Model 682 Manual - Controls Warehouse
Contents
1. 682 15 Piston Flow Meter SERVICE MANUAL TOTAL CONTROL SYSTEMS 2515 Charleston Place Fort Wayne IN 46808 800 348 4753 260 484 0382 Fax 260 484 9230 sales tcsmeters com www tcsmeters com SPECIFICATIONS Type Reciprocating 3 Piston Positive Displacement Connections 1 1 2 companion flange Flow Rate Minimum 0 2 GPM 0 76 LPM Maximum 40 GPM 151 LPM Working Pressure 150 PSI maximum 10 5 Bar Working Model 682SP 20 F to 200 F 28 9 C to 93 3 C Temperature Models 682AF amp 682SS 20 F to 400 F 28 9 C to 204 4 C Units of Measure 1 10 U S Gallons STANDARD Litre s Pounds etc available upon request FLOW METER TYPES SP Standard Petroleum Petroleum base products Gasoline Fuel Oil Av Gas Kerosene Lubrication Oils etc AF All Ferrous Petroleum base products Industrial Chemicals Agricultural products SS Stainless Steel Covers the same products as the SP and AF models but includes special handling liquids such as Acids MATERIALS OF CONSTRUCTION Type Housing Internals Cups Seals SP Cast Iron Cast Iron amp 316 SS Glass filled TFE Teflon AF Cast Iron Cast Iron amp 316 SS Glass filled TFE Teflon SS 316SS 316 SS Glass filled Teflon is a registered trademark of Dupont Do2. 5 6 2 3 2 1 2 3 4 1 2 PROBLEM meter allows product to pass through it but the register meter doesn t move Check the reset knob on the register On older style Veeder Root registers this knob can become stuck in which will disengage registration In this case though the totalizer would still register Check the screws that hold the gear plate onto the bottom of the register If they become loose neither the register nor the totalizer will register The drive gear coupling shaft in the gear plate under the register is broken or pin missing The retaining ring on the counter drive gear has come off or broken allowing the drive gear to disengage from the drive shaft gear assembly The post on the wobble plate inside the meter has snapped off When this happens it usually indicates that air has been pumped though the meter The connector on the piston assembly inside the meter is broken allowing product to pass PROBLEM The meter will not deliver product and will not register Check any air eliminator and or strainer screens in the system for blockage Also check all valves in the system for proper operation If the problem still hasn t been discovered after those checks determine what the pressure is before and after the meter with the pump running Equal readings would indicate the meter isn t necessarily the problem On older style Tokheim 682 meters there is a back pressu
3. 10 year warranty applies to meters only and does not apply to accessories such as valves and air eliminators Parts and equipment not manufactured by TCS may be covered by separate warranties of their respective manufacturers This warranty does not cover any parts or equipment not manufactured by TCS or related companies This warranty does not extend to any equipment that has been altered in any way subjected to misuse negligence accident or if operated in any manner other than in accordance with TCS s operating instructions or have been operated under conditions more severe than or otherwise exceeding those set forth in the specifications General maintenance calibration clean up and normal wear is excluded from this limited warranty CLAIM PROCEDURES In order to obtain performance by TCS of its obligations under this warranty the original purchaser must obtain a Return Goods Authorization RGA number from TCS s customer service department within 30 days of discovery of a purported breach of warranty but not later than the expiration of the warranty period Once authorization is received return the defective meter piece of equipment or component covered by this warranty with transportation charges prepaid to TCS at the address shown below together with a written statement setting forth the nature of the defect and RGA number LIMITATIONS THERE ARE NO OTHER WARRANTIES OF ANY KIND EXPRESS OR IMPLIED TCS SPECIFICALLY DISCLAIMS ANY
