Pump Measure Control CMD 701 Remote Dispenser Installation & Service Manual

INSTALLATION &
SERVICE MANUAL
CMD-701
REMOTE DISPENSER
WITH REEL
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
Phone (770) 667-0667
Fax (770) 667-0476
Table of Contents
Section 1 Installation………………………………………………………………………………………………. 3
Piping………………………………………………………………………………………………..3
Electrical……………………………………………………………………………….…………... 4
Start-Up………………………………..……………………………………………………..…….. 4
Programming……………………………………………………………………………………………. 5
Programming Tables ………………………………………………………………………………...…. 6
Operation………………………………………………………………………………………………... 7
Maintenance…………………………………………………………………………………………….. 7
Rewinding Hose onto the Reel………………………………………………………………………….. 7
Dispenser Calibration ……….…….……………………………………..…………………………….. 9
Section 2 - Parts
M7-P1- Exploded Parts View…………………………………………...……………………………… 10
M7-P1 - Parts List……………………………………………………...………………………………. 13
Section 3 - Component Information
ASCO Solenoid Valve
Installation / Maintenance / Parts for ASCO 8016G Series Solenoid Coil……………….………... 15
Installation / Maintenance / Parts for ASCO 8210G100 Solenoids……………………………...… 19
Liquid Controls Pulse Output Device
Installation / Maintenance / Parts Manual………………………………..……………….………... 25
Section 4 - Technical Data
CMD-xxx Dispenser Control…………………………………………………………………………….35
91-01A65.6 - CMD-xxx Terminal Wire Descriptions……………………………..……………..….
37
91-06A213.1 - CMD-xxx Stand Alone Wiring………...……………………………………………..… 39
91-10G322 - CMD-701 Internal Layout……...……...……………………………………………..… 41
91-03A44 - CPU Wiring Terminal Descriptions……………………………………………………..… 43
91-03A132 - Factor Board Wire Terminal Descriptions………………………………………………. 45
91-03A45 - CPU Indicator LED Descriptions………………………………………………………….. 47
91-10G347 - CMD-701 Upper Unit Wiring Diagram………………………………………………...… 49
91-10G348 - CMD-701 Lower Unit Wiring Diagram………………..……………………………..….. 51
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 both RETAIL and COMMERCIAL versions of the dispenser.
Any references to PRICE settings or PENNY PULSE outputs only apply to the
RETAIL versions. Differences are noted where necessary.
Installation
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 covered by this manual must be fed product through a system that will
maintain near operating pressure on the dispensers when the pump is off. If pressure is not maintained on the unit, the reel’s hose can expand each time the pump is turned ON, causing the dispenser to jump a few counts at the start of a transaction Some 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. The CMD-xxx dispenser footprint can be seen in Figure 3 below.
FRONT OF UNIT
Figure 3– CMD-701-MA-8M dispenser footprint—underground supply feed.
Page 3
3.
The CMD-xxx dispensers must be installed in a system that prevents air from being pumped
through the dispenser. Submersible turbine pumps do not tend to pump air. However, if another
type of pumping device is used, means must be provided to eliminate air from the system before it
reaches the dispenser.
4.
The CMD-xxx dispenser must be installed in a system that incorporates a power operated pump
incorporating a pressure relief that maintains system pressures at or below 50 psi.
5.
Dispensers should be located as close to the supply tank as possible. Supply lines should be sized to
allow simultaneous maximum flow desired for all dispensers fed from it.
6.
The vertical supply riser must be cut to the proper height in order to avoid undue stress on the dispenser when installing the ground joint union. Attach dispenser base to the sump/impact box using
the anchor points.
7.
When the dispenser has been connected to the piping, the lines should be tested for leaks. Remember to allow any fresh pipe compound used in threaded joints to cure or set before performing the
leak tests.
8.
All hoses used with the dispensers shall be sufficiently reinforced as to not affect the operation or
accuracy of the units through its expansion and contraction from pressure.
B. Electrical Wiring
1.
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 internally wired as shown in wiring drawings 91-10G347
and 91-10G348 in Section 4.
4.
Refer to electrical wiring diagrams in Section 4 for details on wiring the dispenser to the field.
C. Start-Up
1.
Page 4
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.
IMPORTANT
BLEED THE AIR FROM
THE LINES VERY
SLOWLY. ALLOWING
THE METER TO REACH
EXCESSIVE RPM CAN
CAUSE SEVERE DAMAGE.
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 SEVERE, AND OFTEN TOTAL, DAMAGE TO THE METER.
3.
After all air has been removed from the supply piping, run 30 to 40 gallons of product through the
dispenser to completely fill the system and discharge all air from the unit.
4.
Although the dispensers are shipped from the factory properly adjusted, rough handling in transit or
special installation conditions can alter this. Before the dispensers are placed into service, their 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.
Programming
1.
The dispensers main CPU board is located behind the rear panel in the unit’s
head. The CPU board has several items
that must be configured so that the dispenser will operate correctly with the
system in which it is installed
2.
PRICE PER VOLUME: (RETAIL
versions only) Setting the price per unit
volume of product is done using four
rotary switches located in the lower right
corner of the board. See Figure 5A.
SW2 sets the dollar amount, SW3, SW4
and 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.
Figure 5A - Corner of CPU board showing price setting and dip- switch loca
tions. Note that price setting only applies to RETAIL dispensers.
3.
DIP SWITCH and JUMPER SETTINGS: The dips switches and jumpers on the main CPU board are used to set operational parameters on start up of the unit. See Figure 5B for location. While dip switch settings can be reset to original positions once altered, changes in the jumper block are permanent. To cut a jumper, press a sharp object through the thin point
of the metal foil for the desired position. (If wire jumpers are used instead of the foil block depicted in Figure 5B, simply cut
the desired jumper with a small pair of wire cutters). To repair a jumper that has been cut, the board must be returned to the
factory. The parameters that the switches and jumpers control are defined in the following tables.
IMPORTANT
AFTER CHANGING ANY
SETTING, THE CPU BOARD
MUST BE RESET BY
CYLING POWER OR PRESSING THE RESET BUTTON.
Figure 5B - Section of CPU board showing dip switch and jumper location
DIP SWITCH PARAMETERS
Position
JUMPER PARAMETERS
Position
Dispenser Operating Mode (Table 6A)
1
Liters / Gallons Unit of Measure (Table 6D)
5
Volumetric Pulse Resolution (Table 6B)
2
Model Selection (Table 6E)
6
Display TEST (Table 6C)
3
Volume or Penny Pulse Output (Table 6F)
7
UNUSED
4
UNUSED
8
Parameter settings are detailed in tables on next page
Page 5
Programming Tables
Dip Switch positions 1-4 and Jumper Positions 5-8
TABLE 6A - Position #1
Dispenser Operating Mode
DIP SWITCH SETTINGS
Dip Switch
Position #1
Requires external 110VAC Permissive
from card system or terminal
Stand-alone mode
OFF*
ON
Volumetric Pulse-out Resolution
TABLE 6B - Position #2
Dip Switch
Position #2
10 pulse per unit volume
100 pulses per unit volume
OFF*
Display Segment Test
Dip Switch
Position #4
No Display Segment Test
OFF*
Liters / Gallons Unit of Measure
Jumper
Position #5
JUMPER SETTINGS
GALLONS
SHORTED*
Dispenser Model
Jumper
Position #6
CMD-501, CMD-502, CMD-700, CMD-1500
SHORTED*
Pulse Output Type
Jumper
Position #7
Penny Pulse Output
Set MODEL of dispenser the CPU board is installed in. Default is CMD-501, CMD-502,
CMD-701 and CMD-1500.
CUT
TABLE 6F - Position #7
Volumetric Pulse Output
Set the Unit of Measure for the dispenser. Default is US Gallons. If Liters is desired, then
CUT the foil or jumper on POSITION #5.
