INSTALLATION & SERVICE MANUAL

INSTALLATION & SERVICE MANUAL
INSTALLATION &
SERVICE MANUAL
MODELS
SF-46 * SF-47 * SF-48
SERIES
REMOTE DISPENSERS
(single and dual hose models)
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
Phone (770) 667-0667
Fax (770) 667-0476
ETL Listed
Table of Contents
Section 1 Installation………………………………………………………………………………………………. 3
Piping……………………………………………………………………………………………….. 3
Electrical……………………………………………………………………………….…………... 4
Start-Up………………………………..……………………………………………………..…….. 4
Programming……………………………………………………………………………………………. 5
Operation………………………………………………………………………………………………... 7
Maintenance…………………………………………………………………………………………….. 7
Dispenser Calibration - SF-46……….………………………………………………………………….. 8
Dispenser Calibration - SF-47 / SF-48………………………………………………………………….. 9
Section 2 - Parts
SF-46 Parts List...…………...………………………………………………………………………….. 11
SF-47 Parts List…………..……………………………………………………………………………... 12
SF-48 Parts List……….…….…………………………………………………………………………... 13
Switch Assembly - Exploded Parts View. ……………………………………………………………… 15
2PM-6 - Exploded Parts View………….………………...……………………………………………... 16
2PM-6 - Parts List……………………………………………………………………………………….. 17
M5-P1- Exploded Parts View…………………………………………………………………………… 19
M5-P1 - Parts List………………………………………………………………………………………. 22
Section 3 - Component Information
ASCO 8016G Series Solenoid Coil…………………………………………………………………...… 25
ASCO 8210 Series Solenoid Body……………………………………………………………………… 29
Veeder-Root 787181-327 Pulser……………………………………………………………………...… 35
Section 4 - Technical Data
Super Flow Dispenser Control………………………………………………………………………….. 39
91-98G07.2 - Internal dispenser wiring as shipped from factory………………………………………. 41
91-04G46.2 - Recommended dispenser wiring when used with TMS 800F Console………….………. 43
91-00A24 - CPU Wiring Terminal Descriptions……………………………………………………..… 45
91-00A25 - CPU Indicator LED Descriptions………………………………………………………….. 47
CPU Functional Wiring Diagram……………………………………………………………………..… 49
Appendix A - Optional Communications Interface
120040-SF Communications Interface Board………………………………………………………….. 51
91-08G271 - 120040x Programming Jumper Settings…………………………..……………………... 53
91-09G157 - Superflow Dispenser wiring to RS-485 Comm D-Box…………………………………... 55
Page 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. (PMC), as shipper, is 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 the single hose and dual hose versions of the Superflow dispensers. Portions of this manual that refer exclusively to one version or the other are indicated.
Installation
All PMC dispensers must be installed according to all applicable NEC, NFPA and local codes. The installation 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 equipped with a hose reel must be fed product through a system that will
maintain near operating pressure on the dispensers when the pump is off. Many submersible pumping systems provide this capability as part of the device. However, if a pumping unit is used that
does not maintain 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.
3.
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.
4.
The vertical supply riser must be cut to the proper height in order to avoid undue stress on the dispenser when installing the ground joint union. Attach dispenser base to the sump/impact box using
the anchor points.
5.
When the dispenser has been connected to the piping, the lines should be tested for leaks. Remember to allow any fresh pipe compound used in threaded joints to cure or set before performing the
leak tests.
6.
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.
7.
If dispenser is used with a hose reel, the hose should not exceed 50 feet in length.
CONTACT FACTORY FOR
INFORMATION ON SPECIFIC
DISPENSER FOOTPRINTS.
B. Electrical Wiring
1.
All electrical wiring should be done by a qualified licensed electrician. All wiring must follow National Electrical Code and satisfy all local rules and regulations.
2.
All field wiring is to be connected to the dispenser in the unit’s junction box.
3.
The dispenser is shipped from the factory wired as shown in wiring drawing 91-098G07 in Sect. 4.
4. Refer to electrical wiring diagrams in Section 4 for details on wiring.
Page 3
C. Start-Up
Page 4
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 meter where it can cause
damage. The SF-40 series dispensers have a 40-mesh
strainer on the inlet to the meter.
2.
IT IS IMPORTANT TO BLEED THE AIR FROM THE
LINES VERY SLOWLY. RUNNING THE METER
RPM UP ON AIR PUSHED THROUGH THE SUPPLY
LINE AHEAD OF THE PRODUCT CAN CAUSE
SEVER, AND OFTEN TOTAL, DAMAGE TO THE METER.
IMPORTANT
BLEED THE AIR FROM
THE LINES VERY
SLOWLY. ALLOWING
THE METER TO REACH
EXCESSIVE RPM CAN
CAUSE SEVER DAMAGE.
3.
After all air has been removed from the supply piping, run
15 to 20 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 calibration should
be verified and any necessary changes made. Refer to the section detailing dispenser calibration.
5.
Before placing unit in service, verify that all displays and the totalizer are functioning properly.
6.
The displays on the dispensers are backed up by a 6V- 4AH lead acid gel-cell battery located in the
head. The battery is located inside the rear cover of the dispenser head, on the left side. The battery
is shipped fully charged, but disconnected. Before placing the dispenser in service, the battery must
be reconnected. To do this, reconnect the red/yellow wire tied to the side of the battery to the battery’s positive(+) terminal. The battery is recharged while the AC power to the dispenser is on. If
there is a power failure, the battery will supply power to keep information on the displays for a minimum of 15 minutes.
Programming
1.
The dispensers main CPU board is located
inside of the rear cover of the dispenser’s
head. The CPU board has several items that
must be configured so that the dispenser will
operate correctly. All items in this section
assume the software installed in the CPU
board is V1.09-xx or later.
IMPORTANT
IF CPU IS EQUIPPED WITH
A RED 120040x-SF COMMUNICATIONS DAUGHTER
BOARD, SEE APPENDIX ‘A’
AND SKIP ITEM #2 BELOW.
Figure 5A - Corner of CPU board showing price setting and dip
2.
PRICE PER VOLUME : If the CPU board is equipped with a 120040x-SF daughter board for communications, see Appendix A for price setting information. 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 SW5 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, & 9. NOTE: If price is set to
‘0.000’, the dispenser will not activate.
3.
JUMPER SETTING: The jumper block on the main CPU board is used to set operational parameters of the dispenser. See Figure 5A for location. The parameters that the jumpers control are defined in the following tables.
JUMPERS 1-8
Position
Dispenser Operating Mode (Table 6A)
1
Volumetric Decimal Point (Table 6B)
2
UNUSED
3
Hose Reel Pressurization Delay (Table 6C)
4
Dispenser Model Selection (Table 6D)
5
Volumetric Pulse Out Resolution (Table 6E)
6
Volumetric Pulse Out Resolution (Table 6E)
7
Display SEGMENT TEST (Table 6F)
8
IMPORTANT
AFTER CHANGING ANY
SETTING, THE CPU
BOARD MUST BE RESET
BY CYCLING POWER OR
PRESSING THE RESET
BUTTON.
Parameter settings are detailed in tables on next page
Page 5
Programming Tables
Jumper positions 1-8
TABLE 6A - Position #1
Jumper #1
OFF*
Console Mode: Requires external AUTHORIZATION from card system or or
console device
ON
Stand-alone mode
JUMPER SETTINGS
TABLE 6B - Position #2
Jumper #2
Total Gallons Display [XXX.XXX]
OFF*
Total Gallons Display [XXXX.XX]
ON
TABLE 6C - Position #4
Jumper #4
Hose Pre-Pressurization Disabled
OFF*
Hose Pre-Pressurization Enabled
ON
TABLE 6D - Position #5
Jumper #5
SF-46
OFF
SF-47 or SF-48
ON*
TABLE 6E - Jumper #6 & #7
Jumper Jumper
#6
#7
1 Pulse Per Gallon
OFF
OFF
10 Pulses Per Gallon
ON
OFF
100 Pulses Per Gallon
OFF
ON
TABLE 6F - Position #8
Jumper #8
Display TEST Disabled
OFF
Display TEST Enabled
ON
* = default setting
Note: Dip Switch position #3 is not used at this time.
Page 6
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 requirement for an external authorize signal to the dispenser. If a 120040x-SF communications
daughter board is installed, See Appendix ‘A’.
Volumetric Decimal Point
Sets the decimal point on the TOTAL GALLONS display. If set to the OFF position, the
display in is hundredths of a gallon. If set to
ON, the display is in thousandths of a gallon.
