TCS 682-15 Manual - Controls Warehouse
Contents
1. Page 26 682 METER BONNET REPAIR INSTRUCTIONS A WARNING All internal pressure must be relieved to ZERO 0 pressure before beginning disassembly of meter or components I A Remove all parts and seals from the meter bonnet and clean them You may air blast parts with a glass bead material to clean parts B Check for excessive wear or corrosion NOTE Problems with any of these following items will require a new bonnet or shafts 1 Drive Shaft 5 2 Compensator Shaft 24 3 Bonnet 12 a Drive shaft packing surface b Compensator shaft surface c Counter drive gear assembly seat 15 amp post II A Insert drive shaft gear assembly 18 with Rulon washer 17 into the meter drive shaft pack ing Install drive shaft packing Kit 9 SEE DRIVE SHAFT PACKING KIT INSTRUC TIONS for more information on page 28 B 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 C Compensator Shaft Assembly 1 Insert AF SP SPA SPD retaining ring 16B or SS SSD cotter pin 16A on to the com pensator 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 on page 27 D Mount Bonnet to Base 1 Place oring 13 into housing 60 2 Move compensator shaft 24 to match pi2. 1 217934 217934 1 217934 217934 49 125046 1 125046 125046 1 130905 130905 50 Main Pivot Assembly 1 219572 4 219572 4 219572 4 219572 4 219572 4 219572 4 51 Compensating Pinion 1 129607 129607 1 129607 129607 1 129607 129607 52 126327 1 126327 126327 1 126327 126327 53 Main Pivot Bracket Assembly 1 218236 4 218236 2 218236 4 219260 6 219260P 54 Slotted Screw 1 4 20 x 1 3 126962 126962 126962 1 126962 126962 55 Screw 1 4 20x1 6 126326 126326 126326 1 126326 126326 56 3 218608 3 218608 3 218608 6 218608 P6 218608 57 Valve 1 219330 219330 1 219330 219330 220496 2 220496 2 58 Seat 1 038618 038622 1 038618 038618 1 310336 P310336 59 Seat Gasket 1 apn TI 038619 1 038619 038619 60 Body Seat and Pin Assembly 1 680125 680122 680124 680126 680118 680128P 61A Flange Bolts 4 702017 702017 702017 702017 702017 702037 61B_ Drilled Flange Bolts 4 702017D 702017D 702017D 702017D 702017D 702037D 62A Flange 1 1 2 NPT 2 701600 701600 701601 701601 701602 701602P 62B Flange 1 1 2 BSPT 2 701603 701603 701621 701621 701812 701812P 63 Flange O ring 2 702012 702012 702013 702013 702013 702812 Page 20 740 Air Eliminator Strainer Assembly Page 21 740 20 Air Eliminator Strainer Assembly Item Description Qty fraa ef some me mene me vem mens Te ES em vener van vene vaner meme ro femsas ves ves Can Jammen i ee vene mens ve
3. 100 9 000 41 080 10 60 280 380 1 400 6 480 9 500 43 000 15 80 300 475 1 500 7 000 10 000 46 500 20 100 320 530 1 700 8 000 15 000 69 400 25 130 340 630 1 800 8 500 20 000 92 500 30 160 360 730 1 900 9 000 30 000 138 500 40 210 380 850 2 000 9 400 40 000 185 000 50 260 400 950 2 200 10 300 50 000 231 000 60 320 420 2 050 2 400 11 200 60 000 277 500 70 370 440 2 160 2 500 11 600 70 000 323 500 80 430 460 2 270 3 000 14 500 80 000 370 000 90 480 480 2 380 3 500 16 500 90 000 415 500 100 530 500 2 480 4 000 18 500 100 000 462 000 120 580 550 2 660 5 000 23 500 125 000 578 000 140 690 600 2 900 5 500 26 000 150 000 694 000 160 790 700 3 380 6 000 28 000 175 000 810 000 180 900 800 3 880 6 500 30 000 200 000 925 000 Centistokes Centipoise Specific Gravity Centipoise Centistokes x Specific Gravity Page 9 System Recommendations Continued AO SP Hydraulic Shock Water Hammer Hydraulic shock is a rise in pressure which happens when an operating system has immediate change in direction of flow such as a fast valve closure at a high operating flow rate Hydraulic shock can damage any item in the way of the product flow such as internal parts of the meter valves and pump System de sign and improper operating procedures will elevate this problem The use of 2 stage preset control valves or surge suppressing bladders or risers will help reduce or eliminate this problem To compute the shock pressure when a
4. 2 126931 1 126931 126931 28 Index Plate 1 226085 226085 1 226085 226085 1 130853 130853 29 Compression Spring 1 130935 130935 1 130935 130935 1 130935 130935 30 Compensator Shaft Seal Kit 1 227000 1 227000 1 227000 1 227000 1 227000 1 680700 2 31A Screw 7 16 14 x 1 1 4 7 600054 600054 700054 700054 700054 700054 31B Drilled Screw 7 16 14 x 1 1 4 2 600054D 600054D 700054D 700054D 700054D 700054D 32 702018 702018 702018 33 Bearing Retainer Plunger 3 126957 126957 1 126957 126957 1 126957 1 126957 34 Plunger Screw 10 32 x 3 8 12 126329 126329 1 126329 126329 1 126329 1 126329 35 219378 1130908 71130008 36 iston Connector Plunger 3 126939 126939 126939 1 126939 P1 126939 37 unger Disc 3 126878 126878 126878 1 126878 P1 126878 38 unger Cup Kit 3 Cups 1 218769 218769 1 218769 218769 1 218769 1 39 unger Cup Support 3 126876 126876 1 126876 P1 126876 40 unger Assembly 3 226182 2 226182 2 226182 2 219407 6 41 ut 1 4 20 3 126321 12632 1 126321 1 126321 42 Washer 1 4 Split Lock 6 126317 126317 1 126317 126317 1 126317 1 126317 43 ack Roller Assembly 1 219800 219800 1 219800 219800 2 680051 44 Washer 0 863 OD x 0 030 Rulon 1 125103 125103 125103 1 125104 1 125104 45 Slack Spring Assembly 1 898 221403 1 221403 2 221403 2 221403 5 221403 5 46 Ball 1 4 Dia 3 124588 124588 1 124588 124588 2 130905 2 130905 47 Wobble Plate Assembly 1 219331 219331 2 219331 1 219331 219901 2 219901P 48 Wear Plate
5. A It is important to test the repeatability and accuracy of your meter To test repeatability 1 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 2 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 successful ly calibrated If the test results differ beyond the rated tolerance of the meter then repairs are necessary before the meter can be calibrated rIQMMUNUY K L M A valve or nozzle must be at the end of the delivery hose at the 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 0 line means the meter is 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 indicat
6. REMOVE ANY CONTAMINATED CLOTHING AND RINSE SKIN THOROUGHLY WITH WATER FOR AT LEAST 15 MINUTES IF SKIN IRRITATION PERSISTS CONTACT A PHYSICIAN IN CASE OF OVEREXPOSURE TO MIST REMOVE VICTIM TO FRESH AIR IF BREATHING IS DIFFICULT ADMINISTER OXY GEN AND CONTACT A PHYSICIAN IMMEDIATELY IF PRODUCT IS INGESTED DO NOT INDUCE VOMITING CONTACT A PHYSICIAN STABILITY THIS PRODUCT IS STABLE UNDER NORMAL STORAGE CONDITIONS HAZARDOUS POLYMERIZATION WILL NOT OCCUR UNDER NORMAL CONDITIONS HAZARDOUS DECOMPOSITION PRODUCTS THERMAL DECOMPOSITION MAY RESULT IN THE FORMATION OF OXIDES OF CARBON AND INCOMPLETELY BURNED HYDROCARBONS IN THE FORM OF FUMES AND SMOKE CONDITIONS TO AVOID AVOID CONTACT WITH OPEN FLAME STORE IN ROOM TEMPERATURE AREA Page 39 Material Safety Data Sheet Continued PRODUCT RP 1039 PAGE 3 INCOMPATIBILITY AVOID CONTACT WITH STRONG OXIDIZING AND REDUCING AGENTS AND STRONG ALKLI STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED FOR SMALL SPILLS SOAK UP SPILL WITH ABSORBENT MATERIAL FOR LARGE SPILLS DIKE SPILL AND PUMP INTO DRUMS FOR PROPER DIS POSAL WASTE DISPOSAL METHOD DISPOSE OF IN ACCORDANCE WITH ALL LOCAL STATE AND FEDERAL REGU LATIONS RESPIRATORY PROTECTION NORMALLY NOT REQUIRED HOWEVER WHEN THE TLV IS EXCEEDED WEAR THE APPROPRICATE MSHA NIOSH APPROVED RESPIRATOR VENTILATION PROVIDE ADEQUATE VENTILATION SUCH AS MECHANICAL OR LOCAL TO ASSURE TLV IS NOT EXCEEDED PROT
