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RDRMANUAL

DIESEL & GASOLINEREFUELERS & DISPENSERS

Since 1924

P.D. McLAREN LIMITED

INTRODUCTION

The RDR Dispenser is designed and manufactured in Canada by P.D. McLaren Limited since 1978. Built to provide the Petroleum Industry with a reliable

electronic refueller for dispensing petroleum products.

RDR DISPENSER SPECS

High (up to 225lpm) HS series and Low Speed (up to 90lpm) LS series Commercial Refuelers:All units come standard with following:Double Skin construction with the internal frame made of satin coat steel #4 Finish Brushed Stainless Steel outer shell (Sides and top)Powder coated lower doors and bezelsHeavy Duty Aluminum Swing Style Operating HandlesHeavy Duty Aluminum Drip Collector Nozzle Boots Internal Piping schedule 40 welded, NPT pipe thread and/or flangedKraus Micon 500 Electronic register with back lighted LCD displaysPulse Output Interface1-1/2" positive displacement oscillating piston flowmeter for HS series1” positive displacement piston flowmeter for LS series

Available Options:ATCFlow SwitchProgrammable Pulse outputs3 window display ($, Litres, Price Per Litre)Volume Only DisplaySelf-Contained suction Dual Hose Dual and Single Product configurationsCombination High and Low Speed UnitsSatellite Internal Feed and controlStainless Steel lower doors and bezelsGilbarco/ Tokheim/ MNET/ RS422 Communication Options

ELECTRICAL TECHNICAL DATA

Electronic Computer Type – Micon 1001 with Optional ATC Automatic Temperature Compensator

(Tested at 25oC unless otherwise noted)

Power Consumption (Operating)

- @ 25oC- @ -40oC

90 – 120 VAC @ .4 amps max90 – 120 VAC @ .4 amps max

Motor Control Output - Up to 15 amps @ 120 VAC continuous

Solenoid Control Output - Up to 1 amp @ 120 VAC continuous

Penny Pulser Output** - Solid State Switch 5 – 30 VDC @ 100ma Max. RS<40 ohms pulser width 7.5m sec.

Volume Pulser Output** - As above except 1 pulser per .1 unit

Authorize Input - 90 – 125 VAC @ 80 ma max.RIN = 2.7k ohms typical

Battery Life in Power Fail Mode - 200 hours minimum

** Actual pulse output may lag actual delivery time depending on delivery rate (see pulsewidth specfication). If delivery rate exceeds minimum pulse width specification,pulses will be stored and will eventuallly be given. Storage rollover will occur at +9999pulses stored.

FUNCTION: Operating Temperature - 55 oC to + 50 oCR.H. 5 to 1005 non condensing

- 50 oC to +70 oCR.H. 50% Maximum

- 50 oC to 70 oCR.H. 25% Maximum

- 40 oC to +50 oCR.H. 50% Maximum

Standing Temperature (1 Day)Storage Temperature (3 Days)Storage Temperature (Indefinite)

DISPLAYS (LCD):

- Viewing angle +/60 nominal- Dollar volume up to 9999.99 per sale +.5 cents maximum- Unit volume up to 999.999 per sale: .004 units metric +/- .001 units normal- Total dollar volume up to 999999.99 before rollover- Total unit volume up to 999999.99 units before rollover- Price set 0 to 9.999 per unit

RDR Pump and Dispenser Commissioning:

Customer_ Location_

Equipment Required :

Micon Communicator, Micon InfoPac, PROVER (Test Measure) . Multimeter.

Procedure:

1. Verify all wiring is connected per wiring diagrams for the units.Check handle and pulser drive shafts.

2. Ensure control power and head power are on the same phase, and from separate breakers.3. Apply power and test the operation of all units. When starting up the units

Pinch the nozzle to minimize flow until the air is purged from the supply lines and hoses. Check internals for leaks, repairSwitch ON inspection switch and use a 20 litre test pail to verify the volumetrics and provide data according to the table provided below. IE: Test pail versus register versus Cardlock reading. On high speed units ie over 100 lpm, a 250 L prover is required for testing. Switch the inspection switch back OFF. Check for wiring feedback by cross testing all hoses on same

pump/STP.

4. Turn over test results including cardlock receipts to owner and sign form. Provide a copy to customer and to P.D. McLaren Limited.

# 1

2345678910

Model Unit # Register Volume L Test Pail L Cardlock L

Signed Technician Signed Owner

Company Company

The dispenser is shipped with the battery turned off. Do not turn the battery on, until 120V is appliedto terminals 1 and 2. If the battery is allowed to drain completely, it cannot be recharged and willhave to be replaced.

After the wiring has been completed, you must change the handle shaft actuator as follows:

(A) Place the actuator shaft in the OFF position (in the OFF position no continuity will be measured between wires No. 14 and O. 15), with no power on.

(B) Remove the cotter pin, which secures the couler assembly to the actuator shaft.

(C) Rotate the acutator shaft 180 Degrees so that the flat side is facing up.(This will activate a micro switch which will energize the battery.)

IMPORTANT NOTE

P.D. McLAREN LIMITEDwww.pdmclaren.com

PHONE: FAX:

(604) 437-0616(604) 434-9120

AUTHORIZATION NUMBER

SERVICE REPORT

CONTRACTOR: DATE OF SERVICE:

IMPORTANT: THIS SERVICE REPORT MUST ACCOMPANY ALL RETURNED PARTS ALSO A DUPLICATE REPORT MUST BE PRESENT WITH THE WARRANTY INVOICE.

EQUIPMENT IDENTIFICATION EQUIPMENT LOCATION

MODEL: NAME:

SERIAL NUMBER: STREET:

DATE OF INSTALLATION: CITY: PROVINCE:

REPORTED PROBLEM:

CORRECTIVE ACTION:

WARRANTY INVOICE BREAKDOWN (IF APPLICABLE)

TOTAL KM’S: TOTAL HRS:

TRAVEL, CENTS PER KLM: RATE PER HR:

TOTAL $ AMOUNT: TOTAL $ AMOUNT:

CUSTOMER SIGNATURE:

CUSTOMER/CONTRACTOR COMMENTS:

CONTRACTOR SIGNATURE: NAME OF P.D. MCLAREN REP. CONTACTED:

http://www.pdmclaren.com/

ELECTRICAL

MOTOR CONNECTIONS

Connect power supply of proper voltage and frequency to motor.