Hose Pressurization Delay
Allows the dispenser to pre-pressurize the hose
before resetting the displays to ZERO. This allows the dispenser to eliminate the meter jump
that occurs when a long length of hose is attached to the outlet of dispenser.
Dispenser Model
Sets the model of the dispenser that the circuit
board is installed in. Extremely important!
Volumetric Pulse Out Resolution
Allows the user to set the output resolution of
the dispenser to 1, 10 or 100 pulses per gallon.
Display Segment Test
Allows the user to select the SEGMENT DISPLAY TEST. If enabled, the dispenser turns all
segments on the displays on at the beginning of a
transaction.
Operation
1.
To start the dispenser, simply remove the nozzle from its boot and lift the ON/OFF lever that it rested
on. If the dispenser is 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
is started.
4.
During delivery, the CPU board in the dispenser will generate two real time output pulse streams for use
by remote devices. One pulse stream represents volume dispensed and its resolution can be set by the
user. See Programming section. The second pulse stream is a pulse per penny. For every one cent
shown on the TOTAL SALE display, a pulse will have been sent out in this stream. The pulse output
drivers are open-collector type. See Super Flow Dispenser Control in Section 4.
Maintenance
The SF-40 series dispensers are designed to give many years of trouble free service. However, like any mechanical device, they require periodic maintenance to prevent problems from developing.
1.
The SF-47 and SF-48 dispensers come equipped with an inlet
strainer just upstream of the meter. The stainless steel strainer
basket located in the strainer housing should be cleaned periodically to remove debris. To clean the strainer basket, remove the
end cap from the strainer housing and pull the basket out. While
cleaning the basket, check for any holes or tears in the screen that BEFORE OPENING ANY
may allow debris to pass and damage the meter. If any are found, PART OF THE FUEL SYSthe screen should be replaced as soon as possible. Contact the
TEM, MAKE SURE IT IS
factory for replacement parts.
DE-PRESURIZED AND
The battery used to backup the displays in the dispenser should be
THE PUMPING SYSTEM
replaced annually.
While doing any maintenance on the dispenser, check the hose for HAS BEEN SHUT-OFF AND
any cracks or tears that can cause leaks.
TAGGED OUT.
Dispensers with integral reels are equipped with grease fittings
that must be periodically lubricated. See reel manufacturer’s information included with dispenser for their recommendations on maintenance.
When cleaning the exterior of the cabinet, use only non-abrasive, non-corrosive cleaning agents. Use only
soft rags.
The exterior stainless panels on the SF dispensers should be polished several times a year to maintain appearance of the units. An automotive grade polish works well.
IMPORTANT
2.
3.
4.
5.
6.
Page 7
Dispenser Calibration (SF-46)
Dresser-Wayne 2PM-6 Meter
The adjuster on the Wayne 2PM-6 meter is accessible by removing the front door on the dispenser.
The following steps will allow the calibration to be set on the meter.
1. Check the dispensers current calibration setting by
delivering product to a reliable, accurate prover.
Perform several delivery tests at normal the flow
rate to verify repeatability.
2. Note the volume in the prover.
3. Each notch of adjustment on the calibration knob
is approximately 1 in³ per 5 gallons (0.08659%).
Determine the number of notches the calibration
knob must be turned to compensate for any calibration error by using the following formula:
Figure 8A—Adjuster knob on 2PM-6
notches =
((volume in prover) - (volume registered by dispenser))
_____________________________________________ x 100
(volume in prover)
/ 0.08659
5. Round the number of notches to the nearest whole unit. If the number of notches is zero (0) after
rounding, no adjustment is needed and the remainder of the procedure can be skipped. Total adjustment of approx. ±2.7% is possible if the calibrator is set in the center of its range.
6. Remove the seal wire from the blade shaft that passes through the calibration knob.
7. When the prover volume is less than the dispenser registered volume, the calibration knob must be
turned clockwise. Lift the calibration knob approximately ¼” on the blade shaft passing through
its center. The lower portion of the calibration knob is hexagonal and, in a normal position, this
portion is inserted into the output shaft assembly. There are 18 vertical notches within the shaft
assembly. As the knob is raised and turned, it can be felt to click over the leading edge of the
notches. Turn the knob the required number of notches to correct for the error and push back
down into the output shaft.
8. When the prover volume is more than the dispenser registered volume, the calibration knob must
be turned counter-clockwise. Follow the process described in step #6, except turn counterclockwise. When the desired number of notches have been moved, the adjustment is complete
9. Run product through the dispenser to allow the adjuster to take a set.
10. Run another prover test to verify the new adjuster setting is correct.
11. Apply a wire seal to secure the adjuster settings.
Page 8
Dispenser Calibration (SF-47 & SF-48)
Liquid Controls M-5 Meter
The adjuster access panel on the SuperFlow dispenser is located
several inches below the ON/OFF lever for the nozzle. Removing
this stainless steel panel will give access to the M-5 adjuster housing. The following steps will allow the calibration to be set on the
M-5.
1. Remove the adjuster housing dust cover. Remove the wire
seal passing through the 5/16” bolts in the bottom of the
cover. Next remove the bolts and the cover. Figure 9A shows
the adjuster housing with the cover removed.
2. Check the dispensers current calibration setting by delivering
product to a reliable, accurate prover. Perform several delivery tests at the normal flow rate to verify the repeatability.
3. Note and record the adjuster’s current setting.
4. Note the volume in the prover. Calculate %correction by using
the following formula:
(volume in prover) - (volume registered by dispenser)
% correction = ___________________________________________
(volume in prover)
Figure 9A—Adjuster hosing
with cover removed
x 100
5. Loosen the adjuster clamp screw. See Figure 3B.
6. When the prover volume is less than the dispenser registered
volume, add the %correction to the original adjuster setting by
turning the thimble towards the arrow marked LARGER
(volume). Correct the original setting by approaching the
number desired from the next larger whole number. For example, assume a desired adjuster setting of 3.20. Turn the
thimble to the left until 4.00 is reached, then back off until
3.20 is reached.
7. When the prover volume is more than the dispenser registered
volume, subtract the %correction from the original adjuster
setting by turning the thimble in the direction of the arrow
marked SMALLER on the adjuster clamp (right).
8. Re-tighten the adjuster clamp screw. Run product through the
dispenser to allow the adjuster to take a set.
Figure 3B - Adjuster Detail
9. Run another prover test to verify the new adjuster setting is correct.
10. Replace the dust cover and apply a wire seal to secure the adjuster settings.
11. Replace the adjuster access panel.
Page 9
Page 10
Parts List for SF-46
Description
Part Number
Comments
Meter
2PM-6
See parts exploded view (page 16)
Pulser
787181-327
See pulser documentation (page 35)
Solenoid Valve (DIESEL)
EF8210G004
See solenoid paperwork (page 25 - 33)
Solenoid Valve (GASOLINE)
EF8210G004(V)
See solenoid paperwork (page 25 - 33)
Solenoid valve repair kit (BUNA)
K302280
See solenoid paperwork (page 29)
Solenoid valve repair kit (VITON) K302280V
See solenoid paperwork (page 29)
Solenoid coil replacement kit
(120VAC—60Hz)
238214-032-D
See solenoid paperwork (page 25)
Straight 1” Flange
FL1
Flanged 1” x 90º Elbow
FL1-90
Strainer Body
ST1-1
Strainer End Cap
ST1-2
Strainer Basket
ST1-3
Meter manifold block
M2-17
Meter Manifold face gasket
GA-4
1” square flange gasket
GA-2
CPU Board
110000B-V1.05-xx
Small display board
110400B-S
Large display board
110400B-L
Battery
6V-4AH GEL-CELL
Thumbscrew for rear cover
Stainless Steel door panel
SF-14
Stainless Steel blank side panel
SF-12
Stainless steel panel, nozzle boot
side of dispenser.
SF-13
S/S adjuster access hole cover
SF-18
Door lock mechanism
CL-58
Door lock key
LS-300
Switch Assembly
SW1/2
Hose hanger
HMS-12
7H-style nozzle boot
SF-38
1290-style nozzle boot
SF-39
See exploded parts drawing (page 15)
70º hose swivel
Page 11
Parts List for SF-47
Description
Part Number
Comments
Meter
M5-P1
See parts exploded view (page 19 - 24)
Pulser
787181-327
See pulser documentation (page 35)
Solenoid Valve (DIESEL)
EF8210G004
See solenoid paperwork (page 25 - 33)
Solenoid Valve (GASOLINE)
EF8210G004(V)
See solenoid paperwork (page 25 - 33)
Solenoid valve repair kit (BUNA)
K302280
See solenoid paperwork (page 29)
Solenoid valve repair kit (VITON) K302280V
See solenoid paperwork (page 29)
Solenoid coil replacement kit
(120VAC—60Hz)
238214-032-D
See solenoid paperwork (page 25)
Straight 1.5” Flange
FL1.5
Flanged 1.5” x 90º Elbow
FL1.5-90
3.5” Square alum. fuel block
SF-17
Strainer Body
SF-19
Strainer End Cap
SF-20
Strainer Basket
SF-21
1.5” square flange gasket
GA-1
CPU Board
110000B-V1.05-xx
Small display board
110400B-S
Large display board
110400B-L
Battery
6V-4AH GEL-CELL
Thumbscrew for rear cover
Page 12
Stainless Steel door panel
SF-14
Stainless Steel blank side panel
SF-12
Stainless steel panel, nozzle boot
side of dispenser.