7. The pipe should be laid out as straight as possible to reduce pressure loss from flow restriction 6 The meter and piping must be installed in such a way as to avoid accidental draining of the meter Meter inlet and outlet should be lower than the associated system plumbing sump position 7 It is not necessary for the air eliminator to be installed directly bolted to the meter It can be installed upstream from the meter For effective operation of the air eliminator it should be mounted between the meter and any valves tees or any other potential places where air may enter the system 8 The metering system should include a means for calibration Protection From Debris On new installations care must be taken to protect the meter from damage during start up It is recom mended to put a strainer before the meter Damage may result from the passage through the meter of dirt sand welding slag or spatter thread cuttings rust etc The insertion of a spool a flanged length of pipe equal in length to the meter and accessories attached to the meter in place of the meter until the system is flushed temporarily bypassing the plumbing around the meter will also protect the meter from debris Once the system has run clean for a period of time the meter may be reinstalled or protective devices removed Thermal Expansion As with most liquids they will expand and contract with temperature In any system where there is a chance for liq
8. Valve Body Assembly kr sk 650127 650227 650327 P650427 Page 24 TORQUE SPECIFICATIONS 682 15 METER ASSEMBLY Foot Lbs Newton Meter Part Number Tool Bolt Nut Size Unlubricated Lubricated Unlubricated Lubricated 5 9 hex 7 i TCS 3 23095 li6 14 UNC 50 375 67 8 50 wrench socket 5 8 hex TCS 1 130876 S I 14 UNC 27 20 36 6 27 wrench socket Du 16 hex 3 TCS 297 050361 s 16 UNC 30 22 5 40 6 30 wrench socket Du 16 hex 3 TCS 1 126353 s 16 UNC 19 7 11 8 26 7 16 wrench socket 1 9 LI 2 6 1 5 TCS 1 128279 10 24 UNC screwdriver TCS5 230958 e 14 13 UNC wrench socket TCS 1 126329 10 32 UNF screwdriver TA TCS 1 126321 Te hex 14 20 NUT wrench socket TCS 1 126327 14 20 UNC screwdriver 7 D Je hex TCS 1 126326 wrench socket 650 15 HYDRAULIC PRESET VALVE ASSEMBLY 14 20 UNC Foot Lbs Newton Meter Part Number Tool Bolt Nut Size Unlubricated Unlubricated 2 hex 5 SE wrench socket Ge E oa e w ose N 16 hex TCS 65032 14 20 UNC 6 3 3 8 8 5 5 2 wrench socket TCS 1 126279 10 24 UNC screwdriver 740 20 AIR ELIMINATOR STRAINER ASSEMBLY No L t N ey Foot Lbs Newton Meter Part Number Tool Bolt Nut Size rot Unlubricated Unlubricated TCS 740050 1 2 hex screw 5 16 18 UNC 2B wrench socket TCS 701017 2116 hex screw 3 8 16 UNC 2B wrench socket TCS 740030 oed 8 32 UNC 2B screwdriver Page 25 682 METER BODY REPAIR INSTRUCTIONS AO H iWARNIN
9. close an upstream valve such that the meter remains full of anti freeze solution 3 Remove the register from the meter and lubricate the drive coupling shaft After lubrication reassemble the register onto the meter When starting the system after a period of storage check the meter s calibration as detailed earlier in the service manual Page 17 682 15 Dimensions 5 34 135 561 REG PRINTER REGISTER PRESET METER AIR ELIMINATOR P ed 1 2 06 357 16 gi D 3 LT MTT Ni I Eg oy 6 90 175 26 HYDRAULIC VALVE STRAINER 6 68 169 55 10 00 254 00 l U 1 1158 598 813 6 50 165 01 3 25 82 55 2 50 es an 63 50 3 3 8 16 MOUNTING HOLES All measurements are in inches millimeters Page 18 682 15 Meter Assembly Page 19 682 15 Meter Assembly ltem Description Qty SP SPA SPD AF SS SSD 1 Screw 3 8 16 x 1 1 8 2 297 050361 297 050361 297 050361 297 050361 1 126333 1 126333 2 Washer 3 8 Split Lock 2 15 050641 15 050641 15 050641 15 050641 1 126334 126334 3 1312518 312518 680050 4 Roll Pin 1 3 130752 3 130752 3 130752 3 130752 3 130752 5 Drive Shaft 1 126900 126900 12690
10. or more often if there is a lot of sediment in the system Make sure there is no ignition source and the system is grounded Replace all plugs that were removed for drainage The metering system is heavy and awkward so take precaution to handle it properly When inspecting the spring loaded preset valves do not place anything inside the housing as the action of the valve will pinch this object when the valve closes Page 16 Maintenance CONTINUED Gs iWARNING Test equipment should be grounded to prevent a possible spark Test area should have no ignition source Operators should wear personal protection and prevent any product exposure and environmental issues 9 When removing gaskets or o rings carefully check for damage or corrosion Any cracked rough worn elongated or swollen o rings need to be replaced When replacing the o rings place grease along the inside of the o ring groove or completely around the o ring to help the o ring stay in the o ring groove during assembly If o ring is pinched or not in the o ring groove the meter system will leak and cause serious problems to the environment and equipment Collect all replaced parts and dispose of properly Do not weld any part of the meter system or accessories as this will weaken the part and allow for leaks 10 All bolts and screws need to be coated with Anti Seize lubricant Then follow the torque specifications for each flow meter air eliminator strainer or
11. 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 position 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 Drive Shaft a ae Counter Drive Gear Ki gt Valve Pivot E S Wobble Place D EE _ Sliding Valve pit pe Plunger N a _ Measuring Chamber Inlet Flow Outlet Flow Page 5 Meter Specifications Flange Connection 1 1 2 NPT Flange Connection 1 and 2 NPT Flange Optional BSPT Slip Weld or ANSI flanges available upon request Flow Rate 0 2 to 50 GPM 0 76 to 189 LPM Maximum Pressure 150 PSI 10 5 BAR Working Temperature 20 F to 160 F 28 9 C to 71 C Meter Types SP Standard Petroleum For metering refined petroleum products such as Fuel Oils Gasoline Diesel Bio Diesel Motor Oils Ker osene Vegetable Oils Ethylene Glycol Naptha etc SPA Standard Petroleum Aviation For metering refined petroleum products such as Aviation Gasoline Fuel Oils Jet Fuels Gasoline Diesel Bio Diesel Kerosene etc SPD Standard Petroleum Ductile Iron For metering refined petroleum products such as Leaded and Unleaded Gasoline Fuel Oils Diesel Bio Diesel Aviation Gasoline Ethanol Blen
12. possible spark Test area should have no ignition source Operators should wear personal protection and prevent any product exposure and environmental issues Start up instruction for new installations or after maintenance and repairs 1 Only properly trained personal should design install or operate metering system 2 Remove plastic threaded plugs placed in meter for shipping protection They are not to be used in meter system because of the PVC plugs low rated pressure compatibility and sealing issues 3 Place the meter in an area with ample workspace secure from vibration and pipe line stress Mount and bolt down on to a fixed stand or platform This prevents meter stress which will cause leakage and metal fatigue 4 Apply thread sealing compound and gasket materials that are compatible with product 5 Do not weld to meter or accessories This will weaken housings and cause o ring and casting leaks 6 Always wear personal safety protection equipment such as goggles steel toed shoes gloves and full body clothing 7 Be sure to install a pressure relief valve or expansion joint in the system to protect against thermal expansion 8 Make sure all system components are properly secured and tightened 9 All meter assembly bolts and connections are tight 10 Air eliminator vapor release is properly vented and piped into a reservoir container or back to the supply tank 11 Electrical connections are properly
