Ref. 1, 2 W Const. Ref. 13 1/2 NPT R.12 [3.2] 4 PLACES Ø.266 [6.8].88 [22] Const. Ref. 5-9, 11, 23, 25, 37,38, K P H P K.59 [15] BOTTOM VIEW SHOWING MOUNTING BRACKET HOLES (OPTIONAL) W 1/2 NPT.69 [18].86 [22] H NPT BOTH ENDS.281 [7.1] DIA 2 MOUNTING HOLES NPT BOTH ENDS OPTIONAL MOUNTING BRACKET L FLOW W [41.3] 14

188 2- WAY 4 2/2 SERIES 8210 Dimensions: inches (mm) Const. Ref. H K L P W Const. Ref. 10, 15, 24, in 8.22 X mm 209 X in 5.25 X mm 133 X /8 DIA. HOLE FOR 1/2 CONDUIT CONN. 32 in 5.69 X mm 145 X P 33 in 6.06 X mm 154 X K H 34 in 6.91 X mm 176 X in 7.34 X NPT BOTH ENDS mm 186 X in 7.66 X mm 1.95 X in mm L FLOW W [42] [41.3].281 [7.1] DIA. 2 MOUNTING HOLES 38 in mm in OPTIONAL MOUNTING BRACKET mm in mm in mm in Const. Ref. 12, 16, 26, 28, 47, 48 mm in mm /2 NPT 44 in mm in mm in P K mm H 47 in mm in mm IN NPT BOTH ENDS 49 in mm in W L mm FLOW 51 in mm IMPORTANT: Valves may be mounted in any position, except as noted in specifications table. 15

189 2- WAY 2/2 SERIES Dimensions: inches (mm) Const. Ref. 39 P H 1/2 NPT K L FLOW NPT BOTH ENDS W.281 [7.1] DIA. 2 MOUNTING HOLES 1.66 [42] SHOWING MOUNTING BRACKET ONLY Const. Ref. 18, 29, 49 1/2 NPT H (BOLT PATTERN MAY VARY) K P NPT BOTH ENDS L W Const. Ref. 20, 21, 27, 30, 50, 51 1/2 NPT K P NPT BOTH ENDS H L W 16