SF-13
S/S adjuster access hole cover
SF-18
Door lock mechanism
CL-58
Door lock key
LS-300
Switch Assembly
SW1/2
Hose hanger
HMS-12
7H-style nozzle boot
SF-38
1290-style nozzle boot
SF-39
See exploded parts drawing (part 15)
Parts List for SF-48
Description
Part Number
Comments
Meter
M5-P1
See parts exploded view (page 19 - 24)
Pulser
787181-327
See pulser documentation (page 35)
Solenoid Valve (DIESEL)
EF8210G022
See solenoid paperwork (page 25 - 33)
Solenoid Valve (GASOLINE)
EF8210G022(V)
See solenoid paperwork (page 25 - 33)
Solenoid valve repair kit (BUNA)
K302284
See solenoid paperwork (page 29)
Solenoid valve repair kit (VITON) K302284V
See solenoid paperwork (page 29)
Solenoid coil replacement kit
(120VAC—60Hz)
238214-032-D
See solenoid paperwork (page 25)
Straight 1.5” Flange
FL1.5
Flanged 1.5” x 90º Elbow
FL1.5-90
3.5” Square alum. fuel block
SF-17
Strainer Body
SF-19
Strainer End Cap
SF-20
Strainer Basket
SF-21
1.5” square flange gasket
GA-1
CPU Board
110000B-V1.05-xx
Small display board
110400B-S
Large display board
110400B-L
Battery
6V-4AH GEL-CELL
Thumbscrew for rear cover
Stainless Steel door panel
SF-14
Stainless Steel blank side panel
SF-12
Stainless steel panel, nozzle boot
side of dispenser.
SF-13
S/S adjuster access hole cover
SF-18
Door lock mechanism
CL-58
Door lock key
LS-300
Switch Assembly
SW1/2
Hose hanger
HMS-12
7H-style nozzle boot
SF-38
1290-style nozzle boot
SF-39
See exploded parts drawing (part 15)
Page 13
Page 14
Technical
Your Authorized PMC Distributor
Typical Switch Assembly Parts
Pump Measure Control, Inc.
1070 Nine North Dr.
Alpharetta, GA 30004
PH 770-667-0667 Fax 770-667-0476
Bulletin SW Assembly Series 06.01.2001
2PM-6 Exploded Parts View
Page 16
2PM-6 Parts List
Page 17
Page 18
PARTS MANUAL
®
®
®
M-5, MA-5, MA-4, &
P9560 Series Meters
LIQUID
CONTROLS
A Unit of IDEX Corporation
Exploded View: M-5/MA-5/MA-4 Meter Covers
CAUTION
IGN COUNTER D
AL
RIV
E
T WITH S
SHA F
LO
T
The 0250 Packing Gland
is field servicable. See
“Servicing the Drive
Components” in the
M/MA Meter Manual.
0
1
0202 Adjuster
assembly
1
2
6
0
5
2
3
4
0609 Screw, mounting
plate (2)
0364 Plate, adjuster mounting
0613 Screw, adjuster
0126 Bracket, counter adapter
0382 Shaft,
adjuster
0366 Plate,
dust cover
0336 Gear
0574 Ring,
retaining
LIQUID
CONTRO
LS CO
LAKE BL
UFF, IL, RP.
USA
MODEL
NO.
SERIAL
NO.
®
ACCURA
CY
FLOW
RATE
PRODUC
T
UK81
1783
VOL/REV
TEMP ER
ATURE
MAX PRES
SURE
0165 Gear,
packing gland
0250 Packing
Gland Assy.
0780 Seal
wire
0705 Washer,
flat (4)
0673 Screw (4)
0123 Cover, front
0310 Bushing,
adjuster drive
0603 Screw (2)
0375 Retaining spring
0630 Screw (2)
How to Order
Replacement Parts
1. Find the item number listed on the exploded
drawing. The 4 digit item numbers are listed
with a word description.
2. Find the computer printout titled Parts List
that has been provided with your meter. 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.
3. 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.
0566 Plug,
pipe-hex socket
(2, one for each cover)
0124 Cover, rear
0627 Standard hex head
bolt (18, for both covers)
r
e
v
o
c
r
a
e
R
0771 Washer,
rotor gear-(3)
0672 Screw, cap-(3)
0163 Gear,
displacement pinion (2)
0146 Plate, rear bearing
0155 Rotor,displacement (2)
0318 Pins, dowel-(4)
0772 Keys, (3)
0711 Washer, Lock
0611 Screw, cap-(8)
0153 Rotor, blocking
0161 Gear, blocking rotor
®
0672 Screw, cap
0110 Housing, M5-Aluminum
0144 Plate, front bearing
0430 O-ring, meter cover (2)
0635 Screw,
Shoulder
0342 Gear, output
0775 Washer
0575 Washer, Lock
0343 Pinion,
M5 output
Front cover
When placing order for replacement parts please
reference the meter's serial number.
Exploded View: M-5/MA-5/MA-4 Meter Element
ITEM
PART#
DESCRIPTION
25075
NAMEPLATE, METER ASSY
EEC APPROVED
1
0678
00306
SCREW, DRV #2 x 0.19
TYPE 'U'
4
0372
49368
NAMEPLATE, METERS
WITH EEC APPROVAL
1
L1102
METER ELEMENT
M-5-1 FOR FORK DRIVE
1
0678
00306
SCREW, DRV #2 x 0.19
TYPE 'U'
2
0611
09079
SCREW, #10-24 X 0.625
HX HD, SEMS, SS
8
0672
09079
SCREW, #8-32 X 0.750 LG
HEX HD 18-8 STAINLESS STL
4
0318
40665
PIN, DOWEL
0.250 DIA X 0.625 LOND
4
0146
44286
PLATE, REAR BEARING
R B/P SV-1-2-3-7-14
1
0144
44287
PLATE, FRONT BEARING
FR B/P SV-1-2-3-7-14
1
0155
48078
ROTOR ASSY, DISP M5
ALUM / SS HC
2
0153
48079
ROTOR, BLKG ASSY M5
ALUM / SS HC
1
0163
48089
GEAR, DISPL PINION M5
SINTERED IRON, TAPER
2
0161
48090
GEAR, BLOCKING M5
SINTERED IRON, TAPER
1
0343
48257
PINION, M5 OUTPUT
SST 32P, 18T
1
0110
48271
HOUSING, M5 ALUMINUM
FOR 2 BOLT ELBOWS
1
0635
48275
SCREW, SHOULDER 0.25D
M5 OUTPUT GEAR
1
0342
48276
GEAR, OUTPUT M5
SINTERED IRON 32P 54T
1
0575
48277
WASHER, LOCK M5
OUTPUT PINION
1
0771
48319
WASHER, ROTOR GEAR
0.19 ID, 0.62 OD, 301 SS
1
0772
48345
KEY, ROTOR GEAR M5
0.093 X 0.125 X 0.437
3
25109
COVER ASSY M5
ALUM COVERS, NEW STYLE
1
0566
06790
PIPE PLUG, 0.250-18 NPT
HEX SCKT HD, 302 SS
0627
09080
SCREW, 0.312-18 X 1.375
HEX WSHR HD, THD FRMG
0123
48272
COVER, FRONT M5
ALUM, NEW STYLE
1
0124
48273
COVER, REAR M5
ALUM, NEW STYLE
1
25127
SEAL KIT
M/MA 5 UL BUNA ALUM
1
09278
O-RING, 5.267 ID BUNA, UL
5.435 OD X 0.099 THK (SQR)
2
48600
PACK GLAND ASSY
AL / BUNA / W/ FORK DRIVER
1
0010
06856
O-RING, 0.88 ID BUNA -N
1.12 OD X 0.12 DIA WAL
1
0012
09079
SCREW, #10-24 X 0.625
HX HD, SEMS, SS
2
0005
09113
RETAINING RING 0.141
NTRNL "E"
1
0009
09172
WASHER, 0.194 ID X 0.375 OD
X 0.032 THICK NYLON
1
0006
09221
SEAL, HUVA CUP; 0.188 ID
0.375 OD, 0.09 THK, BUNA
1
0004
48281
SHAFT, PACKING GLAND
316 SST/HC, NS
1
0002
48282
DRIVER, PACKING GLAND
NS METER OUTPUT
1
0007
48285
THRUST WASHER, RULON
NS PACKING GLAND
1
0008
48286
THRUST WASHER, 316 SST
NS PACKING GLAND
1
0011
48331
PLATE, RETAINING
NS PACKING GLAND, SST
1
0001
49612
HOUSING ASSY, PKG GLAND
ALUM HSG / FORK DRIVE
1
COMPONENT
COMPONENT
COMPONENT
COMPONENT
0430
COMPONENT
QTY
2
18
ITEM
PART#
DESCRIPTION
25170
ADAPTER, COUNTER ASSY
M5, 7 & 15 ALUMINUM
1
0705
06743
FLAT WASHER, 0.265 ID
0.500 OD X 0.062 THK
4
0603
06845
SCREW, #10-24 X 0.375
FLLSTR HD, 316 SS
2
0673
09084
SCREW, 1/4-20 X 1.00
INDT HEX WSHR HD, GR 8
4
0375
48208
RETAINER, BUSHING
ADJUSTER DRIVE SFT/BSHG
1
0126
49434
ADAPTER, COUNTER BRKT
FOR M5, M7 & M15 METERS
1
25175
DUST COVER ASSY
M5, 7, & 15 ALL BUT SS
1
0630
09093
SCREW, #10-32 X 0.500
TAPTITE W/ CROSS HOLE
2
0366
49390
PLATE, ADJUSTER COVER
ALUM, M5, 7 & MA15
1
25000
ADJUSTER ASSY
STD ADJUSTER
1
0609
00362
SCREW #6-32 X 0.25
SLTTD PAN HD, SHKPRF
2
0613
07063
SCREW, 1/4-20 X 0.375
SLTD RDH SLFTPG TYP 23
1
0202
42600
ADJUSTER ASSY