13. preset valve bolt on page 24 11 Recommended levels of maintenance and inspection will depend upon the system variables such as the products being measured their corrosiveness system pressure requirements government or company regulations and age of metering system If hydrostatic testing is required the system pres sure should not exceed 1 5 times the marked meter pressure It is not recommended to pneumatically test the meter system at anytime 12 If any component of the meter system is removed from the system it should be thoroughly flushed with a compatible liquid After this is done immediately refill the meter or accessory with a compatible liquid to prevent corrosion and water build up Storage Instructions Gs Short periods of non use of the meter a week or less should 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 To store the meter when it is left in line flush the system with clean water until 70 80 gallons of water have gone through the meter 2 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
14. the Spring Loaded Back Check Valve and or the Differential Air Check Valve to help the air eliminator operate more effectively Entrained Air is much more diffi cult to remove Typically the best way to eliminate Entrained Air will be to remove the air source of entry into the system Some examples are from cavitating pumps and leaking pump valve seals See Air Elimination in the Service Manual for more information 2 The air return line is not the required minimum of 1 2 ID 3 The metering system has no sufficient way of eliminating the air to atmosphere Example Incor rectly installed Catch Can reservoir lower than the air eliminator itself or the reservoir is al lowed to become full incorrectly sized vent etc Page 36 Preset Valve Trouble Shooting AO D A PROBLEM The valve will not close completely 1 2 3 4 The shaft of the piston may be bent from excessive force Debris may be between the plunger and poppet piston guide The plunger cup seal may be worn cut or torn The Veeder Root preset may have a worn or bent trip mechanism that is not allowing the preset to function correctly B PROBLEM The valve shuts immediately upon first stage trip bypassing the second stage closure 1 2 3 The mechanical linkage might need to be adjusted moving the Nylon locking nuts forward or backwards to change the closing of the preset valve The Veeder Root preset may need to be raked or adj
15. valve assembly Remove valve from meter and piping Remove the roll pin 21 from the valve stem 20 Then remove the screws 26 from the cover 29 and poppet assembly and lift from the body 41 Inspect the seat of the body 41 for pitting or foreign matter Pull the poppet assembly from the cover 29 and inspect for a damaged plunger cup 34 and or valve disc 36 Remove the screws 21 from the poppet guide 38 to inspect the valve seat 37 for pitting or ex cessive wear Replace as necessary To replace the packing seal 27 and orings 28 within the cover 29 remove the compression washer 24 screws 22 washers 23 and stem 20 completely Carefully slide packing seal 27 and orings 28 then spacer 25 over valve stem 20 Reas semble compression washer screws and washers The carbon graphite seals 27 must be heated and carefully formed by rotating each seal on a smooth 3 8 diameter punch or pencil prior to fitting over the valve stem 20 Orings 28 must have the slot facing the fluid for proper installation CAUTION Be certain not to damage seals while forming or during insertion into packing cavity See the illustration below for proper installa tion sequence Replace the previously removed parts and reassemble the valve Drive Shaft 5 Spacer o Retaining Plate 4 Seal 3 Slotted O ring 2 Seal ETS ole fa 1 Slo
16. valve is closed quickly recommended to be less than 6 PSI Shock Pressure PSI 63 x Velocity FPS In order to eliminate hydraulic shock you need to slow down the valve closure rate The time required to close the valve so that the line pressure will not exceed the normal pressure at no flow is Time seconds 0 027 x Lx V N F Velocity in Feet Seconds Length of pipe before the valve in feet Line pressure at no flow Line pressure at full flow TZT Il Products that Dry Congeal Crystallize There are many liquids that crystallize harden and or solidify on contact with air or with an increase in temperature proper system design and a good understanding of the product being measured will help to avoid the possibility of air entering into the system and the product being affected Calibration The meter shall be tested and calibrated with the product it is intended to measure when installed Total Control Systems shall not be responsible for loss of product or any damages resulting from the end user s failure to test this meter to insure proper calibration Every 682 series meter is tested and calibrated at the factory to prove it is calibratable in your system It is the owner s responsibility to report this device to the local Weights and Measures officials for their inspection before the meter is put to use Page 10 Start up Recommendations Gs WARNING Test equipment should be grounded to prevent a
17. 0 1 126900 126900 6 Screw 10 24 x 1 2 6 128279 128279 128279 1 128279 128279 7 _ Washer 10 Split Lock 12 126316 126316 126316 1 126316 126316 8 Compression Washer 2 130872 130872 130872 2 130872 2 130872 9 Drive Shaft Packing Kit 1 226199 1 226199 1 226199 1 226199 1 680699 2 0 126903 1 126903 126903 1 126903 126903 1 Pipe Plug 1 4 2 126146 126146 1 126146 126146 2 126146 2 126146 2 680250 680253 680253 680252 P680155 3 O Ring 1 680210 680210 680212 680212 680212 680810 4 Washer 3 4 OD x 0 015 Rulon 1 125120 125120 125120 1 125120 1 125120 5 Counter Drive Gear Assembly 1 226136 1 226136 1 226136 1 226136 2 226136 1 16A Cotter Pin 1 16 x 1 2 2 e 5 1 126318 126318 168 12053420 17053420 12053420 l 7 Washer 7 8 OD x 0 15 Rulon 1 125407 125407 1 125407 125407 1 125407 125407 8 Drive Shaft Gear 1 226135 1 226135 1 226135 1 226135 1 226135 2 226135 1 9 13 052870 13 052870 13 052870 1 126319 13 052870 20 Drive Shaft Pin 1 4 x 1 3 32 1 126913 126913 126913 1 126914 126913 21 Cotter Pin 1 16 x 1 2 1 126318 126318 126318 1 126318 126318 22 Seal Wire and Seal 1 118849 118849 118849 1 118849 118849 23 Seal Pin 1 019602 019602 1 019602 019602 1 126929 126929 24 Compensator Sha 1 224081 224081 1 224081 224081 1 224119 224119 25 Nut 5 15 18 1 2 050301 2 050301 2 050301 2 050301 1 126320 126320 26 126927 1 126927 126927 1 126927 126927 27 Index Disc 1 126931 126931 1 126931