CUT
TABLE 6E - Position #6
Not Applicable
Set whether to have the Display Segment Test
or not. If selected, the dispenser will show all
‘8’ digits for 5 seconds, then reset and open the
solenoid when the unit is enabled to dispense.
ON
TABLE 6D - Position #5
LITERS
If the pulse output type (see Table 6E below) is
set for Volumetric, then this setting determines
the resolution of the signal. If the pulse output
type is set to PENNY pulse, this setting has no
effect.
ON
TABLE 6C - Position #3
Display Segment Test
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
CUT
Set the pulse output channel to either VOLUMETRIC or PENNY pulse out. If VOLUMETRIC is selected, Table 6B above determines resolution. If PENNY is selected , a pulse per penny
of the TOTAL SALE is transmitted.
SHORTED*
* = default setting
Note: Dip Switch position #4 and Jumper position #8 are not used at this time.
Page 6
Operation
1.
To start the dispenser, simply remove the nozzle from its boot and lift the ON/OFF lever. 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. (for commercial versions of the dispensers, only VOLUME is displayed).
4.
During delivery, the CPU board in the dispenser will generate a real time output pulse stream for use by
remote devices. The CPU board can be configured to transmit a VOLUMETRIC or PENNY pulse
stream (See Programming Section of Manual for details). The pulse output driver is an open-collector
type. See Dispenser Control in Section 4.
Maintenance
The CMD-xxx dispensers are designed to give many years of trouble free service. However, like any mechanical device, they require periodic maintenance to prevent problems from developing.
1.
2.
3.
4.
5.
The CMD-xxx dispensers used in marine and general service applications come equipped with an internal inlet strainer just upstream of the meter. The strainer should be checked periodically
and changed if necessary.
The battery used to backup the displays in the dispenser should be
replaced annually. Replace only with a 7.2V or 8.4V Ni-Cd or
NiMh battery. DO NOT REPLACE WITH AN ALKALINE
BATTERY as the recharging circuit on the board may cause the
battery to leak or explode.
While doing any maintenance on the dispenser, check the hose for
any cracks or tears that can cause leaks.
When cleaning the exterior of the cabinet, use only non-abrasive,
non-corrosive cleaning agents. Use only soft rags.
In SALT-WATER environments, it is recommended that the exterior stainless steel panels be waxed periodically (at least biannually) to maintain the panels at their best appearance.
IMPORTANT
BEFORE OPENING ANY
PART OF THE FUEL SYSTEM, MAKE SURE IT IS
DE-PRESURIZED AND
THE PUMPING SYSTEM
HAS BEEN SHUT-OFF AND
TAGGED OUT.
Page 7
Page 8
Dispenser Calibration
The purpose of calibrating a dispenser is to ensure that the volume displayed on the unit matches the amount
of product dispensed. The calibration of the Fuelhouse dispenser is accomplished by adjusting the correction factor set on the 110500C Factor Board (see Figure 7) located in the head of the dispenser. The factor
board manipulates the raw pulse stream produced by the pulser mounted to the dispenser’s meter. The correction factor has the form of XXX.XX% and has a valid range 000.01% to 199.99%. It is applied as a percentage multiplier to the pulse streams passing through the board. For example, if the meter transmits 410
pulses per gallon and the correction factor is set to 97.56%, then the CPU board will receive 400 pulses per
gallon.
To access the factor board,
remove the rear panel from
the head of the dispenser.
The factor board is located
on the right side of the
opening under a rectangular, tamper resistant cover.
The cover is held in place
by two screws and secured
by a seal wire to prevent
tampering.
Figure 7—110500 Factor Board
Calibration Procedure:
1. Check the dispenser’s current calibration by delivering product to a reliable, accurate prover. The
prover should large enough to accept product from the dispenser at full flow for at least 60 seconds.
Perform several delivery tests to verify repeatability.
2. Make sure the prover has been wetted and run a test load. Note the volume in the prover and the
volume registered by the dispenser.
3. If the unit’s calibration needs to be corrected, then the factor setting on the factor must be changed.
Remove the cover from the factor board by cutting the seal wire. Record the current setting on the
factor switches and use the following formula to determine the what the new setting should be:
New factor =
(volume in prover)
_____________________________________________
(volume in prover registered by dispenser)
x current factor
4. Set the new factor setting on the 110500 Factor Board.
5. Run another prover test to verify the new adjuster setting is correct.
6. If the calibration of the unit needs further correction, repeat the above procedure. If no further
changes are needed, replace the cover on the factor board.
7. Apply a wire seal to secure the adjuster settings.
Example: A prover run is completed in a 100 gallon prover. The prover shows exactly 100.00 gallons while
the dispenser shows 99.35 gallons on the display. If the current factor setting is 72.01, the new factor that needs
to be set on the board is 72.48 to correct the dispenser’s registration to that of the prover.
NOTE: 1 US GALLON = 231 cubic inches
Page 9
PARTS MANUAL
®
®
M-7, MA-7, M-10
®
Meters
LIQUID
CONTROLS
A Unit of IDEX Corporation
Exploded View: M-7/MA-7/M-10 Meter Covers
CAUTION
IGN COUNTER D
AL
RIV
E
T WITH S
SHA F
LO
T
0
1
2
6
0
1
5
2
3
4
0202 Adjuster
assembly
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
FLOW
PRODUC
UK81
1783
T
VOL/REV
CY
RATE
TEMP ER
ATURE
MAX PRES
SURE
0165 Gear,
packing gland
0250 Packing
Gland Assy.
0705 Washer,
flat (4)
0673 Screw (4)
0780 Seal
wire
Driveshaft bushing (2)
0630 Screw (2)
0603 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 inserted in this manual. Look up the item
number on the Parts List. The Parts List shows each
item number with a corresponding part number.
Find the corresponding 5 digit part number for the
item you want to order. The part number represents
an individual piece, a kit or a complete assembly.
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)
0125 Cover, rear
0627 Hex washer head screw
(20, for both covers)
®
0163 Gear,
displacement pinion (2)
0672 Screw, blocking rotor
®
0372 Plate, serial number
NO.
SERIAL
.
CORP
ROLS A
CONT
US
LIQUID BLUFF, IL,
LAKE
L NO.
MODE
0430 O-Ring (2)
0110 Housing
0570 Pipe plug (optional)
Rear cover
0155 Rotor, displacement (2)
0318 Pin, dowel (4)
0144 Plate, bearing (2)
0528 Key (3)
(1 per rotor)
0153 Rotor, blocking
*For M-10 Meter Blocking Rotor,
#0672 Shown HereReplaces #0675
0771 Bellevue washer,
rotor gear (2)
0673 Screw,
hex washer head (2)
0765 Washer, Lock
*0675 Screw,
cap socket head
0326 Driver,
packing gland
0161 Gear,
blocking rotor
0611 Screw, hex head
w/lockwasher (64 per plate)
Front cover
When placing order for replacement parts please
reference the meter's serial number.
Exploded View: M-7/MA-7/M-10 Meter Housing
SOLD AND SERVICED BY
A NETWORK OF HIGHLY TRAINED
FULL SERVICE DISTRIBUTORS
Backed By Our Worldwide Reputation For
Quality, Accuracy and Advanced Design.
WARRANTY:
Liquid Controls (“Seller”) products are warranted against
defects in material or workmanship for a period of one (1)
year from date of installation, provided that the
warranty shall not extend beyond twenty-four (24) months
from the date of original shipment from Seller. Seller’s
obligations, set forth below, shall apply only to failure(s) to
meet the foregoing obligations provided that Seller is given
written notice within thirty (30) days of any occurrence
from which a claim of defect arises. If a warranty dispute
occurs, the Purchaser shall be required to provide Seller
with proof of date of sale. The minimum requirement to
establish date of sale shall be a copy of the Seller’s invoice.