4. All foreign particles must be removed 1 dirt metal shavings Replace all damaged air eliminator parts Reassemble the float and bracket assembly to the cover assembly with screws 4 Do not tighten screws until the bracket assembly 2 is properly adjusted between the shut off valve 15 and seal 18 Once float and bracket assembly are tightened reassemble air eliminator HYDRAULIC VALVE ASSEMBLY 650 15 OD gt BD BW 09 Lol QI Lo 6 9 Lol wW AW Yoo 9 os 6 N SCH TS 2 ae Con eg Lay N Q Vi SJ O 19 AA 9 NGS er e 1 1 d 67 AAMA 2 VM gt AMANA MH 1 9 HYDRAULIC VALVE ASSEMBLY 650 15 DESCRIPTION QTY AF SS 1 Retaining Ring 1 6 052482 6 052482 2 Washer Flat 1 65034 65034 3 Spacer 2 1 130852 1 130852 4 Bracket 1 1 226102 1 226102 5 Screw 2 65005 65005 6 Locknut 2 65008 65008 7 Swivel Block 1 1 128140 1 128140 8 Connecting Link 1 65025 65025 9 Cotter Pin 4 1 126318 1 126318 10 Washer 2 65003 65003 11 Actuating Arm 1 65016 65016 12 Lifter 1
5. Emory cloth may buff these out 2 Compensator Shaft 24 Emory cloth may buff these out 3 Bonnet 12 a Drive shaft packing gland b Compensator shaft gland c Counter drive gear assembly seat amp post Insert drive shaft gear assembly 18 with Rulon washer 17 into the meter drive shaft packing Install drive shaft packing Kit 9 SEE DRIVE SHAFT PACKING KIT INSTRUCTIONS for more information Slide the counter drive gear assembly 15 with Rulon washer 14 over the post Each meter uses about 3 4 washers 10 before the cotter pin 21 is inserted Compensator Shaft Assembly 1 Insert AF SP retaining ring 32 or SS cotter pin 16 on to the compensator shaft 24 2 Insert compensator shaft into packing gland 3 Install compensator shaft packing kit 30 SEE COMPENSATOR SHAFT PACKING KIT INSTRUCTIONS for more information Mount Bonnet to Base 1 Place gasket 13 into bonnet 12 2 Move compensator shaft 24 to match pinion 51 in the base by using the index disc 27 3 Mount bonnet 12 to base 60 4 Insert screws 31 and tighten COMPENSATOR SHAFT SEAL KIT INSTRUCTIONS 1 2 3 4 5 6 7 8 9 Remove screws that bolt meter cover assembly to meter body Loosen and remove the entire meter cover assembly Cut seal wire and remove seal pin from index disc Unscrew hex nut from the compensator shaft Remove compensator washer in
6. 51 in its slot For AF amp SP meters unscrew the pinion and main pivot bracket assembly 5 full turns For SS meters unscrew the pinion and main pivot bracket assembly 3 1 full turns This should help bring meter within range while calibrating Drop the slotted screws 54 into bracket Place bracket with screws into main pivot bracket assembly Set 5 8 ball bearing 49 into position Place the wear plate 48 over the screws 54 Set wobble plate 47 onto the screws 54 and fasten down with lock nuts 41 amp lock washers 42 7 Set slack spring assembly 45 on wobble plate post with Rulon washer 44 amp slack roller 43 8 Mount main pivot bracket assembly to valve 57 amp seat 58 with lock washers 42 amp screws 52 AM P Lab Connect Pistons Wobble Plate 1 Carefully slide connector 36 over the wobble plate 47 bearing seats 2 Place 1 2 ball bearing 46 onto wobble plate and cover with bearing seat 35 amp retainer 33 3 Rotate wobble plate 47 amp pistons 40 through each cylinder to make sure of smooth flowing characteristics 682 METER BONNET REPAIR INSTRUCTIONS Remove all parts and seals from meter bonnet and clean them You air blast parts with a glass bead material to clean parts Check for excessive wear NOTE Problems with any of these following items will require a new bonnet or shafts 1 Drive Shaft 5
7. 65010 65010 13 Valve Handle Shaft 1 65005 65005 14 Retaining Ring 2 65026 65026 15 Shaft Bearing 2 65004 65004 16 Bracket 1 65012 65012 17 Screw 1 4 20 X 1 2 3 65032 65032 18 Washer Split Lock 3 1 126317 1 126317 19 Valve Stem 1 65018 65018 20 Roll Pin 5 32 X 1 1 65027 65027 21 Screw 10 24 X 1 2 7 1 128279 1 128279 22 Washer 3 1 126316 1 126316 23 Compression Washer 1 1 130872 2 130872 24 Spacer 1 1 130893 1 130893 25 Screw 5 16 18 X 1 4 65033 65033 26 Packing Seal 1 600102 600102 27 Cover 1 65031 2 65031 4 28 Pipe Plug 3 2 051913 2 126146 29 Poppet Spring 1 65007 65007 30 Washer Flat 2 65035 65035 31 Plunger Cup Support 1 65014 65014 32 Plunger Cup 1 65013 65013 33 Plunger 1 65030 65030 34 Valve Disc 1 65009 65009 35 Valve Seat 1 65006 65006 36 Poppet Guide 1 65029 65029 37 Screw 10 24 X 5 8 4 2 128279 2 128279 38 Gasket 1 65021 65021 39 O Ring 1 65001 65001 40 Valve Body Assembly 1 65036 1 65036 2 650 HYDRAULIC VALVE REPAIR INSTRUCTIONS 1 2 3 4 5 6 Remove screws 17 from bracket 16 and lift arm linkage from valve assembly Remove the roll pin 20 from the valve stem 19 Then remove the screws 25 from the cover 27 and poppet assembly and lift from the body 40 Inspect the seat of the body 40 for pitting or foreign matter Pull the poppet assembly from the cover 27 and inspect for a damaged plunger cup 32 and or valve disc 34 Remove the screws 37 fro