190 EC-Type Certificate, IECEx and KC Installation Instructions: Cable Connection The cable entry device shall be certified in type of explosion protection flameproof enclosure d, suitable for conditions of use and correctly installed. For Ta 65 C cable and cable gland rated 90 C shall be used. Conduit Connection An Ex d certified sealing device such as a conduit seal with setting compound shall be provided immediately to the entrance of the valve housing. For Ta 65 C wiring and setting compound, in the conduit seal, rated 90 C shall be used. Note: ATEX, IECEx and KC units only: The temperature class is determined by the maximum ambient and or process temperature. Units are intended to be used in ambient of -20 C Tamb 75 C. Units may be used in process temperatures up to 105 C providing the enclosure and switch body temperature do not exceed 75 C. The standard Temperature Class is T6 Process Temp 75 C. Alternate Temperature Class of T5 Process Temp 90 C and 115 C (T4) Process Temp 105 C are available consult factory. Refer to Certificate No: IECEx DEK for conditions of safe use for IECEx compliant units. All wiring, conduit and enclosures must meet applicable codes for hazardous areas. Conduits and enclosures must be properly sealed. For outdoor or other locations where temperatures vary widely, precautions should be taken to prevent condensation inside switch or enclosure. Electrical components must be kept dry at all times. CAUTION: To prevent ignition of hazardous atmospheres, disconnect the device from the supply circuit before opening. Keep assembly tightly closed when in use. MAINTENANCE Inspect and clean wetted parts at regular intervals. The cover should be in place at all times to protect, the internal components from dirt, dust and weather and to maintain hazardous location ratings. Disconnect device from the supply circuit before opening to prevent ignition of hazardous atmosphere. Repairs to be conducted by Dwyer Instruments, Inc. Units in need of repair should be returned to the factory prepaid. V6 With Tee Cold Water - Factory Installed Tee Approximate actuation/deactuation low Rates GPM upper, M 3 /HR lower 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT Air-Factory Installed Tee Approximate actuation/deactuation flow rates SCFM upper, NM 3 /M lower 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT V6 Low Flow, Field Adjustable Cold Water - Low Flow Models Approximate actuation/deactuation flow rates GPM upper, M 3 /HR lower Minimum Maximum Air - Low Flow Models Approximate actuation/deactuation flow rates SCFM upper, NM 3 /M lower Minimum Maximum Example V6 EP B B S 2 B MT V6EPB-B-S-2-B-MT flow switch; brass upper housing, brass lower housing, brass tee with 3/4 NPT connections, SPDT snap switch, and high temperature option Series V6 Series V6 flow switch Construction EP Explosion Proof and Weatherproof Upper Body Material Lower Body Material Circuit (Switch) Type Process Connection Size Process Connection Type Switch Options Options B S B S S D LF 0 B FS MI PVC PVCSW S S150 MV MT AT CSA IEC KC CV FTR GL ID JCTLH ORFB ORFS RV TBC VIT A 031 Brass 303 Stainless Steel Brass 303 Stainless Steel SPDT DPDT 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT Low Flow Model (1/2 NPT connections) No Tee, Male NPT Connection, Field Trimmable Vane Brass Tee Forged Steel Tee Iron Tee PVC Tee with NPT* PVC Tee with sweat joints* 304 Stainless Steel Tee 304 Stainless Steel 150# Tee (For LF Model no tee material chosen, tee material matches lower housing choice) Gold Contacts on snap switch for dry circuits (see specifications for ratings) High Temperature switch rated 400 F (205 C) (see specifications for ratings)* ATEX approved construction (weatherproof and explosion-proof junction box) CSA approved construction (weatherproof and explosion-proof junction box)* IECEx approved construction (weatherproof and explosion-proof junction box) Korean certified (KC) approved construction (with JCT option standard) Custom Vane Flow Test Report Ground Lead* Customer Information on standard nameplate Weatherproof and explosion-proof junction box, left side Orifice Brass Orifice Stainless Steel Reinforced Vane Terminal Block Connector* Viton O-rings in place of Buna-N on low flow models.018 Spring.020 Spring.022 Spring.022 Spring with Alnico magnet.031 Spring * Options that do not have ATEX, IECEx or KC. Attention: Units without the AT suffix are not Directive 94/9/EC (ATEX) compliant. These units are not intended for use in potentially hazardous atmospheres in the EU. These units may be CE marked for other Directives of the EU.

191 V6 With Field Trimmable Vane Cold Water - Brass or Cast Iron Reducing Tee Approximate actuation/deactuation flow rates GPM upper, M 3 /HR lower Air - Brass or Cast Iron Reducing Tee Approximate actuation/deactuation flow rates SCFM upper, NM 3 /M lower Vane 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT Full Size a b c d e f g h i j k l m n o Cold Water - Stainless or Forged Steel Straight Tee and Bushing Approximate actuation/deactuation flow rates GPM upper, M 3 /HR lower Air - Stainless or Forged Steel Straight Tee and Bushing Approximate actuation/deactuation flow rates SCFM upper, NM 3 /M lower Vane 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT 1/2 NPT 3/4 NPT 1 NPT 1-1/4 NPT 1-1/2 NPT 2 NPT Full Size a b c d e f g h i j k