In the event that a factory inspection by Seller or its
designee(s) supports the validity of a claim, at the
discretion of Seller, repair, replacement or refund shall be
the sole remedy for defect and shall be made, free of
charge, ex-works factory. In no event shall Seller be liable
for any special, consequential, incidental, indirect or
exemplary damages arising out of warranty, contract, tort
(including negligence) or otherwise, including but not limited to, loss of profit or revenue, loss of use of the product or
any associated products and/orequipment, cost of substitute
goods or services, downtime costs or claims of or by
Purchaser’s clients or customers. In any event, the total
liability of Seller for any and all claims arising out of or
resulting from the performance, non-performance or use of
the product shall not exceed the purchase price of the individual product giving rise to the claim. All other guaranties,
warranties, conditions and representations, either express or
implied, whether arising under any statute, common law,
commercial usage or otherwise are excluded. Electronic
Products require installation, start-up and servicing by
local factory-trained service representatives. In the absence
of installation, start-up and servicing of Electronic Products
by Seller trained service representatives, this warranty is
null and void. Seller’s obligations as set forth above shall
not apply to any product, or, or any component or part
thereof, which is not properly installed, used, maintained
or repaired, or which is modified other than pursuant to
Seller’s instructions or approval. NOTE: The above
warranty applies only to products manufactured by Liquid
Controls, Lake Bluff, Illinois. Private label, OEM, and/or
products manufactured by Liquid Controls licensee(s) are
specifically excluded from the above warranty. Consult
factory for all non-Liquid Controls manufacturers’
warranties. NO IMPLIED OR STATUTORY WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE SHALL APPLY.
Backed By Our Worldwide Reputation For Quality, Accuracy and Advanced Design.
LIQUID
CONTROLS
A Unit of IDEX Corporation
LIQUID CONTROLS
A Unit of IDEX Corporation
105 Albrecht Drive
Lake Bluff, IL 60044-2242
(847) 295-1050
FAX: (847) 295-1057
Website: www.lcmeter.com
Distributed By:
Printed with vegetable inks on recycled paper. Please Recycle!
© 2001 Liquid Controls
Printed in U.S.A.(03/01)
Bulletin #48496B $1
OWNERS MANUAL PARTS LIST - M7A1-LP
ITEM
PART#
DESCRIPTION
L2102
METER ELEMENT
M-7-1 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
10
0765
06174
LOCK WASHER, 0.250
HVY HLCL SPR, 18-8 SS
1
0318
40665
PIN, DOWEL
0.250 DIA X 0.625 LOND
4
0675
07483
SCREW, 1/4-20 X 1.00
HEX SCKT HD CAP, 316SS
1
0144
41804
PLATE, BEARING NI-RESIST
SV-1-2-3-7-14
2
0161
47646
GEAR, BLOCKING ROTOR
GEAR BLKG RTR M7
1
0163
47647
GEAR, PINION
PINION GEAR
2
0153
48306
BLOCKING ROTOR ASSY M7
ALUM / 316 SST-HC
1
0528
48332
KEY, ROTOR GEAR M7
0.12 X 0.15 X 0.5 316 SST
3
0771
48348
WASHER, ROTOR GEAR
0.25 ID, 1.0 OD, 301 SS
2
0155
48366
DISPLACEMENT ROTOR ASSY
M7 ALUM / 316 SST-HC
2
0200
48496
MANUAL, M7 / MA7 / M10
METER (LC-158)
1
0326
48756
DRIVER, PACKING GLAND
M15 METERS
1
0372
49444
NAMEPLATE, METER HOUSING
SERIAL NUMBER
1
0110
49445
HOUSING, M7 METER
ALUMINUM NEW STYLE
1
0673
09027
SCREW, 1/4-20 X 0.75 L
HX HDEAD CAP, 18-8 SS
2
25214
COVER ASSY M5
ALUM COVERS, NEW STYLE
1
0566
06790
PIPE PLUG, 0.250-18 NPT
HEX SCKT HD, 302 SS
2
0627
09080
SCREW, 0.312-18 X 1.375
HEX WSHR HD, THD FRMG
20
0123
48301
COVER, FRONT M7
DIE CAST ALUM
1
0125
48302
COVER, REAR M7
DIE CAST ALUM
1
25227
SEAL KIT
M7 UL BUNA AL / CI / BRASS
1
09578
O-RING, 6.25" ID BUNA, UL
6.4375 OD X 0.093 THK (SQR)
2
A2210
FLANGE ASSY, M5 & M7
ALUM / BUNA / 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
48394
FLANGE, COMP; 2" NPT
ALUM, O-RING STYLE
2
0620
06851
SCREW, 3/8-16 X 1.500
HEX HD CAP, GR 8
8
COMPONENT
COMPONENT
COMPONENT
0430
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
2-WAY INTERNAL PILOT-OPERATED SOLENOID VALVES
NORMALLY CLOSED OPERATION
2 OR 2½ NPT
IMPORTANT: See separate solenoid installation and
maintenance instructions for information on: Wiring,
Solenoid Temperature, Cause of Improper Operation, Coil
or Solenoid Replacement.
8211
I&M No.V6296R2
INSTALLATION
Check nameplate for correct catalog number, pressure,
voltage, frequency, and service. Never apply incompatible
fluids or exceed pressure rating of the valve. Installation and
valve maintenance to be performed by qualified personnel.
Future Service Considerations
DESCRIPTION
Series 8210 valves are 2-way normally closed, internal pilot
operated solenoid valves designed for general service.
These valves are made of rugged forged brass and have an
integral adjustable bleed device for controlling the opening
and closing speed of the piston. Series 8210 valves are
supplied with general purpose, or explosionproof/waterĆ
tight solenoids.
Series 8211 valves are the same as Series 8210 except they
are provided with a metal explosionproof/watertight soleĆ
noid enclosure.
OPERATION
Normally Closed: Valve is closed when solenoid is
de-energized; open when energized.
IMPORTANT: Minimum operating pressure differential
required is 5 psi.
Adjustable Bleed Device
Series 8210 valves have an integral adjustable bleed device
for controlling the opening and closing speed of the piston.
When valve leaves the factory, the bleed adjusting screw
(metering pin) has been preset to provide quick shockless
closing for most applications. If faster or slower closing is
required, adjust the screw (metering Pin) as follows:
1. Turn metering pin in (clockwise) as far as possible
without over tightening. Back out tightening. Back out
metering pin (counterclockwise) two complete turns.
From this point, adjustments may be made to suit
system.
2. Turn metering pin clockwise for slower closing.
3. Turn metering pin counterclockwise for faster closing.
Manual Operation (Optional Feature)
Valves with suffix MO in the catalog number are provided
with a manual operator which allows manual operation
when desired or during an electrical power outage.
To engage manual operator, rotate stem fully clockwise
(approximately 180). Valve will now be in the same
position as when the solenoid is energized.
To disengage manual operator, rotate stem fully
counterclockwise (approximately 180) before operating
electrically.
CAUTION: Manual operator stem must be fully rotated
counterclockwise before electrical operation.
Provision should be made for performing seat leakage,
external leakage, and operational tests on the valve with a
nonhazardous, noncombustible fluid after disassembly and
reassembly.
Temperature Limitations
For maximum valve ambient and fluid temperatures, refer
to chart below. Check catalog number prefix on nameplate
to determine the maximum temperatures.
Construction
Catalog
Number
Prefix
Coil
Class
Maximum
Ambient
Temp.F
Maximum
Fluid
Temp.F
AC
None or
FT
F
122
180
HT
None,FT
or HT
H
140
180
F or H
77
150
DC
Positioning
This valve is designed to perform properly when mounted in
any position. However, for optimum life and performance, the
solenoid should be mounted vertically and upright to reduce
the possibility of foreign matter accumulating in the solenoid
base sub-assembly area.