For motors with a connection diagram on nameplate or decal, refer to them for proper connections.

For motors with two terminal posts, connect one power line to each lead.

For motors with unused speed tap leads, insulate each unused lead separately.

Motors rated at 230 Volts will operate satisfactorily on 208 Volt systems.

Figure 2

Wire Size For 115 & 230 Volt Single Phase Circuits

Distance – Motor To Fuse Or Meter Box -- Feet

Motor HP

100 Ft. 200 Ft. 300 Ft. 500 Ft.115V. 230V. 115V. 230V. 115V. 230V. 115V. 230V.

1/4 #14 #14 #10 #12 #8 #10 #6 #81/3 #12 #14 #10 #12 #6 #10 #4 #8½ #10 #12 #8 #10 #6 #8 #4 #6¾ #10 #12 #6 #10 #4 #8 #2 #61 #8 #10 #6 #8 #4 #6 #4

1 – ½ #4 #10 #0 #8 #6 #42 #8 #6 #4 #2

INSTALLATION GUIDELINES

PIPING AND INSTALLATION

INSTALLATION INSTRUCTION

1. GENERAL:

Locate the pump and the tank as close together as possible. It is recommended, that the totalsuction lift (verticle lift plus suction line resistance) should not exceed 12’ when pumpinggasoline. (15’ when pumping diesel fuel).

If the pump is to be used with an above ground storage tank, a special solenoid valvearrangement is required on the suction side of the pump. Consult the nearest RDRRepresentative for details.

2. FOUNDATION:

In constructing the pump island, make sure you box around the suction pipe under the pump.To provide for future servicing of the suction line and line check valve if one is located at thispoint. Fill this boxed in section with dry sand to keep condensation in the pump housing to aminimum. Anchor bolts should be provided and the pump firmly bolted to the pump island. Werecommend a spill containment box. Example: Containment Box Models RDR CB1 or CB2.

3. SUCTION LINE (UNDER THE PUMP):

(A) Use new 2” pipe and make sure it and the tank is clean. Make sure all threads are properly cut and the inside reamed to remove burrs. Use gasoline-resistant pipe compound in male threads only; pipe compound used on female threads can be squeezed in to the suction line where it can enter thepoduct stream and become lodged in the pump or meter. Install swing joints under the pump and at the tank to avoid breaks in the suction line from settling or frost heave.

(B) Fiberglass pipe is preferred over steel. We recommend a flex connector be used under the pump. SEE TYPICAL LAYOUT – PAGE 12.

4. To avoid product vaporization problems, it is important, there are no traps in the suction line.The suction line should go straight down beneath the pump to an elbow 18” below ground leveland pitch down to the storage tank. The suction line should be as short as possible. Supportthe horizontal run of pipe on a compacted sand bed or on pea gravel for fiberglass pipe.

5. A suction line check valve is required for the HS-1. An angle check valve can be installed at the top of the tank or a line check valve directly under the pump. The type and location of this valve should be provided with an extractor assembly.

IT IS RECOMMENDED THAT THE CHECK VALVE BE PRESSURE RELIEVED BACK TO THE TANK.

6. Before testing, remove any water in the tank through the fill opening with a pump suitable for this service. Do not use the RDR Pump to remove the water from the tank. Do not use a Submersible Pump on water either.

To test the pump system, a sufficient volume of product should be put into the storage tank to ensure that the liquid level is above the bottom of the suction pipe. Operate thePump several times, to be sure of satisfactory performance. Voltage readings should betaken while the pump is operating on bypass and while making a delivery. Any voltage drop in excess of 10% during pump operation should be considered a low voltage condition and corrective action should be taken to ensure an adequate power supply to the pump. After determining that the pump is operating satisfactorily and the system is fully primed, check the pump and piping to make sure that all connections are tight.

POST INSTALLATION CHECK

After rotating the actuator and checking all wiring connections the correct operation should be as follows: (SEE PAGE 4 ELECTRICAL INSTALLATION)

1) Turn on the 120 Volt head power circuit and observe that volume and dollars displays show slowly flashing zeros.

2) Enter a price described in Section C. (PAGE 25)

3) After entering a price restore the 120 Volt head power.

4) Place the pump handle in the OFF position. Turn on pump motor power and ensure that the pump motor does not run and that no product can be dispensed.

5) Place the handle switch in the ON position. The pump motor should run and/or the solenoidvalve should energize. The displays should flash to all 8’s momentarily and then return tozero.

6) Dispense a convenient amount of product into a test tank and check that the head displays the proper volume and dollars amount.

7) Place the pump handle in the OFF position and ensure that the pump motor and/or solenoid shuts off.

This completes the POST INSTALLATION check. If the unit does not function as described on the previous page contact your Factory or Service Representative.

***NOTICE***

When this unit is used in retail trade, Weights and Measures should be notified of theinstallation or service of this unit. This unit is subject to inspection upon installation and atsuch other times as the regulations state. When electronic calibration or A.T.C. is used, theenclosure cover must be sealed by an inspector and the unit must be re-inspected, if the sealis broken.

STRAINER CHECK:

Check the strainer regularly, and clean when necessary. The strainer should also be checked if the pump flow rate begins to drop.

PUMP VACCUM CHECK:

With the pump in-operative, install a vacuum gauge on the suction side of the pum using pipe dope on the threads. Block the suction line and start the pump. If it does not, check for air leaks in the seal andgasket.

Open the suction line and read the vaccum gauge with the pump primed and at operating speed. Shut off the pump and read the gauge again to determine if the vacuum remains at the maximum developed by the pump. If the vacuum falls off rapidly, an air leak exists, check to make certain that the air leak is not from vacuum gauge connection.