192 Bulletin E-22 Series V6 FLOTECT Flow Switch Specifications - Installation and Operating Instructions The Series V6 FLOTECT Flow Switch is an inexpensive, explosion-proof flow switch for use on air, water or other compatible gases and liquids. Three configurations are available - 1. Factory installed in a tee. 2. With a trimmable vane for field adjustment and installation in a suitable tee. 3. Low flow models with an integral tee and adjustable valve. All are available with an optional enclosure which is UL and CSA listed, or Directive 94/9/EC (ATEX) compliant for II 2 G Ex d IIC T6 Gb Process Temp 75 C or IECEx compliant for Ex d IIC T6 Gb Process Temp 75 C. INSTALLATION Unpack and remove any packing material found inside lower housing or tee. Switch can be installed in any position but the actuation/deactuation flow rates in the charts are based on horizontal pipe runs and are nominal values. For more precise settings, units can be factory calibrated to specific flow rates. V6 Models with Tee are supplied in 1/2-2 NPT sizes. Install in piping with arrow pointing in direction of flow. V6 Low Flow Models have 1/2 NPT connections and are field adjustable. Install in piping with arrow pointing in direction of flow. To adjust, loosen the four socket head cap screws on bottom. The adjustment valve rotates 90 between O (open) and C (closed). See flow charts for approximate ranges. Tighten screws once the required flow rate has been set. V6 with Field Trimmable Vane. These models enable the installer to choose approximate actuation/deactuation points by trimming the full size vane at appropriate letter-designated marks on a removable template. Flows are defined in the following charts. Note that the charts are based on either brass or cast iron reducing tees or stainless or forged steel straight tees with bushings where necessary. Install in piping with arrow pointing in direction of flow. When bushings are used, they must be back drilled to allow proper clearance for unrestricted vane travel. Bore the I.D. to 13/16 (20 mm) on 1/2 x 3/4 bushings or 1 (25 mm) on larger bushings. The depth of the bore must leave internal threads 9/16 (14 mm) high for proper engagement between the lower housing of the switch and the bushing. Check for proper vane travel and switch operation after installation. SPECIFICATIONS Service: Gases or liquids compatible with wetted materials. Wetted Materials: Standard V6 Models: Vane: 301 SS; Lower Body: brass or 303 SS; Magnet: ceramic; Other: 301, 302 SS; Tee: brass, iron, forged steel, or 304 SS. V6 Low Flow Models: Lower Body: brass or 303 SS; Tee: brass or 304 SS; Magnet: ceramic; O-ring: Buna-N standard, Fluoroelastomer optional; Other: 301, 302 SS. Temperature Limits: -4 to 220 F (-20 to 105 C) Standard, MT high temperature option 400 F (205 C) (MT not UL, CSA, ATEX, IECEx or KC) ATEX Compliant AT, IECEx IEC Option and KC (KC Option), Ambient Temperature -4 to 167 F (-20 to 75 C) Process Temperature: -4 to 220 F (-20 to 105 C). Pressure Limit: Brass lower body with no tee models 1000 psig (69 bar), 303 SS lower body with no tee models 2000 psig (138 bar). Brass tee models 250 psi (17.2 bar), iron tee models 1000 psi (69 bar), forged and stainless steel tee models 2000 psi (138 bar), low flow models 1450 psi (100 bar). Enclosure Rating: Weatherproof and Explosion-proof. Listed with UL and CSA for Class I, Groups A, B, C and D; Class II, Groups E, F, and G. (Group A on stainless steel body models only) II 2 G Ex d IIC T6 Gb Process Temp 75 C Alternate Temperature Class T5 Process Temp 90 C, 115 C (T4) Process Temp 105 C consult factory. EC-type Certificate No.: KEMA 04ATEX2128. ATEX Standards: EN : 2009; EN : IECEx Certified: For Ex d IIC T6 Gb Process Temp 75 C Alternate Temperature Class T5 Process Temp 90 C, 115 C (T4) Process Temp 105 C consult factory. IECEx Certificate of Conformity: IECEx DEK ; IECEx Standards: IEC : 2007; IEC : 2007; Korean Certified (KC) for: Ex d IIC T6 Gb Process Temp 75 C; KTL Certificate Number: Switch Type: SPDT snap switch standard, DPDT snap switch optional. Electrical Rating: UL models: VAC. CSA, ATEX and IECEx models: 125/250 VAC (V~); 5A res., 3A 30 VDC (V ). MV 125 VAC (V~). MT option: VAC (V~). [MT option not UL, CSA, ATEX or IECEx]. Electrical Connections: UL models: 18 AWG, 18 (460 mm) long. ATEX/CSA /IECEx models: terminal block. Upper Body: Brass or 303 stainless steel. Conduit Connections: 3/4 male NPT standard, 3/4 female NPT on junction box models. Process Connection: 1/2 male NPT on models without a tee. Mounting Orientation: Switch can be installed in any position but the actuation/deactuation flow rates in the charts are based on horizontal pipe runs and are nominal values. Set Point Adjustment: Standard V6 models none. Without tee models vane is trimmable. Low flow models are field adjustable in the range shown. See set point charts on opposite page. Weight: 2 to 6 lb (.9 to 2.7 kg) depending on construction. Options not Shown: Custom calibration, bushings, PVC tee, reinforced vane, DPDT relays. ELECTRICAL CONNECTIONS Connect wire leads in accordance with local electrical codes and switch action required. N.O. contacts will close and N.C. contacts will open when flow increases to the actuation point. They will return to normal condition when flow decreases to the deactuation point. Black = Common, Blue = Normally Open and Red = Normally Closed. For units supplied with both internal ground and external bonding terminals, the ground screw inside the housing must be used to ground the control. The external bonding screw is for supplementary bonding when allowed or required by local code. When external bonding conductor is required, conductor must be wrapped a minimum of 180 about the external bonding screw. See below. Some CSA listed models are furnished with a separate green ground wire. Such units must be equipped with a junction box, not supplied but available on special order. LOCKWASHER SCREW CLAMP CONDUCTOR FRONTVIEW DETAIL SIDE VIEW DETAIL W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC. P.O. BOX 358 MICHIGAN CITY, INDIANA U.S.A. Phone: 219/ Fax: 219/ info@dwyermail.com

