91-10G347 CMD-701-8M Wiring.mcd
Contents
1. AUMNUNNEWSTE t 9 peur 6 6 1 06 PXHOERDOA 2 __ _ _____ ___ __ ___ __ CONFONENT pues ponse AUWGUVERSNEWSTRE 1 I I pee 990 IPE PLUG SENT Rs ess per 20590 REXWSHRHDTHOFAMG 2 ovemRERRW SE CASTACM COMPONENT ___ __ __________ _____ ___ __ CONFONENT FUANGEASSY WENT 0 8 72 50 AT WASHER 040610 DEE 8 pe BUNANUL 81200 0288 pus pem 5885 NI Installation amp Maintenance Instructions NSdRed Hat i OPEN FRAME GENERAL PURPOSE WATERTIGHT EXPLOSIONPROOF SOLENOIDS SERVICE NOTICE ASCO solenoid valves with design change letter G in the catalog number example 8210G 1 have an epoxy encapsulated ASCO Red Hat II solenoid This solenoid replaces some of the solenoids with metal enclosures and open frame constructions Follow these installation and maintenance instructions if your valve or operator uses this solenoid DESCRIPTION Catalog numbers 8016G1 and 8016G2 are epoxy encapsu2. O 5 Om SO 10 e A0 3 c CMD 701 MA 8M INTERNAL LAYOUT Pump Measure Control Inc 7 414 03 1070 Nine North Drive Suite 100 w Alpharetta GA 30004 p PH 770 667 0667 FAX 770 667 04768 THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND IS SUBJECT TO UMBER 91 1 0G322 COPYRIGHT OWNERSHIP BY PMC INC UNI 00 8L9GrvECH LEAL 91 91 61 W0 606686 P N 120000 Aie 7831234567 8 TB41 2345678 r 592599 TB 1 AC POWER TB 3 DC External Permissive Input 12 VDC Power Supply Dispenser Handle Input Pump Start Output 12 VDC Solenoid 1 Output solenoid 2 Output Meter Pulse Input Channel A Earth Ground Meter Pulse Input Channel B AC Neutral DC Pulse Out AC Power DC Pulse Out TB 2 RELAY CONTACT 2 Nozzle Switch Relay Contact Common Display Communications Display Communications Volume Pulse Out 12 VDC DC Ground ON OFF Lever Input CPU BOARD P N 120000 PMC TERMINAL DESCRIPTIONS Pump Measure Control Inc 1070 Nine North Drive Suite 100 220 03 SAT PH 770 667 0667 FAX 770 667 0476f THIS DRAWING CONTAINS PROPRIETARY DRAWING NUMBER INFORMATION AND IS SUBJECT TO 91 03A44 COPYRIGHT OWNERSHI
3. FRONT OF UNIT Figure 3 CMD 701 MA 8M dispenser footprint underground supply feed Page 3 3 The CMD xxx dispensers must be installed in a system that prevents air from being pumped through the dispenser Submersible turbine pumps do not tend to pump air However if another type of pumping device is used means must be provided to eliminate air from the system before it reaches the dispenser 4 The CMD xxx dispenser must be installed in a system that incorporates a power operated pump incorporating a pressure relief that maintains system pressures at or below 50 psi 5 Dispensers should be located as close to the supply tank as possible Supply lines should be sized to allow simultaneous maximum flow desired for all dispensers fed from it 6 The vertical supply riser must be cut to the proper height in order to avoid undue stress on the dis penser when installing the ground joint union Attach dispenser base to the sump impact box using the anchor points 7 When the dispenser has been connected to the piping the lines should be tested for leaks Remem ber to allow any fresh pipe compound used in threaded joints to cure or set before performing the leak tests 8 All hoses used with the dispensers shall be sufficiently reinforced as to not affect the operation or accuracy of the units through its expansion and contraction from pressure B Electrical Wiring 1 electrical wiring should be done by a qualified licensed e
4. 4 Screw 10 24 x 625 09079 5 Screw 10 24 x 625 40107 8 Screw 8 32 x 625 08192 POD Internal Components Item No Description Part No PC Board Assembly See Below Cover Assembly Housing Assembly Drive Assembly Screw 10 24 x 625 Hub Magnet Assembly O Ring Buna N Screw 5 40 x 125 O Ring Buna N or Teflon Screw 6 32 x 375 Hub Magnet Assembly O 07677 Screw Modei No POD1 POD2__ Pops Pond Po ____ 1 81794 81794 81794 81794 ____ 817941 ____2 ___ 81164 81164 81164 81164 81164 7 N S Not for Sale Illustrated Parts Breakdown POD Extension Models 49754 amp 49756 Item No Description Pulser Extension Driver Pulser Housing Screw 10 24 x 2 00 Dowel Pin O Ring Buna N 49754 O Ring Teflon 49756 Mag Bearing Fork Driver 8 Fork Drive Shaft Q N S Not for Sale Part No N S N S 09228 N S 06856 09151 N S 48282 N S 10 Illustrated Parts Breakdown POD Extension Models 49757 amp 49759 No Description Part No 1 Pulser Extension Driver N S 2 Pulser Housing N S 3 Screw 10 24 x 2 00 09228 4 Dowel Pin N S 5 O Ring Buna N 49757 06856 O Ring Teflon 49759 09151 6 Mag Bearing N S 7 Blade Driver N S 8 Roll Pin 06051 9 Drive Blade 40812 N S Not for Sale 11 1629 CONTROLS t
5. DIN Plug Connector Remove center screw from DIN plug connector Disconnect DIN plug connector from adapter Remove socket head screw use 5 32 hex key wrench DIN terminal adapter and gasket from solenoid Snap off red cap from top of solenoid base sub assembly Push down on solenoid Then using a suitable screwdriver insert blade in slot provided between solenoid and nameplate retainer Pry up slightly and push to remove Then remove solenoid from solenoid base sub assembly 5 Reassemble using exploded views for parts identification and placement Disassembly and Reassembly of Solenoids 1 Remove solenoid see Solenoid Replacement 2 Remove finger washer or spring washer sub assembly 3 Unscrew solenoid base sub assembly NOTE Some solenoid constructions have a plugnut core tube sub assembly bonnet gasket and bonnet in place of the solenoid base sub assembly To remove bonnet use special wrench adapter supplied in ASCO Rebuild Kit For wrench adapter only order ASCO Wrench Kit No K218948 4 The core is now accessible for cleaning or replacement 5 If the solenoid is part of a valve refer to basic valve installation and maintenance instructions for further disassembly 6 Reassemble using exploded views for identification and placement of parts ORDERING INFORMATION FOR ASCO SOLENOIDS from solenoid base When Ordering Solenoids for ASCO Solenoid Operators or Valves order the number
6. ms A3d 1OA DIDS 5 OY 2 4 ospo d spd 40 VSN 3 STOULNOI LIQUID CONTROLS Unit of IDEX Corporation IEX IDEX CORPORATION SOLD AND SERVICED BY A NETWORK OF HIGHLY TRAINED SERVICE DISTRIBUTORS FULL v 4 Backed By Our Worldwide Reputation For WARRANTY sn Controls Seller products are warranted against defects in material or workmanship for a period of one 1 year from date of installation provided that the warranty shall not extend beyond twenty four 24 months from the date of original shipment from Seller Seller s obligations set forth below shall apply only to failure s to meet the foregoing obligations provided that Seller is given written notice within thirty 30 days of any occurrence from which a claim of defect arises If a warranty dispute occurs the Purchaser shall be required to provide Seller with proof of date of sale The minimum requirement to establish date of sale shall be a copy of the Seller s invoice In the event that a factory inspection by Seller or its designee s supports the validity of a claim at the discretion of Seller repair replacement or refund shall be the sole remedy for defect and shall be made free of 2001 Liquid Contro
7. body 5 Before removing the stem retainer from the manual operator body note the location of captive spacing washer on the stem lever sub assembly The captive spacing washer will be on the inside of the fork on the stem retainer for AC construction and on the outside for DC construction Location of this captive spacing washer is important for reassembly 6 Remove stem lever sub assembly with stem gasket from manual operator body Remove solenoid base gasket core assembly with core spring No V6296R2 ASCA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com 7 Refer to Valve Disassembly sections step 5 for further disassembly Manual Operator Reassembly Refer to steps 1 through 9 of Valve Reassembly then proceed as follows 1 Position stem gasket on stem lever sub assembly 2 Preassemble manual operator parts as follows Position core assembly with core spring into manual operator body from the bottom Install stem lever sub assembly into manual operator body Install stem retainer and be sure the captive spacing washer on the stem lever sub assembly is located on the inside of the fork on the stem retainer for AC construction and on the outside of the fork on the stem retainer for DC construction 3 Replace body gasket in valve body 4 Screw manual operator body intact into valve body Torque manual operator body to 175 25 in Ibs 19 8 2 8 Nm ORDERING INFORMATION F
8. Nm 8 Replace valve seat with a small amount of thread compound on the seat threads Torque valve seat to 65 15 in lbs 7 3 1 7 Nm 9 Install metering pin with metering pin gasket into valve body Replace retainer and refer to Adjustable Bleed Device section for metering pin adjustment 10 If the valve being serviced has a manual operator refer to Manual Operator Reassembly section 11 Replace solenoid base gasket core assembly core spring and solenoid base sub assembly Torque solenoid base sub assembly to 175 25 in Ibs 19 8 2 8 12 Install solenoid see separate instructions and make electrical hookup WARNING To prevent the possibility of death personal injury or property damage check valve for proper operation before returning to service Also perform internal seat and external leakage tests with a nonhazardous noncombus tible fluid 13 Restore line pressure and electrical power supply to valve 14 After maintenance is completed operate the valve a few times to be sure of proper operation A_metallic click signifies the solenoid is operating Manual Operator Disassembly 1 Refer to Valve Disassembly section and follow step 1 and 2 2 For AC construction refer to Figure 1 on page 3 DC construction Figure 2 on page 3 3 Unscrew solenoid base sub assembly from manual operator body 4 Unscrew manual operator body and remove this assembly intact Remove body gasket from main valve