ADJ N/S
1
0364
42660
PLATE, ADJUSTER MTG
MTG PLATE ADJ N/S
1
25150
DRIVE SHAFT ASSY
M5, M7 & M15 - NEW STYLE
1
0574
02188
RETAINING RING, 0.250
XTRNL "E"
1
0310
41786
BUSHING, ADJUSTER DRIVE
BUSHING ADJ DR M15, M30
2
0382
48287
SHAFT, 0.25 HEX ADJ DRV
M5 / M7 / M15 STD & ROF
1
A1070
ELBOW ASSY, M5 - 2 BOLT
ALUM / BUNA - 1.5" 45 DEG
2
0003
09082
SCREW, 3/8-16 X 1.375"
HX WSHR HD, T45, SS
4
0002
09117
0-RING, 2.31 ID BUNA-N
2.50" OD X 0.09 DIA WALL
2
0001
48290
ELBOW, M-5 2 BOLT
1-1/2" 45 DEGREE
2
A2110
FLANGE ASSY, M5 & M7
ALUM / BUNA / 1-1/2" NPT
2
0750
04498
FLAT WASHER, 0.406 ID
0.812 OD X 0.062 THK
8
0420
06854
O-RING, 2.88" ID BUNA-N UL
3.12 OD X 0.12 DIA WALL
2
0135
48397
FLANGE, COMP; 1-1/2" NPT
ALUM, O-RING STYLE
2
0620
06851
SCREW, 3/8-16 X 1.500
HEX HD CAP, GR 8
8
25050
FACE GEAR & PINION ASSY
1:1 W / DELRIN FACE GR
1
0336
40122
GEAR, FACE
1:1 DELRIN
1
0165
48283
GEAR, PKG GLAND 1:1
24 TOOTH, PM, NS
1
COMPONENT
COMPONENT
COMPONENT
COMPONENT
COMPONENT
COMPONENT
COMPONENT
QTY
Installation & Maintenance Instructions
SERIES
8016G
OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS
ĊSERVICE NOTICEĊ
FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY
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 encapsulated 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, & D) Explosionproof Class I, Division 1,
Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-Ignitionproof Class II,
Division 1, Groups E, F, & G. The Class II, Groups F & G 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:
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 Only
Junction Box
This junction box construction meets Enclosure Types 2,3,3S,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).
DIN Plug Connector Kit 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,Ăserious
injury or property damage, install the open - frame
solenoid in an enclosure.
MM
Form No.V6583R7
All Rights Reserved.
50 Hanover Road, Florham Park, New Jersey 07932
CAUTION: To prevent fire or explosion, do not install solenoid and/or valve
where ignition temperature of hazardous atmosphere is less than
165 C. On valves used for steam service or when a class H" solenoid is used, do
not install in hazardous atmosphere where ignition temperature is less than
180C. 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 or a shorted
solenoid, etc. This unique feature is a standard feature only in solenoids with
black explosionproof/dust-ignitionproof enclosures (Types 7 & 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 90C. 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 supply 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
Rating
Catalog
Number Coil
Prefix
Class of
Insulation
Maximum Ambient Temp.
6.1, 8.1,
9.1, & 11.1
None, FB, KF, KP,
SF, SP, SC, & SD
F
125F (51.7C)
6.1, 8.1,
9.1, & 11.1
HB, HT, KB, KH,
SS, ST, SU, & ST
H
140F (60C)
10.6
None, KF,
SF, & SC
F
104F (40C)
10.6
HT, KH,
SU, & ST
H
104F (40C)
Minimum ambient temperature -40F (-40 C).
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
accumulating in the solenoid base sub-assembly area.
Wiring
Wiring must comply with local codes and the National Electrical Code. All
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 90C or greater. Torque terminal block screws to
Printed in U.S.A.
www.ascovalve.com
Page 1 of 4
10 ± 2 in-lbs [1,0 ± 1,2 Nm]. A tapped hole is provided in the solenoid for
grounding, use a #10-32 machine screw. Torque grounding screw to 15 -20
in-lbs [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-lbs [1,7 - 2,3 Nm]. with a 5/32 hex key wrench.
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 90C or greater for connections. For
steam service use 105C rated wire up to 50 psi or use 125C rated wire above
50 psi. After electrical hookup, replace cover gasket, cover, and screws.
Tighten screws evenly in a crisscross manner.
DIN Plug Connector Kit 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 90C or greater for
connections. Strip wire leads back approximately 1/4for 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 gasket, 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 (See 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 solenoid, 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.
Cleaning
All 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
Keep the medium flowing through the solenoid operator or valve as free
from dirt and foreign material as possible.
While in service, the solenoid operator or valve should be operated at least
once a month to insure proper opening and closing.
Depending on the medium and service conditions, periodic inspection of
internal valve 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.
Junction Box
Remove conduit and socket head screw (use 5/32 hex key wrench) from
center of junction box. Disconnect junction box from solenoid.
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.
3. Snap off red cap from top of solenoid base sub-assembly.
4. 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
from solenoid base
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
When Ordering Solenoids for ASCO Solenoid Operators or Valves, order
the number stamped on the solenoid. Also specify voltage and frequency.
Page 2 of 4
Form No.V6583R7
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 (3/8 or 1/2 NPT pipe size)
Torque Value in Inch-Pounds
175 ± 25
90 ± 10
25
Torque Value in Newton-Meters
19,8± 2,8
10,2 ± 1,1
2,8
bonnet screw (3/4 NPT pipe size)
40
4,5
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
red cap
nameplate/
retainer
solenoid
with 1/2 NPT
grounding wire green or green with
yellow stripes
For special wrench
adapter order kit
No. K218948
wave
washer
valve
bonnet
spring washer
0.750-28 UN-2A
thread
bonnet
gasket
solenoid base
sub-assembly
plugnut/core tube
sub-assembly
Tapped hole in core
0.250-28 UNF-2B
0.38 minimum full thread.
core
3/4 Bonnet Construction
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
0.9375-26 UNS -2A
thread
core
core
(AC)
(DC)
Side View
finger
washer
collar to face
valve body
Alternate
Construction
15/16 Bonnet Construction
Figure 1. Series 8016G solenoids
red cap
See torque chart
for bonnet screws
nameplate/retainer
red cap
solenoid with 1/2 NPT
grounding wire green or green with
yellow stripes
nameplate/
retainer
spacer
1.312 diameter
mounting hole
solenoid
finger
washer
valve
bonnet
core
tube
retainer
spring
washer
valve
bonnet
bonnet
gasket
Remove red cap and
push solenoid down.