193 DIMENSIONS Series V6 FLOTECT Flow Switch 4-1/2 [114.3] 3-15/16 [100.0] 3/4 NPT 1-1/8 SQ. [28.57] 8-5/8 [219.1] [184.2] 3-3/8 [85.72] DIA. 1-1/8 SQ. [28.57] 6-1/8 [155.5] 13/16 [20.63] EXTERNAL GROUND 3/4 FEMALE NPT 6-5/16 [160.34] LOCKINGCOLLAR ASSEMBLY 3/4NPT UPPERHOUSING SWITCHSUPPORTS SPDT (ORDPDT) SNAPSWITCH MAGNETLEVERPIN MAGNETLEVER ASSEMBLY MAGNETS LOWERHOUSING BRASS ORSTAINLESS STEEL VANESPRING VANEPIVOTPIN VANEPIVOT BRACKET SNAPRING 1/2NPT STAINLESS STEELVANE OVERALL LENGTH WITH 1-1/4 TEECONNECTION APPROXIMATELY 8 INLET 1/2 FEMALE NPT 3-5/8 [92.07] OUTLET 1/2 FEMALE NPT INLET 1/2 FEMALENPT 3-5/8 [92.07] OUTLET 1/2 FEMALE NPT V6 with Field Trimmable Vane.625 [15.87] V6 Low Flow V6 Low Flow with CSA, ATEX Conduit Enclosure Pipe Size 1/2 3/ /4 1-1/2 2 Brass/Ductile Iron Forged/Stainless Steel Malleable Iron Dim. A Dim. B Dim. A Dim. B Dim. A Dim. B 2-1/4 (57) 2-3/8 (60) 2-1/2 (64) 2-5/8 (67) 2-7/8 (73) 3 (76) 1-1/8 (29) 1-1/4 (32) 1-3/8 (35) 1-1/2 (38) 1-5/8 (41) 1-7/8 (48) 2-1/4 (57) 2-5/8 (67) 3 (76) 3-1/2 (89) 4 (102) 4-3/4 (121) 1-1/8 (29) 1-7/8 (47) 2-1/8 (54) 2-1/2 (64) 2-3/4 (70) 3-1/8 (79) 2-1/2 (64) 1-1/4 (32) 2-5/8 (67) 1-3/8 (35) 2-7/8 (73) 1-1/2 (38) 3 (76) 1-3/4 (44) 3-1/4 (83) 1-7/8 (48) 3-1/2 (89) 2-1/8 (54) 3-3/8 [85.72] DIA. 13/16 [20.63] [47.62] 3/4 FEMALE NPT Trimmable Vane 3/4 NPT 9-1/4 [235.0] 5-3/8 [136.5] SPDT "B" "B" "A" V6 with Tee "A" V6 with Tee and CSA, ATEX Conduit Enclosure DPDT Terminal Connections CSA, ATEX Enclosures Copyright 2014 Dwyer Instruments, Inc. Printed in U.S.A. 9/14 FR# Rev. 10 W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC. P.O. BOX 358 MICHIGAN CITY, INDIANA U.S.A. Phone: 219/ Fax: 219/ info@dwyermail.com