18. 1 2 3 Replace the strainer screen into the housing Place the end cover o ring in the groove of the end cover Put the end cover with o ring installed on the strainer housing Replace and fasten end cover with the 4 screws and washers Tighten the screws according to the torque chart Page 31 iWARNING All internal pressure must be relieved to ZERO 0 pressure before beginning disassembly of meter or components 1 Using a 1 2 wrench or socket remove the cover screws from air eliminator cover plate 2 Remove cover plate 3 Remove valve plate inspect and replace as needed 1 To remove the air eliminator assembly remove the four screws and washers attaching it to the strainer assembly 2 Using a flathead screwdriver remove the screws attaching reed valves to air eliminator housing 3 Remove the two screws on the diffuser screen 4 Slide out diffuser shaft assembly 5 Remove the two screws attaching reed valve to the float assembly Inspect and replace reed valves as needed Page 32 650 15 Hydraulic Valve Repair Instructions A QOO iWARNING All internal pressure must be relieved to ZERO 0 pressure before beginning disassembly of meter or components 1 2 3 5 6 7 8 9 Drain all fluid from metering system prior to valve removal Remove the linkage from valve assembly by removing the screws 18 from the bracket 17 and lift the arm linkage from the
19. 65005 15 oO N N oo Retaining Ring Shaft Bearing Bracket Screw 1 4 20 x 1 2 KM l xl kl ak lM Aa 65026 65026 65004 65004 sh Washer Split Lock 1 126317 1 126317 k o 20 Valve Stem 65018 65018 65026 65004 1 126317 65018 65026 65004 65012 65012 65012 65012 65032 65032 65032 65032 1 126317 65018 21 Roll Pin 5 32 x 1 kite FE 65027 65027 65027 65027 22 Screw 10 24 x 1 2 1 128279 1 128279 1 128279 1 128279 23 Washer 1 126316 1 126316 1 126316 1 126316 24 25 Spacer 26A Screw 5 16 18 x 1 26B Compression Washer Drilled Screw 5 16 18 x 1 1 130872 1 130872 hm Mm PM 2 7 28 Seal O Ring 9 Cover 650015 65031 2 1 130872 2 126898 65031 4 1 130872 1 130893 1 130893 1 130893 1 130893 65033 65033 65033 65033 65033D 65033D 65033D 65033D 2 126898 5 311554 5 311554 5 311554 650803 P65031 4 30 Pipe Plug 2 051913 2 051913 2 126146 2 126146 31 Poppet Spring 65007 65007 65007 65007 32 Washer Flat 65035 65035 65035 65035 33 34 35 Plunger 36 Valve Disc 37 38 Poppet Guide 39 Plunger Cup Support Plunger Cup Valve Seat Gasket 65014 65014 skl l k lM ls la lA lM k aa 65021 65021 65014 65021 65014 65022 40 O Ring 65001 65001 65001 65002 41
20. ECTIVE GLOVES NORMALLY NOT REQUIRED HOWEVER IF HANDS ARE FREQUENTLY IN FLUID WEAR OIL AND CHEMICAL IMPERVIOUS GLOVES EYE PROTECTION SAFETY GLASSES REQUIRED FOR NORMAL USAGE WEAR CHEMICAL GOGGLES WHEN EXCESSIVE SPLASHING MAY OCCUR OTHER PROTECTIVE EQUIPMENT NORMALLY NOT REQUIRED HOWEVER WHERE REPEATED CONTACT OCCURS WEAR IMPERVIOUS CLOTHING AND BOOTS HYGIENIC PRACTICES FOLLOW STANDARD INDUSTRIAL HYGIENE PRACTICES LAUNDER ANY CONTAMI NATED CLOTHING BEFORE RE USE PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE DO NOT STORE IN THE PRESENCE OF HEAT SPARKS FLAME OR ANY OTHER SOURCES OF IGNITION STORE AWAY FROM STRONG OXIDIZING AGENTS EMPTY DRUMS MAY CONTAIN PRODUCT RESIDUES ALL SAFETY PRECAUTIONS TAKEN WHEN HANDLING THIS PRODUCT SHOULD ALSO BE TAKEN WHEN HANDLING EMPTY DRUMS AND CONTAINERS OTHER PRECAUTIONS NONE Page 40 Material Safety Data Sheet Continued PRODUCT RP 1039 PAGE 4 HMIS HEALTH 1 FLAMMABILITY 2 REACTIVITY 0 PERSONAL PROTECTION C NFPA HEALTH 1 FLAMMABILITY 2 REACTIVITY 0 SPECIFIC HAZARD DOT HAZARDOUS NATURAL DESCRIPTION THE INFORMATION CONTAINED HEREIN IS TO THE BEST OF OUR KNOWLEDGE AND BELIEF ACCURATE HOWEVER SINCE THE CONDITIONS OF HANDLING AND USE ARE BEYOND OUR CONTROL WE MAKE NO GUARANTEE OF RESULTS AND ASSUME NO LIABILITY FOR DAMAGES INCURRED BY USE OF THIS MATERI AL IT IS THE RESPONSIBILITY OF THE USER TO COMPLY WITH ALL APPLICABLE FEDERAL STATE AND LOCAL LAWS AND REGULA
21. G All internal pressure must be relieved to ZERO 0 pressure before beginning disassembly of meter or components I A Remove all parts and seals from the meter body and clean them You may air 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 C Check for 1 Excessive wear on the wobble plate 47 guide holes 2 Pitting on ball bearings 49 amp 46 3 Excessive wear on the guide posts on main pivot bracket assembly 53 4 Wear on the SP SPA SPD AF valve 57 or SS SSD valve insert 57 5 Wear on the valve seat 58 6 Wrinkles on the sleeves in cylinders of the body NOTE Honing sleeves with Emory wheel may buff out wrinkles II A Mount valve seat 58 to body 60 with seat gasket 59 B Lap valve 57 for SP SPA SPD AF SS or SSD 1 SP SPA SPD amp AF 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 fin ished 2 SS SSD 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 C Replace plunger cups 38 in piston 40 and carefully place into cylinders SEE PLUNGER CUP KIT for piston repair instructions on pa
22. ODOR EVAPORATION RATE NA APPEARANCE AMBER LIQUID SOLUBILITY INSOLUBLE VOLATILE BY WEIGHT NA PRODUCT DENSITY 0 790 VOLATILE BY VOLUME NA FLAMMABILITY CLASSIFICATION COMBUSTIBLE FLASH POINT 150 F LEL NA CLEVELAND OPEN CUP UEL NA DOT COMBUSTIBLE LIQUID EXTINGUISHING MEDIA CARBON DIOXIDE DRY CHEMICAL FOAM Page 38 Material Safety Data Sheet Continued PRODUCT RP 1039 PAGE 2 UNUSUAL FIRE AND EXPLOSION HAZARDS DO NOT DIRECT A SOLID STREAM OF WATER ONTO BURNING PRODUCT THIS MAY CAUSE SPREADING AND INCREASE THE FIRES INTENSITY COMBUSTION MAY PRO DUCE OXIDES OF CARBON AND INCOMPLETELY BURNED HYDROCARBONS IN THE FORM OF FUMES AND SMOKE SPECIAL FIREFIGHTING PROCEDURES WEAR A SELF CONTAINED BREATHING APPARATUS WITH FULL FACEPIECE EFFECTS OF OVER EXPOSURE MAY CAUSE MILD EYE IRRITATION AND REDNESS PROLONGED OR RE PEATED EXPOSURE TO THE SKIN MAY RESULT IN LOSS OF NATURAL OILS ACCOMPANIED BY DRYNESS CRACKING AND DERMATITIS INGESTION MAY RESULT IN NAUSEA DIARRHEA AND GASTRO INTESTINAL IRRITATION OVEREXPOSURE TO MIST MAY CAUSE UPPER RESPIRATORY TRACT IRRITATION AND DIFFI CULTY BREATHING MEDICAL CONDITIONS PRONE TO AGGRAVATION BY EXPOSURE NONE KNOWN PRIMARY ROUTE S OF ENTRY DERMAL INHALATION INGESTION EMERGENCY AND FIRST AID PROCEDURES IN CASE OF EYE CONTACT IMMEDIATELY FLUSH EYES WITH CLEAN WATER FOR AT LEAST 15 MINUTES IF EYE IRRITATION PERSISTS CONTACT A PHYSICIAN IN CASE OF SKIN CONTACT
23. RS OTAL ONTROL 682 15 Piston Meter The Standard of Measurement Laon 0 0 I C Ch CH Installation Operation amp Maintenance Manual Page 2 Table of Contents Safety Warning Symbols 2 Air Eliminator amp Strainer Assembly 20 Receipt amp Inspection 3 Air Eliminator amp Strainer Assembly Continued 21 Notice 3 Hydraulic Preset Valve Assembly 22 Meter Overview 4 Hydraulic Preset Valve Assembly Continued 23 Meter Specifications 5 Torque Specifications 24 Meter Types 5 Meter Body Repair 25 Material of Construction 6 Meter Bonnet Repair 26 System Recommendations 6 Compensator Shaft Repair 27 System Recommendations Continued 7 Drive Shaft Repair 28 System Recommendations Continued 8 Plunger Cup Replacement 29 System Recommendations Continued 9 Air Eliminator Repair 30 Start Up Recommendations 10 Air Eliminator Repair Continued 31 Start Up Recommendations Continued 11 Hydraulic Valve 32 Meter Calibration 11 Hydraulic Valve Continued 33 Meter Calibration Continued 12 Meter Trouble Shooting 34 Meter Calibration Continued 13 Air Eliminator Trouble Shooting 35 Calibration Adjustment 14 Hydraulic Preset Valve Trouble Shooting 36 Maintenance 15 Material Safety Data Sheet 37 Maintenance Continued 16 MSDS Continued 38 Storage Instructions 16 MSDS Continued 39 Dimensions 17 MSDS Continued 40 Meter Assembly 18 Notes 41 Meter Assembly Continued 19 Notes 42 Warranty 43