Then pry here to lift
nameplate/retainer
and push to remove.
finger washer
0.69 diameter
mounting hole
.062 to .093 maximum
thickness of panel
for mounting
For special wrench
adapter order kit
No. K218948
plugnut/core tube
sub-assembly
solenoid base
sub-assembly
core
core
Bolted Bonnet
Construction
3/4 Bonnet Construction
Figure 2. Series 8016G solenoid
15/16 Bonnet Construction
Figure 3. Series 8016G panel mounted solenoids
Form No.V6583R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 3 of 4
Torque Chart
Part Name
terminal block screws
socket head screw
center screw
Torque Value in Inch-Pounds
10 ± 2
15 - 20
5±1
Open-Frame Solenoid
with Screw Terminals.
Socket head screw is
used for grounding.
Open-Frame Solenoid
with 1/4 Spade Terminals
See
torque chart
above
Open-Frame Solenoid
with DIN Terminals.
Indicates parts supplied
in Termination Module
Kit No. K256104
screw terminal
adapter
terminal
block
screw
tapped hole for
#10-32 grounding screw
(not included)
Torque Value in Newton-Meters
1,1 ± 0,2
1,7 - 2,3
0,6 ± 0,1
gasket
DIN terminal
adapter
socket head
grounding screw
(5/32 hex key wrench)
socket head screw
(5/32 hex key wrench)
Figure 4. Open-frame solenoids
screw terminal block
(see note)
Junction Box Solenoid
with 1/4 Spade Terminals
or Screw Terminals
cover screw
See
torque chart
above
cover
cover gasket
grounding screw
and cup washer
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.
junction box with
1/2 conduit connection
and grounding terminal
socket head screw
(5/32 hex key wrench)
Figure 5. Junction box (optional feature)
Open-Frame Solenoid
with DIN Terminal
Plug Connector
Indicates that these parts are included
in DIN plug connector Kit No. K236034
gasket
DIN terminal
adapter
See
torque chart
above
connector
gland nut
gasket
gland gasket
socket head screw
(5/32 hex key wrench)
Notes:
1. Connector cover may be
rotated in 90 increments from
position shown for alternate
position of cable entry.
2. Refer to markings on DIN
connector for proper
electrical connections.
DIN connector
terminal block
(see note 2)
washer
center screw
connector cover
(see note 1)
Figure 6. DIN plug connector kit No. K236034 (optional feature)
Page 4 of 4
Form No.V6583R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Installation & Maintenance Instructions
SERIES
8210
8211
2-WAY INTERNAL PILOT-OPERATED SOLENOID VALVES
NORMALLY CLOSED OPERATION Ċ GENERAL SERVICE
1I, 1¼I OR 1½I NPT
NOTICE: See separate solenoid installation and maintenance
instructions for information on: Wiring, Solenoid Temperature,
Cause of Improper Operation, Coil or Solenoid Replacement.
Temperature Limitations
For maximum valve ambient and fluid temperatures, refer to chart
below. Check catalog number prefix and watt rating on nameplate.
Watt
Rating
DESCRIPTION
Series 8210 valves are 2-way normally closed internal
pilot-operated solenoid valves designed for general service. Valves
are made of rugged forged brass. Series 8210 valves are provided
with a general purpose solenoid enclosure.
Series EF8210 and 8211 are the same as Series 8210 except they are
provided with an explosionproof or explosionproof/watertight
solenoid enclosure.
AC/DC
6
AC
OPERATION
6.1
Normally Closed: Valve is closed when solenoid is de-energized;
open when energized.
AC
IMPORTANT: Minimum operating pressure differential is 5 psi.
Manual Operator (optional feature)
Manual operator allows manual operation when desired or during an
electrical power outage. To engage manual operator (open the valve),
turn lever clockwise until it hits a stop. Valve will now be in the same
position as when the solenoid is energized. To disengage manual
operator (close the valve), turn lever counterclockwise until it hits a
stop.
To engage, turn lever
clockwise until it
hits a stop.
I&M No.V5436R7
11.2
DC
11.6
DC
Catalog
Number
Prefix
Solenoid
Class
None or DF
F
HT
H
None, KF,
SF or SC
HT, KH,
ST or SU
F
H
Maximum
Ambient
Temp.
Maximum
Fluid
Temp.
122_F
(50_C)
140_F
(60_C)
125_F
(54_ C)
140_F
(60_C)
180_F
(82_C)
180_F
(82_C)
180_F
(82_C)
180_F
(82_C)
None or HT
F or H
77_F
(25_C)
150_F
(65_C)
None, HT,
KF, KH, SC,
SF or ST
F or H
104_F
(40_C)
150_F
(65_C)
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 to valve according 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.
Partial view of
Manual Operator
CAUTION: For valve to operate electrically, manual
operator lever must be fully rotated counterclockwise.
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.
CAUTION: 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,
serious 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.
Page 1 of 4
e
50 Hanover Road, Florham Park, New Jersey 07932
www.ascovalve.com
E177856
All Rights Reserved.
Cleaning
All 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 is 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 strainer or filter when cleaning the valve.
Preventive Maintenance
S Keep medium flowing through the valve as free from dirt and
foreign material as possible.
S 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.
S 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
S Incorrect Pressure: Check valve pressure. Pressure to valve must
be within range specified on nameplate.
S Excessive Leakage: Disassemble valve and clean all parts. If parts
are worn or damaged, install a complete ASCO Rebuild Kit.
Valve Disassembly
1. Disassemble valve in an orderly fashion using exploded views
for identification and placement of parts. Refer to Figure 1 for
AC construction; Figure 2 for DC construction. For 1I or 1 ¼I
NPT valve construction, see Figure 1; for 1 ½I NPT valve
construction, see Figure 2.
2. Remove solenoid enclosure. See separate instructions.
S For valves supplied with optional manual operators, see section on
Disassembly of Manual Operator.
3. Unscrew solenoid base sub-assembly from valve body. Then
remove core assembly with core spring and solenoid base
gasket. For AC construction (Figure 1) core spring is a loose
piece.
4. For normal maintenance (cleaning) it is not necessary to
remove the valve seat. However, for valve seat removal use a
7/16I thin wall socket wrench
5. Remove bonnet screws, valve bonnet, diaphragm spring,
diaphragm assembly, body gasket, body passage eyelet (present
on current valve constructions only) and body passage gasket.
6. All parts are now accessible for cleaning or replacement. If
parts are worn or damaged, install a complete ASCO Rebuild
Kit.
- Service Notice -
When installing a new ASCO Rebuild Kit, please be aware that the
diaphragm assembly may not be identical to the diaphragm
assembly in the valve. See Figure 1 for alternate diaphragm
constructions.
The two diaphragm constructions are
interchangeable and will perform equally well.
CAUTION: To ensure proper valve operation, install all
parts supplied in ASCO Rebuild Kit. Do not mix old and new
parts.
Valve Reassembly
1. Lubricate body gasket, body passage gasket, bonnet gasket and
solenoid base gasket with DOW CORNINGr 200 Fluid
lubricant or an equivalent high-grade silicone fluid.
2. Install body passage gasket, body passage eyelet, diaphragm
assembly, diaphragm spring, valve bonnet and bonnet screws.
Hand thread screws as far as possible. Then torque bonnet
screws in a crisscross manner to 144 ± 15 in-lbs [16,3 ± 1,7
Nm].
3. If removed, install valve seat in valve body. Apply a small
amount of thread compound compatible with valve media to
valve seat threads. Torque valve seat to 75 ± 10 in-lbs
[8,5 ± 1,1 Nm].
S For valves supplied with optional manual operator, see section on
Reassembly of Manual Operator.
4. For AC construction (Figure 1), install core spring in core
assembly. Wide end of core spring in core first, closed end
protrudes from top of core.
5. Install solenoid base gasket, core assembly with core spring and
solenoid base sub-assembly in valve body. Torque solenoid
base sub-assembly to 175 ± 25 in-lbs [19,8 ± 2,8 Nm].
6. Install solenoid. See separate instructions.
WARNING: To prevent the possibility of death,
serious injury or property damage, check valve for
proper operation before returning to service. Also
perform internal seat and external leakage tests with
a nonhazardous, noncombustible fluid.
7. Restore line pressure and electrical power supply to valve.
8. After maintenance is completed, operate the valve a few times
to be sure of proper operation. A metallic click indicates the
solenoid is operating.
Disassembly of Manual Operator
1. Unscrew solenoid base sub-assembly from manual operator
body.