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196 MICRO SWITCH Hazardous Location Switches EX Series Datasheet

197 MICRO SWITCH EX Series Hazardous Location Limit Switches MICRO SWITCH EX Series switches feature the smallest UL-listed housings available for use in hazardous locations. The EX Series switch cavity is designed to cool expanding gases below the ignition temperature of the surrounding explosive atmosphere. The EX Series is capable of switching up to 20 amps while providing ample wiring space for ease of installation. Single and double conduit openings are available. Dual conduit openings may allow for through wiring of multiple switches. The EX Series can be mounted from any of the switch s four sides. What makes our switches better? Honeywell has over 80 years of switch manufacturing experience covering most environment types Proven technology plus superior quality and service are offered world-wide. The EX Series holds multiple agency approvals, including CE, IEC Ex, UL, CSA, and ATEX directives Multiple actuator options make the EX Series a good choice for indoor explosion-proof applications Smallest UL-listed, power-load carrying switch available for use in hazardous locations nts Manufactured for harsh and explosive environme 2 sensing.honeywell.com FLEXIBILITY IN MOUNTING RELIABILITY ACTUATION VARIETY

198 Features and Benefits COMPACT AND RUGGED HOUSING Often used in applications where space is at a premium, MICRO SWITCH EX Series switches feature ample wiring space that eases installation time. The four-sided mounting with optional mounting bracket simplifies installation in most applications. The EX Series offers dual conduit openings on select models that allow for through wiring making it easier to wire multiple switches in a single circuit. International approvals for use around the world WIDE VARIETY OF PRODUCT OFFERINGS AND VARIATIONS Broad range of actuator styles available in pin plunger and rotary configurations. Switching capacity from 1 A for low energy loads, up to 20 A for most industrial electrical loads. DESIGN FLEXIBILITY Rotary actuators are field adjustable for quick set up and application adaptability. Roller lever actuators are adjustable through 360 of rotation. 1EX and 2EX listings have dual conduit openings enabling wire through or allowing the user to split the wiring of a double pole switch with one pole exiting each side. Potential Applications INDUSTRIAL PAINT BOOTHS Position detecting in automated paint booths used by indoor industrial painting companies Automotive paint booth door position detection assures the door is closed before paint can be applied PETROLEUM AND CHEMICAL PLANTS Valve position in indoor potentially explosive environments in petroleum refineries and chemical plants PROCESSING FACILITIES Position sensing indoors at grain handling and processing plants, pulp and paper processing, lumber and other types of facilities where dust and other fine particles in the atmosphere may create the potential for explosions sensing.honeywell.com 3

199 EX Series Table 1. Specifications Characteristic Parameter Product type MICRO SWITCH hazardous location limit switches Actuators overtravel top plunger side roller lever one-way roller lever adjustable roller lever rod lever manually activated paddle adjustable rod lever with one-inch nylon roller Circuitry Electrical Housing material Termination types Sealing Operating temperature 1 Agency approvals and standards SPDT, DPDT 1 A, 3 A, 5 A, 10 A, 15 A, and 20 A Aluminum die-cast 1/2-14 NPT conduit, preleaded NEMA 1, 7, and 9, UL listed, and CSA certified: Class I, Div.1 & 2, Groups B*, C, and D [*Group B - only as noted in order guide] Class II, Div.1 & 2, Groups E, F, and G -40 C to 71 C [-40 F to 160 F] *High temp models available up to 204 C [400 F] (refer to order guide on pages 6 and 7) IEC Ex, ATEX (CE), UL, CSA UL listed #E14274 CSA certified ATEX directive 2 #LR57324 KEMA 04ATEX2312X IEC Ex certified KEM X UNSPSC code UNSPSC commodity Switches and controls and relays 1 Refer to order guide 2 Most models, refer to individual specifications for selected catalog listings Table 2. Agency Approvals and Standards UL, CE/ATEX, CSA, IEC Ex, INMETRO Standards & Designations UL listed #E14274 UL 1203 CSA certified #LR57324 C22.2 No. 25 and No. 30 ATEX directive * KEMA 04ATEX2312X II 2 G Ex d IIB + H2 T6 Gb (EX) II 2 G Ex d IIB + H2 T2 Gb (EXHT) EN and EN IEC Ex certified * KEM X II 2 G Ex d IIB + H2 T6 Gb (EX) II 2 G Ex d IIB + H2 T2 Gb (EXHT) IEC and IEC *Most INMETRO models, certified refer to* individual specifications for selected In process catalog listings IEC and IEC sensing.honeywell.com