8. giving away 2 of the product it meters The top disc on the calibrator has a tab sticking up The tab is marked with a plus and a minus sign This indicates plus product and minus product By turning the disc in one direction or the other product delivery will be increased or decreased A full revolution of the disc will change the calibration of the meter 3 Therefore if the meter shows 4 9 gallons on the register the disc should be turned 2 3 of one revolution 2 in the minus direction since in this case we want less product through the meter 5 gallons passed through it in the test and only registered 4 9 gallons Empty the prover and let it drip for 30 seconds Run a second test and make a fine adjustment and then another test to check your fine adjustment Replace the pin into the disc and seal it with the seal wire NOTE If your meter has a mechanical or electronic preset it should be set high enough so that it doesn t affect the calibration process Only a valve at the prover should be used to control the flow during calibration KEY FEATURES OF 682 METER TYPICAL ACCURACY CURVE 32 SSU SOLVENT 2 0 2 E 01 0 gt 0 1 e 0 2 0 5 10 15 2 25 30 35 40 GALLONS PER MINUTE The 682 meter s linear accuracy percent of error over or under the zero error level remains within design parameters 0 2 over its 0 2 to 40 GPM flow range This exceeds the maintenance requirem
9. using the product being metered by the user Generally calibrating it to a specific product and installation maximizes any meter s accuracy The 682 meter exceeds the accuracy requirements specified in NIST Handbook 44 which is 0 2 at the factory In the field NIST Handbook 44 maintenance test accuracy requirements are 0 5 on a special test and 0 2 on a normal test In a five gallon test 0 2 2 31 cubic inches 0 3 3 47 cubic inches and 0 5 5 78 cubic inches STORAGE INSTRUCTIONS Short periods of non use of the meter a week or less will present no problem provided that the meter remains full of product For long periods of non use such as winter storage the following procedure is recommended Before long term storage a good practice is calibration of the meter to determine that it is functioning properly 1 2 3 4 To store the meter when it is left in line flush the system with clean water until 40 50 gallons of water have gone through the meter Pump a 50 anti freeze 50 water solution through the entire system 100 RV antifreeze may be used instead With the pump running shut off a valve downstream from the meter making sure that anti freeze solution is present at that point Then close an upstream valve such that the meter remains full of anti freeze solution Remove the register from the meter and lubricate the drive coupling shaft After lubrication it replace the register onto the me
10. WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE TCS will determine if all parts or meter defect falls within the warranty guidelines and will repair or replace within a reasonable time span TCS is not responsible for any in or out bound freight TCS s sole obligation that shall represent the buyer s sole and exclusive remedy shall be to repair or at TCS s option to replace any product or part determined to be defective In no event shall TCS be liable for any special direct indirect incident consequential or other damages of similar nature including without limitation loss of profits products production time or loss of expenses of any nature incurred by the buyer or any third party TCS has not authorized on its behalf any representation or warranties to be made nor any liability to be assumed except as expressly provided herein there is no other express or implied warranty REPAIR WARRANTY All repair work is warranted for 90 days from the date of shipment to customer Some parts may be warranted for longer periods by the Original Equipment Manufacturer DESIGN AND EQUIPMENT CHANGES Any changes in design or improvements added shall not create any obligation to install same on equipment previously sold or ordered 6825 4 01 01 03 TOTAL CONTROL SYSTEMS 2515 Charleston Place e Fort Wayne IN 46808 800 348 4753 260 484 0382 Fax 260 484 9230 sales tcsmeters com www tcsmeters com