24. TIONS Page 41 Notes Page 42 Notes Page 43 Warranty Information 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 manu factured new equipment or components are warranted for a period of one 1 year from the date of shipment under nor mal 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 transporta tion charges prepaid and the TCS s examination discloses the parts or workmanship to have been defective upon deliv ery to the purchaser EXCLUSIONS TCS s ten 10 year warranty applies to meters only and does not apply to accessories such as valves and air elimi nators Parts and equipment not manufactured by TCS may be covered by separate warranties of their respective manu facturers 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 ac
25. Warning Symbols CAUTION Follow the warning instructions within the fol lowing information to avoid equipment failure personal injury or death TURN POWER OFF ei Before performing any maintenance be sure to EYE PROTECTION Pressurized systems may cause hazardous leaks and spray that may be dangerous for your eyes Always wear eye protection around pressurized systems and its hazardous liquids INJURY Wear gloves for protection from hazardous liq uids that may cause irritation or burns turn system power off to avoid any potential electric spark FLAMMABLE Flammable liquids and their vapors may cause a fire or explosion if ignited READ Read and understand all related manuals thor oughly The Engineering and OIM manuals will provide the knowledge for all systems mainte nance and operation procedures If you have any questions please consult the factory SO Page 3 Receipt amp Inspection Upon receipt of meter shipment be sure to inspect the packaging and the flow meter assembly for any damage be fore signing the receipt of the shipment Notify the delivery company about possible damage and refuse receipt of the shipment Flow Meter Identification Plate Meters are individually boxed and are protected with packing material Each package is identified with the flow meter assembly part number de scription direction of flow and serial number G KC Verify the meter model is the correct model
26. acking cavity Dynamic seal must have the stainless steel spring in the down position Figure 2 Remove the packing tool and place spacer over the shaft Use a long 3 8 socket and a hammer to carefully push seal into packing cavity Replace the compression spring index plate index disc compensator washer and hex nut to the com pensator 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 Cali brate the meter according to instructions PIECE SEAI RING TOWARD TOP SPRING FACING BOTTOM Page 28 DRIVE SHAFT SEAL KIT INSTRUCTIONS SS un 10 11 12 13 Remove screws that bolt the meter cover assembly to the meter body Loosen and remove the entire meter cover assembly Carefully remove the roll pin from the drive shaft Remove 3 screws 3 lock washers and the compression washer From inside the cover housing remove the cotter pin from the counter drive shaft Remove the coun ter drive gear and washers Slide the drive shaft assembly from the housing Lift the old packing from the housing Be sure there are no foreign particles or corrosion in the cavity Replace the drive shaft assembly into the cover housing Secure in position by reassembling the coun ter drive gear with the Rulon washers and cotter pin previously removed Support the counter drive shaft assem
27. and plunger disc d S Ka we 3 Discard the old plunger cup kit Place the new plunger cup on the plunger disc 4 Add the cup support and secure with the two 6 After the cup is partially formed place the 2 round head screws previously removed plunger assembly into the meter body and press into the piston cylinder L NOTE Apply Red Loctite 271 or equivalent 7 Turn the assembly in the piston cylinder to as to the screw threads Be sure the cup is evenly sure the cup is evenly formed to the cylinder spaced on the plunger disc and support 8 Replace previously removed parts and reassem ble meter Test and calibrate meter for accura cy Page 30 AOGOOG WARNING All internal pressure must be relieved to ZERO 0 pressure before beginning disassembly of meter or components 1 2 3 4 5 1 Using a hex or socket wrench remove the four screws and washers from the cover plate Remove the cover plate and o ring from the housing Remove the strainer screen Check inside housing for any debris and remove using a clean cloth Clean strainer screen by rinsing with a liquid cleaning agent compatible to your product application A brush may be used to remove imbedded particles If screen is too dirty to clean then replace the screen Wipe clean the face of the cover plate and seal ring Check o rings for damage and replace as needed Reassembly of 720 Strainer Assembly
28. aracteristics include the material compatibil ity lubricity viscosity suspensions pH and whether the product can congeal crystallize or leave a dry film Failure to select the correct flow meter may result in system failure or serious injury Air Elimination In any system that the tank may be completely drained or multiple products manifold into one metering system the possibility of air being present increases The solution is an air or vapor eliminator located before the flow meter to vent the air or vapor from the system before it can be measured Air or vapor elimination is required for all weights and measures regulatory approvals in custody transfer applications Control Valves Safety and isolation valves should be used throughout the metering system In any pumping system where there is one 1 pump and multiple flow meters a digital or hydro mechanical Rate of Flow control valve must be used at each flow meter to prevent over speeding of the flow meters Page 7 System Recommendations Continued AO SP Best Plumbing Configuration 1 Flow meter must have secure mounting to a riser or foundation 2 The inlet and outlet piping must be securely supported in a manner of not to allow pipe stress on flow meter 3 System should be designed to keep the flow meter full of liquid at all times 4 System piping should have full 1 1 2 pipe diameter throughout the metering system to allow for minimal pressure loss 5
29. bly from beneath while packing the spacer bearings washers and the new seal Pack first spacer bearing with flat surface on top and push down into packing cavity Rulon bearing material is preassembled into each spacer bearing Use caution so as to not damage the surface of the Rulon material Figure 1 Lubricate the seal inside up and outer oring prior to installation using bearing grease Place the pack ing tool TCS 600100 over shaft to slide the dynamic seal into the packing cavity Dynamic seal must have the stainless steel spring in the down position Figure 2 Insert second spacer bearing with flat surface on the bottom Replace the compression washer with the screws and lock washers Insert the roll pin in the drive shaft Be sure to support the shaft while doing this to prevent bending it Reassemble the meter cover assembly to the meter body assembly and tighten down the screws CLOSED END AT TOP Le UPPER SPACER BEARING ONE PIECE SEAL RULON INSERT mg RING TOWARD TOP ei SPRING FACING BOTTOM CLOSED END AT TN S SN LOWER SPACER BEARING RULON INSERT Page 29 1 Remove plunger assembly from meter body 5 Form the cup by turning the plunger assembly 2 Loosen and remove two 2 round head in your hand using your thumb to roll the edge screws and lift plunger cup support from slightly plunger cup