PRIMING:

Install the pump and piping as described in “INSTALLATION”. Make sure that the piping connections are tight and that the pump is securely mounted. Check the pump is properly lubricated.(SEE LUBRICATION in MAINTENANCE AND REPAIR).

***CAUTION***

NEVER OPERATE THIS PUMP, UNLESS THE VOLUTE (CAVITY AROUND IMPELLER) ISFILLED WITH LIQUID. THE PUMP WILL NOT PRIME WHEN DRY. EXTENDED OPERATION OFA DRY PUMP WILL DESTROY THE SEAL ASSEMBLLY.

FILL WITH LIQUID:

A) When the pump is being put into service for the first time.

B) When the pump has not been used for a considerable length of time.

C) When the liquid in the volute housing has evaporated.

When the volute housing is full, pump will prime and reprime as necessary.

To fill the volute, remove the fill plug at the top of the volute housing and add clean liquid.Be certain to reinstall the fill plug before operating the pump.

***WARNING***

AFTER FILLING THE VOUTE HOUSING, DO NOT ATTEMPT TO OPERATE THE PUMP UNLESSTHE FILL PLUG AND ALLCONNECTINGPIPING IS SECRELY INSTALLED. OTHERWISE,LIQUID IN THE PUM FORCED OUT UNDER PRESSURE, COULD CAUSE INJURY TOPERSONNEL. PRIMING PLUG MAY BE REMOTE FROM VOLUTE CHAMBER.

SERVICE

HS1 – PUMP MAINTENANCE

TROUBLE: PUMP FAILS TO PRIME

POSSIBLE CAUSE: a) Air leak in suction lineb) Lining of suction hose collapsedc) Leaking or worn seal or pump gasketd) Suction lift or discharge head too highe) Loose inlet union

PROBABLE REMEDY: a) Correct leakb) Replace suction hosec) Check pump vacuum. Replace leaking or worn seal or gasket

TROUBLE: PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

POSSIBLE CAUSE: a) Air leak in suction lineb) Suction intake not submerged at proper levelc) Lining of suction hose collapsedd) Impeller or other moving parts worn or damagede) Impeller cloggedf) Suction lift too highg) Strainer cloggedh) Leaking or worn seal or pump gaskets

PROBABLE REMEDY: a) Correct leakb) Check installation and correct as neededc) Check submergence chartd) Replace suction hosee) Replace worn or damaged partsf) Check that impeller is properly centered and rotates freelyg) Free impeller of debrish) Reduce suction lifti) Check strainer and clean if necessaryj) Check pump vaccum. Replace leaking or worn seal or pump gaskets

TROUBLE: EXCESSIVE NOISE

POSSIBLE CAUSE: a) Cavitation in pumpb) Pumping entrained airc) Pump or drive not securely mountedd) Impeller clogged or damaged

PROBABLE REMEDY: a) Reduce suction lift and/or friction losses in suction lineb) Locate and eliminate source of air bubblec) Clean out debris; replace damaged parts

-Page 64-

HS1 AND HS2 METER MAINTENANCE

ERRATIC REGISTRATION

Erratic registration is an indication of trouble in the system caused by air or dirt in the measuring chamber. Do not try to correct this by recalibrtion of the meter, but first check over the piping for air leaks, clean the strainer and then if the trouble has not been found, clean the meter. If this does not correct the trouble, check for faulty installation.

Over-registration is an indication of air, whereas under-registration is generally caused by direct or pipe scale in the measuring chamber, or the liquid by-passing the meter in some manner.

CONSISTENT OVER OR UNDER REGISTRATION

When the meter registers consistently either more or less than is delivered, the calibration may be corrected.

MEASURING CHAMBER

TO REMOVE AND DISASSEMBLE

This operation is not difficult and may be performed by an competent mechanic. No special tools arerequired. No trouble need be expected, if these few simple, but important directions are followed. Donot open the meter until you have checked over all other possible causes of erratic registration.

1. Prepare a clean surface on which to place the parts as they are removed. The parts aremachined to close tolerances and should be handled with care. Have a replacement gasketready before opening the meter.

2. Remove the meter cover taking care not to damage the gasket.

3. Lift the measuring chamber from the meter casing.

4. Remove the upper cylinder head by inserting a screw driver in one of the slots provided and prying it off. Be careful not to scratch or nick any part of the chamber.

5. Lift out the pisten by it’s spindle. If care is taken to draw it straight, it should come out easily. Do not force it.

6. Remove the control roller and seal pin from the lower cylinder head.

TO REPLACE THE CHAMBER IN THE METER:

Before reassembling the meter, rinse all parts in gasoline. If possible, flush out the meter body.Assemble the parts carefully, they should slide together easily without hammering or forcing. It Isessential that all contact surfaces between the upper and lower cylinder heads and the cylinder, orbetween the measuring chamber and it’s seat in the casing, be clean and free from nicks.

1. Assemble diaphragm and seal pin in chamber if replacement was necessary.

2. Replace the seal pin. Place the control roller on it’s pin and see that it will rotate freely.

3. Replace the piston and oscillate it carefully by hand, it should move easily without binding. If it sticks, do not force it, but remove and locate the cause. Do not file down the roller as this will impair the accuracy of the meter.

4. Replace the upper cylinder head and again oscillate the piston to make sure that it is free.

5. When replacing the measuring chamber in the casing, be sure that the seat is clean and free from nicks. Make sure the dowel pin in the main casing enters the slot in the bottom cylinder head properly and allows the chamber to reset on it’s seat.

6. Before replacing the cover, first be sure the chamber is properly seated and inspect the gasket. Then set the arm of the gear train so that it will not come down on the piston spindle.

7. Make sure that the cover is down on it’s seat before tightening the bolts.

TO REPAIR LEAKING “U” CUP SEAL STUFFING BOX

1. Remove the register (FIGURE 25)

2. Remove the star connection(1), using a No. 8 Allen wrench.

3. Remove the stufffingbox nut (2).

4. Remove shaft seal (3). Inspect upper end of spindle to be sure its free of burrs which might damage tne new shaft seal when it is placed on the spindle.