9. Only e Junction Box This junction box construction meets Enclosure Types 2 3 3 4 and 4X Only solenoids with 1 4 spade or screw terminals may have a junction box The junction box provides a 1 2 conduit connection grounding and spade or screw terminal connections within the junction box See Figure 5 e DIN Plug Connector No K236034 Use this kit only for solenoids with DIN terminals The DIN plug connector kit provides a two pole with grounding contact DIN Type 43650 construction See Figure 6 OPERATION When the solenoid is energized the core is drawn into the solenoid base sub assembly IMPORTANT When the solenoid is de energized the initial return force for the core whether developed by spring pressure or weight must exert a minimum force to overcome residual magnetism created by the solenoid Minimum return force for AC construction is 11 ounces and 4 ounces for DC construction INSTALLATION Check nameplate for correct catalog number service and wattage Check front of solenoid for voltage and frequency WARNING Electrical hazard from the accessibility of live parts To prevent the possibility of death serious injury or property damage install the open frame solenoid in an enclosure All Rights Reserved ASCA SERIES 8016G Form No V6583R7 BLACK ENCLOSURE TYPES 7 AND 9 ONLY CAUTION 10 prevent fire or explosion do not install solenoid and or valve where ign
10. adapter gt lt 0 0705 Washer flat 4 0673 Screw 4 0250 Packing Gland Assy 0566 Plug pipe hex socket 2 one for each cover 0125 0627 Hex washer head screw 20 for both covers 5 0 5 E gt lt gt 3 gt O 5 2 Q x 823 ur X 40104 2 90 GL90 4 UMOUS ZL90 10104 Hulyoojg 1949 OL IN 104 z 0870 OLLO 2 1826 10101 JOYSEM 1 0 z 1ueueoe dsip 610 z Buueeq 2 uoiuid 2910 1 quunu eues 2120 pesu xeu 9195 2290 7 8120 za 000 99 0 so 7080 d d quem 1 Cw 2 Mie WY 5 S a D 19 09 deo F Xx 8728 9 90 puejb 5 9220 10101 Burx4oo q 0104 494 e959 1910 8290 jejd sad p 5 peeu xeu M S 1190 8 6 1 201 910 jeuondo edid 50 Lyn onaosa 553 4 JIWA MOTI eee i E IUNIVHIAdNIL AOVUNIIV
11. on DIN connector for proper electrical connections junction box with 1 2 conduit connection and grounding terminal DIN terminal adapter connector gasket socket head screw 5 32 hex key wrench DIN connector terminal block see note 2 connector cover see note 1 socket head screw 5 32 hex key wrench cover SCrew above cover cover gasket grounding screw and cup washer socket head screw 5 32 hex key wrench Indicates that these parts are included in DIN plug connector Kit No K236034 gland nut gland gasket washer X center screw gt 47 Figure 6 DIN plug connector kit No 236034 optional feature Page 4 of 4 Form No V6583R7 ASCA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Installation amp Maintenance Instructions 2 WAY INTERNAL PILOT OPERATED SOLENOID VALVES NORMALLY CLOSED OPERATION 2 OR 212 NPT IMPORTANT See separate solenoid installation and maintenance instructions for information on Wiring Solenoid Temperature Cause of Improper Operation Coil or Solenoid Replacement DESCRIPTION Series 8210 valves are 2 way normally closed internal pilot operated solenoid valves designed for general service These valves are made of rugged forged brass and have an integral adjustable bleed device for controlling the opening and closing speed of the p
12. open when the Pump Output signal becomes active If either control signal 15 removed turned off the solenoid will immediately close and the dispenser goes inactive For the dispenser to go active again both signals must be cycled off then on again They can be turned off and on in either order and do not necessarily need to be off at the same time DC Pulse Outputs The dispenser can produce a Penny Pulse or a Volumetric Pulse on TB3 7 and TB3 8 during fueling operation The Penny Pulse Output supplies a pulse out for every cent of product dispensed by the system The Progammable Pulse Output can be set to supply 10 or 100 pulses for every unit volume See Dispenser Programming in this manual for further details 1 04 99 Pulsers Wiring detail For target systems that require the P to Ground Dispenser CPU Board Target System Pulse Input For target systems that require the Pulse Input to be pulled to Vcc Dispenser CPU Board 220 Ohm 1 4W Target System Your Authorized PMC Distributor p M easu trol Inc Nine North Drive d NGA MAIN JUNCTION Y BOX 5 5 C5 LO N PULSE OUTPUT PULSE OUTPUT FIELD CONDUIT lt gt ENTRY DC Electrical Specification 1 Power Supply AC 1 2 220VAC 50Hz 2 Permissive IN 20mA 220VAC 50Hz 3 Pump Start 0 5 220VAC 50Hz 4 ON OFF Relay Dry contact rat
13. stamped on the solenoid Also specify voltage and frequency Form No V6583R7 ASCA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Torque Chart Part Name solenoid base sub assembly valve bonnet 3 4 bonnet construction bonnet screw 3 4 NPT pipe size Remove red cap and push solenoid down red cap Then pry here to lift gt Remove red cap and nameplate retainer nameplate push solenoid down and push to remove retainer Then pry here to lift nameplate retainer solenoid b grounding wire and push to remove with 1 2 green or green with wave gt For special wrench SALONE stipes washer adapter order kit i ke 0 750 28 UN 2A thread solenoid base T sub assembly oide View lugnut core tube asket 9 sub assembly E 2 A washer Tapped hole in core collar to face 0 250 28 UNF 2B valve body 0 38 minimum full thread Alternate Construction See torque chart red cap lt push solenoid down red cap solenoid with 1 2 NPT Then pry here to lift nameplate retainer nameplate grounding WIre and push to remove retainer W green or green with spacer i yellow stripes 1 312 diameter 7 solenoid mounting hole finger washer nameplate retainer lt 2 finger spring 0 69 diameter washer washer oy mounting hole 062 to 093 maximum solenoid base valve thickness of panel sub assembl
14. 7 0667 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY DRAWING NUMBER 1 u 1 0G347 COPYRIGHT OWNERSHIP BY PMC INC LLI 3 5 O 2 4 lt LU gt x 1 D O 2 1 d lt fa de 2 5 1 TRS x al m di SE 212 DIE lt m Q lt lt lt C Sic w ol E o gj 248 C mo O VAPOR BARRIER lt oo mosti 3 4 CONDUIT 1 2 CONDUIT TO HEAD TO PULSER _ 1 2 CONDUIT A TO SWITCH im N BLACK WHT ORANGE Wi E i E E x i 82WHT ORANGE NOZZLE SWITCH b N N b 11 11 11 20 BLACK j 24 RED 1 y N y METER A 88 gt PULSER gt SOLENOID rl JUNCTION rx o t dio gt olol DID S w D O w w gt gt D siae gt 22 we u o 2 z 2 m gt gt O SE L m MN V3 yp ME a ec IEEE EUN od e VETO a n EE A FIELD CONDUIT gt Ni FIELD CONDUIT ENTRY DC i ENTRY P EEE gt 265 lt m m 3 gt CMD 701 MA
15. 8M gt LOWER UNIT WIRING DIAGRAM mM D gt U U _ DATE DRAWN BY gt 2 Pump Control Inc 7 14 03 CAT 1070 Nine North Drive Suite 100 d Alpharetta 30004 5 5 770 667 0667 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY DRAWING NUMBER INFORMATION AND IS SUBJECT TO 91 1 0G348 COPYRIGHT OWNERSHIP BY PMC INC
16. HEAD E 9 RED BLACK DISPLAY BOARD uu NENNEN a ID 8 9SvtclialL 61 41 m zu WHITE a m SUPPLY T O booe 6 y P N 120000 E 311189 8488971811 78 T1B41 2345678 O w 5 6 6 009 Pe ygg umaman em rss remi Peli ee A LU L L L c I EE 11 CPU BOARD BLACK BLACK fio dE E REEL SWITCH 9 0 1 9 0 1 901 9 0 1 9 0 1 Q 9 Q s 5 gt ND s 5 9 II 954 654 FACTOR MUST BE LESS THAN 200 00 6 GREEN NH 2 19 GREEN zi ul cr u zZ o LL x C x u tul Z O E 302399013335 22808 32 gt ean q 245 lt E 3913803 in i EE CMD 701 MA 8M Na 4 2 dds kn HEAD WIRING DIAGRAM a a TO e TE z 5313 ci I DATE DRAWN BY Pump Measure Control Inc 7 14 03 CAT m 1070 Nine North Drive Suite 100 3 4 CONDUIT 1 2 CONDUIT 1 2 CONDUIT Alpharetta GA 30004 HEAD TO PULSER 1 TO SWITCH NR 770 66
17. INSTALLATION amp SERVICE MANUAL CMD 701 REMOTE DISPENSER WITH REEL PMC Pump Measure Control Inc 1070 Nine North Drive Suite 100 Alpharetta GA 30004 Phone 770 667 0667 Fax 770 667 0476 gt m 2 lt EUM EQUIPMENT INS ITUTE Table of Contents Section 1 OT mr 3 Pipa 3 Electtical tapa qaa 4 Pasian AN 4 PHOS EIA 5 Prosramimmimns Fables 2829 aus alabakuk 6 OPETAN ODs podus obedit oa VE GIGI RR PIA 7 the aoi odio DE naa __ esed a 7 DispensertCalibration bad 9 Section 2 Parts s N 10 13 Section 3 Component Information ASCO Solenoid Valve Installation Maintenance Parts for ASCO 8016G Series Solenoid Coll 15 Installation Maintenance Parts for ASCO 8210G100 Solenoids 19 Liquid Controls Pulse Output Device Installation Maintenance Parts Manual 25 Section 4 Technical Data CMD xxx Dispenser C ODtFOl dalia 35 91 01A65 6 C