30. cordance with TCS s operating instructions or have been operated under con ditions 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 pur ported 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 pre paid to TCS 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 DIS CLAIMS ANY 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 repre sent 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 c
31. ds Methanol Blends Kerosene Vegetable Oils Motor Oils Ethylene Glycol Antifreeze etc AF All Ferrous For metering Pesticides Nitrogen Solutions Fertilizer Chlorinated Solvents and Paints Inks Alcohols Adhesives Motor Oils Molasses Liquid Feeds etc SS Stainless Steel For metering the same liquids as the SP SPA SPD and AF flow meters but includes food processing and special handling fluids such as Nitric Phosphorus and Glacial Acetic Acids Anti Icing Fluids Vinegar Fruit Juices etc SSD Stainless Steel Diesel Exhaust Fluid For metering Diesel Exhaust Fluid DEF AdBlue ARLA and AUS32 Page 6 Material of Construction Housing lone SC Ductile Iron Ductile Iron Stainless Steel Stainless Steel Aluminum Aluminum Internal Iron Steel amp Iron Steel amp Iron Steel amp Stainless Steel Ni Resist I Stainless Steel Stainless Steel Stamnes Steel SRE Stainless Steel Stainless Steel Stainless Steel Stainless Steel Bearings Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Hardware Simriz is a registered trademark of Freudenberg NOK System Recommendations SP Meter Selection The flow meter must be carefully chosen from the Meter Selection factors in the Engineering Manual The meter must be selected based on the operating system and product characteristics System variables include flow rate temperature and pressure The product ch
32. e next test is to be run Making the Tests The setup is now ready for accuracy the test Reset the register to zero and run the required test through the meter Do not exceed the maximum recommended rate of flow for the meter Maximum and minimum recommended rates of flow are marked on the 682 flow meter s identification plate and maintenance man uals Determining Test Results Run the meter to the mark on the indicator corresponding to the prover capacity and read the over or un der delivery in cubic inches or percent on the calibrated plate on the neck of the prover If the plate is cali brated in cubic inches the percentage error can readily be computed on the following basis a One gallon equals 231 cu in b A 100 gallon prover holds 23 100 cu in Therefore 23 1 cu in represents 0 1 error Page 13 Meter Calibration Continued Gs The National Institute of Standards and Technology in its NIST Handbook 44 specifies a tolerance of plus or minus the following Tolerance Indication of Device Acceptance Test Maintenance Test Special Test Wholesale 0 2 0 3 0 5 Vehicle 0 15 0 3 0 45 METER TOLERANCE Acceptance tolerances apply to new meters and repaired meters after reconditioning Repeatability When multiple tests are conducted at approximately the same flow rate and draft size the range of test results for the flow rate shall not exceed 40 of the absolute value of the maintenance no
33. e 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 offset Tokheim 682 meters there is a back pressure valve on the discharge of the meter which can be come 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 seat 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 If the meter is more than 7 inaccurate register reading of 4 65 or less gallons in a 5 gallon test then it can not be calibrated until repairs are made PROBLEM The meter delivers less product than 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 wo
34. en made to remove the calibration fluid before shipment All TCS flow meters are plugged and foam packed flow meters are enclosed in a plastic bag A Material Safety Data Sheet MSDS can be reviewed on PAGE 37 Appropriate precautions should be taken regarding any personal environmental and material compatibil ity with the end use system Notice Total Control Systems TCS shall not be liable for technical or editorial errors in this manual or omissions from this manual TCS makes no warranties express or implied including the implied warranties of merchantability and fitness for a particular purpose with respect to this manual and in no event shall TCS be liable for special or conse quential damages including but not limited to loss of production loss of profits etc The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees expressed or implied re garding the products or services described herein or their use or applicability We reserve the right to modify or improve the designs or specifications of such products at any time TCS does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any TCS product remains solely with the purchaser and end user All rights reserved No part of this work may be reproduced o
35. es 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 mi nus 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 cali bration Page 15 Maintenance Gs WARNING Test equipment should be grounded to prevent a possible spark Test area should have no ignition source Operators should wear personal protection and prevent any product exposure and environmental issues 1 2 3 4 5 6 Th 8 Keeping accurate maintenance and calibration records can be an excellent tool in determining the frequency of inspection or maintenance for a system As the meter wears the calibration will be af fected and require adjustment A personal
36. ge 29 D 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 51 in its slot For AF SP SPA SPD meters unscrew the pinion and main pivot bracket assembly 5 full turns For SS SSD meters unscrew the pinion and main pivot bracket assembly 3 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 Set slack spring assembly 45 on wobble plate post then the Rulon washer 44 amp slack roller 43 Mount main pivot bracket assembly to valve 57 amp seat 58 with lock washers 42 amp screws 52 D IAE D E nnect Pistons to Wobble Plate Co 1 Slide piston plunger assembly into each cylinder careful not to cut or crimp the plunger cup 2 3 Carefully slide connector 36 over the wobble plate 47 bearing seats Place 1 2 ball bearing 46 onto wobble plate and cover with bearing seat 35 amp retainer 33 Tighten bearing seat 33 with lock washers 7 and screws 34 4 Rotate wobble plate 47 amp pistons 40 through each cylinder to make sure of smooth flowing charac teristics
37. installed and start stop switches are off and locked out 12 Flooded suction to the Pump Fluid is available to system and will not starve or cavitate pump 13 Slow flooding of system Start up system with all shut off valves in the closed position When a pump is turned on and a valve opened in a new dry system tremendous liquid and air 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 pistons which could cause damage to the register piston arms plunger cups main pivot bracket assembly drive gear and other internal 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 Page 11 Start Up Recommendations CONTINUED AO D 14 When operating the meter with accessories valves should be opened slowly to avoid a pressure surge that can damage the meter or air eliminator System pressures should be maintained below 70 PSI 4 9 BAR 15 Custody transfer metering systems must be calibrated by a regulatory agency before product can be sold off the meter Contact your local authorities for proper calibration 16 Strainers should be cleaned frequently or have a maintenance schedule This will ensure a clean system and long service life Meter Calibratio