5. Replace shaft seal with new part. Be sure expander (4) and spring (5) are in position before inerting new seal.

6. Assemble nut and tighten down all the way.

AIR RELEASE VALVE

TROUBLES WITH THIS UNIT MAY ARISE FROM:

(A) Collapsed ball float allowing vent to remain open.

(B) Dirty or worn valve seat.

(C) Improper position of float.

TO IMPACT THIS UNIT:

1. Remove the Strainer (FIGURE 23)

2. Uncouple the vent connection.

3. Remove the cap screws on the air release cover and lift out the mechanism.

4. If the float is damaged, remove by taking out the hinge pins and replace with a new one.

5. If the valve is leaky:

a) Remove the air release unit from the underside of the cover.(by unscrewing three small screws).

b) Take off the sleeve with piston seal.

c) Move the ball in the direction of the valve housing as far as possible and remove valve disc assembly.

d) Inspect piston seal for any obvious deterioration.

e) The valve disk assembly should be taken apart to inspect for dirt or defective pilot valve seat. A pair of fine nose pliers is needed for this. Replace valve if seats are defective.

f) When re-assembling, make sure that the piston seal is properly positioned and that the valve disk assembly moves freely in sleeve.

TO REMOVE BACK PRESSURE VALVE

1. Remove Air Release and Strainer from the line by unbolting at inlet flange and meter inlet.

2. Remove strainer sleeves and air release valve.

3. Remove drain plug.

4. Hold block of wood (1-3/4” diam.) against back pressure valve and knock valve out of housing by means of ½” diameter rod inserted through drain plug hole.

GENERAL METER MAINTENANCE

In the maintenance of the accuracy of RDR Meters, little is necessary other than to see that theproper conditions of operaton are preserved. These conditions, once the pump has been properlyinstalled, consist merely in guarding against foreign matter such as air, sediment and water, enteringthe measuring chamber.

SEDIMENT

The liquid passing through the measing chamber must be free of grit and other forms of sediment inorder to prevent unnecessary friction and the scoring of the piston and chamber walls. Evidence oftrouble from the source is under-registration of the meter.

Periodic cleaning of the strainer at the inlet of the meter will help to ensure against trouble. In thedesign of this unit, particular care has been taken to make this operation as simple as possible.

AIR

Being an instrument which measures by volume, a meter will record the passage of air as well as theliquid being measured. Over-registration is the result. The air release valve is intended to preventthis condition by venting this air before it passes through the measuring chamber.

WATER

Incidental water will cause no damage to the meter. Trouble from this source may be expected onlywhen water is allowed to stand in the meter for considerable periods of time.

TESTING

Test with 250 litres test measure. Do not base calibration on 20 litre measure.

-Page 71-

TO LOCATE TROUBLE

1. REGISTER NOT WORKING WHEN LIQUID IS FLOWING

** Set screw loose, check flat spot on shaft.

LEAKAGE AT THE STUFFING BOX2.

** Loose stuffing box nut or worn spindle.

3. CHRONIC LEAKAGE AT THE METER MAIN CASE GASKET

** Excessive line or shock pressure.** Broken gasket or loose bolts.

4. REDUCTION IN THE RATE OR COMPLETE STOPPAGE OF DISCHARGE

** Pump sucking air.** Air release valve fails to close allowing the liquid to escape out the air vent** Worn pump** Blocked strainer due to sediment or frost ** Piston in meter stuck, caused by dirt. Check strainer and clean measuring chamber.

5. LIQUID LEAKING OUT THE AIR RELEASE VENT

** Worn, damaged or defective valve unit (refer to Red Seal Manual)

6. OVER-REGISTRATION-ERRATIC** Air release valve jamming allowing air to pass through the meter (SEE FIGURE 26)** Vent line from the air release valve plugged causing air to pass through the meter.** Leaks in the suction line such as at valve stems, pump packing, or flange gaskets.** Air pockets in closed-end piping in the suction line.** Manifold valves only partly open causing excessive suction.** Suction piping too small causing excessive suction.

7. UNDER-REGISTRATION-ERRATIC

** Dirt in the measuring chamber** Badly worn control roller or diaphragm** Main casing distorted or damaged** Dirt under the seat of the measuring chamber at the outlet port (after cleaning)** Leakage around the meter due to partly open valve

8. CONSISTENT OVER OR UNDER REGISTRATION

** Meter in need of calibration

KRAUS MICON 500 ELECTRONIC REGISTER

MICON 500 FAULT CODES

CODE DESCRIPTIONC026 Pulser FaultC027 Pulser Buffer Overflow FaultC028 Display Disconnect FaultC029 EEProm Checksum Is BadC030 Excessive Reverse CountsC031 ATC Probe OpenC032 ATC Probe ShortC034 Pulser Voltage LowC035 One Pulse Line MissingC036 Pulser UnrecognizedC037 No Pulser

MICON 500C/H ONLY(CNG)C051 Excess Flow Fault

C076 Pressure Transducer 1 Out of RangeC077 Pressure Transducer 2 Out of RangeC078 Ambient Temperature Probe FaultC079 Gas Temperature Transducer Out of RangeC080 Pressure Transducers 1 and 2 Out of ToleranceC081 Air Purge or Pressure Switch KillC082 Excess Fill Fault

Kraus Global Inc.

25 Paquin Road

Winnipeg, Manitoba

CANADA R2J 3V9

© 2002, Kraus Global Inc.

Publication Number:

234AY09.INS R04

Printed in Canada

Kraus Global Inc.