11. dex disc index plate and compression spring from the shaft From inside the cover housing turn the compensator shaft until the attached truarc E retaining ring or cotter pin clears the edge of the counter drive gear Slide the compensator shaft assembly from the housing Remove the spacer Lift the old packing from the housing Be sure there are no foreign particles left in the cavity Replace the compensator shaft assembly into the cover housing Support the shaft from beneath while packing the new seal and spacer Packing SEE ILLUSTRATION FOR PACKING SEQUENCE Seal Replace the compression spring index plate index disc compensator washer and hex nut to the compensator shaft Do not fully tighten the hex nut until the meter has been calibrated Reassemble the meter cover assembly to the meter body assembly and tighten down the screws Calibrate the meter according to instructions Compensator Shaft METER DRIVE SHAFT PACKING KIT INSTRUCTIONS 1 2 3 4 5 6 7 8 9 Remove screws that bolt the meter cover assembly to the meter body Loosen and remove the entire meter cover assembly Drive Shaft Carefully remove the roll pin from the drive shaft Remove 3 screws 3 lock washers the compression washer From inside the cover housing remove the retaining ring or cotter from the counter drive shaft Remove the Bearing counter drive gear and washers Slide the drive shaft assembly from the h
12. embly 1 226136 1 226136 1 226136 2 16 TCS Cotter Pin 1 16 X 1 2 1 1 126318 17 TCS Washer 7 8 OD X 0 15 Rulon 1 1 125407 1 125407 1 125407 18 TCS Drive Shaft Gear 1 226135 1 226135 1 226135 2 19 TCS Cotter Pin 3 16 1 1 4 1 13 052870 13 052870 1 126319 20 TCS Drive Shaft Pin 1 4 X 1 3 32 1 1 126913 1 126913 1 126914 21 TCS Cotter Pin 1 16 X 1 2 1 1 126318 1 126318 1 126318 22 TCS Seal Pin 1 1 019602 1 019602 1 126929 23 TCS Wire and Seal 1 1 118849 1 118849 1 118849 24 TCS Shaft 1 1 224081 1 224081 1 224119 25 TCS Nut 5 16 18 1 2 050301 2 050301 1 126320 26 TCS _ Compensating Washer 1 1 019797 1 019797 1 126927 27 TCS Index Disc 1 1 126931 1 126931 1 126931 28 TCS Index Plate 1 1 226085 1 226085 1 130853 29 TCS Compression Spring 1 1 130935 1 130935 1 130935 30 TCS Compensator Shaft Seal Kit 1 227000 1 227000 1 227000 1 31 TCS Screw 7 16 14 X 1 1 4 10 3 230958 3 230958 1 130879 32 TCS Retaining Ring 0 320 ID 0 025 T 1 12 053420 12 053420 2 33 TCS Bearing Retainer Plunger 3 1 126957 1 126957 1 126957 34 TCS Plunger Screw 10 32 X 3 8 12 1 126329 1 126329 1 126329 35 TCS Bearing Seat Plunger 3 1 219378 1 219378 1 130908 36 TCS Piston Connector Plunger 3 1 126939 1 126939 1 126939 37 TCS Plunger Disc 3 1 126878 1 126878 1 126878 38 TCS Plunger Cup Kit 3 Cups 1 218769 1 218769 1 218769 1 39 TCS Cup Support 3 1 126876 1 126876 1 126876 40 TCS Plu
13. ents for accurate custody transfer of product as specified in the National Institute of Standards and Technology NIST Handbook 44 PRESSURE DROP CURVE 32 SSU SOLVENT 20 10 0 5 10 15 20 25 30 35 40 GALLONS MINUTE The 682 meter is mechanically capable of accurately metering products as slow as 0 2 GPM and as quick as 40 GPM Comparing the lowest and the highest flow rate results in a 200 1 turn down ratio for the 682 meter The nameplate on the 682 meter states the flow rate as 2 40 GPM This matches the flow range across which the meter was tested while earning a Certificate of Conformance from the National Type Evaluation Program NTEP It should be noted that as viscosity increases maximum flow rate may decrease See the viscous liquids performance graph for specific information Viscosity is a measure of the flow ability of a product VISCOUS LIQUIDS PERFORMANCE SR SE RR ES GE ee CL SSS RES RA 515555525590 CC 11142 E KT 23 ED PRESSURE DROP 5 1 682 METER EXCHANGE PROGRAM Overview TCS offers an exchange program on the 682 AF and SP meters The exchange price equal to less than 1 3 the price of a new meter after the credit given from the returned meter core This makes the exchange program a powerful value added option for 682 owners Exchange meters are available for same day shipping For the exchange program to con