2. Unscrew manual operator body from valve body. Then remove
stem retainer from base of manual operator body and
stem/spacer sub-assembly.
3. Pull stem/spacer sub-assembly with stem gasket from side of
manual operator body. Then remove core assembly with core
spring, solenoid base gasket and manual operator bonnet
gasket.
4. For further disassembly refer to section on Valve Disassembly
step 4.
Reassembly of Manual Operator
1. Lubricate stem gasket with DOW CORNINGr 111
Compound lubricant or an equivalent high-grade silicone
grease.
2. For AC construction (Figure 1), install core spring in core
assembly. Wide end of core spring in core first, closed end
protrudes from top of core.
3. Holding the manual operator body in a horizontal position,
install core assembly with core spring from the bottom end.
4. Insert the stem/spacer sub-assembly with the stem gasket into
the side hole of the manual operator body. Rotate the lever of
the stem/spacer sub-assembly to the 12 o'clock position.
5. Install stem retainer on base of manual operator body and
simultaneously engage it into the slot provided on the
stem/spacer sub-assembly.
IMPORTANT: The spacer on the stem/spacer sub-assembly must
be inside of the stem retainer for AC construction (Figure 1) and
outside of the stem retainer for DC construction (Figure 2).
6. Install manual operator bonnet gasket and body with
preassembled parts into valve body. Torque manual operator
body to 175 ± 25 in-lbs [19,8 ± 2,8 Nm].
7. Replace solenoid base gasket and solenoid base sub-assembly.
Torque solenoid base sub-assembly to 175 ± 25 in-lbs
[19,8 ± 2,8 Nm].
8. For further reassembly, refer to Valve Reassembly step 6.
Page 2 of 4
I&M No.V5436R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Torque Chart
Part Name
ORDERING INFORMATION
FOR ASCO REBUILD KITS
Torque Value
Inch-Pounds
Torque Value
Newton-Meters
175 ± 25
19 8 ± 2
19,8
2,8
8
144 ± 15
16,3 ± 1,7
75 ± 10
8,5 ± 1,1
Solenoid base
sub-assembly
Manual operator
body
Bonnet screw
Valve seat
IMPORTANT
Captive spacer on stem/spacer
sub-assembly must be located
on the inside of stem retainer
when reassembled.
Parts marked with an asterisk (*) in the exploded view are supplied in
Rebuild Kits. When 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.
spacer
stem/spacer
sub-assembly
MANUAL OPERATOR
(OPTIONAL)
stem retainer
solenoid base
sub-assembly
solenoid base
sub-assembly
stem gasket
solenoid base
gasket
stem/spacer
sub-assembly
manual operator
body
core spring
(see note)
core assembly
stem retainer
core spring
(see note)
core assembly
solenoid base gasket
bonnet gasket
valve seat
valve seat
valve body
body passage gasket
body passage eyelet
body gasket
PARTIAL VIEW
diaphragm
assembly
Indicates Parts Supplied
In ASCO Rebuild Kits
This part is NOT
supplied in all kits
diaphragm spring
diaphragm
assembly
IMPORTANT
See torque
chart
Partial View of
Alternate Construction
Note:
Wide end of core spring in core first,
closed end protrudes from top of core.
valve bonnet
bonnet screw (4)
Figure 1. Series 8210 valve without solenoid, AC construction with 1I or 1 ¼I NPT valve body shown.
I&M No.V5436R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 3 of 4
MANUAL OPERATOR
(OPTIONAL)
IMPORTANT
Captive spacer on stem/spacer
sub-assembly must be located on
the outside of stem retainer
when reassembled.
solenoid base
sub-assembly
spacer
solenoid base
gasket
stem gasket
stem/spacer
sub-assembly
stem/spacer
sub-assembly
stem retainer
manual operator
body
stem retainer
core assembly
with core spring
bonnet gasket
valve seat
solenoid base
sub-assembly
PARTIAL VIEW
core assembly
with core spring
IMPORTANT
See torque
chart
solenoid base gasket
valve seat
valve body
body passage gasket
body passage eyelet
body gasket
diaphragm assembly
diaphragm spring
valve bonnet
Indicates Parts Supplied
In ASCO Rebuild Kits
This part is NOT
supplied in all kits
bonnet screw (6)
Figure 2. Series 8210 valve without solenoid, DC construction with 1 ½I NPT valve body shown.
Page 4 of 4
I&M No.V5436R7
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 33
Page 34
Page 35
Page 36
Page 37
Page 38
Technical
Super Flow 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 supplement to 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 repre-
Table 1
Terminal
Connection
Signal Name
Description
Input or Output
Signal Type
TB1-1
AC Power
Electronics AC power source
Input
110VAC referenced to TB1-2
TB1-2
AC Neutral
Electronics AC neutral source
Input
AC Neutral
TB1-3
Earth Ground
Earth Ground
Input
Earth Ground
TB2-1
On/Off Lever Signal
Activity signal from the On/Off
lever on the dispenser.
Input
110VAC referenced to TB1-2.
10mA max load.
TB2-3
Dispenser Authorize
External signal to the dispenser Input
authorizing its use.
110VAC referenced to TB1-2.
10mA max load.
TB2-5
Pump Start output
Output from the dispenser that
can be used as a pump start
signal.
Output
110VAC referenced to TB1-2.
100W max load.
TB5-5
Penny Pulse Out (+)
One pulse per penny output.
Pulse signal is referenced to
TB5-6. See reverse for wiring
details.
Output
Open-Collector Drain (DC)
TB5-6
Penny Pulse Out (-)
Reference signal for penny
pulse output. See reverse for
wiring details.
Output
Open-Collector Source (DC)
TB6-1
Volume Pulse Out (+)
Programmable volume pulse
output. Pulse signal is referenced to TB6-2. See reverse
for wiring details.
Output
Open-Collector Drain (DC)
TB6-2
Volume Pulse Out (-)
Reference signal for programmable volume pulse output.
See reverse for wiring details.
Output
Open-Collector Source (DC)
Dispenser Operation:
AC Inputs:
The SF dispenser requires both the Dispenser Authorize (TB2 -3) and the On/Off Lever Signal (TB2-1) to be pulled to 110VAC for the dispenser to operate. The Dispenser Authorize signal voltage is normally supplied by an external control device such as a card reader or console. The On/Off Lever signal voltage is supplied by the On/Off lever switch installed in the lower part of the dispenser. In the event the
dispenser is operated in a stand alone installation, the Dispenser Authorize can be jumpered to the On/Off lever input.
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 open when the Pump Output
signal becomes active. If either signal is 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 supplies a Penny Pulse Output and a Programmable Pulse Output during a 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 an 1 pulse, 10 pulses, or
100 pulses for every unit volume. These signals are electrically independent and can be used singularly or simultaneously. The details on
wiring can be found on the back of this data sheet.
1/04/99
Page 39
SF Pulsers – Wiring Detail
Equivalent Circuit
1
2
+
TB-6 Penny Pulse Out
_
NPN
5
6
+
Programmable Volume
_ TB-5 Pulse Out
NPN
For target systems that require the
Pulse Input to be pulled to Ground
Dispenser CPU Board
Target System
Pulse +
Pulse Input
Pulse -
Ground
For target systems that require the
Pulse Input to be pulled to Vcc
Dispenser CPU Board
220 Ohm, 1/4W
Target System
Pulse +
Pulse Input
Pulse -
Ground
Vcc (+9-15 VDC)
Your Authorized PMC Distributor
Page 40
Pump Measure Control, Inc.
1070 Nine North Drive
Alpharetta, GA 30004
PH (770) 667-0667 Fax (770) 667-0476
REVISIONS
NO.
DESCRIPTION
1 REVISED WIRE NUMBERING
DISPENSER
CONTROLLER
BOARD
TB1-1
TB1-2
BLACK
1
WHITE
2
TB1-3
GREEN
3
TB6-1
TB6-2
ORANGE
WHITE / ORANGE
12
13
TB5-5
TB5-6
TB4-1
TB4-2
TB6-4
BLUE
WHITE / BLUE
14
15
RED
9
WHITE
BLACK
10
11
YELLOW
4
ORANGE/WHT
5
ORANGE
6
RED / YELLOW
7
RED / BLACK
8
RED
16
RED
17
GREEN
18
BLUE
19
YELLOW
20
TB2-1
TB2-3
TB2-5
TB2-7
TB2-8
NOZZLE HOOK SWITCH
SOLENOID
VALVE
100:1 SOLID
STATE PULSER
COMMUNICATIONS
DAUGHTER BOARD
DISPENSER JUNCTION BOX
RED
21
BLACK
22
RED
23
WHITE
24
BLACK
25
PURPLE
30
BROWN
32
WHITE/PURPLE
31
OPTIONAL
+
GND
-
2 CONNECTION RED#23 TO OR/WH#6
1/1/04
3 ADDED COMM WIRES
4/16/09
APPLICABLE TO DISPENSER SERIAL NUMBERS
12000 and HIGHER
FIELD WIRING
CONDUIT ENTRIES
NO.