MICON 500L™

ELECTRONIC REGISTER

INSTALLATION INSTRUCTION MANUAL:

NORTH AMERICAN AND EUROPEAN

THIS IS OUR GUIDE TO INSTALLING THE

MICON 500LM ELECTRONIC

REGISTER DESIGNED TO

SIMULATEMECHANICALREGISTERS

i

TABLE OF CONTENTS

IMPORTANT NOTICES 11.0

2.0 PRE-INSTALLATION CHECK 2

3.0 PHYSICAL MOUNTING CONSIDERATIONS 6

1. HANDLE SWITCH COUPLING 6

2. HANDLE SHAFT ACTUATION 9

3. ACCESSORY MOUNTING KITS 11

4.0 CUSTOMER HARNESS LEAD ELECTRICAL CONNECTIONS 13

1. IMPORTANT WARNINGS 13

2. WIRING DETAIL – MICON 500LN 15

3. MICON 500LN WIRING DIAGRAM 16

4. WIRING DETAIL – MICON 500LE 17

5. MICON 500LE WIRING DIAGRAM 18

6. COMMUNICATION INTERFACE CONNECTIONS 19

7. PULSE OUTPUT CIRCUIT DIAGRAM. 20

8. DUAL TWO PRODUCT DISPENSER WIRING DIAGRAM 21

4.9 DUAL SINGLE PRODUCT DISPENSER WIRING DIAGRAM 22

DUAL TWO PRODUCT / SINGLE PRODUCT DISPENSER WIRING DIAGRAM 234.10

5.0 POST INSTALLATION CHECK 24

6.0 MICON 500L OPERATION 25

1. CONSOLE ASSESSING FOR PRICE CHANGING:MCIU 25

2. READING TOTALIZERS ON A SINGLE TIER DISPENSER 26

1. READING TOTALIZERS ON A SINGLE TIER DISPENSER 26

2. SETTING PRICES ON A SINGLE TIER DISPENSER 27

3. TWO TIER PRICE OPERATION 28

1. TWO TIER OPTION INSTALLATION 28

2. SETTING PRICES ON A TWO TIER DISPENSER 28

3. MAKING DISCOUNT PRICE SALES ON A TWO TIER DISPENSER 29

4. READING TOTALIZERS ON A TWO TIER DISPENSER 29

4. ELECTRONIC AUDIT TRAILS 30

ii

TABLE OF CONTENTS (CONT’D)

7.0 ELECTRONIC CALIBRATOR ADJUSTMENT 31

8.0 AUTOMATIC TEMPERATURE COMPENSATION 34

9.0 PULSER ASSEMBLY REPLACMENT 36

10.0 MICON DISPLAY FAULT CODES 37

11.0 TROUBLE SHOOTING AND REPAIR GUIDE 39

TABLES

1. KRAUS MICON RETROFIT ADAPTOR KIT 11

2. TOKHEIM MICON RETROFIT ADAPTOR KITS 11

3. GASBOY MICON RETROFIT ADAPTOR KIT 11

4. GILBARCO MICON RETROFIT ADAPTOR KITS 11

5. WAYNE MICON RETROFIT ADAPTOR KITS 11

6. ASTRO MICON RETROFIT ADAPTOR KITS 12

7. BENNETT MICON RETROFIT ADAPTOR KITS 12

8. SCHWELM MICON RETROFIT ADAPTOR KITS 12

9. MICON 500LN (NORTH AMERICAN) WIRING DESCRIPTION 15

10. MICON 500LE 230 VAC (EUROPEAN) WIRING DETAIL 17

11. COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LN(NORTH AMERICAN) 19

12. COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LE(EUROPEAN) 19

13. MICON 500L FAULT CODES 37

iii

FIGURES

1. BATTERY OFF ACTUATOR SHAFT POSITION 2

2. COUPLER ASSEMBLY HANDLE OFF POSITION 3

3. INFO-PAC AND CONFIGURATION EVENT COUNTERS ON THE MICON 500L 4

4. RECEIVING DATA FROM MICON 500L 5

5. STANDARD ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION 5

6. INTRINSICALLY SAFE 2 PIN PLUG 8

7. CUSTOMER LEAD EXIT 8

8. ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION FOR

CLOCKWISE ROTATION 9

9. HANDLE SHAFT ACTUATION FOR COUNTERCLOCKWISE ROTATION 10

10. PRICE SETTING USING THE MICON COMMUNICATOR 24

11. DISPLAY DOLLAR AND VOLUME TOTALS 26

12. PRICE SETTING USING THE MICON COMMUNICATOR 27

13. READING TOTALIZERS 30

14. THERMAL WELL LOCATION 34

1.0 IMPORTANT NOTICES

All wiring must be installed in accordance with National and local electrical codes.

SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY.

LA SUBSTITUTION DE COMPOSANTS PEUT COMPROMETTRE LA SÉCURITÉ INTRINSÈQUE.

When this unit is used in retail trade in Canada, Measurement Canada, anagency of Industry Canada, must be notified of the installation or service of thisunit. This unit is subject to inspection upon installation and at such other timesas the regulations may state.

When ATCTM (automatic temperature compensation) is used, a thermal wellmust be provided. In addition to the thermal well and probe fitting, newinstallations will require two BC-256 labels reading "CORRECTED TO 15° C".These labels must be attached to each faceplate of the dispenser and be visibleto the customer. These labels are provided with the MICON 500L, and additionallabels are available upon request.

!WARNING

!ATTENTION

!AVERTISSEMENT

1

2002KRAUS GLOBAL INC. assumes no liability or responsibility whatsoever pertaining to theaccuracy or currency of the information supplied in this manual. Installation of MICON500L™ electronic pumpheads in every case is the sole responsibility of the installerperforming the work. Kraus Global Inc. assumes no liability or responsibility whatsoeverresulting from any type of installation, operation, or configuration, whether performedproperly, improperly or in any other way. The information supplied herein is a guide only.

MICON 500 is a registered trademark of Kraus Global Inc.ATC is a registered trademark of Kraus Global Inc.

2

2.0 PRE-INSTALLATION CHECK

The MICON 500L is a computerized pumphead designed for use with liquid fuel (e.g.,diesel, propane, butane) dispensers.

After carefully unpacking the MICON 500L, inspect for shipping damage. Refer to the optionslabel(s) on the MICON 500L shipping box(es) to ensure the MICON 500L is properly configuredfor the intended application. A preliminary electrical check should be performed as follows:

1. Observe position of the pump handle. The MICON 500L is normally shipped with theactuator shaft in the battery OFF position: flat (beveled) surface on the end of theshaft facing DOWN. Current drain will be negligible, however, if unit shipped withbattery ON.