18. MD xxx Terminal Wire Descriptions 37 OT 06 A2 IS TL C Winnie od e Ro Ro Gap 39 9151061527 C NIDETOT Internal Way dela 41 91 03A44 CPU Wiring Terminal Descriptions 43 91 03 132 Factor Board Wire Terminal Descriptions 45 91 03 45 CPU Indicator LED Descriptions 47 91 10G347 CMD 701 Upper Unit Wiring Diagram 49 91 10G348 CMD 701 Lower Unit Wiring Diagram 51 1 Page 2 IMPORTANT Examine the shipment immediately on arrival to ensure there has been no damage or loss in transit Pump Measure Control Inc as shipper 1 not liable for the hazards of transportation Read all instructions and tags concerning the dispenser carefully and entirely before starting the installation An improperly installed dispenser is dangerous and is likely to be a source of ongoing problems This manual covers both RETAIL and COMMERCIAL versions of the dispenser Any references to PRICE settings or PENNY PULSE outputs only apply to the RETAIL versions Differences are noted where necessary Installation PMC dispensers must
19. OFF state Page Number General Information 2 POD MOOGI enni Specifications rin NEST Removing Existing Hardware Installing the POD Extension Wiring the POD m Wiring Diagrams Illustrated Parts Breakdown POD Assemblies POD Extension Assemblies The electronics compartment also serves as a conduit junction box The POD has an O Ring sealed threaded cover The standard wire entrance is a 2 14 NPT female hub which accepts threaded conduit or a cable gland A screw type removable terminal block on the circuit board facilitates wiring of the unit With the wiring entrance sealed and the cover in place the housing has a weatherproof rating of NEMA 4X In addition the housing is UL and Canadian UL explosion proof rated when installed with approved conduit and ATEX rated flameproof pending POD Models There are five POD models available POD1 Fork Drive with Buna N O Ring 100 PPR Quad Pulser 8 to 24 VDC POD2 Fork Drive with Teflon O Ring 100 PPR Quad Pulser 8 to 24 VDC PODS Blade Drive with Buna N O Ring 100 PPR Quad Pulser 8 to 24 VDC POD4 Blade Drive with Teflon O Ring 100 PPR Quad Pu
20. OR ASCO REBUILD KITS Parts marked with an asterisk in the exploded view are supplied in Rebuild Kits eWhen Ordering Rebuild Kits for ASCO valves order the Rebuild Kit number stamped on the valve nameplate If the number of the kit is not visible order by indicating the number of kits required and the Catalog Number and Serial Number of the valve s for which they are intended Torque Chart Part Name Torque Value in Inch Pounds Torque Value in Newton Meters Solenoid Base Sub Assembly 175 25 19 8 28 Manual Operator Body Valve Seat 65 15 7 3 1 7 IMPORTANT For AC construction captive spacer on stem spacer sub assembly must be located on thanside of stem retainer when reassembled solenoid base space sub assembly stem spacer a solenoid sub assembly gasket stem retainer A manual operator OSS body uN 62 stem retainer stem spacer sub assembly core spring i see note stem gasket core assembly X Indicates that these parts are included in rebuild kit body gasket valve seat Note Wide end in core first Closed end protrudes from top of core valve body assembled Figure 1 Manual Operator Assembly AC Construction I amp M No V6296R2 IMPORTANT For DC construction captive spacer on stem spacer sub assembly must be located on theoutside of stem retainer when reassembled spacer X P solenoid base sub ass
21. P BY PMC INC REVISIONS DESCRIPTION DATE 2 5 O O TB a N 1 2 3 453 NIDO Zoo n 0 01 901 9 19 3 3 3 7 3 654 e 85 6 5 4 FACTOR MUST BE LESS THAN 200 00 DISCRIPTION TBI 0 _ 12 VDC SUPPLY DC GROUND COMMON CHANNEL 1 12 VDC SUPPLY DC GROUND COMMON CHANNEL 1 110500C FACTOR BOARD CHANNEL 2 PO Nine orth Drie uite 1 1070 Nine North Drive Suite 100 9 22 03 CAT Alpharetta GA 30004 Bares 1 1 l 770 667 0667 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY DRAWING NUMBER INFORMATION AND IS SUBJECT TO 9 1 03A1 32 COPYRIGHT OWNERSHIP BY PMC INC O O O O Z 8 LED INDICATORS Solenoid 2 Red Solenoid 1 Red Pump Start Out Red Dispenser Handle AC Yellow External Permissive Yellow Relay Energized Red 12 VDC OK Green Pulse Input Channel A Yellow Pulse Input Channel B Yellow Programmable Pulse Out Red Volume Pulse Out Red Dispenser Handle Switch DC Yellow AC Power Detect Yellow CPU BOARD P N 120000 PMC LED FUNCTIONS i 1070 Nine North Drive Suite 100 2 28 03 CAT Alpharetta GA s0004 i uo PH 770 667 0667 FAX 770 667 0476f THIS DRAWING CONTAINS PROPRIETARY DRAWING NUMBER INFORMATION AND IS SUBJECT TO 9 1 03A45 COPYRIGHT OWNERSHIP BY PMC INC DISPENSER
22. P OPERATION 9 RED BLACK MAIN DISPENSER 2 8 ORANGE JUNCTION BOX 10 RED YELLOW j Ae 11 BLUE ETA PULSE PER PENNY OUTPUT 12 WHT BLUE i PULSE PER PENNY OUTPUT 20 Et DE E via the Pump Control Contactor NOTES 1 Ellipses represent conduit openings groupings within the junction box 2 Wire colors for field wiring are unknown 3 Operating Voltage Standard 120VAC 60Hz 1Phase OPTIONAL 220VAC 50Hz 1 Phase 4 DIP Switch 1 must be in the ON position for Stand Alone operation Pump Control Signal from dispenser is switched to L1 to activate pump L1 Line Voltage L2 HIGH CURRENT CONTACTS FOR PUMP OPERATION CONTROL COIL L2 Pump Control Contactor Coil Voltage Rated for L1 L2 VAC WIRING REVISION 1 1 04 DESCRIPTION ATE REVISIONS l 2 51 _ FUELHOUSE and CMD MC STAND ALONE WIRING Pump Measure Control Inc 11 20 01 1070 Nine North Drive Suite 100 Alpharetta GA 30004 NTS meg 770 667 0667 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND IS SUBJECT TO COPYRIGHT OWNERSHIP BY PMC INC 40 gt RAW N NO BB GEARREDUCER 3 820 ELECTRONICS HOUSING 5 7 10 11 Q
23. Refer to the section detailing dispenser calibration 5 Before placing unit in service verify that all displays and the totalizer are functioning properly Page 4 Programming 1 The dispensers main CPU board 1 lo cated behind the rear panel in the unit s head The CPU board has several items that must be configured so that the dis penser will operate correctly with the system in which it is installed 2 PRICE PER VOLUME RETAIL versions only Setting the price per unit volume of product is done using four rotary switches located in the lower right corner of the board See Figure 5A SW2 sets the dollar amount SW3 SW4 and SWS set the 10 1 and 0 1 amounts respectively For a price of 1 399 per gallon switches 2 thru 5 would be set to 1 3 9 amp 9 5 52 Swa 54 2555 Figure 5 Corner of CPU board showing price setting and dip switch loca tions Note that price setting only applies to RETAIL dispensers 3 DIP SWITCH and JUMPER SETTINGS The dips switches and jumpers on the main CPU board are used to set opera tional parameters on start up of the unit See Figure 5B for location While dip switch settings can be reset to original posi tions once altered changes in the jumper block are permanent To cut a jumper press a sharp object through the thin point of the metal foil for the desired position If wire jumpers are used instead of the foil block depicted in Figure 5B simply cut the desired
24. Test ON TABLE 60 Position 5 Jumper Position 5 LITERS CUT GALLONS SHORTED TABLE 6E Position 6 Jumper Position 6 Not Applicable CUT CMD 501 CMD 502 CMD 700 CMD 1500 SHORTED TABLE 6F Position 7 Jumper Position 7 Volumetric Pulse Output CUT Penny Pulse Output SHORTED default setting Note Dip Switch position 4 and Jumper position 8 are not used at this time Dispenser Operating Mode If the dispenser is controlled by a console or card system then this position should be set to OFF Setting this to ON bypasses the require ment for an external authorize signal to the dis penser Volumetric Pulse out Resolution If the pulse output type see Table 6E below is set for Volumetric then this setting determines the resolution of the signal If the pulse output type is set to PENNY pulse this setting has no effect Display Segment Test Set whether to have the Display Segment Test or not If selected the dispenser will show all 8 digits for 5 seconds then reset and open the solenoid when the unit is enabled to dispense Liters Gallons Unit of Measure Set the Unit of Measure for the dispenser De fault is US Gallons If Liters is desired then CUT the foil or jumper on POSITION 5 Dispenser M odel Set MODEL of dispenser the CPU board 15 in stalled in Default is CMD 501 CMD 502 CMD 701
25. achine screw Torque grounding screw to 15 20 10 165 1 7 2 3 Nm On solenoids with screw terminals the socket head screw holding the terminal block to the solenoid is the grounding screw Torque the screw to 15 20 in Ibs 1 7 2 3 Nm with a 5 32 hex key wrench e Junction Box The junction box is used with spade or screw terminal solenoids only and is provided with a grounding screw and a 1 2 conduit connection Connect 12 18 AWG standard copper wire only to the screw terminals Within the junction box use field wire that is rated 90 C or greater for connections For steam service use 105 C rated wire up to 50 psi or use 125 C rated wire above 50 psi After electrical hookup replace cover gasket cover and screws Tighten screws evenly in a crisscross manner DIN Plug Connector No K236 034 1 The open frame solenoid is provided with DIN terminals to accommodate the DIN plug connector kit 2 Remove center screw from plug connector Using a small screwdriver pry terminal block from connector cover 3 Use 12 18 AWG stranded copper wire rated at 90 C or greater for connections Strip wire leads back approximately 1 4 installation in socket terminals The use of wire end sleeves is also recommended for these socket terminals Maximum length of wire end sleeves to be approximately 1 4 Tinning of the ends of the lead wires is not recommended 4 Thread wire through gland nut gland ga