TB1-1
TB1-2
TB1-3
TB6-1
TB6-2
TB5-5
TB5-6
TB4-1
TB4-2
TB6-4
TB2-1
TB2-3
TB2-5
TB2-7
TB2-8
TERMINAL DESCRIPTIONS
DESCRIPTION
110VAC HOT
NEUTRAL
EARTH GROUND
PROGRAMMABLE PULSE PER UNIT OF VOLUME OUTPUT +
PROGRAMMABLE PULSE PER UNIT OF VOLUME OUTPUT -
PULSE PER ¢ OUTPUT +
PULSE PER ¢ OUTPUT +12VDC
DC GROUND
SIGNAL
PUMP LEVER ON INPUT
PERMISSIVE INPUT
PUMP START OUT
DISPENSER SOLENOID
DISPENSER SOLENOID
SF DISPENSER WIRING
AS SHIPPED FROM FACTORY
TB1
SEE APPENDIX 'A'
NOTES:
1. Ellipses represent conduit openings (groupings) within the junction box.
2. Tied off blue wire is unused. Extra and/or pull wire.
DATE
1/1/04
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-98G07.2
DATE:
DRAWN BY:
06/21/98
SCALE:
GJG
PART NO:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
REVISIONS
NO.
DESCRIPTION
1 REVISED WIRING
DISPENSER JUNCTION BOX
Unconnected in
dispenser head
DATE
1/1/04
PURPLE
30
2 ADDED CALL SIGNAL INTERFACE
1/1/04
BROWN
32
3 ADDED COMM WIRING
4/16/09
WHITE/PURPLE
31
UNUSED
APPLICABLE TO DISPENSER SERIAL NUMBERS
DISPENSER CONTROLLER BOARD
12000 and HIGHER
TB1-1
TB1-2
BLACK
1
WHITE
2
TB1-3
GREEN
3
TB6-1
TB6-2
ORANGE
12
WHITE / ORANGE
13
TB5-5
TB5-6
TB4-1
TB4-2
TB6-4
BLUE
WHITE / BLUE
14
15
RED
9
WHITE
10
BLACK
11
TB2-1
TB2-3
TB2-5
TB2-7
TB2-8
YELLOW
4
ORANGE/WHT
5
ORANGE
6
RED / YELLOW
7
RED / BLACK
8
110VAC
TO 110VAC
SUPPLY
NEUTRAL
NEUTRAL
L1 In
NOZZLE HOOK SWITCH
SOLENOID
VALVE
RED
16
RED
17
GREEN
18
BLUE
19
YELLOW
20
L1 Out
Neutral
Auth
MR
Valve
Pulser
Com
21
TMS 800F Relay / IO Board
RED
100:1 SOLID
STATE PULSER
23
WHITE
24
BLACK
25
NOTES:
1. Ellipses represent conduit openings (groupings) within the junction box.
2. Wire colors for field wiring are unknown.
3. DIP SW Position #8 must be set to the OFF position.
FIELD WIRING
RED
22
DISPENSER WIRING
BLACK
SF RETAIL DISPENSER WIRING
TO A TMS-800F CONSOLE
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-04G46.2
DATE:
DRAWN BY:
07/12/00
SCALE:
GJG
PART NO:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
TB3
TB2
DALLAS
TB1
1 2 3
1 2 3 4 5 6 7 8
F1
6 7
RESET
L1
F2
L14
L3
L4
DISPENSER
Vxxxxx
L6
L2
L7
L8
L9
L10 L11
1 2 3 4 5 6 7 8
L15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
TB5
TB4
TB-1 AC POWER
$
TB6
1
4
5
9
TB-4 DC POWER OUT
Terminal
Connection
1.
AC Hot
2.
AC Neutral
3.
Earth Ground
Type
Input
Input
Input
TB-2 AC I/O
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
O
F
F
L12 L13
Connection
On / Off Input + (Switch to 110VAC)
On / Off Input - (Tie to AC Neutral)
Dispenser Enable (Switch to 110VAC)
Dispenser Enable - (Tie to AC Neutral)
Pump Output (110VAC)
Pump Output Return (AC Neutral)
Solenoid Output (110VAC)
Solenoid Return (AC Neutral)
Type
Input
Input
Input
Input
Output
Output
Output
Output
Terminal Connection
1.
+12 VDC - To solid state pulser
2.
Ground - Common for solid state pulser
3.
+12 VDC - To electromechanical totalizer
4.
N/A
5.
+12 VDC - Jumper to TB5-8
6.
Ground - Jumper to TB6-3
7.
+5 VDC - To LCD's
8.
Ground - To LCD's
Type
Output
Output
Output
N/A
Output
Output
Output
Output
TB-5 DC I / O
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
Connection
N/A
N/A
N/A
N/A
Pulse per Penny Output +
Pulse per Penny Output Pulse per Unit Volume +
Pulse per Unit Volume -
Type
N/A
N/A
N/A
N/A
Output
Output
Output
Output
TB-3 COMMUNICATIONS
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Connection
N/A
N/A
N/A
N/A
N/A
DATA Bus to Displays (+)
DATA Bus to Displays (-)
N/A
N/A
N/A
Type
N/A
N/A
N/A
N/A
N/A
Input / Output
Input / Output
N/A
N/A
N/A
TB-6 DC I / O
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
Connection
Programmable Volume Pulse Out +
Programmable Volume Pulse Out DC Product Pulse Input +
DC Product Pulse Input N/A
N/A
N/A
N/A
Type
Output
Output
Output
Output
N/A
N/A
N/A
N/A
SF RETAIL TERMINAL
WIRING - REV. B
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-00A24
DATE:
DRAWN BY:
8/28/00
SCALE:
CAT
PART NO:
NONE
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
TB3
TB2
DALLAS
TB1
1 2 3 4 5 6 7 8
1 2 3
F1
6 7
RESET
L1
F2
L14
L3
L4
DISPENSER
Vxxxxx
L6
L2
L7
L8
L9
L10 L11
O
F
F
L12 L13
1 2 3 4 5 6 7 8
L15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
TB5
TB4
TB6
$
1
4
5
9
LED INDICATORS
LED Number
L1
L2
L3
L4
L6
L7
L8
L9
L10
L11
L12
L13
L14
L15
Function
Solenoid Output
Pump Output
AC Permissive Input
AC On / Off Input
N/A
N/A
Penny Pulse Output
1 Pulse per Gallon Output
Programmable Pulse Output
High Speed Pulse Input
N/A
N/A
+ 12 VDC Output
+ 5 VDC Output
Color
Red
Red
Yellow
Yellow
N/A
N/A
Red
Red
Red
Yellow
N/A
N/A
Green
Green
SF RETAIL
WIRING - LED FUNCTIONS
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-00A25
DATE:
DRAWN BY:
8/28/00
SCALE:
CAT
PART NO:
NONE
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
UNIT SERIAL NUMBERS
LED Indicators
No.
Function
Color
GREEN 3
EARTH GROUND
WHITE 2
NEUTRAL
BLACK 1
HOT (110VAC)
RED / BLACK 8
SOLENOID
RED / YELLOW 7
SOLENOID
TO DISPENSER
JUNCTION BOX
(REFER TO DRAWING NOS.
91-98G07 OR 91-98G12)
L1
Solenoid Output
Red
L2
Pump Output
Red
ORANGE 6
PUMP START OUT
L3
AC Permissive Input
Yellow
ORANGE / WHITE 5
L4
PERMISSIVE INPUT
AC On/Off Input
Yellow
L6
YELLOW 4
Not Used
Yellow
PUMP LEVER "ON" INPUT
L7
Not Used
Yellow
L8
Cents Pulse Output
Red
L9
Pulse Per Gallon Output
Red
L1 0
Programmable PulseOutput
Red
L1 1
High Speed Pulse Input
Yellow
L12
Not Used
Yellow
L13
Not Used
Yellow
L14
+12 VDC Out
Green
L15
+5 VDC Out
Green
TB2
DALLAS
TB1
1 2 3
1 2 3 4 5 6 7 8
F1
TB3-A
L1
F2
L14
L3
L4
L7
L8 L9
L10 L11
1 2 3 4
DISPENSER
Vxxxxx
L6
L2
O
F
F
L12 L13
RS 485 +
RS 485 -
1 2
RESET
TB3-B
1 234 567 8
+12VDC
DC GROUND
DC SIGNAL
EARTH GROUND
L15
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
TB4
1 2 3 4 5 6 7 8
TB5
TB6
$
1
4
5
100:1 SOLID
STATE PULSE
TRANSMITTER
9
RED
BLACK
RED 9
WHITE 10
BLACK 11
ORANGE 12
+12VDC BLACK
WHITE / ORANGE 13
BLUE14
WHITE / BLUE 15
PULSE PER UNIT OUTPUT BLACK
PROGRAMMABLE PULSE PER UNIT OF VOLUME INPUT +
PROGRAMMABLE PULSE PER UNIT OF VOLUME OUTPUT PULSE PER ¢ OUTPUT +
PULSE PER ¢ OUTPUT -
TO DISPENSER
JUNCTION BOX
(REFER TO DRAWING NOS.