FIGURE 1 – BATTERY OFF ACTUATOR SHAFT POSITION

2. Battery is ON whenever flat (beveled) side of shaft is facing any direction exceptDOWN. Battery should be ON with flat (beveled) side of shaft facing UP whenhandle OFF.

Prepare handle switch for a preliminary check by positioning shaft and coupler assembly in handle OFF position:

a) Pull cotter pin.b) Rotate the coupler assembly to the desired “OFF” position.c) Rotate actuator shaft until the flat (beveled) side faces UP.d) Re-install cotter pin.

The handle OFF coupler assembly will appear as in Figure 2. Coupler assembly mayrest against stop pin #1 or stop pin #2, as long as flat (beveled) side of shaft facesUP when handle OFF.

battery OFF when flat (beveled) side of shaft facing DOWN

3

2.0 PRE-INSTALLATION CHECK (CONT’D)

3. The MICON 500L digital display can be manually triggered to display configurationevent counter data in the dollar display, model number in the volume display, andsoftware version number in the price display, as shown in Figure 3. To do this:

Flip the handle switch rapidly ON, then OFF. The display will indicate as shownin Figure 3.

The event counter in the dollar display indicates the number of times thesettings have been changed with the INFO-PAC. The INFO-PAC is a hand-held,self-contained battery powered unit designed to monitor and program MICONelectronic pumpheads.

FIGURE 2 – COUPLER ASSEMBLY HANDLE OFF POSITION

COUPLER ASSEMBLY

STOP PIN #1 STOP PIN #2

COTTER PIN

ACTUATOR SHAFT

FLAT (BEVELED) SIDE UP IS HANDLE OFF (BATTERY ON) POSITION

4


MICON 500L Display

4. Figure 3 above indicates the event counter in the MICON 500L dollar display is setto 0001, which means the pumphead has been programmed once already using theINFO-PAC. To check the current configuration of your MICON 500L, use the INFO-PAC receive function, described in the INFO-PAC Programming of MICON 500LPumpheads manual, and outlined in steps a) to d) below:

The RX MICON setting on the INFO-PAC is designed to receive MICON 500L settings from pumpheads which have already been programmed.

To receive information from the MICON 500L:

a) Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON.

configuration event counter in dollar display:

Indicates number of times settings have been changed with the INFO-PAC.

MICON model in volume display:

software version number in price display

INFO-PAC model M500L is designed to configure MICON 500L pumpcomputer heads used to control flow of liquid fuel product from dispensers.

The INFO-PAC is a transmitter and receiver. Programmable pumpheadfeatures can be set up in the INFO-PAC memory, then transmitted to MICONheads. The INFO-PAC also receives and displays features alreadyprogrammed to MICON pumpheads.

INFO-PAC

FIGURE 3 – INFO-PAC AND CONFIGURATION EVENT COUNTERS ON THE MICON 500L

5


The MICON 500L display should be flashing. If display goes blank, unit is insleep (i.e., battery save) mode. To correct this, turn handle ON and OFF.Display will start flashing.

b) Turn INFO-PAC ON by pressing left arrow key. Using up or down arrow key,scroll to INFO-PAC RX MICON option. Set RX MICON on by pressing left orright pointing arrow key.

c) Take INFO-PAC and go to the front display of the MICON 500L electronicpumphead. Locate optical sensor (oval “hole”) at right of price display on MICON500L.

Aim INFO-PAC receiver / transmitter (located behind red tinted filter at centeredge of INFO-PAC) at MICON 500L optical sensor.

Red LED (light emitting diode) to left of MICON 500L price display flashes as INFO-PAC receives data from MICON 500L.

d) When INFO-PAC has received a copy of the MICON 500L setup informationcorrectly, INFO-PAC display will show “Received Micon”. To view each setting,scroll with the up or down arrow key.

FIGURE 5 – “RECEIVED MICON” INFO-PAC DISPLAY

INFO-PAC

MICON 500Lelectronic pumphead display

Aim top of INFO-PAC(red window) at opticalsensor

NO

FIGURE 4 – RECEIVING DATA FROM MICON 500L

6

2.0

7

PRE-INSTALLATION CHECK (CONT’D)

5. Enter a price. See section 6.2.2 – Setting Prices on a Single Tier Dispenser, for adescription of the procedure. Price reading is also described in section 6.2.1 –

Reading Totalizers on a Single Tier Dispenser.

Setting prices and reading totalizers on two tier dispensers is described in sections6.3.2, 6.3.3 and 6.3.4.

6. Note the reading of the mechanical counter. Rotate the input shaft on the bottom ofthe MICON 500L in one direction until the mechanical counter has incremented by1.00 units. On the MICON 500L the volume display should indicate 1.000 units. If thegallon to litre conversion option is used with the MICON 500L, the display shouldindicate 3.780 units. With a MICON 500L using ATC™, the volume display shouldindicate the multiplication factor ("MF") of the ATCTM. For example, if the ATCTM hasan MF of four, the display should indicate 4.000 units.

7. Rotate the coupler assembly back to the original battery-off position. Flat side ofactuator shaft will be facing down.

If any faults are detected during this preliminary check, consult your factory or service representative.

3.0 PHYSICAL MOUNTING CONSIDERATIONS

3.1 HANDLE SWITCH COUPLING

1. The handle switch coupling on the side of the MICON 500L must be connected tothe dispenser handle. In most installations, the dispenser handle can be coupleddirectly to the MICON 500L, without use of an adapter kit. The MICON 500L handleswitch can be turned to the ON position by rotating the actuator shaft 90 degrees ineither a clockwise or counterclockwise direction. The direction of rotation isdependent upon the position of the dispenser handle in relation to the coupler.

To verify correct placement of the actuator, the flat (beveled) side of the shaftshould be in the battery ON position when the dispenser handle is OFF. Thiswill be flat side UP (battery actually is ON in any position except flat sideDOWN).