38. ity profile can be created for each meter to help guide in a maintenance schedule Great care should be utilized in the maintenance of the metering system Personal safety protection environmental hazards and government regulations need to be the foremost priority Only fully trained personnel should be involved in maintenance Failure to use original TCS replacement parts will void any Weights amp Measures approvals and risk damage to the meter system ALWAYS RELIEVE INTERNAL SYSTEM PRESSURE TO ZERO BEFORE DISASSEMBLY OR INSPECTION SERIOUS INJURY OR DEATH FROM FIRE OR EXPLOSION COULD RESULT FROM MAINTENANCE OF AN IMPROPERLY DEPRESSURIZED AND EVACUATED SYSTEM Total Control Systems flow meters and accessories are often used with petroleum solvents chemi cals and other liquids that may be explosive extremely flammable very toxic oxidizing and corro sive Severe injury or fatalities may arise if appropriate safety precautions are not followed Before replacing or cleaning filter strainer screen the electrical system must be turned off Product needs to be drained from system Collect all product and return to storage or dispose of properly Replace all drain plugs that were removed Personal safety protection must be warn at this time Make sure there is adequate ventilation in the area The metering system will not completely drain so make sure you collect extra product when you remove the strainer cover Clean the screen once a week
39. n AO SP The method of proving should be selected and necessary provisions made during the design stage of the installation Of the most common used systems portable provers have the advantage of more closely re producing the condition under which the product is normally delivered Use Accurate Prover Scientifically designed provers are commercially available for proving meters and no other kind should be used Even scientifically designed provers should be checked periodically for accuracy Weights and Measures officials have been very cooperative in giving assistance to checking privately owned volumet ric provers Recommended size of test measure The prover capacity should be equal to at least one minute s flow through the meter at its maximum rate These provers are not merely truck compartments or drums but are scientifically designed test measures having proper drainage means built into them a calibration gauge glass neck and protection against de formation which causes volume changes A homemade prover whether a drum or a tank is not likely to be satisfactory and may cause expensive errors due to inaccurate meter calibration Setting a Prover The prover should be set level using the levels provided on the prover or separate ones This insures con sistent results when moving the prover from meter to meter Page 12 Meter Calibration Continued AO D Where to Test a Meter The best place to test is i
40. n its normal operating position instead of a test stand In this way the correct ness of the installation and of the operation conditions will be verified by the test Always test a meter with the same liquid it is to measure because a difference in viscosity temperature and system plumbing slightly affects meter accuracy Discharge Line from Meter Where a portable prover is used the liquid is generally discharged in to the prover in the same manner as a normal delivery would be made Where a special test connection is used the discharge line must be ar ranged to drain to the same point on each test The meter flow rate and off on is controlled at the end of the discharge line Wetting the Prover Reset the meter register to zero and fill the prover to the zero or 100 marking of the scale Disregard the meter reading Drain the prover and reset the register The reason for disregarding the first meter reading is that the prover must be wetted as its calibrated capacity is determined on its wet measure ca pacity by its manufacturer and because the prover will be wet for the subsequent tests to be run After the prover has drained allow a definitive time of a few minutes for drainage from the sides of the tank Total drainage time should be the same between all tests to insure uniform results If a considerable length of time is to elapse between tests the wetting operation can be eliminated by allowing the prover to remain full until th
41. ne ver Ca forener mem H eee rns rem moms rus EH H vane rome ram meme vane Ca Jomo ef es ee one vo va gt Ca H ee ON meme vom vams Ce ferea AO ee vene van vom ves gt beer A en meme ra Les vom UE 740050D 740051 740018 P740018 740716 740718 P740718 740215 740215 740205 740030 740030 740077 740013 740013 740035 740035 740019 740809 742023 P742023 742005 742005 P742010 742803 Page 22 650 15 Hydraulic Preset Valve Assembly Page 23 650 15 Hydraulic Preset Valve Assembly Description SP AF SS SSD Retaining Ring 6 052482 6 052482 6 052482 6 052482 Washer Flat 65034 65034 65034 65034 Spacer 1 130852 1 130852 1 130852 1 130852 Preset Bracket 1 226102 1 226102 1 226102 1 226102 G lO BR ow Pp 9 Connecting Link 1 Washer Split Lock Screw Locknut Swivel Block Cotter Pin ZPW 1 4LW ZPW 1 4LW 68004 68004 ImbpIm m mnm 1 128140 1 128140 1 126318 1 126318 ZPW 1 4LW 68004 1 128140 1 126318 ZPW 1 4LW 68004 65008 65008 65008 65008 1 128140 65025 65025 65025 65025 1 126318 11 Washer 1 126903 1 126903 1 126903 1 126903 12 Actuating Arm 65016 65016 65016 65016 13 Lifter 65010 65010 65010 65010 14 Valve Handle Shaft 65005 65005 65005
42. nion 51 in the base by using the index disc 27 3 Mount bonnet 12 to base 60 4 Insert screws 31 and washers 32 then tighten Page 27 COMPENSATOR SHAFT SEAL KIT INSTRUCTIONS 1 Remove screws that bolt the meter cover assembly to the meter body Loosen and remove the entire meter cover assembly 2 Cut seal wire and remove seal pin from index disc 10 11 12 Unscrew hex nut from the compensator shaft Remove compensator washer index 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 and it is without corrosion Replace the compensator shaft assembly into the cover housing Support the shaft from beneath while packing the new seal and spacer Place the packing tool TCS 600200 over shaft If you do not have the TCS packing tool please use masking or other adhesive tape to fully cover the threads on the compensator shaft to protect the seal from being damaged by the sharp threads as the seal is set into place Figure 1 Lubricate the seal on the inside up and outside oring prior to installation with bearing grease to help the seal slide into the p
43. onsequential 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 or replace equipment previ ously sold or ordered The Standard of Measurement 2515 Charleston Place Fort Wayne IN 46808 Toll Free 800 348 4753 Phone 260 484 0382 Fax 260 484 9230 Email sales tcsmeters com TCS900020 REV 2
44. r copied in any form or by any means graphic electronic or mechanical without first receiving the written permission of Total Control Systems Fort Wayne Indiana USA Page 4 Meter Overview 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 3 plungers are fitted within their respective cy lindrical 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 po sition to open one measuring cylinder The plunger for that particular cylinder will be at the upper posi tion 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