26. aintenance Keep medium flowing through the valve as free from dirt and foreign material as possible Periodic exercise of the valve should be considered if ambient or fluid conditions are such that corrosion elastomer degradation fluid contamination build up or other conditions that could impede solenoid valve shifting are possible The actual frequency of exercise necessary will depend on specific operating conditions A successful operating history is the best indication of a proper interval between exercise cycles Depending on the medium and service conditions periodic inspection of internal valve parts for damage or excessive wear is recommended Thoroughly clean all parts If parts are worn or damaged install a complete rebuild kit Causes of Improper Operation Incorrect Pressure Check valve pressure Pressure to valve must be within range specified on nameplate e Excessive Leakage Disassemble valve and clean all parts If parts are worn or damaged install a complete ASCO Rebuild Kit Valve Disassembly Refer to Figure 3 on page 4 1 Disassemble valve in an orderly fashion Use exploded views for identification and placement of parts 2 Remove solenoid see separate instructions 3 If the valve being serviced has a manual operator suffix MO in the catalog number refer to section on Manual Operator Disassembly 4 Unscrew solenoid base sub assembly and remove solenoid base gasket core assembly with co
27. and CMD 1500 Pulse Output Type Set the pulse output channel to either VOLU METRIC or PENNY pulse out If VOLUMET RIC is selected Table 6B above determines reso lution If PENNY is selected a pulse per penny of the TOTAL SALE is transmitted Operation 1 Tostartthe dispenser simply remove the nozzle from its boot and lift the ON OFF lever If the dis penser 1 stand alone or is authorized to dispense by a control system the dispenser will reset and be ready to dispense 2 After delivery is complete the ON OFF lever is pushed down and the nozzle returned to its boot This will end the transaction 3 During delivery TOTAL SALE and VOLUME delivered will be displayed on the face of the dispenser At the completion of a transaction this information will remain on the displays until the next transaction 15 started for commercial versions of the dispensers only VOLUME is displayed gt During delivery the CPU board in the dispenser will generate a real time output pulse stream for use by remote devices The CPU board can be configured to transmit a VOLUMETRIC or PENNY pulse stream See Programming Section of Manual for details The pulse output driver is an open collector type See Dispenser Control in Section 4 Maintenance The CMD xxx dispensers are designed to give many years of trouble free service However like any mechani cal device they require periodic maintenance to prevent problems from developing 1 T
28. be installed according to all applicable NEC NFPA and local codes The installa tion portion of this manual is intended to provide some points to watch for when designing and installing the system the dispenser is to operate with It is the responsiblility of the installer and end customer to ensure that the entire system tanks pumps dispensers etc is designed and installed correctly A Piping 1 The remote dispensers covered by this manual must be fed product through a system that will maintain near operating pressure on the dispensers when the pump is off If pressure is not main tained on the unit the reel s hose can expand each time the pump is turned ON causing the dis penser to jump a few counts at the start of a transaction Some submersible pumping systems pro vide this capability as part of the device However if a pumping unit is used that does not main tain pressure a check valve with thermal relief must be installed at the outlet of the pump The check valve should be spring loaded to provide a good positive seal 2 Each dispensers should be installed over a sump with provision to mount a LISTED emergency shut off valve The shut off valve is installed to stop the flow of fuel to the dispenser in the event of fire or if the dispenser is knocked off the island The CMD xxx dispenser footprint can be seen in Fig ure 3 below 7 000 9 500 lt INLET APPROX 17 250 9 16 DIA 6 HOLES 17 250 36 500
29. ced by the pulser mounted to the dispenser s meter The cor rection factor has the form of XXX XX and has a valid range 000 01 to 199 99 It is applied as a per centage multiplier to the pulse streams passing through the board For example if the meter transmits 410 pulses per gallon and the correction factor is set to 97 56 then the CPU board will receive 400 pulses per gallon To access the factor board remove the rear panel from the head of the dispenser The factor board 15 located on the right side of the opening under a rectangu lar tamper resistant cover The cover 1 held in place by two screws and secured by a seal wire to prevent O O 12 3 4 3 4000 tampering e e e 9 9 a i Pa FACTOR MUST BE LESS THAN 200 00 Figure 7 110500 Factor Boar
30. d Calibration Procedure 1 Check the dispenser s current calibration by delivering product to a reliable accurate prover The prover should large enough to accept product from the dispenser at full flow for at least 60 seconds Perform several delivery tests to verify repeatability 2 Make sure the prover has been wetted and run a test load Note the volume in the prover and the volume registered by the dispenser 3 Ifthe unit s calibration needs to be corrected then the factor setting on the factor must be changed Remove the cover from the factor board by cutting the seal wire Record the current setting on the factor switches and use the following formula to determine the what the new setting should be volume in prover New factor x current factor volume in prover registered by dispenser 4 Set the new factor setting on the 110500 Factor Board Run another prover test to verify the new adjuster setting 1s correct 6 If the calibration of the unit needs further correction repeat the above procedure If no further changes are needed replace the cover on the factor board 7 Apply a wire seal to secure the adjuster settings Example A prover run is completed in a 100 gallon prover The prover shows exactly 100 00 gallons while the dispenser shows 99 35 gallons on the display If the current factor setting is 72 01 the new factor that needs to be set on the board is 72 48 to correct the dispenser s registration to
31. d servicing of Electronic Products by Seller trained service representatives this warranty is null and void Seller s obligations as set forth above shall not apply to any product or or any component or part thereof which is not properly installed used maintained or repaired or which is modified other than pursuant to Seller s instructions or approval NOTE The above warranty applies only to products manufactured by Liquid Controls Lake Bluff Illinois Private label OEM and or products manufactured by Liquid Controls licensee s are specifically excluded from the above warranty Consult factory for all non Liquid Controls manufacturers warranties NO IMPLIED OR STATUTORY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL Distributed By Bulletin 48496B 1 OWNERS MANUAL PARTS LIST M7A1 LP PART DESCRIPTION COMPONENT 2102 METER ELEMENT M 7 1 FOR FORK DRIVE 0908 68708 968 _ pres pera poor WASHER 0 250 VAIO SPR _ pss pra iw PLATE 266 GERA LOCKING ROTOR o oo 03 595 BLOCKNGROTORAGSYW RLUMTSTOSSTHO 526 880865 50 190938 _ 08 DiSPLACEMENTROTORASSY MrALUMISISSSTHG _ 1 00 5 6 MANUAL M MATI METER pe __
32. e parts for damage or excessive wear is recommended Thoroughly clean all parts Replace any worn or damaged parts Causes of Improper Operation Faulty Control Circuit Check the electrical system by energizing the solenoid A metallic click signifies that the solenoid is operating Absence of the click indicates loss of power supply Check for loose or blown fuses open circuited or grounded solenoid broken lead wires or splice connections Burned Out Solenoid Check for open circuited solenoid Replace if necessary Check supply voltage it must be the same as specified on nameplate retainer and marked on the solenoid Check ambient temperature and check that the core is not jammed Low Voltage Check voltage across the solenoid leads Voltage must be at least 85 of rated voltage Solenoid Replacement 1 On solenoids with lead wires disconnect conduit coil leads and grounding wire NOTE Any optional parts attached to the old solenoid must be reinstalled on the new solenoid 2 Disassemble solenoids with optional features as follows Spade or Screw Terminals Remove terminal connections grounding screw grounding wire and terminal block screw terminal type only NOTE For screw terminals the socket head screw holding the terminal block serves as a grounding screw e Junction Box Remove conduit and socket head screw use 5 32 hex key wrench from center of junction box Disconnect junction box from solenoid