Piping
Connect piping or tubing to valve 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.
IMPORTANT: To protect the solenoid valve, install a
strainer or filter, suitable for the service involved, in the inlet
side as close to the valve as possible. Clean periodically
depending on service conditions. See ASCO Series 8600,
8601 and 8602 for strainers.
MAINTENANCE
WARNING: To prevent the possibility of
death, personal injury or property damage, turn
off electrical power, depressurize valve, and vent
fluid to a safe area before servicing the valve.
Note: It is not necessary to remove the valve from the
pipeline for repairs.
Page 1 of 4
50 Hanover Road, Florham Park, New Jersey 07932
www.ascovalve.com
E181142
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 valve strainer or filter when cleaning
the valve.
Preventive Maintenance
Keep medium flowing through the valve as free from dirt
and foreign material as possible.
Periodic exercise of the valve should be considered if
ambient or fluid conditions are such that corrosion,
elastomer degradation, fluid contamination build up, or
other conditions that could impede solenoid valve
shifting are possible. The actual frequency of exercise
necessary will depend on specific operating conditions. A
successful operating history is the best indication of a
proper interval between exercise cycles.
Depending on the medium and service conditions, periodic
inspection of internal valve parts for damage or excessive
wear is recommended. Thoroughly clean all parts. If parts
are worn or damaged, install a complete rebuild kit.
Causes of Improper Operation
Incorrect Pressure: Check valve pressure. Pressure to
valve must be within range specified on nameplate.
Excessive Leakage: Disassemble valve and clean all
parts. If parts are worn or damaged, install a complete
ASCO Rebuild Kit.
Valve Disassembly (Refer to Figure 3 on page 4)
1. Disassemble valve in an orderly fashion. Use exploded
views for identification and placement of parts.
2. Remove solenoid, see separate instructions.
3. If the valve being serviced has a manual operator, suffix
MO in the catalog number, refer to section on ManualĂ
Operator Disassembly.
4. Unscrew solenoid base sub-assembly and remove
solenoid base gasket, core assembly with core spring.
5. For normal maintenance, it is not necessary to remove
the valve seat. However, if valve seat removal is
required, use a 7/16 socket wrench.
6. Dislodge retainer from metering pin passageway and
remove metering pin with gasket. Then remove
metering pin gasket from metering pin.
7. Remove bonnet screws, valve bonnet, piston spring,
piston assembly, support, lip seal, body gasket, and body
passage gasket.
8. Remove aspirator tube and disc with disc gasket from
piston.
9. All parts are now accessible to clean or replace. If parts
are worn or damaged, install a complete ASCO Rebuild
kit.
Valve Reassembly
1.
2.
Reassemble valve using exploded views for
identification and placement of parts.
Lubricate the solenoid base gasket, body gasket, body
passage gasket, metering pin gasket, and the surface of
the piston which contacts the lip seal with
DOW CORNING 200 Fluid lubricant.
3. Lubricate disc and disc gasket with DOW CORNING
111 Compound lubricant or an equivalent high-grade
silicone grease.
4. Position body gasket, body passage gasket, and support
in valve body.
5. Install aspirator tube and disc with disc gasket in piston.
6. Position lip seal, flanged end out, onto piston assembly.
Install piston assembly with lip seal into support in valve
body cavity.
7. Replace piston spring, valve bonnet, and bonnet screws.
Torque bonnet screws in a crisscross manner to 144± 15
in-lbs [16,3 ± 1,7 Nm].
8. Replace valve seat with a small amount of thread
compound on the seat threads. Torque valve seat to 65
± 15 in-lbs [7,3 ± 1,7 Nm].
9. Install metering pin with metering pin gasket into valve
body. Replace retainer and refer to Adjustable Bleed
Device section for metering pin adjustment.
10. If the valve being serviced has a manual operator, refer
to Manual Operator Reassembly section.
11. Replace solenoid base gasket, core assembly, core
spring, and solenoid base sub-assembly. Torque
solenoid base sub-assembly to 175 ± 25 in-lbs [19,8 ±
2,8].
12. Install solenoid, see separate instructions and make
electrical hookup.
WARNING: To prevent the possibility of
death, personal injury or property damage, check
valve for proper operation before returning to
service. Also perform internal seat and external
leakage tests with a nonhazardous, noncombusĆ
tible fluid.
13. Restore line pressure and electrical power supply to valve.
14. After maintenance is completed, operate the valve a
few times to be sure of proper operation. A metallic
click signifies the solenoid is operating.
Manual Operator Disassembly
1. Refer to Valve Disassembly section and follow step 1 and 2.
2. For AC construction refer to Figure 1 on page 3; DC
construction Figure 2 on page 3.
3. Unscrew solenoid base sub-assembly from manual
operator body.
4. Unscrew manual operator body and remove this
assembly intact. Remove body gasket from main valve
body.
5. Before removing the stem retainer from the manual
operator body, note the location of captive spacing
washer on the stem/lever sub-assembly. The captive
spacing washer will be on the inside of the fork on the
stem retainer for AC construction and on the outside for
DC construction. Location of this captive spacing
washer is important for reassembly.
6. Remove stem/lever sub-assembly with stem gasket
from manual operator body. Remove solenoid base
gasket, core assembly with core spring.
Page 2 of 4
I&M No.V6296R2
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
7. Refer to Valve Disassembly sections, step 5 for further
disassembly
Manual Operator Reassembly
Refer to steps 1 through 9 of Valve Reassembly then proceed
as follows:
1. Position stem gasket on stem/lever sub-assembly.
2. Preassemble manual operator parts as follows: Position
core assembly with core spring into manual operator
body from the bottom. Install stem/lever sub-assembly
into manual operator body. Install stem retainer and be
sure the captive spacing washer on the stem/lever
sub-assembly is located on the inside of the fork on the
stem retainer for AC construction and on the outside of
the fork on the stem retainer for DC construction.
3. Replace body gasket in valve body.
4.
Screw manual operator body intact into valve body.
Torque manual operator body to 175± 25 in-lbs [19,8±
2,8 Nm].
ORDERING INFORMATION FOR
ASCO REBUILD KITS
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.
Torque Chart
Part Name
Solenoid Base Sub-Assembly
Manual Operator Body
Valve Seat
Torque Value in Inch-Pounds
Torque Value in Newton-Meters
175 ± 25
19,8 ± 2,8
65 ± 15
7,3 ± 1,7
IMPORTANT
For AC construction,captive spacer on stem/spacer
sub-assembly must be located on theinside
of stem retainer when reassembled.
spacer
solenoid base
sub-assembly
solenoid base
gasket
stem/spacer
sub-assembly
stem retainer
manual operator
body
stem retainer
stem/spacer
sub-assembly
core spring
(see note)
core assembly
stem gasket
IMPORTANT
For DC construction,captive spacer on stem/spacer
sub-assembly must be located on theoutside
of stem retainer when reassembled.
spacer
stem/spacer
sub-assembly
stem retainer
body gasket
valve seat
Note: Wide end in
core first. Closed end
protrudes from top
of core.
solenoid base
gasket
manual operator
body
stem retainer
stem/spacer
sub-assembly
stem gasket
Indicates that these
parts are included
in rebuild kit
solenoid base
sub-assembly
Indicates that these
parts are included
in rebuild kit
core assembly
core spring
body gasket
valve seat
valve body
(assembled)
valve body
(assembled)
Figure 1. Manual Operator Assembly, AC Construction.
Figure 2. Manual Operator Assembly, DC construction.