14. is not running One way to do this is to have the inlet and outlet of the meter lower than the associated system plumbing sump position Also undue strain on the meter s 150 flanges from the connected piping must be avoided Slow Flooding Of System When a pump is turned on and a valve opened in a new dry system tremendous pressure can be built up in the piping and forced through the meter The high pressure and volume of air causes the meter to operate more quickly than normal When product reaches the meter there is an abrupt slowing of the meter plungers which could cause damage to the register plunger gears or other components The recommended method of starting any system is to flood the piping gradually This allows product to slowly force the air from the entire system Protection From Debris On new installations care must be taken to protect the meter from damage during start up Damage may result from the passage through the meter of welding slag or spatter thread cuttings rust etc There are several methods of protecting meters from this material including the insertion of a spool a flanged length of pipe equal in length to the meter and any accessories attached to the meter in place of the meter until the system is flushed temporarily bypassing the plumbing around the meter or by installing a strainer ahead of the meter in the line Calibration The meter s calibration must be checked and adjusted if necessary
15. m meter body clean them You may blast parts with a glass bead material to clean parts Always replace bracket 56 screws 54 amp 34 plunger cups 38 and Rulon seals 14 17 amp 44 Check for Excessive wear on the wobble plate 47 guide holes Pitting on ball bearings 49 amp 46 Excessive wear on the guide posts on main pivot bracket assembly 53 Wear on the AF SP valve 57 or SS valve insert 57 Wear on the valve seat 58 Wrinkles on the sleeves in cylinders TCS 1 126891 of the body NOTE Honing sleeves with Emory wheel may buff out wrinkles ON es Mount valve seat 58 to body 60 with seat gasket 59 B Lap valve 57 for AF SP or SS 1 AF amp SP Use Rectorseal Clover lapping compound or equivalent on valve 57 amp seat 58 Move valve repeatedly in a Figure 8 and clean compound off valve and seat thoroughly when finished 2 SS Use 220 amp 320 grit silicon sand paper to lap valve amp insert 57 Move valve repeatedly in a Figure 8 on 220 grit paper then use the 320 grit paper Wipe valve Rulon insert clean Replace plunger cups 38 in piston 40 and carefully place into cylinders SEE PLUNGER CUP KIT for piston repair instructions DO NOT cut or crimp plunger cups Main Pivot amp Wobble Plate Assembly 1 Screw the main pivot assembly 50 all the way into main pivot bracket assembly 53 and place pinion
16. m the poppet guide 36 to inspect the valve seat 35 for pitting or excessive wear Replace as necessary To replace the packing seal 12 within the cover 27 remove the compression washer 23 screws 21 washers 22 and stem 19 completely Carefully slide packing seal 12 and spacer 24 over valve stem 19 Reassemble compression washer screws and washers Replace the previously removed parts and reassemble the valve NOTES 682 METER EXCLUSIVE LIMITED WARRANTY WARRANTY New 682 piston meters manufactured by Total Control Systems a division of Murray Equipment Inc TCS with which this warranty is enclosed are warranted by TCS to the original purchaser only for a period of ten 10 years from the date of shipment to be free under normal use and service from defects in material and workmanship TCS manufactured new equipment or components are warranted for a period of one 1 year from the date of shipment under normal use and service This warranty is extended only to the original purchaser For defects occurring within the stated warranty period TCS will repair or replace at TCS s option provided that part or parts are returned to TCS transportation charges prepaid and the TCS s examination discloses the parts or workmanship to have been defective upon delivery to the purchaser EXCLUSIONS TCS s ten
17. med place the plunger assembly into the meter body and press into the piston cylinder Turn the assembly in the piston cylinder to assure the cup is evenly formed to the cylinder Replace previously removed parts and reassemble meter Test and calibrate meter for accuracy AIR ELIMINATOR ASSEMBLY 640 15 AIR ELIMINATOR ASSEMBLY 640 15 ITEM DESCRIPTION QTY AF SS 1 Cover 1 64002 2 64002 3 2 Bracket Assembly 1 64019 64019 3 Lock Washer 3 1 126316 1 126316 4 Screw 3 64010 64010 5 Short Link Pin 2 64023 64023 6 Connecting Arm 2 64007 64007 7 Lever Arm 1 64006 64006 8 Cotter Pin 6 1 126318 1 126318 9 Float Assembly 1 64005 64005 10 Pipe Plug 1 2 051913 2 126146 11 Base 1 64003 2 64003 3 12 Gasket 1 64004 64004 13 Shut Off Arm 1 64015 64015 14 Long Link Pin 2 64012 64012 15 Shut Off Valve 1 64016 64016 16 Valve Seat 1 64001 64001 17 External Valve O Ring 1 64013 64013 18 Internal Valve O Ring 1 64014 64014 19 Screw 10 64021 64021 640 AIR ELIMINATOR REPAIR INSTRUCTIONS 1 2 3 4 5 Remove screws 19 that bolt the air eliminator base 11 to cover assembly 1 Remove the screws 4 and washers 3 that mount the float and bracket assembly 2 to the cover assembly 1 Inspect for damage to float and bracket assembly making sure no liquid is inside the float 9 and o rings 17 amp 18 are not torn or cut