200 MICRO SWITCH Hazardous Location Limit Switches Table 3. Circuitry and Electrical Ratings Rating Circuitry Electrical rating code A SPDT UL/CSA Rating: 15 A, 125, 250, or 480 Vac 1/8 HP, 125 Vac; 1/4 HP, 250 Vac 0.5 A, 125 Vdc; 0.25 A 250 Vdc B SPDT UL/CSA Rating: 20 A, 125, 250, or 480 Vac 10 A, 125 Vac L 1 HP, 125 Vac; 2 HP, 250 Vac 0.5 A, 125 Vdc; 0.25 A, 250 Vdc C DPDT UL/CSA Rating: 10 A, 125 or 250 Vac 0.3 A, 125 Vac; 0.15 A 250 Vdc D SPDT UL/CSA Rating: 10 A, 125, 250, or 480 Vac 0.5 A, 125 Vdc; 0.25 A 250 Vdc E SPDT UL Rating: 1 A, 125 Vac F SPDT UL/CSA Rating: 3 A, 125 or 250 Vac 1/10 HP, 125 Vac; 1/6 HP, 250 Vac G SPDT UL/CSA Rating: 5 A, 125, 250, or 480 Vac; 0.50 A, 125 Vdc; 0.25 A, 250 Vac Table 4. Hazardous Location Classifications Rating Classification code 1 Explosion Proof-UL listed for Hazardous Locations NEMA 7, Class I, Groups B, C, and D NEMA 9, Class II, Groups E, F, and G 2 Explosion Proof-UL listed for Hazardous Locations NEMA 7, Class I, Groups C and D NEMA 9, Class II, Groups E, F, and G 3 European Hazardous Locations Designation: Ex diib + H2 T6 Category II 2 G 4 European Hazardous Locations Designation: Ex diib + H2 T2 Series Code ATEX Temperature Rating Category II 2 G EX T6-40 C to 70 C [-40 F to 158 F] EXHT T2-40 C to 204 C [-40 F to 400 F] sensing.honeywell.com 5

201 Catalog Listing Actuation Circuitry Electrical Rating UL/CE Haz. Location Code Operating Force Pretravel max. mm [in] Overtravel max. Diff. Travel max. mm [in] Notes EX Series MICRO SWITCH EX SERIES ORDER GUIDE EX-AR CW* SPDT 15 A (A) 2, 3 2,22 N to 5,56 N [8 oz to 20 oz] 5,56 [0.219] (8 ) 90 0,18 [0.007] (0.25 ) EX-AR141 CW* SPDT 15 A (A) 2, 3 2,22 N to 5,56 N [8 oz to 20 oz] 5,56 [0.219] (8 ) 90 0,18 [0.007] (0.25 ) No mounting bracket EXA-AR CW* SPDT 20 A (B) 2, 3 3,34 N to 8,90 N [12 oz to 32 oz] 5,56 [0.219] (8 ) 25 0,304 [0.012] EXA-AR20 CW* SPDT 15 A (B) 2, 3 5,56 [0.219] (8 ) 25 No lever furnished (order separately) EX-AR16 CW or CCW* SPDT 15 A (A) 2, 3 0,56 N [2 oz] max. 5,56 [0.219] (8 ) 90 0,18 [0.007] (0.25 ) Low O.F. (no return spring) with- out mounting bracket EX- AR1613 CW* SPDT 15 A (A) 2, 3 0,56 N [2 oz] max. 16 ± 2 40 min in x 5.28 in aluminum lever (no mounting bracket) EX-AR20 CW* SPDT 15 A (A) 2, 3 3,81 N to 9,53 N [12.5 oz to oz] 5,56 [0.219] (8 ) 90 0,18 [0.007] (0.25 ) No lever furnished (order separately) EX-AR230 CCW* SPDT 15 A (A) 2, 3 0,45 Nm [4.0 in-lb] 1,65 [0.065] 25 0,18 [0.007] (0.25 ) No lever furnished (order separately) EX- AR471-3 CW* SPDT 15 A (A) 2, 3 3,34 N to 7,32 N [12 oz to 24 oz] 5,56 [0.219] (8 ) 90 0,533 [0.021] (0.75 ) 36 inch leadwire EX-AR50 Manua l operation SPDT 15 A (A) 2, 3 11,12 N [40 oz] 3,18 [0.125] min. 0,077 [0.003] approx. Large 3 in x 3.5 in paddle *Note: CW (Clockwise) and CCW (Counter-Clockwise) when looking at nameplate. EX Series switches are not sealed against liquids and are not intended to be used in liquid splash environments or outdoor use without protection. NEMA 1, 7, 9 only. 6 sensing.honeywell.com