I&M No.V6296R2
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Page 3 of 4
Torque Chart
Part Name
Solenoid Base Sub-Assembly
Bonnet Screws
Valve Seat
AC Construction
Torque Value in Inch-Pounds
175 ± 25
144 ± 15
65 ± 125
Torque Value in Newton-Meters
19,8 ± 2,8
16,3 ± 1,7
7,3 ± 1,7
DC Construction
solenoid base
sub-assembly
solenoid base
sub-assembly
core spring
(see note 1.)
core assembly
core spring
core assembly
Notes:
retainer
solenoid base
gasket
metering pin
metering pin gasket
valve seat
Indicates that these
parts are included
in rebuild kit
1. Wide end in core first. Closed end
of spring protrudes from top of core.
2. Disc gasket not present on all
constructions.
valve body
body passage gasket
body gasket
support
lip seal
piston assembly
bonnet screw
piston spring
disc
disc gasket
(see note 2.)
valve bonnet
aspirator tube
piston
Figure 3. Series 8210 valve without solenoid.
Page 4 of 4
I&M No.V6296R2
50 Hanover Road, Florham Park, New Jersey 07932 www.ascovalve.com
Installation & Parts Manual
Pulse Output Device (POD)
Installation
www.lcmeter.com
Table of Contents
Description
Page Number
General Information ................................................................ 2
POD Models ............................................................................ 2
Specifications .......................................................................... 3
Installation ............................................................................... 4-8
Removing Existing Hardware ..................................... 4
Installing the POD ....................................................... 5
Installing the POD Extension ...................................... 6
Wiring the POD .......................................................... 7
Wiring Diagrams ......................................................... 8
Illustrated Parts Breakdown .................................................... 9-11
POD Assemblies ........................................................ 9
POD Extension Assemblies ........................................ 10-11
General Information
The electronics compartment also serves as a conduit
junction box. The POD has an O-Ring sealed, threaded
cover. The standard wire entrance is a ½-14 NPT female
hub which accepts threaded conduit or a cable gland. A
screw-type, removable, terminal block on the circuit board
facilitates wiring of the unit. With the wiring entrance
sealed and the cover in place, the housing has a
weatherproof rating of NEMA 4X. In addition, the housing
is UL and Canadian-UL explosion-proof rated (when
installed with approved conduit) and ATEX rated
flameproof (pending).
The Liquid Controls Pulse Output Device (POD) converts
the rotary motion of the Liquid Controls Positive
Displacement Flowmeter into electronic pulses. This
allows the meter to interface with a wide variety of
electronic monitoring devices and control equipment.
The POD mounts directly to the front cover of any Liquid
Controls meter in place of the packing gland. The motion
of the meter’s blocking rotor is magnetically coupled
through a stainless steel wall to the electronics
compartment of the POD. This eliminates the dynamic
seal of the packing gland and isolates the electronics from
the process fluid in the meter.
POD Models
There are five POD models available:
Inside the electronics compartment, an optical shaft
encoder converts the rotary motion into a high resolution,
two-channel, quadrature square wave. Both outputs are
driven by field effect transistors (FETs) and switch from
zero volts in the “ON” state to the user’s power supply
voltage in the “OFF” state. As supplied from the factory,
there is a 1.0 KΩ pull-up resistor on each output which
can be removed from the circuit in the field to produce a
true “Open Drain” (Open Collector) output. As Open Drain
devices, the outputs can sink up to 100 mA in the “ON”
state and sustain up to +30 VDC in the “OFF” state.
POD1: Fork Drive with Buna-N O-Ring,
100 PPR Quad Pulser, +8 to +24 VDC
POD2: Fork Drive with Teflon O-Ring,
100 PPR Quad Pulser, +8 to +24 VDC
POD3: Blade Drive with Buna-N O-Ring,
100 PPR Quad Pulser, +8 to +24 VDC
POD4: Blade Drive with Teflon O-Ring,
100 PPR Quad Pulser, +8 to +24 VDC
POD5: Fork Drive with Buna-N O-Ring,
100 PPR Quad Pulser, +5 VDC
2
Specifications
Dimensions
NOTE: Dimensions shown are not for construction use. Consult factory when certified Engineering Drawings
are required.
•
•
•
•
•
•
•
Voltage: (V+): +8 to +24 VDC
(POD5 is +5 VDC) ±5%.
Current supply: 26 mA typical.
Output Signal Resolution: 100 pulses per encoder
revolution, unscaled. For actual meter resolution, see
table below.
Square Wave: Single or dual quadrature channel
output.
Pulse Timing: Nominal 50% on and 50% off.
Rise/Fall Time of Pulse: <5 µs.
Operating Temperature Range: -40ºF to +185ºF
(-40ºC to +85ºC).
•
•
•
•
•
•
•
Output: Current sinking 100 mA maximum in “ON”
state; V+ supply @ 1.0 KΩ in “OFF” state. Optional
Open Drain FET (Field Effect Transistor). FET rating
(drain to source voltage) +30 VDC maximum.
Humidity Range: 0-100 %, non-condensing.
Shock: 50 G’s for 10 ms.
Vibration: 1 G at 10-150 Hz.
Electromagnetic Compatibility (EMI, RFI, etc.): to IEC
801 Standard.
Pulse Transmission Distance: Up to 5,000 feet
(1,524 meters).
Operates in bidirectional flow applications.
Output Signal Resolution
M & MA
Series Meters
MA-4
M-5, MA-5 (3:1)
M-5, MA-5 (1:1)
M-7, MA-7
M-10
M-15, MA-15
M-25
M-30, M-40
M-340
M-60 (new style)
M-60 (old style)
M-80
Pulses/
Gallon/
Channel
407.9
407.9
1,223.7
555.5
555.5
205.8
205.8
74.2
74.2
39.8
25.5
39.8
Pulses/
Litre/
Channel
107.8
107.8
323.4
146.8
146.8
54.4
54.4
19.6
19.6
10.5
6.7
10.5
Max
Output kHz
0.27
0.41
1.22
0.93
1.48
0.69
0.86
0.43
0.53
0.40
0.26
0.53
3
MS
Series Meters
MS-7
MS-15
MS-25
MS-30
MS-40
MS-75
MS-120
Pulses/
Gallon/
Channel
555.5
205.8
205.8
74.2
74.2
25.5
15.8
Pulses/
Litre/
Channel
146.8
54.4
54.4
19.6
19.6
6.7
4.2
Max
Output kHz
0.93
0.69
0.86
0.43
0.53
0.30
0.26
Installation
New Installations
When ordered with the flowmeter, the POD comes factory
installed on the meter and ready for wiring. Refer to the
detailed wiring information which begins on Page 7.
POD Installed on meter.
! WARNING
Relieve Internal Pressure
All internal pressure must be relieved to zero before
disassembly or inspection of the meter or any of the meter accessories.
Serious injury or death from fire or explosion could result from
servicing an improperly depressurized and evacuated system.
Retrofit Installations
Removing Existing Hardware
1. Relieve the pressure from the process piping to the
meter.
2. Drain the meter by opening the meter’s drain plugs.
3. Remove the mechanical counter, adjuster, and
adjuster drive shaft from the front of the meter.
4. Some meters have a counter adapter bracket which
is bolted on. If this is the case, remove the counter
bracket by removing the bolts that hold it in place. If
the counter adapter bracket is integral to the meter, it
cannot be removed. In this case, one of four POD
Pulser Extensions will be required.
Remove Packing Gland Mounting Screws
NOTE: Ensure there is no pressure inside the flowmeter
before attempting to remove the packing gland. LINE
PRESSURE MUST BE 0.0 PSI.
5. Remove the packing gland mounting screws. Pull
the packing gland out of the meter. If the O-Ring
does not come out with the packing gland, be sure to
remove it from the packing gland well before installing
the POD.
When this is complete, the POD can be installed.
Packing Gland Removed
4
Installation
Installing the POD
1. Verify that the proper POD Model was obtained by
comparing the driver tang on the POD to the driver
tang on the packing gland that was removed in Step
5 of Removing Existing Hardware on Page 4. There
are two types of packing gland/POD driver tangs:
blade type and fork type. Blade type packing glands
must be replaced with blade type PODs. Fork type
packing glands must be replaced with fork type PODs.