33. ed 1A VAC Contact Opens and closes with nozzle hook handle Mo T S in zl 2 To T lt Se lt Sie con zi mi m d lt lt gt gt G OC OC cou at o 6 LUI LU SESSO 2 2 0 O fr lt lt ce gt Dr pr FIELD CONDUIT te ENTRY AC lt lt NO JDISCRIPTION C CONNECTIONS 1 VAC 50Hz 2 1220 VAC 50Hz EUTRAL EUTRAL 5 JEARTH GROUND EARTH GROUND 7 JPERMISSIVE IN PUMP START OUT 9 ON OFF Relay Contact ON OFF Relay Contact C CONNECTIONS ULSE OUTPUT ULSE OUTPUT FUELHOUSE TERMINAL WIRE DESCRIPTIONS DATE DRAWN BY Pump Measure Control Inc 11 20 01 1070 Nine North Drive Suite 100 fee Alpharetta GA 30004 770 667 0667 DRAWIN NUMBER 91 01 65 6 FAX 770 667 0476 THIS DRAWING CONTAINS PROPRIETARY INFORMATION AND IS SUBJECT TO COPYRIGHT OWNERSHIP BY PMG INC FIELD CONDUIT ENTRY AC 2 1 BLACK WHITE 0 2 BLACK YELLOW 2 3 WHITE 1 x EGND 2 4 WHITE EARTH GROUND 7 BROWN PUMP START OUT HIGH CURRENT CONTACTS FOR PUM
34. embly stem spacer Gi sub assembly solenoid base gasket stem retainer manual operator body p stem retainer stem spacer sub assembly core assembly 3 stem gasket core spring body gasket X E Indicates that these parts are included in rebuild kit valve seat valve body assembled Figure 2 Manual Operator Assembly DC construction Page 3 of 4 ASCA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Torque Chart Part Name Torque Value in Inch Pounds Torque Value in Newton Meters solenoid Base Sub Assembly 175 25 19 8 2 8 144 15 163 1 7 Valve Seat 65 125 Z9 1 7 AC Construction DC Construction solenoid sub assembly solenoid base sub assembly ib 1 Indicates that these core spring core assembly pan uild ki see note 1 4 spring assembly _ Notes 24 base ap elaine 1 Wide end in core first Closed end of spring protrudes from top of core RICE metering pin 2 Disc gasket not present on all metering pin gasket constructions valve body body passage gasket body gasket support lip seal piston assembly 5 bonnet screw 4 see note 2 valve bonnet aspirator tube piston Figure 3 Series 8210 valve without solenoid Page 4 of 4 amp No V6296R2 ASCA 50 Hanover Road Florham Park New Jersey 07932 w
35. he CMD xxx dispensers used in marine and general service ap lications come equipped with an internal inlet strainer just up of the meter The strainer should be checked periodically M PO RTANT and changed if necessary 2 The battery used to backup the displays in the dispenser should be replaced annually Replace only with a 7 2V or 8 4V Ni Cd BEFORE OPENING ANY NiMh battery DO NOT REPLACE WITH AN ALKALINE PART OF THE FUEL SYS BATTERY as the recharging circuit on the board may cause the TEM MAKE SURE IT IS battery to leak or explode DE PRESURIZED AND 3 While doing any maintenance on the dispenser check the hose for any cracks or tears that can cause leaks THE PUMPING SYSTEM 4 When cleaning the exterior of the cabinet use only non abrasive HAS BEEN SHUT OFF AND non corrosive cleaning agents Use only soft rags TAGGED OUT 5 In SALT WATER environments it is recommended that the exte rior stainless steel panels be waxed periodically at least bi annually to maintain the panels at their best appearance Page 7 Page 8 Dispenser Calibration The purpose of calibrating a dispenser 1 to ensure that the volume displayed on the unit matches the amount of product dispensed The calibration of the Fuelhouse dispenser is accomplished by adjusting the correc tion factor set on the 110500C Factor Board see Figure 7 located in the head of the dispenser The factor board manipulates the raw pulse stream produ
36. he unit Signal Output The diagram below shows the voltage output for a clockwise rotation of the Pulse Output Device POD with Channel A leading Channel B For reverse flow applications counterclockwise Channel B leads Channel A Wiring Diagrams For PODs with Serial Number 04 24531 and higher Single Channel Applications 405LR 414LR O 6119 Shield DC Ground Pulse Out A JUL 8 to 24 VDC 12 VDC Earth Ground Fixed Installations Description POD J1 Terminal 405LR 414LR Terminal Power 20 11 12 VDC Channel A or B 21 or 22 9 Ground 23 12 Shield Wire No Connection Earth Ground Screw Dual Channel Quadrature Applications LectroCount LCR LCR II amp LCS O Shield E N 9 DC Ground quc o Pulse Outa U L Quadrature ice La 8 to 24 VDC m Chassis Ground Truck Applications Earth Ground Fixed Installations Earth 7 Description POD J1 Terminal LCR LCR II J8 LC3 J3 Power 20 31 19 Channel B 21 34 17 Channel A 22 33 18 Ground 23 38 15 Shield Wire No Connection J6 13 14 Wiring Information 1 Use metallic conduit with individual wires or use 3 conductor 22 AWG shielded cable 2 Strip 1 off of outer sheathing Remove exposed shield and drain wire and then tape Strip 1 4 insulation from each conductor and connect to the terminal blocks 8 Illustrated Parts Breakdown POD Assemblies No Description Part No
37. id nameplate retainer and red cap 15 16 Valve Bonnet Construction 1 Install solenoid base sub assembly through 0 69 diameter mounting hole in customer panel 2 Position spring washer on opposite side of panel over solenoid base sub assembly then replace Solenoid Temperature Standard solenoids are designed for continuous duty service When the solenoid is energized for a long period the solenoid becomes hot and can be touched by hand only for an instant This is a safe operating temperature MAINTENANCE WARNING To prevent the possibility of death serious injury or property damage turn off electrical power depressurize solenoid operator and or valve and vent fluid to a safe area before servicing Page 2 of 4 Cleaning solenoid operators and valves should be cleaned periodically The time between cleaning will vary depending on medium and service conditions In general if the voltage to the solenoid is correct sluggish valve operation excessive noise or leakage will indicate that cleaning is required Clean strainer or filter when cleaning the valve Preventive Maintenance e Keep the medium flowing through the solenoid operator or valve as free from dirt and foreign material as possible e While in service the solenoid operator or valve should be operated at least once a month to insure proper opening and closing e Depending on the medium and service conditions periodic inspection of internal valv
38. ignal Resolution Pulses Gallon Litre Output M amp MA Series Meters Channel Channel kHz Pulses __ 15 MA 15 258 544 0 69 M80 MS 75 MS 120 M 80 Installation New Installations When ordered with the flowmeter the POD comes factory installed on the meter and ready for wiring Refer to the detailed wiring information which begins on Page 7 POD Installed on meter WARNING Relieve Internal Pressure All internal pressure must be relieved to zero before disassembly or inspection of the meter or any of the meter accessories Serious injury or death from fire or explosion could result from servicing an improperly depressurized and evacuated system Retrofit Installations Removing Existing Hardware 1 Relieve the pressure from the process piping to the meter 2 Drain the meter by opening the meter s drain plugs 3 Remove the mechanical counter adjuster and adjuster drive shaft from the front of the meter 4 Some meters have a counter adapter bracket which is bolted on If this is the case remove the counter bracket by removing the bolts that hold it in place If the counter adapter bracket is integral to the meter it cannot be removed In this case one of four POD Pulser Extensions will be required NOTE Ensure there is no pressure inside the flowmeter before attempting to remove the packing gland LINE PRESSURE MUST BE 0 0 PSI 5 Remove the packing gland mounting
39. ignal from the On Off Input Low Voltage 12V Input lever on the dispenser from proximity switch TB1 1 Dispenser Authorize External signal to the dispenser Input 110VAC referenced to TB1 7 authorizing its use 10 max load TB1 3 Pump Start output Output from the dispenser that Output 110VAC referenced to TB1 7 can be used as a pump start 100W max load signal TB3 7 Pulse Out Pulse output Pulse signal is Output Open Collector Drain DC referenced to TB5 6 See pro gramming section to configure for volumetric or penny pulse output See reverse for wiring details TB3 8 Pulse Out Reference signal for penny Output Open Collector Source DC pulse output See reverse for wiring details Dispenser Operation AC Inputs The CMD dispenser requires both the Dispenser Authorize TB1 1 and the On Off Lever to be active for the dispenser to operate The Dis penser Authorize signal voltage 15 normally supplied by an external control device such as a card reader or console If no external Authorize signal is available the unit can be set in a stand alone mode by turning dip switch position to the ON position See Dispenser Program ming in this manual When both signals are active the dispenser will reset the displays and turn on the Pump Output signal If the board is set to do a SEGMENT test on the displays the solenoid will open after a 5 second display If no segment test is done the solenoid will
40. iston Series 8210 valves are supplied with general purpose or explosionproof water tight solenoids Series 8211 valves are the same as Series 8210 except they are provided with a metal explosionproof watertight sole noid enclosure OPERATION Normally Closed Valve is closed when solenoid 15 de energized open when energized IMPORTANT Minimum operating pressure differential required is 5 psi Adjustable Bleed Device Series 8210 valves have an integral adjustable bleed device for controlling the opening and closing speed of the piston When valve leaves the factory the bleed adjusting screw metering pin has been preset to provide quick shockless closing for most applications If faster or slower closing is required adjust the screw metering Pin as follows Turn metering pin in clockwise as far as possible without over tightening Back out tightening Back out metering pin counterclockwise two complete turns From this point adjustments may be made to suit system 2 Turn metering pin clockwise for slower closing 3 Turn metering pin counterclockwise for faster closing Manual Operation Optional Feature Valves with suffix MO in the catalog number are provided with a manual operator which allows manual operation when desired or during an electrical power outage To engage manual operator rotate stem fully clockwise approximately 180 Valve will now be in the same position as when the solenoid is energi