202 Catalog Listing Actuation Circuitry Electrical Rating UL/CE Haz. Location Code Operating Force Pretravel max. mm [in] Overtravel max. Diff. Travel max. mm [in] Notes MICRO SWITCH Hazardous Location Limit Switches MICRO SWITCH EX SERIES ORDER GUIDE, CONTINUED EX-AR128 CW* SPDT 15 A (A) 2, 3 2,22 N to 5,56 N [8 oz to 20 oz] 5,56 [0.219] (8 ) 90 0,18 [0.007] (0.25 ) One-way roller lever EXD-AR-3 CW* DPDT 10 A 1, 3 2,44 N to 7,32 N 6, ,77 36 inch wire leads (C) [8 oz to 24 oz] [0.25] [0.109] EXA-N Plunger SPDT 20 A (B) 2, 3 15,57 N [56 oz] 2,77 [0.109] 3,18 [0.125] min. 0,229 [0.009] With seal boot EXA-Q Plunger SPDT 20 A (B) 2, 3 8,90 N [32 oz] 1,27 [0.05] 3,18 [0.125] min. 0,229 [0.009] EXHT-Q Plunger SPDT 3 A (F) 1, 4 8,90 N [32 oz] 1,27 [0.05] 3,18 [0.125] min. 0,229 [0.009] 400 high temperature EX-Q400 Plunger SPDT 5 A 1 13,34 N [48 oz] 1,98 4,78 0, high temperature (G) [0.078] [0.188] [0.004] intermittent exposure EXHT-AR CW* SPDT 3 A (F) 1, 4 3,34 N to 8,90 N [12 oz to 32 oz] 5,56 [0.219] (8 ) 25 0,406 [0.016] 400 high temperature 1EX1 CW* SPDT 15 A (A) 2, 3 2,22 N to 5,56 N [8 oz to 20 oz] 5,56 [0.219] (8 ) 90 0,18 [0.007] (0.25 ) Dual conduit openings 2EX1 CW* DPDT 20 A (B) 2, 3 3,34 N to 8,90 N [12 oz to 32 oz] 5,56 [0.219] (8 ) 25 0,305 [0.012] (0.5 ) Dual conduit openings *Note: CW (Clockwise) and CCW (Counter-Clockwise) when looking at nameplate. EX Series switches are not sealed against liquids and are not intended to be used in liquid splash environments or outdoor use without protection. NEMA 1, 7, 9 only. sensing.honeywell.com 7

203 EX Series DIMENSIONAL DRAWINGS mm [in] Figure 1. MICRO SWITCH EX Series, no lever Figure 5. MICRO SWITCH EX Series, rod lever Figure 2. MICRO SWITCH EX Series, side rotary Figure 6. MICRO SWITCH EX Series, top pin plunger Figure 3. MICRO SWITCH EX Series, side rotary with two conduit openings Figure 7. MICRO SWITCH EX Series, boot sealed Figure 4. MICRO SWITCH EX Series, one-way lever Figure 8. MICRO SWITCH EX Series, manually actuated 8 sensing.honeywell.com

