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"