91-98G07 OR 91-98G12)
DOLLAR DISPLAY
TB1
O
F
F
12 345 678
O
F
F
12 345 678
O
F
F
12 345 678
DALLAS
1
2
3
4
Binary Switches
1-On
2-Off
3-Off
4-Off
5-On
6-Off
7-Off
8-Off
VOLUME DISPLAY
TB1
PURPLE (RS 485+)
YELLOW (RS 485-)
RED (+5VDC)
BLACK (GROUND)
DALLAS
1
2
3
4
Binary Switches
1-Off
2-Off
3-Off
4-Off
5-On
6-Off
7-Off
8-Off
PRICE PER GALLON DISPLAY
TB1
DALLAS
1
2
3
4
Binary Switches
1-Off
2-On
3-Off
4-Off
5-On
6-Off
7-Off
8-Off
Note: The binary switches set the address for the display and the baud rate.
If two displays are reading the same data - make sure that the binary switches
are set as indicated.
DISPENSER HEAD
SF DISPENSER RETAIL
HEAD WIRING CONNECTIONS
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-01A09.1
DATE:
2/28/01
SCALE:
DRAWN BY:
CAT
PART NO:
NONE
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
APPENDIX A
The 120040x-SF communications daughter board for the 110000
CPU board allows the dispenser to communicate via EIA-485 to a
POS system that supports the PMC protocol. Contact PMC for
POS systems that support this protocol. The board is red in color
and is mounted to the CPU board towards the upper left corner.
The board is shown in the box to the right.
Minimum Requirements:
For the 120040x board to function, five conditions must exist:
1. It must be installed correctly on the 110000x CPU board.
2. The CPU board hardware version must be a 110000H hardware version or later as identified in the upper right corner with white text
on a green background.
3. The firmware chip (U16 in the center of the CPU board) must be
label as “110000x V2.01” or later.
4. The dispenser must be set for “Console Mode” as defined in the
‘Programming’ section (page 6) of this manual.
5. The 120040x board must be programmed for the correct address of
the dispenser and protocol used.
120040x Comm Daughter Board.
PROGRAMMING
NOTE: AFTER CHANGING ANY SETTING, THE CPU BOARD MUST BE
RESET BY CYCLING POWER OR PRESSING THE RESET BUTTON
Address / Protocol:
The 120040x communications board must be programmed via the 8 position jumper block located on the board.
The communications address and protocol for the dispenser is set using these jumpers. See drawing #91-08G271
on the following page for definitions of these jumpers.
Product Price Per Volume:
Console Mode
In normal “Console Mode” operation (see page 6), the price setting for the product dispensed is set remotely via communications from the POS system. The price setting switches SW2 thru SW5 on the CPU
board should be set to ‘0.000’ when in console mode to prevent confusion since they are not being used.
Stand Alone Mode
If the dispenser is set to operate in “Stand Alone Mode”, the 120040x board is not recognized by the CPU
board and therefore, the price setting is determined by SW2 thru SW5 on the the CPU board (see page 5).
The price setting on the switches must be set to any value other then ‘0.000’ for the dispenser to operate.
Valid reasons for setting the dispenser to “Stand Alone Mode” with a 120040x board installed include failure of the POS system and initial startup / testing. When returning the dispenser to ‘Console Mode’, be
sure to set the rotary price switches back to ‘0.000’.
NOTE: AFTER CHANGING ANY SETTING, THE CPU BOARD MUST BE
RESET BY CYCLING POWER OR PRESSING THE RESET BUTTON
WIRING
See drawing 91-09G157 in the following section for details.
Page 51
JUMPERS ON THE 120040 CPMM BOARD SETS THE COMMUNICATIONS ADDRESS FOR THE
DISPENSER AND AND THE TPYE OF PROTOCOL USED.
PART# 120040x
PROTOCOL
2-WIRE, EIA-485
COMMUNICATIONS
BOARD
S0 S1 S2
NOT USED
OFF OFF OFF
PMC
ON OFF OFF
NOT USED
OFF ON OFF
NOT USED
ON ON OFF
NOT USED
OFF OFF ON
NOT USED
ON OFF ON
NOT USED
OFF ON ON
NOT USED
ON ON ON
J2
PUMP MEASURE CONTROL, INC.
ON
OFF
+
-
ADDRESS MISC
TxD RxD
COMM
TERMINAL
ADDRESS A0 A1 A2 A3 A4
NOT VALID
0
ON
OFF
OFF OFF OFF
1
OFF
ON
OFF OFF OFF
2
ON
ON
OFF OFF OFF
3
OFF
OFF
ON OFF OFF
4
ON OFF ON OFF OFF
5
OFF ON ON OFF OFF
6
ON ON ON OFF OFF
7
OFF
OFF OFF ON OFF
8
ON
OFF OFF ON OFF
9
OFF
ON OFF ON OFF
10
ON ON OFF ON OFF
11
OFF OFF ON ON OFF
12
ON OFF ON ON OFF
13
OFF
ON ON ON OFF
14
ON
ON ON ON OFF
15
OFF OFF ON
OFF
OFF
16
ON
OFF
OFF OFF ON
17
OFF ON OFF OFF ON
18
ON ON OFF OFF ON
19
OFF OFF ON OFF ON
20
ON OFF ON OFF ON
21
OFF
ON ON OFF ON
22
ON
ON ON OFF ON
23
OFF
OFF
OFF ON ON
24
ON OFF OFF ON ON
25
OFF ON OFF ON ON
26
ON ON OFF ON ON
27
OFF
OFF ON ON ON
28
ON
OFF ON ON ON
29
OFF
ON ON ON ON
30
ON ON ON ON ON
31
MISC
A0
A1
A2
A3
A4
S0
S1
S2
ADDRESS JUMPERS
T1 1 2 3
120040x PROGRAMMING
JUMPER DEFINITIONS
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-08G271
DATE:
DRAWN BY:
09/10/2008
GJG
SCALE:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
SUPERFLOW DISPENSER J-BOX
1 BLACK
2 WHITE
115VAC
TO AC
POWER
SOURCE
NEUTRAL
EARTH GROUND
6 ORANGE
TO PUMP CONTROLLER
FIELD CONDUIT
ENTRY (AC)
PIE 485 DBOX INTERFACE
GND
+
-
1
2
3
4
1
2
3
4
1
2
3
4
13
14
15
16
13
14
15
16
13
14
15
16
TWISTED PAIR / SHIELDED
FIELD CONDUIT
ENTRY (DC)
30 PURPLE
Communications 485+
31 WH / PU
Communications 485-
32 BROWN
Signal Ground
MAIN
JUNCTION
BOX
SUPERFLOW WIRING TO
RS485 COMM D-BOX
*NOTES:
1. ONLY FIELD WIRING CONNECTIONS SHOWN IN MAIN JUNCTION BOX
2. FOR COMMUNICATIONS, DISPENSER CPU BOARD MUST HAVE A 120040 DAUGHTER BOARD INSTALLED.
3. CONNECT COMMUNICATIONS WIRING TO TERMINALS IN PIE DBOX CORRESPONDING TO THE ADDRESS OF
THE DISPENSER BEING CONNECTED. FOR EXAMPLE, WIRING FOR DISPENSER #1 IS SHOWN ABOVE.
4. THE PIE D-BOX MUST BE INSTALLED PER INSTRUCTIONS SUPPLIED WITH THE UNIT. (MANUFACTURED BY
PROGRESSIVE INTERNATIONAL ELECTRONICS IN RALEIGH, NC.)
5. ORANGE #6 CAN BE USED AS THE PUMP START SIGNAL.
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-09G157
DATE:
DRAWN BY:
04/16/2009
GJG
SCALE:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
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