204 MICRO SWITCH Hazardous Location Limit Switches Table 5. Replacement Catalog Listings EX Series Part Number Internal Switching Element/ Basic Switch Actuator Internal Springs EXA-AR BA-2R-P4 6PA5-EX 33PA6-EX EXA-Q BZ-2R-P4 8PA15-EX EX-AR BZ-2R-P4 6PA5-EX 33PA7-EX EX- AR128 BZ-2R-P4 6PA130-EX 33PA7-EX EX-AR16 BZ-2RW88-P5 6PA5-EX EX-AR1613 BZ-2RW88-P5 6PA136-EX EX-AR20* BZ-2R-P4 * 33PA7-EX EX-AR30 BZ-2R-P4 6PA5-EX 33PA5-EX EX-AR50 BZ-2R-P4 6PA134-OP 33PA7-EX EX-AR800 BZ-2R-P4 6PA5-EX 33PA7-EX EXD-AR-3 DT-2R4-A7 6PA5-EX 33PA6-EX EXD-AR30-3 DT-2R711-A7 6PA5-EX 33PA5-EX EXD-Q-3 DT-2R-A7 8PA77-EX EXH-AR3 4HS202 6PA5-EX 33PA6-EX EXH-AR33 4HS203 6PA5-EX 33PA6-EX EX-N15 BZ-2R15-P4 8PA12-EX EX-Q BZ-2R-P4 8PA15-EX EX-Q800 BZ-2R-P4 8PA15-EX Double Conduit 1EX1 BZ-2R-P4 6PA5-EX 33PA6-EX 2EX1 BZ-2R-P4 6PA5-EX 33PA6-EX 4EX1-3 DT-2R4-A7 6PA5-EX 33PA6-EX * Order levers separately Table 6. Actuator Order Codes Type Part Number GROUNDING SCREW ASSEMBLY (for equipped models only) One-way roller lever (for CW actuation) 6PA130-EX (bronze roller) Pan-head Phillips screw with external lock washer One-way roller lever (for CCW actuation) Adjustable length roller lever 43 mm to 76 mm [1.7 in to 3 in] Rod lever 134 mm [5.28 in] Adjustable length 317,5 mm [12.5 in] max. rod lever with 25,4 mm [1 in] nylon roller Roller lever 6PA142-EX (bronze roller) 6PA138-EX (nylon roller) 6PA136-EX (aluminum rod) 6PA204-EX 6PA5-EX (bronze roller) 6PA127-EX (nylon roller) Metal clamp Adapter screw Washer sensing.honeywell.com 9

205 EX Series Table 7. Mounting Brackets 15PA85-EX (for side rotary) 15PA86-EX (for top plunger) used for top, bottom, back, or end mounting. It is furnished with each switch, except where noted in the order guides. ordered separately for top mounting of plunger switches. EX switches may also be direct mounted, using UNF screws. This datasheet supports the following MICRO SWITCH EX Series Hazardous Location Limit Switches 1EX1 EX-AR1613 EX-AR800 EXH-AR3 EX-Q173 6PA130-EX 2EX1 EX-AR1620 EX-AR830 EXH-AR33 EX-Q19 6PA136-EX 4EX1-3 EX-AR-1621 EX-AR87 EXH-AR7 EX-Q22 6PA138-EX 4EX5-3 EX-AR182 EXD-AR20-3 EXH-AR7-R1 EX-Q400 6PA142-EX EXA-AR EX-AR20 EXD-AR-3 EXH-N EX-Q62 6PA204-EX EXA-AR20 EX-AR230 EXD-AR30-3 EXH-Q26-2 EX-Q800 6PA5-EX EXA-AR62 EX-AR30 EXD-AR30-6 EXHT-AR 15PA85-EX 8PA12-EX EXA-N EX-AR400 EXD-AR62-3 EXHT-AR403 19PA4-EX 8PA15-EX EXA-Q EX-AR420 EXD-AR87-3 EXHT-Q 33PA1-EX 8PA77-EX EX-AR EX-AR EXD-N-3 EX-N15 33PA5-EX EX-XR3 EX-AR128 EX-AR471-3 EXD-Q26-2 EX-N152 33PA6-EX EX-XR9 EXAR-141 EX-AR50 EXD-Q-3 EX-Q 33PA7-EX EX-YQ-3 EX-AR16 EX-AR68 EXD-Q62-3 EX-Q1 6PA126-EX EX-AR8 EXH-AR2 EX-Q171 6PA127-EX 10 sensing.honeywell.com