18. nger Assembly 3 226182 2 226182 2 226182 2 41 TCS Nut 0 3 1 126321 1 126321 1 126321 42 TCS Washer 1 4 Split Lock 3 1 126317 1 126317 1 126317 43 TCS Slack Roller Assembly 1 219800 1 219800 1 219800 2 44 TCS Washer 0 863 OD 0 030 Rulon 1 1 125103 1 125103 45 TCS Slack Spring Assembly 1 221403 2 221403 2 221403 5 46 TCS 1 4 Dia 3 1 124588 1 124588 2 130905 47 TCS Wobble Plate Assembly 1 219331 1 219331 1 219901 2 48 TCS Wear Plate 1 1 217934 1 217934 1 217934 49 TCS 5 8 Dia 1 1 125046 1 125046 1 130905 50 TCS Main Pivot Assembly 1 219572 4 219572 4 219572 4 51 TCS Compensating Pinion 1 1 129607 1 129607 2 129607 52 TCS Screw 1 4 20 X 4 3 1 126327 1 126327 1 126327 53 TCS Pivot Bracket Assembly 1 218236 4 218236 4 219260 6 54 TCS Slotted Screw 1 4 20 X 1 3 1 126962 1 126962 1 126962 55 TCS Screw 1 4 20 1 6 1 126326 1 126326 1 126326 56 TCS 1 3 218608 3 218608 6 218608 57 5 1 1 219330 1 219330 220496 2 58 TCS Seat 1 1 038618 1 038618 1 310336 59 TCS Gasket Teflon 1 1 038619 1 038619 1 038619 60 TCS Body Seat and Pin Assembly 1 227093 2 227093 2 227093 4 61 TCS 1 2 13 X 1 3 4 8 5 230958 5 230958 62 TCS Flange 2 1 226166 1 226166 63 TCS Flange Gasket 2 2 221453 2 221453 2 221453 64 TCS Nut 1 2 13 8 1 231174 1 231174 682 METER BODY REPAIR INSTRUCTIONS Remove all parts and seals fro
19. oise Check the calibrator on the meter If it is adjusted too far out excessive knocking is possible If the problem isn t the calibrator then the meter valve or another internal part may need repair or replacement METER ASSEMBLY 682 15 0 emmer 30 TS br DDO 6 METER ASSEMBLY 682 15 ITEM DESCRIPTION QTY SP AF Ss 1 TCS Screw 3 8 16 X 1 1 8 1 297 050361 297 050361 1 126333 2 TCS Washer 3 8 Split Lock 1 15 050641 15 050641 1 126334 3 TCS Counter Support 1 1 312518 1 312518 1 312518 4 TCS Pin 1 49 052910 49 052910 3 130752 5 TCS Shaft 1 1 114815 1 114815 1 126900 6 TCS Screw 10 24 2 6 252 50001 252 50001 1 128279 7 TCS Washer 10 Split Lock 12 1 126316 1 126316 1 126316 8 TCS Compression Washer 2 1 130872 1 130872 2 130872 9 TCS Drive Shaft Packing Kit 1 226199 1 226199 1 226199 1 10 TCS Washer 9 16 OD X 0 10 T 10 1 125095 1 125095 1 126903 11 TCS Plug 1 4 2 2 051913 2 051913 2 126146 12 TCS Cover amp Post Assembly 1 227006 1 227006 1 227006 3 13 TCS Gasket 8 3 16 ID Teflon 1 68 311105 1 315423 1 315423 14 TCS Washer 3 4 OD X 0 015 Rulon 1 1 125120 1 125120 1 125120 15 TCS Counter Drive Gear Ass
20. on and the cycle will repeat so long as product continues to enter the meter If product flow stops pressure in the meter equalizes and motion stops Thus the meter only operates when product is flowing a Drive Shafi Center Crear Post Valve Pivol Wobble Flite Plunger Guide Fin Sliding Valve Measuring Chamber Inlet Outlet METER APPLICATION When installing a meter into a system several factors must be considered Flow Rate The flow rate of the system must be within the meter s capability The 682 meter can operate between 0 2 and 40 GPM The flow rate of the system is dependent upon the system s pump capabilities and the plumbing configuration and the product to be measured Operating Pressure The 682 meter can operate at pressures up to 150 PSI 10 5 BAR Compatibility Products with suspended solids in them will scratch the piston liners and tear the plunger cups The liquid to be metered must also be compatible with the meter The standard petroleum SP is for service in petroleum with the meter The all ferrous AF is for industrial and agricultural products and the stainless steel SS is for service on products which required 316 stainless steel for proper handling Note that the 682 meter should not be used on water Water has no lubricity and will drastically shorten the meter s service life It is recommended that if the meter is to be used on water it should be derated about 40 to 50 percen