41. ition temperature of hazardous atmosphere is less than 165 On valves used for steam service or when a class H solenoid is used not install in hazardous atmosphere where ignition temperature is less than 180 C See nameplate retainer for service NOTE These solenoids have an internal non resetable thermal fuse to limit solenoid temperature in the event that extraordinary conditions occur which could cause excessive temperatures These conditions include high input voltage a jammed core excessive ambient temperature a shorted solenoid etc This unique feature is a standard feature only in solenoids with black explosionproof dust ignitionproof enclosures Types 7 amp 9 CAUTION To protect the solenoid valve or operator install a strainer or filter suitable for the service involved in the inlet side as close to the valve or operator as possible Clean periodically depending on service conditions See ASCO Series 8600 8601 and 8602 for strainers Temperature Limitations For maximum valve ambient temperatures refer to chart The temperature limitations listed only indicate maximum application temperatures for field wiring rated at 90 C Check catalog number prefix and watt rating on nameplate to determine maximum ambient temperature See valve installation and maintenance instructions for maximum fluid temperature NOTE For steam service refer to Wiring section Junction Box for temperature rating of sup
42. jumper with a small pair of wire cutters To repair a jumper that has been cut the board must be returned to the factory The parameters that the switches and jumpers control are defined in the following tables d Position 4 Positian Dip Switeh Jumper Block IMPORTANT AFTER CHANGING ANY SETTING THE CPU BOARD MUST BE RESET BY CYLING POWER OR PRESS ING THE RESET BUTTON Figure 5B Section of CPU board showing dip switch and jumper location DIP SMTCH PARAMETERS Position JUMPER PARAMETERS Position Dispenser Operating Mode Table 6A 1 Liters Gallons Unit of Measure Table 6D 5 Volumetric Pulse Resolution Table 6B 2 Model Selection Table 6E 6 Display TEST Table 6C 3 Volume or Penny Pulse Output Table 6F 7 UNUSED 4 UNUSED 8 Parameter settings are detailed in tables next page Page 5 DIP SWITCH SETTINGS JUMPER SETTINGS Page 6 Programming Tables Dip Switch positions 1 4 and Jumper Positions 5 8 TABLE 6 Position 1 Dip Switch Position 1 Requires external 110VAC Permissive from card system or terminal OFF Stand alone mode ON TABLE 6 Position 2 Dip Switch Position 2 10 pulse per unit volume OFF 100 pulses per unit volume ON TABLE 6 Position 3 Dip Switch Position 4 Display Segment Test OFF No Display Segment
43. lated pull type solenoids The green solenoid with lead wires and 1 2 conduit connection is designed to meet Enclosure Type 1 General Purpose Type 2 Dripproof Types 3 and 3S Raintight and Types 4 and 4X Watertight The black solenoid on catalog numbers prefixed EF is designed to meet Enclosure Types 3 and 3S Raintight Types 4 and 4X Watertight Types 6 and 6P Submersible Type 7 A B C amp D Explosionproof Class I Division 1 Groups B C amp D and Type 9 E amp G Dust Ignitionproof Class II Division 1 Groups E amp The Class II Groups amp Dust Locations designation is not applicable for solenoids or solenoid valves used for steam service or when a class H solenoid is used See Temperature Limitations section for solenoid identification and nameplate retainer for service When installed just as a solenoid and not attached to an ASCO valve the core has a 0 250 28 UNF 2B tapped hole 0 38 minimum full thread Series 8016G solenoids are available in e Open Frame Construction The green solenoid may be supplied with 1 4 spade screw or DIN terminals Refer to Figure 4 Panel Mounted Construction These solenoids are specifically designed to be panel mounted by the customer through a panel having a 062 to 093 maximum wall thickness Refer to Figure 3 and section on Installation of Panel Mounted Solenoid Optional Features For Type 1 General Purpose Construction
44. lectrician All wiring must follow Na tional Electrical Code and satisfy all local rules and regulations 2 field wiring is to be connected to the dispenser in unit s junction box 3 The dispenser is shipped from the factory internally wired as shown in wiring drawings 91 10G347 and 91 10G348 in Section 4 4 Refer to electrical wiring diagrams in Section 4 for details on wiring the dispenser to the field C Start Up IMPORTANT 1 Make sure all filtration and or strainers are in place prior to filling the piping system with product Any loose debris in the piping must be prevented from passing through the BLEED THE AIR FROM meter where it can cause damage THE LINES VERY 2 IT IS IMPORTANT TO BLEED THE AIR FROM THE SLOWLY ALLOWING LINES VERY SLOWLY RUNNING THE METER MITE RPM UP ON AIR PUSHED THROUGH THE SUPPLY THE METER TO REACH LINE AHEAD OF THE PRODUCT CAN CAUSE SE EXCESSIVE RPM VERE AND OFTEN TOTAL DAMAGE TO THE ME CAUSE SEVERE DAMAGE TER 3 After all air has been removed from the supply piping run 30 to 40 gallons of product through the dispenser to completely fill the system and discharge all air from the unit 4 Although the dispensers are shipped from the factory properly adjusted rough handling in transit or special installation conditions can alter this Before the dispensers are placed into service their cali bration should be verified and any necessary changes made
45. ls Quality Accuracy and Advanced Design charge ex works factory In no event shall Seller be liable for any special consequential incidental indirect or exemplary damages arising out of warranty contract tort including negligence or otherwise including but not lim ited to loss of profit or revenue loss of use of the product or any associated products and orequipment cost of substitute goods or services downtime costs or claims of or by Purchaser s clients or customers In any event the total liability of Seller for any and all claims arising out of or resulting from the performance non performance or use of the product shall not exceed the purchase price of the indi vidual product giving rise to the claim All other guaranties warranties conditions and representations either express or implied whether arising under any statute common law commercial usage or otherwise are excluded Electronic Products require installation start up and servicing by local factory trained service representatives In the absence Backed By Our Worldwide Reputation For Quality Accuracy and Advanced Design LIQUID CONTROLS A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff IL 60044 2242 847 295 1050 FAX 847 295 1057 agg Website www lcmeter com DNY CERTIFICATED FIRM Certificate No 8732 Printed in U S A 03 01 Printed with vegetable inks on recycled paper Please Recycle of installation start up an
46. lser 8 to 24 VDC POD5 Fork Drive with Buna N O Ring 100 PPR Quad Pulser 5 VDC Dimensions CAUTION KEEP COVER va WHILE CIRCUITS ARE LIVE ATTENTION GARDEZ COUVERCLE BIEN FERME TANT QUE LES CIRCUITS Voltage V 8 to 24 VDC POD5 is 5 VDC 5 Current supply 26 mA typical Output Signal Resolution 100 pulses per encoder revolution unscaled For actual meter resolution see table below Square Wave Single or dual quadrature channel output Pulse Timing Nominal 50 on and 50 off Rise Fall Time of Pulse lt 5 us Operating Temperature Range 40 F to 185 F 40 C to 85 C Specifications Threaded Conduit Hub 1 14 NOTE Dimensions shown are not for construction use Consult factory when certified Engineering Drawings are required e Output Current sinking 100 mA maximum in ON state V supply 1 0 KQ in OFF state Optional Open Drain FET Field Effect Transistor FET rating drain to source voltage 30 VDC maximum e Humidity Range 0 100 96 non condensing e Shock 50 Gs for 10 ms e Vibration 1 G at 10 150 Hz Electromagnetic Compatibility EMI RFI etc to IEC 801 Standard Pulse Transmission Distance Up to 5 000 feet 1 524 meters Operates in bidirectional flow applications Pulses Max Gallon Litre Output MS Series Meters Channel Channel kHz _Ms 15 258 j 544 069 0 53 0 30 0 26 Max Pulses Output S