3.1 HANDLE SWITCH COUPLING (CONT’D)

battery ON when flat (beveled) side of shaft facing UP

FIGURE 5 – STANDARD ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION

COUPLER ASSEMBLY

STOP PIN #1 STOP PIN #2

COTTER PIN

ACTUATOR SHAFT


THE COUPLER ASSEMBLY SHOWN REQUIRES A 90 DEGREE CLOCKWISE ROTATION TO TURN ON.

IF COUPLER ASSEMBLY RESTS AGAINST STOP PIN #1 WHEN HANDLE OFF, ASSEMBLY WOULD REQUIRE 90 DEGREE COUNTERCLOCKWISE ROTATION TO TURN ON.

IN EITHER INSTANCE, FLAT (BEVELED) END OF ACTUATOR SHAFT SNAPS TO POSITIVE OR NEGATIVE 90 DEGREE ANGLE WHEN HANDLE ON AND BATTERY ON.

BATTERY IS ACTUALLY ON WHENEVER FLAT (BEVELED) SIDE OF SHAFT IS FACING ANY DIRECTION EXCEPT DOWN.

8

FIGURE 6

INTRINSICALLY SAFE 2 PIN PLUG

FIGURE 7

CUSTOMER LEAD EXIT

3.1 HANDLE SWITCH COUPLING (CONT’D)

2. If desired, a normally open handle switch can be connected to the intrinsically safe 2pin plug. In this case, the actuating shaft need not be connected and should be leftin the handle OFF position.

3. Customer lead exit, located on the top of the explosion-proof housing, must beconnected to a suitable junction box with rigid conduit (North American only). A sealfitting must be installed between the MICON 500LN and the junction box, and mustbe within 18” of the MICON 500LN.

4. In Canada, Measurement Canada, an agency of Industry Canada, requires that theMICON 500L have control of product flow so that the MICON 500L can stop productflow if a measurement fault is detected. Some dispensers in submersible systemsincorporate a mechanically controlled valve which is not compatible with the MICON500L installation. In such a case an electrically controlled valve would have to beinstalled.

North America: Connectrigid conduit at customer lead exit.

intrinsically safe 2 pin plug located in MICON 500L tub

Battery ON when flat (beveled) side of actuator shaft facing UP.

9

FIGURE 8

ACTUATOR SHAFT AND COUPLER ASSEMBLY POSITION FOR CLOCKWISE ROTATION

2. HANDLE SHAFT ACTUATION

As outlined in the explanation accompanying Figure 5, the MICON 500L handle switch may beswitched ON by rotating the actuator shaft 90 degrees in either direction. As shipped from thefactory, a clockwise rotation of the coupler assembly (as viewed from the coupler side) isrequired to switch the pumphead ON.

If the installation requires a counterclockwise rotation to turn the head ON, see Figure 9 and complete the following steps:

a) Turn the coupler assembly to the desired handle OFF position (i.e., against stop pin#1).

b) Remove the cotter pin which secures the coupler assembly to the actuator shaft.c) Rotate the actuating shaft until the flat (beveled) surface on the end is facing

upwards, and re-install the cotter pin.

THE COUPLER ASSEMBLY SHOWN IS RESTING AGAINST STOP PIN #1 WHEN IN HANDLE OFF (BATTERY ON) POSITION, AND REQUIRES A 90 DEGREE COUNTERCLOCKWISE ROTATION TO TURN ON.

FLAT (BEVELED) END OF ACTUATOR SHAFT IS FACING UP WHEN HANDLE OFF AND SNAPS TO 90 DEGREE ANGLE WHEN HANDLE ON AND BATTERY ON.

COUPLER ASSEMBLY

STOP PIN #1

STOP PIN #2

ACTUATOR SHAFT


COTTER PIN

ON

10

FIGURE 9

HANDLE SHAFT ACTUATIONFOR COUNTERCLOCKWISEROTATION

3.2 HANDLE SHAFT ACTUATION (CONT’D)

Remove cotter pin from coupler assembly after turning the assembly to the desired OFF position.

11

Rotate actuating shaft until flat side of actuator shaft faces UP when handle OFF, then re-install cotter pin.

3.3 ACCESSORY MOUNTING KITS

The installation of the MICON 500L in certain dispensers requires the use of accessory kits.Kits are available for a variety of Tokheim, Gasboy, Gilbarco, Wayne, Astro, Bennett andSchwelm dispensers.

See DS Kit manuals for installation details. The DS kits available for different pumpmanufacturers are:

TABLE 1 - KRAUS MICON RETROFIT ADAPTOR KIT

12

TABLE 2 - TOKHEIM MICON RETROFIT ADAPTOR KITS

TABLE 4 - GILBARCO MICON RETROFIT ADAPTOR KITS

TABLE 5 - WAYNE MICON RETROFIT ADAPTOR KITS

TABLE 3 - GASBOY MICON RETROFIT ADAPTOR KIT

DS KIT NUMBER TYPEDS 18 HLU HANDLE LINK UNIT

DS KIT NUMBER TYPEDS 1 KIT TOKHEIM SINGLE CENTER MOUNT, ELECTRIC RESETDS 2 KIT TOKHEIM SINGLE OFFSET MOUNT, ELECTRIC RESETDS 3 KIT TOKHEIM SINGLE CENTER MOUNT, MECHANICAL RESETDS 4 KIT TOKHEIM SINGLE OFFSET MOUNT, MECHANICAL RESETDS 5 KIT TOKHEIM DUAL, ELECTRIC RESETDS 6 KIT TOKHEIM DUAL, MECHANICAL RESETDS 20 KIT RDR/TOKHEIM HS1, SINGLE CENTER MOUNT (GLASS AND LINKAGE KIT)DS 21 KIT RDR/TOKHEIM HS1 D1, SINGLE OFFSET MOUNT (GLASS AND LINKAGE KIT)DS 22 KIT RDR/TOKHEIM DUAL (LINKAGE ONLY)DS 24 KIT RDR/TOKHEIM DUAL (GLASS AND LINKAGE KIT)DS 25 KIT TOKHEIM DUAL, ELECTRIC RESET, NARROW