21. ousing If the upper or lower housing is chipped cracked welded or similarly damaged and in need of replacement then the dealer s core credit will be reduced accordingly DIMENSIONS 1 FLANGED INLET 1 FLANGED OUTLET 1 11 5 16 10 dee 11 16 REG REGISTER PRESET 8 11 16 5 1 4 METER X KX PRESET x 3 3 4 REGISTER x REG PRINTER _X x 203 1914 16 8 Ll HEIGHT 15 578 12 28 2 11 16 em 1 1 1 AIR GR EIS 8 4 HYDRAULIC VALVE 31 374 6 3 8 16 MOUNTING HOLES 4 11 16 6 FRONT 2 11 16 6 6 1 8 5 7 16 Measurements Inches 2 0 TROUBLE SHOOTING THE 682 METER The following is a list of common problems that can be encountered with a 682 meter and possible causes and solutions for them A 2 3 4
22. ousing Washers Lift the old packing from the housing Be sure there are no foreign particles left in the cavity Replace the drive shaft assembly into the cover housing Secure in position by reassembling the counter drive gear Dr Shaft with the washers and retaining ring or cotter pin previously removed Gear Support the counter drive shaft assembly from beneath while packing the spacer bearings washers and the new seal SEE ILLUSTRATION FOR PACKING SEQUENCE Replace the compression washer with the screws and lock washers WY SE es 10 Insert the roll pin drive shaft Be sure to support shaft while doing this to prevent bending it 11 Reassemble the meter cover assembly to the meter body assembly and tighten down the screws PLUNGER CUP REPLACEMENT 2 Remove plunger assembly from meter body Loosen and remove two 2 round head screws and lift plunger cup support from plunger cup and plunger disc Discard the old plunger cup kit Place the new plunger cup on the plunger disc Add the cup support and secure with the two 2 round head screws previously removed NOTE Apply Loctite 271 or equivalent to the screw threads Be sure the cup is evenly spaced on the plunger disc and support 5 Form the cup by turning the plunger assembly in your hand using your thumb to roll the edge slightly 6 7 8 After the cup is partially for
23. re valve on the discharge of the meter which can become stuck shut If it is determined that the problem is in the meter itself then the meter valve inside the meter is stuck down onto the valve body PROBLEM The meter delivers more product then what is registered First the meter should be tested for repeatability To test repeatability run a fast high gallons per minute test in your prover and record how much the meter is under registering Do NOT change the meter s calibration Then run a slow low gallons per minute test and again record the amount that the meter is under registering If the results from the fast and the slow test are the same or close to the same the meter has repeatability and can be calibrated If the test results differ beyond the rated tolerance of the meter then repairs are necessary NOTE the meter is more than 7 inaccurate register reading of 4 65 or less gallons a 5 gallon test then it cannot be calibrated until repairs are made PROBLEM The meter delivers less product then what it registers The meter could have the wrong gear train in its register Check for leaks on the suction side of the pump including the pump seal Air which is sucked into the system and pushed though the meter would affect registration After eliminating these possible causes check the meter s repeatability as outlined in problem C above Register may need repair PROBLEM The meter has excessive knocking n
24. t of flow Operating Temperature The temperature range of the product to be metered must be within the meter s range The SP meter can operate between 20 F and 200 F The AF and SS meters can operate between 20 F and 400 F Temperatures above 200 F require a heat extension Registration The 682 meter normally uses a Veeder Root 5 wheel resetable register in 1 10 U S gallons with an 8 digit non resetable totalizer Litre s ounces pounds or nearly any other unit of measure can be accommodated upon request Weights amp Measures Approved Device The TCS model 682 series flow meter holds the National Type Evaluation Program NTEP Certificate of Conformance meeting the National Institute of Standards and Technology NIST Handbook 44 requirements The TCS model 682 series flow meter combines outstanding linear accuracy 0 1 over entire 200 1 range with superior performance At constant flow with all other conditions being constant the flow meter does not vary more than 0 01 in repeatability The TCS model 682 series flow meter is virtually unaffected by changing viscosities The inline meter design allows the TCS model 682 series flow meter to have a wide operating range 0 2 to 40 GPM and fluid compatibility that has been proven over many years of service INSTALLATION AND START UP Best Plumbing Configuration Meters and piping should be installed to prevent drainage of product from the meter when the system