47. ording to markings on valve body Apply pipe compound sparingly to male pipe threads only If applied to valve threads the compound may enter the valve and cause operational difficulty Avoid pipe strain by properly supporting and aligning piping When tightening the pipe do not use valve or solenoid as a lever Locate wrenches applied to valve body or piping as close as possible to connection point IMPORTANT To protect the solenoid valve install a strainer or filter suitable for the service involved in the inlet side as close to the valve as possible Clean periodically depending on service conditions See ASCO Series 8600 8601 and 8602 for strainers MAINTENANCE WARNING To prevent the possibility of death personal injury or property damage turn off electrical power depressurize valve and vent fluid to a safe area before servicing the valve Note It is not necessary to remove the valve from the pipeline for repairs Maximum Maximum Page 1 of 4 Rights Reserved Cleaning solenoid valves should be cleaned periodically The time between cleanings will vary depending on the medium and service conditions In general if the voltage to the coil 1 correct sluggish valve operation excessive noise or leakage will indicate that cleaning is required In the extreme case faulty valve operation will occur and the valve may fail to open or close Clean valve strainer or filter when cleaning the valve Preventive M
48. over Rotate the POD to the desired orientation and thread in the mounting screws until they are snug Using a 7 32 box end wrench tighten the screws and torque them to 21 25 inch pounds Proceed to Page 7 for wiring instructions NOTE If a POD Extension Kit is required it must be installed prior to installation of the POD This is addressed on Page 6 Installation POD Conduit Hub Orientations Fork Style Tang Mounting Holes O Ring Position amp Mounting Holes Mounting Holes Mounting Holes Installation Installing the POD Extension The POD Extension is used when the meter has an integral counter adapter bracket or for high temperature applications The POD Extension is used to extend the connection away from the meter There are four POD Extension models available 49754 Fork Drive with Buna N O Ring Use with POD1 or PODS 49756 Fork Drive with Teflon O Ring Use with POD2 49757 Blade Drive with Buna N O Ring Use with POD1 or PODS 49759 Blade Drive with Teflon O Ring Use with POD2 NOTE Regardless of the POD Extension being used the POD Pulser must be a FORK drive pulser Once the existing hardware has been removed as described on Page 4 the POD Extension can be installed 1 Verify that the proper POD Extension Model was obtained by comparing the driver tang on the POD Extension to the driver tang on the packing gland that was removed in Step 5 of Remo
49. p aF k IT ae F a E Mr Backed by our Worldwide reputation for Quality Accuracy and Advanced Design LIQUID CONTROLS A Unit of IDEX Corporation 105 Albrecht Drive Lake Bluff IL 60044 2242 1 800 458 5262 847 295 1050 Fax 847 295 1057 www lcmeter com 2004 Liquid Controls Pub No 500003A 04 04 ISO 9001 ISO 14001 DNV DNV CERTIFICATED FIRM CERTIFICATED FIRM Certificate No 08732 Certificate No 05049 ANN Technical Fuelhouse and Commander Dispenser Control The following Technical Data sheet is designed to assist the installer with understanding the input output control signals to the dispenser control board and how they affect the units operation It is intended as a supplementto the wiring information supplied with the dispenser Table 1 lists the field wiring connections to the board This list only represents control wiring to from the CPU board that must be considered when hooking up the dispenser to an external control device such as a card access system or console Internal dispenser wiring is not represented in the list Table 1 Terminal Signal Name Description Input or Output Signal Type Connection TB1 8 AC Power AC source for AC output control Input 110VAC referenced to TB1 7 signals TB1 7 AC Neutral AC Neutral reference for AC Input AC Neutral input control signals TB1 6 Earth Ground Earth Ground Input Earth Ground TB4 8 On Off Lever Signal Activity s
50. ply wires Temperature Limitations For Series 8016G Solenoids for use on Valves Rated at 6 1 8 1 9 1 10 6 or 11 1 Watts Watt Catalog Rating Number Coil Prefix Maximum Ambient Temp Class of Insulation 104 F 40 C 104 F 40 C Minimum ambient temperature 40 F 40 Positioning This solenoid is designed to perform properly when mounted in any position However for optimum life and performance the solenoid should be mounted vertically and upright to reduce the possibility of foreign matter accumulatingin the solenoid base sub assembly area Wiring Wiring must comply with local codes and the National Electrical Code solenoids supplied with lead wires are provided with a grounding wire which is green or green with yellow stripes and a 1 2 conduit connection To facilitate wiring the solenoid may be rotated 360 For the watertight and explosionproof solenoid electrical fittings must be approved for use in the approved hazardous locations Additional Wiring Instructions For Optional Features Open Frame solenoid with 1 4 spade terminals For solenoids supplied with screw terminal connections use 12 18 AWG stranded copper wire rated at 90 C or greater Torque terminal block screws to Printed in U S A Page 1 of 4 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com 10 2 in lbs 1 0 1 2 Nm A tapped hole is provided in the solenoid for grounding use a 10 32 m
51. re spring 5 For normal maintenance it is not necessary to remove the valve seat However if valve seat removal is required use a 7 16 socket wrench 6 Dislodge retainer from metering pin passageway and remove metering pin with gasket Then remove metering pin gasket from metering pin 7 Remove bonnet screws valve bonnet piston spring piston assembly support lip seal body gasket and body passage gasket 8 Remove aspirator tube and disc with disc gasket from piston 9 All parts are now accessible to clean or replace If parts are worn or damaged install a complete ASCO Rebuild kit Valve Reassembly 1 Reassemble valve using exploded views for identification and placement of parts 2 Lubricate the solenoid base gasket body gasket body passage gasket metering pin gasket and the surface of Page 2 of 4 the piston which contacts the lip seal with DOW CORNING 200 Fluid lubricant 3 Lubricate disc and disc gasket with DOW CORNING 111 Compound lubricant or an equivalent high grade silicone grease 4 Position body gasket body passage gasket and support in valve body 5 Install aspirator tube and disc with disc gasket in piston 6 Position lip seal flanged end out onto piston assembly Install piston assembly with lip seal into support in valve body cavity 7 Replace piston spring valve bonnet and bonnet screws Torque bonnet screws in a crisscross manner to 144 15 in lbs 16 3 1 7
52. screws Pull the packing gland out of the meter If the O Ring does not come out with the packing gland be sure to remove it from the packing gland well before installing the POD When this is complete the POD can be installed Bomovda the POD Verify that the proper POD Model was obtained by comparing the driver tang on the POD to the driver tang on the packing gland that was removed in Step 5 of Removing Existing Hardware on Page 4 There are two types of packing gland POD driver tangs blade type and fork type Blade type packing glands must be replaced with blade type PODs Fork type packing glands must be replaced with fork type PODs Determine the desired orientation of the conduit hub The hub can be positioned in one of eight possible orientations as shown in the figure to the right NOTE Meters with only two packing gland mounting screws are limited to four orientations NOTE When using a cable gland to seal the wire entrance any of the eight orientations can be used However when using conduit the hub should face down so moisture that may accumulate in the conduit will drain away from the POD electronics 6 Position the O Ring over the bottom of the POD as shown to the right Align the fork style or blade style driver with the drive mechanism in the meter and guide the POD into the opening in the meter cover When properly aligned the POD will go in until its mounting flange abuts the meter c
53. sket washer and connector cover NOTE Connector cover may be rotated in 90 increments from position shown for alternate positioning of cable entry 5 Check DIN connector terminal block for electrical markings Then make electrical hookup to terminal block according to markings on it Snap terminal block into connector cover and install center screw 6 Position connector gasket on solenoid and install plug connector Torque center screw to 5 1 in lbs 0 6 1 1 Nm NOTE Alternating current AC and direct current DC solenoids are built differently To convert from one to the other it may be necessary to change the complete solenoid including the core and solenoid base sub assembly not just the solenoid Consult ASCO Installation of Solenoid Solenoids may be assembled as a complete unit Tightening is accomplished by means of a hex flange at the base of the solenoid The 3 4 bonnet construction Figure 1 must be disassembled for installation and installed with a special wrench adapter Installation of Panel Mounted Solenoid Sce Figure 3 Disassemble solenoid following instruction under Solenoid Replacement then proceed 3 4 Valve Bonnet Construction 1 Install retainer convex side to solenoid in 1 312 diameter mounting hole in customer panel 2 Then position spring washer over plugnut core tube sub assembly 3 Install plugnut core tube sub assembly through retainer in customer panel Then replace soleno