45. rmal tolerance and the results of each test shall be within the applicable tolerance Changing Meter Calibration Refer to meter literature for method of changing meter calibration Any change in the meter calibration adjustment will change the delivery in the same amount for all rates of flow That is the calibration curve retains its shape but is moved up or down Therefore if a meter tests satisfactorily at full flow but drops off too much at low flow changing the calibration will not remedy this condition it will bring the low flow test to 100 but it will also bring the full flow above 100 by the same amount that the low flow was raised A condition of this kind is caused either by the metering system need for meter cleaning or repairs or because of an attempt to retain accuracy below the minimum recommended rate of flow for the meter Temperature Correction If the conditions of testing are such that there will be a change of more than a few degrees in the tempera ture of the liquids between the time it passes through the meter and the time the prover is read it will be advisable to make a temperature correction to the prover readings To do this it is necessary to install thermowells to take readings of the temperature of the liquids in the meter and in the prover and to take the degrees API of the liquid Corrections can then be easily made by the use of the National Standard API Tables Page 14 Calibration Adjustment
46. size Fort Wayne IN 46808 U S A and configuration as ordered Contact your dis C a Ex 0618 une MMQ 10 Liters ue TEMP METER CAPACITY MAX s r GPU 0 50 60 150 PSI enee Cen ATEX FILE No 07XT304 SABS No 1130 Made in the U S A tributor if there is any discrepancy or question Meter assemblies should be handled with appro priate methods for the awkwardness of size and weight involved Appropriate clothing and shoes need to be uti lized Transport the meter package to the installation site with appropriate transportation methods careful not to damage the flow meter Be careful of any loose or protruding staples from the packaging as they can be very sharp and may potentially cause injury If foam has been used to protect meter carefully remove top foam layer before attempting to remove meter assem bly from box Foam packaging maybe formed around the meter assembly making it difficult to remove If meter is bolted upon a wood pallet remove bolts while being careful not to let the meter tip over when the support has been removed Do not lift the meter assembly by flex hoses thermowells wires pulsers or put objects through meter Removing meter assembly from packaging without adhering these warnings may cause serious injury The wooden pallets and bases meet the ISPM 15 Guidelines for Regulating Wood Packaging Material in Interna tional Trade through the Timber Products Inspection Company TP 2134 Every effort has be
47. tted O ring SSS Page 33 650 15 Hydraulic Valve Repair Instructions A QOO Page 34 Meter Trouble Shooting AO SP OM 1 2 3 4 5 6 1 2 3 1 2 1 2 3 4 1 2 PROBLEM The meter allows product to pass through it but the register on the 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 th
48. uid to be captured between closed valves without relief thermal expansion will likely occur and create dangerously high pressures within the system Care should be taken in designing the system in which thermal shock may occur by implementing Pressure Relief Valves or Thermal Expansion Joints in the system design When product is trapped within the system the pressure will increase by 126 PSI 8 69 BAR for every one 1 temperature degree increase System Recommendations Continued Viscosity VS Pressure Loss Page 8 AOG OOG The product viscosity will have a direct relationship on the flow rate of the system The following chart is the flow meter limi tation in relation to the flow rate and pressure loss based on product viscosity If the system flow rate and viscosity do not meet your requirements please select a flow meter from our range of 700 series rotary flow meters that have the capability to handle higher flow rates with a lower pressure loss ne SHADED AREA Pa RECOMMENDED a OPERATING LIMITS Cc JI m TD Lam U 20 40 60 80 100 OF RATED FLOW Viscosity Conversion Chart Specific Gravity 1 SSU SSU SSU SSU CPS Saybolt CPS Saybolt CPS Saybolt CPS Saybolt Centipoise Universal Centipoise Universal Centipoise Universal Centipoise Universal 200 000 4 300 7 000 32 500 2 34 220 100 1 000 4 600 8 000 37 000 4 38 240 200 1 200 5 620 8 500 39 500 7 47 260 280 1 300 6
49. uld 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 noise 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 Page 35 Air Eliminator Trouble Shooting AO SP A PROBLEM Product is flowing from the Air Eliminators vents 1 Foreign matter located in between seal plate orings and metal reeds 2 The seal plate oring may be worn through service life 3 The seal plate oring may be cut or dislodged and requires replacement 4 The float may have been punctured containing liquid not allowing the float to rise and seal the air vents 5 The float may have been ruptured from a surge of pressure within the system 6 The metal reeds may be fatigued and requires replacement 7 The metal reeds may be out of alignment with the seal plate B PROBLEM The meter is still registering air within the system 1 There can be numerous reasons why the meter may still register air First look at the system con figuration and see where air is being introduced into the system Then determine if the meter is registering free air or entrained air Free Air is much easier to remove from the metering sys tem and may require the use of
50. usted for the correct shut off volume See Veeder Root 7889 preset service manual for further instructions which may need to be download ed from the www veeder com website The Veeder Root preset may have a worn or bent trip mechanism that is not allowing the preset to function C PROBLEM The preset batch over or under registers correct volume A The mechanical linkage might need to be adjusted moving the Nylon locking nuts forward or backwards to change the closing of the preset valve B The Veeder Root preset may need to be raked or adjusted for the correct shut off volume See Veeder Root 7889 preset service manual for further instructions C The Veeder Root preset may have a worn or bent trip mechanism that is not allowing the preset to function Page 37 Material Safety Data Sheet 24 HOUR EMERGENCY ASSISTANCE GENERAL MSDS ASSISTANCE 260 833 3173 260 484 0301 CODE RPS HAZARD RATING gt LEAST 0 SLIGHT 1 MODERATE 2 HIGH 3 EXTREME 4 DR LUBRICANTS INC DATE 01 21 06 4611 NEWAYGO ROAD SUITE D FORT WAYNE IN 46808 TELEPHONE NUMBER 260 484 0301 PRODUCT RP 1039 OCCUPATIONAL WT PERCENT EXPOSURE LIMITS CHEMICAL NAME CAS NUMBER IS LESS THAN TLV TWA TLV STEL PETROLEUM 64741 65 7 90 0 100MG M3 HYDROCARBON PETROLEUM 64742 53 6 10 0 SMG M3 HYDROCARBON ITEMS NOT SHOWN ARE NOT LISTED IN THE OSHA T S C A HAZARDOUS CHEMICALS LISTING BOILING RANGE NA VAPOR DENSITY NA ODOR PETROLEUM
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