2. Determine the desired orientation of the conduit hub.
The hub can be positioned in one of eight possible
orientations as shown in the figure to the right.
NOTE: Meters with only two packing gland mounting
screws are limited to four orientations.
Blade Style Tang (Left) and Fork Style Tang (Right)
NOTE: When using a cable gland to seal the wire
entrance, any of the eight orientations can be used.
However, when using conduit, the hub should face down
so moisture that may accumulate in the conduit will drain
away from the POD electronics.
3. Position the O-Ring over the bottom of the POD as
shown to the right.
4. Align the fork style or blade style driver with the drive
mechanism in the meter and guide the POD into the
opening in the meter cover. When properly aligned,
the POD will go in until its mounting flange abuts the
meter cover.
POD Conduit Hub Orientations
Fork Style
Tang
5. Rotate the POD to the desired orientation and thread
in the mounting screws until they are snug. Using a
7/32” box end wrench, tighten the screws and torque
them to 21-25 inch-pounds.
O-Ring
Mounting
Holes
6. Proceed to Page 7 for wiring instructions.
NOTE: If a POD Extension Kit is required, it must be
installed prior to installation of the POD. This is addressed
on Page 6.
O-Ring Position & Mounting Holes
Mounting
Holes
Mounting Holes
5
Installation
Installing the POD Extension
The POD Extension is used when the meter has an
integral counter adapter bracket or for high temperature
applications. The POD Extension is used to extend the
connection away from the meter.
There are four POD Extension models available.
49754:
Fork Drive with Buna-N O-Ring
(Use with POD1 or POD5)
49756:
Fork Drive with Teflon O-Ring
(Use with POD2)
49757:
Blade Drive with Buna-N O-Ring
(Use with POD1 or POD5)
49759:
Blade Drive with Teflon O-Ring
(Use with POD2)
NOTE: Regardless of the POD Extension being used,
the POD Pulser must be a FORK drive pulser.
Once the existing hardware has been removed as
described on Page 4, the POD Extension can be installed.
1. Verify that the proper POD Extension Model was
obtained by comparing the driver tang on the POD
Extension to the driver tang on the packing gland that
was removed in Step 5 of Removing Existing
Hardware on Page 4. There are two types of Packing
Gland/POD Extension driver tangs: blade type and
fork type. Blade type packing glands must be
replaced with blade type POD Extensions. Fork type
packing glands must be replaced with fork type POD
Extensions.
2. Install the POD Extension using the two screws
provided. There are two sets of holes in the POD
Extension for these screws; one set is 1.625” apart
and the other is 1.5” apart. Line up the holes with the
meter to determine which set to use. Tighten the
screws and torque them to 21-25 inch-pounds.
3. Once the POD Extension is in place, the POD may
be installed onto the POD Extension. Align the POD
Fork Tang with the internal POD Extension Driver.
Use the two screws provided to mount the POD to
the POD Extension using two of the tapped holes in
the POD Extension. Using a 7/32” box end wrench,
tighten the screws and torque them to 21-25 inchpounds.
Pod
Extension
Driver
4. Proceed to Page 7 for wiring instructions.
6
Installation
Wiring the POD
Plug the terminal block back into the board if it was
removed. Be sure it is properly oriented with the four
pins.
Wiring Conduit System
When wiring the POD, the wires must enter through the
POD’s conduit hub. For explosion proof rated systems
(Class I, Div 1.), the wiring must be in rigid conduit that is
rated for explosion proof installation. The conduit must
be engaged five (5) full threads into the female hub on
the POD to meet explosion proof requirements.
Wiring Configurations
The wiring configuration used depends on the system
needs. The POD can be wired using only one of the two
channels (Channel A or B) if the flowmeter has flow in
only one direction. To detect both forward and reverse
flow, both channels, which are in quadrature to each other,
must be used. Channel A will lead Channel B by 90º in
one flow direction and Channel B will lead Channel A in
the reverse direction. Quadrature is required in most
Weights & Measures approved installations.
When installing in a Division 2 location, use either rigid
conduit, flexible conduit, or no conduit. When no conduit
is used, the instrument cable must be brought into the
POD conduit hub using a cable gland to seal the wiring to
maintain the Enclosure NEMA 4X rating. Regardless of
the type of connection used, thread sealant should be
applied to prevent moisture from getting into the POD
electrical housing.
Conversion to Open Drain Output
As supplied by the factory, the POD has a 1.0 KΩ pull-up
resistor to the positive power supply on each output
transistor. The unit can be modified in the field to provide
true Open Drain (Open Collector) outputs if desired. To
modify the POD to Open Drain outputs, follow these steps.
Wiring Cable
Multi-wire cable with an overall shield is recommended
for POD wiring. Use individual wires between 16 and 20
AWG or shielded cable no less than 22 AWG.
Cable runs up to 5000 ft (1524 m) are possible, however
cable runs over 200 ft (61 m) should use lower AWG wire
to reduce the IR voltage drop and the inter-wire
capacitance. In addition, long runs may require a lower
value pull-up resistor due to the additional cable
capacitance that the pulser must drive. Cable that has a
metalized foil plastic shield with a drain wire is
recommended over cable with woven shields because it
is easier to terminate the drain wire type cable.
1. Turn off power to the unit and remove the cover by
turning it counterclockwise.
2. Loosen the three circuit board mounting screws using
a Philips screwdriver. Remove the entire circuit board
assembly from the POD housing.
3. Clip out R1 and R2 using a sharp, diagonal cutter.
4. Reassemble the unit.
Signal Output
The diagram below shows the voltage output for a
clockwise rotation of the Pulse Output Device (POD) with
Channel A leading Channel B. For reverse flow
applications (counterclockwise) Channel B leads Channel
A.
Terminal Block
Removing the cover of the POD will expose a 4 position
terminal block for connection to the user’s electrical
system. The terminal block can be unplugged from the
board for ease of wiring. Pull it straight up to remove.
The terminal block screws require a straight blade
screwdriver with a tip less than 1/8” wide. Before inserting
wires into the terminal block, strip ¼” of insulation off each
wire. Turn each terminal screw counterclockwise a few
turns to make sure that the wiring slot is fully open to
accept wire. Insert the stripped end of the wire and tighten
the terminal block screw.
7
Wiring Diagrams
(For PODs with Serial Number 04-24531 and higher)
Single Channel Applications (405LR/414LR)
Description
Power
Channel A or B
Ground
Shield Wire
POD: J1 Terminal
20
21 or 22
23
No Connection
405LR/414LR Terminal
11 (+12 VDC)
9
12
Earth Ground Screw
Dual Channel Quadrature Applications (LectroCount LCR, LCR-II™, & LC³)
Description
Power
Channel B
Channel A
Ground
Shield Wire
POD: J1 Terminal
20
21
22
23
No Connection
LCR, LCR-II™: J8
31
34
33
38
J6-13
LC³: J3
19
17
18
15
14
Wiring Information
1 Use metallic conduit with individual wires or use 3 conductor, 22 AWG, shielded cable.
2 Strip 1½” off of outer sheathing. Remove exposed shield and drain wire and then tape.
3 Strip ¼” insulation from each conductor and connect to the terminal blocks.
8
Illustrated Parts Breakdown
POD Assemblies
Item No.
4
5
8
Description
Screw, #10-24 x .625
Screw, #10-24 x .625
Screw, #8-32 x .625
Part No.
09079
40107
08192
POD Internal Components
Item No.
1
2
3
4
5
6
7
8
9
10
11
Description
PC Board Assembly
Cover Assembly
Housing Assembly
Drive Assembly
Screw #10-24 x .625
Hub Magnet Assembly
O-Ring, Buna-N
Screw, #5-40 x .125
O-Ring, Buna-N or Teflon
Screw, #6-32 x .375
Hub Magnet Assembly
Model No.