25. ter When starting the system after a period of storage rechecking the meter s calibration as detailed earlier in the service manual CALIBRATION OF THE 682 METER A 1 2 It is important to test the repeatability and accuracy of your meter To test repeatability Run a fast high gallons per minute test in your prover and record how much the meter is over or under registering Do NOT change the meter s calibration Run a slow low gallons per minute test and again record how much the meter is over or under registration If the results from the fast and the slow test are the same or close to the same the meter can be successfully calibrated If the test results differ beyond the rated tolerance of the meter then repairs are necessary before the meter can be calibrated TOMO Ow A valve or nozzle must at end of delivery hose at prover Turn on the pump and purge the system of air Leave the pump on Shut off the valve at the end of the delivery hose and let the system pressurize Wet the prover and empty it letting it drip for 30 seconds Reset the register on the meter to 0 Fill the prover to the line marked 0 Record what the register reads Every1 10 gallon difference between the register and the 5 gallons known to be in the prover equals a 2 inaccuracy For example a reading of 4 9 gallons on the register compared with a 5 gallon prover filled to the line means the meter is
26. tinue smoothly the used meter must be returned to TCS as promptly as possible especially in the spring months Exchange Program Highlights 1 Exchange meters are always in stock 2 Fast service to your customer minimizes downtime 3 Customer needs fewer parts for inventory to ensure continuous operation 4 exchange meters maintain NTEP Certificate of Conformance 5 The program applies to one meter or several meters at a time 6 Meters are factory tested and calibrated 7 Saves your customer money 8 Repeat business for distributor 9 Meter can be rebuilt numerous times Program Details When a meter is exchanged the user retains his register and adapter as well as any other accessories he may have presets ticket printers etc Separate exchange programs exist for registers and some other accessories The exchange meter which is shipped from TCS is calibrated and freshly painted The exchange meter is guaranteed to be free of defects in material and workmanship for 180 days from the date it ships to the end user or distributor The used meter returned to TCS should be shipped freight prepaid truck shipments are recommended for the safety of meter It must be flushed and have a Material Safety Data Sheet MSDS identifying the product that was in the meter Regardless of the condition of the internal parts of the meter the only additional charge a distributor may be subject to is for the upper or lower h
27. w Elastomers L L C 682 METER OPERATION The 682 meter is a true Positive Displacement Meter with the inlet and outlet on the same horizontal plain straight in straight out Within the meter three plungers are fitted within their respective cylindrical measuring chambers The plungers are joined to a wobble plate which has a shaft extending from its upper surface The wobble plate also has a valve pivot attached beneath it The valve pivot drives a sliding valve from piston to piston as product flows controlling the sequence of events The wobble plate shaft is always held at an inclined position by the center gear post and the wobble plate itself is prevented from rotating by four guide pins on the pivot bracket assembly As product enters the meter it initially flows into the upper housing The sliding valve will now be in position to open one measuring cylinder The plunger for that particular cylinder will be at the upper position With the pressure below it relieved and an upper housing full of product the pressure on top of that plunger will cause it to move toward the bottom of the cylinder thus forcing out the remaining product As this occurs another plunger will be forced from the down position to the upper position The sliding valve moves via the wobble plate to open the inlet of this cylinder As the plunger moves upward it draws product into the measuring cylinder from the bottom Once this plunger reaches the upper positi
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