54. sure that the wiring slot is fully open to accept wire Insert the stripped end of the wire and tighten the terminal block screw V Supply Channel A V Supply Channel B OV One Cycle Installation Plug the terminal block back into the board if it was removed Be sure it is properly oriented with the four pins Wiring Configurations The wiring configuration used depends on the system needs The POD can be wired using only one of the two channels Channel A or B if the flowmeter has flow in only one direction To detect both forward and reverse flow both channels which are in quadrature to each other must be used Channel A will lead Channel B by 90 in one flow direction and Channel B will lead Channel A in the reverse direction Quadrature is required in most Weights amp Measures approved installations Conversion to Open Drain Output As supplied by the factory the POD has a 1 0 KQ pull up resistor to the positive power supply on each output transistor The unit can be modified in the field to provide true Open Drain Open Collector outputs if desired To modify the POD to Open Drain outputs follow these steps 1 Turn off power to the unit and remove the cover by turning it counterclockwise 2 Loosenthe three circuit board mounting screws using a Philips screwdriver Remove the entire circuit board assembly from the POD housing 3 Clip out R1 and R2 using a sharp diagonal cutter 4 Reassemble t
55. that of the prover NOTE I US GALLON 231 cubic inches Page 9 PARTS MANUAL LIQUID CONTROLS 7 M A 7 1 0 re FS A Unit of IDEX Corporation Exploded View M 7 MA 7 M 10 Meter Covers 0609 Screw mounting plate 2 0613 Screw adjuster 0366 Plate 0382 Shaft dust cover adjuster mm 0336 Gear 89 p 0574 Ring retaining re gt Lau UID CONT M BLUFF Q y Korn RATE Vai No n VOUREY TP ETRE 0780 Seal wire 0630 Screw 2 0603 Screw How to Order 0165 Gear packing gland Driveshaft bushing 2 2 Replacement Parts Find the item number listed on the exploded drawing The 4 digit item numbers are listed with a word description Find the computer printout titled Parts List that has been inserted in this manual Look up the item number on the Parts List The Parts List shows each item number with a corresponding part number Find the corresponding 5 digit part number for the item you want to order The part number represents an individual piece a kit or a complete assembly Inform your distributor of the part number that you need The part number is the only number that allows the distributor to find the correct component for your meter 0202 Adjuster qvam a Ca assembly 3 M 0364 Plate adjuster mounting ff 0126 Bracket counter
56. uit or no conduit When no conduit is used the instrument cable must be brought into the POD conduit hub using a cable gland to seal the wiring to maintain the Enclosure NEMA 4X rating Regardless of the type of connection used thread sealant should be applied to prevent moisture from getting into the POD electrical housing Wiring Cable Multi wire cable with an overall shield is recommended for POD wiring Use individual wires between 16 and 20 AWG or shielded cable no less than 22 AWG Cable runs up to 5000 ft 1524 m are possible however cable runs over 200 ft 61 m should use lower AWG wire to reduce the IR voltage drop and the inter wire capacitance In addition long runs may require a lower value pull up resistor due to the additional cable capacitance that the pulser must drive Cable that has a metalized foil plastic shield with a drain wire is recommended over cable with woven shields because it is easier to terminate the drain wire type cable Terminal Block Removing the cover of the POD will expose a 4 position terminal block for connection to the user s electrical system The terminal block can be unplugged from the board for ease of wiring Pull it straight up to remove The terminal block screws require a straight blade screwdriver with a tip less than 1 8 wide Before inserting wires into the terminal block strip of insulation off each wire Turn each terminal screw counterclockwise a few turns to make
57. ving Existing Hardware on Page 4 There are two types of Packing Gland POD Extension driver tangs blade type and fork type Blade type packing glands must be replaced with blade type POD Extensions Fork type packing glands must be replaced with fork tyoe POD Extensions Install the POD Extension using the two screws provided There are two sets of holes in the POD Extension for these screws one set is 1 625 apart and the other is 1 5 apart Line up the holes with the meter to determine which set to use Tighten the screws and torque them to 21 25 inch pounds Once the POD Extension is in place the POD may be installed onto the POD Extension Align the POD Fork Tang with the internal POD Extension Driver Use the two screws provided to mount the POD to the POD Extension using two of the tapped holes in the POD Extension Using a 7 32 box end wrench tighten the screws and torque them to 21 25 inch pounds 4 Proceed to Page 7 for wiring instructions Pod Extension Driver Wiring the POD Wiring Conduit System When wiring the POD the wires must enter through the POD s conduit hub For explosion proof rated systems Class Div 1 the wiring must be in rigid conduit that is rated for explosion proof installation The conduit must be engaged five 5 full threads into the female hub on the POD to meet explosion proof requirements When installing in a Division 2 location use either rigid conduit flexible cond
58. ww ascovalve com Installation amp Parts Manual LIQUID Pulse Output Device POD CONTROIS Ic CONTROLS Installation www lcmeter com Table of Contents Description General Information The Liquid Controls Pulse Output Device POD converts the rotary motion of the Liquid Controls Positive Displacement Flowmeter into electronic pulses This allows the meter to interface with a wide variety of electronic monitoring devices and control equipment The POD mounts directly to the front cover of any Liquid Controls meter in place of the packing gland The motion of the meter s blocking rotor is magnetically coupled through a stainless steel wall to the electronics compartment of the POD This eliminates the dynamic seal of the packing gland and isolates the electronics from the process fluid in the meter Inside the electronics compartment an optical shaft encoder converts the rotary motion into a high resolution two channel quadrature square wave Both outputs are driven by field effect transistors FETs and switch from zero volts in the ON state to the user s power supply voltage in the OFF state As supplied from the factory there is a 1 0 KQ pull up resistor on each output which can be removed from the circuit in the field to produce a true Open Drain Open Collector output As Open Drain devices the outputs can sink up to 100 mA in the ON state and sustain up to 30 VDC in the
59. y bonnet valve for mounting bonnet For special wrench core adapter order kit tube No K218948 plugnut core tube sub assembly core Bolted Bonnet 3 4 Bonnet Construction 15 16 Bonnet Construction Figure 2 Series 8016G solenoid Figure 3 Series 8016G panel mounted solenoids Form No V6583H7 Page 3 of 4 ASCA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com Torque Chart Open Frame Solenoid Open Frame Solenoid Open Frame Solenoid with 1 4 Spade Terminals tapped hole for 10 32 grounding screw not included Junction Box Solenoid with 1 4 Spade Terminals or Screw Terminals with Screw Terminals Socket head screw is used for grounding screw terminal adapter with DIN Terminals Indicates parts supplied in Termination Module Kit No K256104 gasket DIN terminal adapter terminal socket head grounding screw 5 32 hex key wrench screw terminal block see note junction box gasket Note Junction box with screw terminals shown With screw terminal block removed remaining parts comprise the junction box for spade terminal construction Open Frame Solenoid with DIN Terminal Plug Connector above Notes 1 Connector cover may be rotated in 90 increments from position shown for alternate position of cable entry Refer to markings
60. zed To disengage manual operator rotate stem fully counterclockwise approximately180 before operating electrically CAUTION Manual operator stem must be fully rotated counterclockwise before electrical operation ASCA 50 Hanover Road Florham Park New Jersey 07932 www ascovalve com E181142 SERIES 8210 8211 1 amp No V6296R2 INSTALLATION Check nameplate for correct catalog number pressure voltage frequency and service Never apply incompatible fluids or exceed pressure rating of the valve Installation and valve maintenance to be performed by qualified personnel Future Service Considerations Provision should be made for performing seat leakage external leakage and operational tests on the valve with a nonhazardous noncombustible fluid after disassembly and reassembly Temperature Limitations For maximum valve ambient and fluid temperatures refer to chart below Check catalog number prefix on nameplate to determine the maximum temperatures Ambient Fluid Catalog Coil Construction Number Class Prefix Temp F Temp F AC Noneor 122 180 140 180 None FT Positioning This valve is designed to perform properly when mounted in any position However for optimum life and performance the solenoid should be mounted vertically and upright to reduce the possibility of foreign matter accumulating in the solenoid base sub assembly area Piping Connect piping or tubing to valve acc
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