Item No.
1
2
3
4
6
7
8
9
10
11
POD1
Part No.
81794
81164
N/S*
81165
N/S*
09212
09211
06856
08177
81159
Part No.
(See Below)
POD2
POD3
POD4
POD5
81794
81164
N/S*
81165
N/S*
09212
09211
09151
08177
81159
81794
81164
N/S*
81172
N/S*
09212
09211
06856
08177
81159
81794
81164
N/S*
81172
N/S*
09212
09211
09151
08177
81159
817941
81164
N/S*
81165
N/S*
09212
09211
06856
08177
501241
*N/S = Not for Sale
9
Illustrated Parts Breakdown
POD Extension
Models 49754 & 49756
Item No. Description
1
Pulser Extension Driver
2
Pulser Housing
3
Screw, #10-24 x 2.00
4
Dowel Pin
5
O-Ring, Buna-N (49754)
O-Ring, Teflon (49756)
6
Mag Bearing
7
Fork Driver
8
Fork Drive Shaft
Part No.
N/S*
N/S
09228
N/S
06856
09151
N/S
48282
N/S
*N/S = Not for Sale
10
Illustrated Parts Breakdown
POD Extension
Models 49757 & 49759
Item No. Description
1
Pulser Extension Driver
2
Pulser Housing
3
Screw, #10-24 x 2.00
4
Dowel Pin
5
O-Ring, Buna-N (49757)
O-Ring, Teflon (49759)
6
Mag Bearing
7
Blade Driver
8
Roll Pin
9
Drive Blade
Part No.
N/S
N/S
09228
N/S
06856
09151
N/S
N/S
06051
40812
*N/S = Not for Sale
11
A Unit of IDEX Corporation
105 Albrecht Drive
Lake Bluff, IL 60044-2242
1.800.458.5262 • 847.295.1050
Fax: 847.295.1057
www.lcmeter.com
© 2004 Liquid Controls
Pub. No. 500003A
(04/04)
Fuelhouse and Commander
Dispenser Control
Technical
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 represented in
the list.
Table 1
Terminal
Connection
Signal Name
Description
Input or Output
Signal Type
TB1-8
AC Power
AC source for AC output control Input
signals.
110VAC referenced to TB1-7
TB1-7
AC Neutral
AC Neutral reference for AC
input control signals.
Input
AC Neutral
TB1-6
Earth Ground
Earth Ground.
Input
Earth Ground
TB4-8
On/Off Lever Signal
Activity signal from the On/Off
lever on the dispenser.
Input
Low Voltage (12V) - Input
from proximity switch
TB1-1
Dispenser Authorize
External signal to the dispenser
authorizing its use.
Input
110VAC referenced to TB1-7.
10mA max load.
TB1-3
Pump Start output
Output from the dispenser that
can be used as a pump start
signal.
Output
110VAC referenced to TB1-7.
100W max load.
TB3-7
Pulse Out (+)
Pulse output. Pulse signal is
referenced to TB5-6. See programming section to configure
for volumetric or penny pulse
output. See reverse for wiring
details.
Output
Open-Collector Drain (DC)
TB3-8
Pulse Out (-)
Reference signal for penny
pulse output. See reverse for
wiring details.
Output
Open-Collector Source (DC)
Dispenser Operation:
AC Inputs:
The CMD dispenser requires both the Dispenser Authorize (TB1-1) and the On/Off Lever to be active for the dispenser to operate. The Dispenser Authorize signal voltage is normally supplied by an external control device such as a card reader or console. If no external Authorize
signal is available, the unit can be set in a ‘stand alone’ mode by turning dip switch position 1 to the ‘ON’ position. See ‘Dispenser Programming” in this manual.
When both signals are active, the dispenser will reset the displays and turn on the Pump Output signal. If the board is set to do a SEGMENT
test on the displays, the solenoid will open after a 5 second display. If no segment test is done, the solenoid will open when the Pump Output
signal becomes active. If either control 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 can produce a ‘Penny Pulse’ or a ‘Volumetric Pulse’ on TB3-7 and TB3-8 during the fueling operation. The Penny Pulse
Output supplies a pulse out for every cent of product dispensed by the system. The Progammable Pulse Output can be set to supply 10 or
100 pulses for every unit volume. See ‘Dispenser Programming’ in this manual for further details.
1/04/99
FH / CMD Pulsers – Wiring detail
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
Pump Measure
Control, Inc.
1070 Nine North Drive
FIELD CONDUIT
ENTRY (DC)
Electrical Specification:
1. Power Supply AC-1, 2 220VAC / 50Hz 5A
2. Permissive IN: 20mA @ 220VAC / 50Hz
3: Pump Start Out: 0.5A @ 220VAC / 50Hz
4. ON/OFF Relay: Dry contact rated 1A VAC
Contact Opens and closes with nozzle
hook handle
1 BLACK / WHITE
AC SUPPLY
(ELEC REWIND MODELS)
2 BLACK / YELLOW
AC SUPPLY
3 WHITE
NEUTRAL
4 WHITE
(ELEC REWIND MODELS)
NEUTRAL
7 BROWN
PERMISSIVE IN
8 ORANGE
PUMP START OUT
9 RED / BLACK
ON/OFF Relay Contact
10 RED / YELLOW
ON/OFF Relay Contact
11 BLUE
PULSE OUTPUT +
12 WHT / BLUE
PULSE OUTPUT -
6 GREEN
5 GREEN
MAIN
JUNCTION
BOX
NO. DISCRIPTION
AC CONNECTIONS
1
FIELD CONDUIT
ENTRY (AC)
220 VAC / 50Hz
2 220 VAC / 50Hz
3 NEUTRAL
4 NEUTRAL
5 EARTH GROUND
6 EARTH GROUND
7 PERMISSIVE IN
8 PUMP START OUT
9 ON / OFF Relay Contact
10 ON / OFF Relay Contact
DC CONNECTIONS
11
PULSE OUTPUT +
12
PULSE OUTPUT FUELHOUSE TERMINAL
WIRE DESCRIPTIONS
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-01A65.6
DATE:
DRAWN BY:
11/20/01
CAT
SCALE:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
L1
FIELD CONDUIT
ENTRY (AC)
Line Voltage
L2
1 BLACK / WHITE
2 BLACK / YELLOW
3 WHITE
EGND
4 WHITE
EARTH GROUND
HIGH CURRENT
CONTACTS FOR
PUMP OPERATION
HIGH CURRENT
CONTACTS FOR
PUMP OPERATION
7 BROWN
PUMP START OUT
8 ORANGE
9 RED / BLACK
10 RED / YELLOW
PULSE PER PENNY OUTPUT +
PULSE PER PENNY OUTPUT -
CONTROL
COIL
L2
FIELD CONDUIT
ENTRY (DC)
11 BLUE
12 WHT / BLUE
MAIN DISPENSER
JUNCTION BOX
Pump Control Contactor
Coil Voltage Rated for
(L1 - L2) VAC
Pump Control Signal from dispenser
is switched to L1 to activate pump
via the Pump Control Contactor
1. WIRING REVISION
NO.
1/1/04
DESCRIPTION
DATE
REVISIONS
NOTES:
1. Ellipses represent conduit openings (groupings) within the junction box.
2. Wire colors for field wiring are unknown.
3. Operating Voltage Standard 120VAC / 60Hz, 1Phase. OPTIONAL: 220VAC / 50Hz, 1 Phase.
4. DIP Switch #1 must be in the ON position for Stand Alone operation
FUELHOUSE and CMD
STAND ALONE WIRING
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-06A213.1
DATE:
DRAWN BY:
CAT
11/20/01
SCALE:
PART NO:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
NO
1
2
3
4
5
6
7
9
9
10
11
6
5
PART NO
50-XIF030603
SS234-35-36
820
M7A1 w/POD
AS-EF8210G100V
40-9915.0232
40-9915.0333
NB-1A
40-ROLLER-3
DESCRIPTION
3:1 GEAR REDUCER
MAIN JCT BOX
2" HOSE REEL ASSY
2 ELEMENT FILTER ASSY
2" LC METER w/ PULSER
ELECTRONICS HOUSING
2" SOLENOID VALVE
115VAC/60Hz EX PROOF MOTOR
230VAC/50Hz EX PROOF MOTOR
NOZZLE BOOT ASSY
HOSE ROLLER ASSY
4
7
3
10
9
2
11
1
CMD-701-MA-8M
INTERNAL LAYOUT
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-10G322
DATE:
DRAWN BY:
7/14/03
CAT
SCALE:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
DALLAS
RESET
PMC
CPU BOARD
P/N: 120000
TB-3 DC
TB-1 AC POWER
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
Connection
External Permissive Input
Dispenser Handle Input
Pump Start Output
Solenoid #1 Output
Solenoid #2 Output
Earth Ground
AC Neutral
AC Power
MADE IN U.S.A.
Type
Input
Input
Output
Output
Output
Input
Input
Input
TB-2 RELAY CONTACT
Terminal
Connection
1.
Nozzle Switch Relay Contact Normally Open
2.
Nozzle Switch Relay Contact Common
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
Connection
+12 VDC Power Supply
DC Ground
+12 VDC
DC Ground
Meter Pulse Input (Channel A)
Meter Pulse Input (Channel B)
DC Pulse Out +
DC Pulse Out -
Type
Input
Input
Output
Output
Input
Input
Output
Output
TB-4 DC
Terminal
1.
2.
3.
4.
5.
6.
7.
8.
Connection
Type
Output
Output
Output
Output
Output
Output
Output
Input
+12 VDC
DC Ground
Display Communications +
Display Communications Volume Pulse Out
+12 VDC
DC Ground
ON / OFF Lever Input
CPU BOARD P/N 120000
TERMINAL DESCRIPTIONS
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-03A44
DATE:
DRAWN BY:
2/28/03
SCALE:
CAT
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
REVISIONS
DESCRIPTION
NO.
NO.
TB1
1
2
3
4
TB2
1
2
3
4
DATE
DISCRIPTION
+12 VDC SUPPLY
DC GROUND (COMMON)
CHANNEL 1
CHANNEL 2
+12 VDC SUPPLY
DC GROUND (COMMON)
CHANNEL 1
CHANNEL 2
110500C FACTOR BOARD
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-03A132
DATE:
DRAWN BY:
9/22/03
SCALE:
CAT
1" = 1"
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
L6
L1
L2
L3
L4
L5
L7
DALLAS
L8
L9
L10
RESET
L11 L12 L13
PMC
CPU BOARD
P/N: 120000
MADE IN U.S.A.
LED INDICATORS
LED Number
L1
L2
L3
L4
L5
L6
L7
L8
L9
L10
L11
L12
L13
Function
Solenoid #2
Solenoid #1
Pump Start Out
Dispenser Handle (AC)
External Permissive
Relay Energized
+12 VDC OK
Pulse Input (Channel A)
Pulse Input (Channel B)
Programmable Pulse Out
Volume Pulse Out
Dispenser Handle Switch (DC)
AC Power Detect
Color
Red
Red
Red
Yellow
Yellow
Red
Green
Yellow
Yellow
Red
Red
Yellow
Yellow
CPU BOARD P/N 120000
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
91-03A45
DATE:
DRAWN BY:
2/28/03
SCALE:
CAT
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
7 BROWN
DISPENSER HEAD
8 ORANGE
15 RED
6 GREEN
3 WHITE
1 BLACK / WHITE
9 RED / BLACK
10 RED / YELLOW
DISPLAY BOARD
BLACK
WHITE
WHITE
BLACK
105-132
VAC
PMC
CPU BOARD
P/N: 120000
- +
RED / YELLOW
DALLAS
RESET
TB1- 1 2 3 4 5 TOTALIZER
RED
BLACK
YELLOW
PURPLE
DALLAS
PS-12
POWER SUPPLY
MADE IN U.S.A.
WHT / OR
12 WHT / BLUE
BLACK
11 BLUE
BLACK
RED
ORANGE
BLACK
BLACK
REEL
SWITCH
2 BLACK / YELLOW
18 PURPLE
16 PURPLE / WHT
17 LIGHT BLUE
6 GREEN
1/2" CONDUIT
TO PULSER
25 RED
26 BLACK
21 WHITE / ORANGE
19 GREEN
24 RED
3/4" CONDUIT
TO HEAD
20 BLACK
23 ORANGE
22 WHT / ORANGE
2 BLACK / YELLOW
18 PURPLE
16 PURPLE / WHT
17 LIGHT BLUE
9 RED / BLACK
10 RED / YELLOW
7 BROWN
8 ORANGE
15 RED
1 BLACK / WHT
3 WHITE
6 GREEN
11 BLUE
12 WHT / BLUE
13 ORANGE
14 WHT / ORANGE
19 GREEN
CMD-701-MA-8M
HEAD WIRING DIAGRAM
1/2" CONDUIT
TO SWITCH
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
DRAWING NUMBER:
FAX 770-667-0476
91-10G347
DATE:
7/14/03
DRAWN BY:
CAT
SCALE:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
3/4" CONDUIT
TO HEAD
26 BLACK
21 WHITE / ORANGE
25 RED
19 GREEN
20 BLACK
23 ORANGE
22 WHT / ORANGE
24 RED
2 BLACK / YELLOW
18 PURPLE
16 PURPLE / WHT
17 LIGHT BLUE
9 RED / BLACK
10 RED / YELLOW
7 BROWN
8 ORANGE
15 RED
1 BLACK / WHT
3 WHITE
6 GREEN
11 BLUE
12 WHT / BLUE
13 ORANGE
14 WHT / ORANGE
VAPOR BARRIER
1/2" CONDUIT
TO SWITCH
1/2" CONDUIT
TO PULSER
21 WHITE / ORANGE
26 BLACK
25 RED
NOZZLE
SWITCH
19 GREEN
20 BLACK
GND
CHB
CHA
+VDC
22 WHT / ORANGE
23 ORANGE
24 RED
POD
METER
PULSER
SOLENOID
26 RED
27 RED
GREEN
15 RED
4 WHITE
5 GREEN
16 PURPLE / WHT
1 BLACK / WHITE
2 BLACK / YELLOW
3 WHITE
4 WHITE
5 GREEN
7 BROWN
8 ORANGE
9 RED / BLACK
10 RED / YELLOW
6 GREEN
11 BLUE
12 WHT / BLUE
13 ORANGE
14 WHT / ORANGE
MAIN
JUNCTION
BOX
17 LIGHT BLUE
18 PURPLE
1 2 3 4 5 6
MOTOR
J-BOX
REEL
MOTOR
FIELD CONDUIT
ENTRY (DC)
FIELD CONDUIT
ENTRY (AC)
115VAC
NEUTRAL
PERMISSIVE IN
PUMP START OUT
ON/OFF LEVER SWITCH (NO)
EARTH GROUND
PULSE OUTPUT +
PULSE OUTPUT -
CMD-701-MA-8M
LOWER UNIT WIRING DIAGRAM
Pump Measure Control, Inc.
1070 Nine North Drive, Suite 100
Alpharetta, GA 30004
PH. 770-667-0667
FAX 770-667-0476
DRAWING NUMBER:
91-10G348
DATE:
7/14/03
DRAWN BY:
CAT
SCALE:
NTS
"THIS DRAWING CONTAINS PROPRIETARY
INFORMATION AND IS SUBJECT TO
COPYRIGHT OWNERSHIP BY PMC, INC"
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