DS KIT NUMBER TYPEDS 18 KIT GASBOY 150 AND 153 (NO PANELS)DS 19 KIT GASBOY 53 (NO PANELS)

DS KIT NUMBER TYPEDS 7 KIT GILBARCO SINGLEDS 7L KIT GILBARCO SINGLE (NO PANELS)DS 8 KIT GILBARCO DUALDS 8L KIT GILBARCO SINGLE (NO PANELS)DS 23 KIT GILBARCO 625 (NO PANELS)

DS KIT NUMBER TYPEDS 9 KIT WAYNE SINGLE CENTER MOUNTDS 10 KIT WAYNE DUAL E-732 & 33DS 11 KIT WAYNE SINGLE OFFSET MOUNT

3.3

13

ACCESSORY MOUNTING KITS (CONT’D)

TABLE 6 - ASTRO MICON RETROFIT ADAPTOR KITS

TABLE 7 - BENNETT MICON RETROFIT ADAPTOR KITS

TABLE 8 - SCHWELM MICON RETROFIT ADAPTOR KIT

DS KIT NUMBER TYPEDS 12 KIT ASTRO UNIVERSAL DUAL (NO PANELS)DS 13 KIT ASTRO UNIVERSAL SINGLE (NO PANELS)

DS KIT NUMBER TYPEDS 14 KIT BENNETT DUAL (NO PANELS)DS 15 KIT BENNETT SINGLE OFFSET MOUNT (NO PANELS)DS 17 KIT BENNETT SINGLE CENTER MOUNT (NO PANELS)

DS KIT NUMBER TYPEDS 16 KIT LTS SINGLE SCHWELM METER LPG (NO PANELS)

4.0 CUSTOMER HARNESS LEAD ELECTRICAL CONNECTIONS

4.1 IMPORTANT WARNINGS

!!! IMPORTANT – PLEASE READ !!!

When performing installation or maintenance work of any kind, includingservicing MICON 500L electronic pumphead main boards or using theINFO-PAC to program pumpheads, it is the responsibility of the serviceperson performing the work to ensure:

1. All power to MICON pumphead(s) is turned OFF.

2. All supply of gas to dispenser(s) being serviced is shut OFF.

3. The customer lead exit, located on the top of the explosion-proofhousing, must be properly sealed when exiting into a Division 2 area(North American only). A suitable batting material must first be usedto prevent the sealing compound from entering the housing. The sealmust be a minimum depth of 5/8 inches or the inside diameter of theopening, whichever is the greater.

4. All wiring must be installed in accordance with national and/or localelectrical codes.

5. All unused wires must be capped or otherwise securely terminated.

6. External equipment connected to the customer harness shall notexceed or generate more than 125 VAC for all units with 120 VACrated input or controller outputs.

7. This unit must be connected to an appropriate power source asspecified by the rating nameplate.

8. Independent motor and solenoid power must not exceed the ratingsspecified on the rating nameplate.

9. This unit must be grounded by means of all ground wires provided.

10. The local supply ground to which this device is connected and/orany metal structure upon which this unit is mounted shall be at thesame potential as the I.S. barrier ground.

!CAUTION

14

4.1 IMPORTANT WARNINGS (CONT’D)

11. When this unit is used in retail trade in Canada, MeasurementCanada, an agency of Industry Canada, must be notified of theinstallation or servicing of this unit. This unit is subject toinspection upon installation and at such other times as theregulations may state.

12. When the ATCTM is used, a thermal well must be provided. Inaddition to the thermal well and probe fitting, new installations willrequire two BC-256 labels reading “CORRECTED TO 15° C”. Theselabels must be attached to each faceplate of the dispenser and bevisible to the customer. These labels are supplied with the MICON500L. Additional BC-256 labels are available upon request.

Substitution of components may impair intrinsic safety.

La substitution de composants peut compromettre la sécurité intrinsèque.

KRAUS GLOBAL INC. ASSUMES NO RESPONSIBILITY FOR PERSONAL INJURY OR EQUIPMENT DAMAGE CAUSED BY NON-OBSERVANCE OF SAFETY WARNINGS, OR NON-COMPLIANCE WITH NATIONAL OR INTERNATIONAL LEGAL REGULATORY REQUIREMENTS.

!WARNING

!AVERTISSEMENT

15

4.2

16

WIRING DETAIL: MICON 500LN

TABLE 9 – MICON 500LN 120 VAC (NORTH AMERICAN) WIRING DESCRIPTION REFERENCE: 4.3 WIRING DIAGRAMWire No. Wire Colour AWG# Description

1 BLACK 18 Head power hot line. If the power is interrupted on these lines, the head will go into standby and power fail modes.

2 WHITE 18 Neutral or 240 VAC line 2 for head power and main board authorize/authorize request circuit.

3A & 3B GREEN 14 Ground 1 and ground 2. Connected internally to the casting and must be connected to the service ground.

6 ORANGE 18 Solenoid control output. Used to supply power to a slow flow or cut-off solenoid under MICON control.

7 BLACK 14 Pump motor power input / Solenoid input. Connected to wire #6 and #8 when the MICON is authorized and the handle switch is ON. This circuit must be supplied through a circuit breaker and wiring adequate to power the pump motors.

8 ORANGE 14 Pump motor control output.

14 BROWN 18 Authorize input. Application of 120 VAC will authorize the MICON 500LN to dispense product.

15 GREY 18 Authorize return. When 120 VAC is applied to wire #14, and the handle switch is ON, 120 VAC will be present on this line. If 120 VAC is not present when the handle switch is turned on, the MICON 500LN applies a 2.7 Kn capacitive reactance between this line and wire #2 to serve as an authorize request load for Kraus Group Inc. self-serve equipment.

Low Voltage Lines4 YELLOW 18 Money pulser positive input. Normally connected to the pulser power supply positive

line (+30 VDC Max) and provides power to money pulser line.

5 RED 18 Money pulser negative output. The MICON will source a maximum of 100 mA from the pulser positive (#4) to this line to form a pulse once for each penny of product dispensed.

18 BLUE 18 Volume pulser negative output. Provides a pulse for each specified fraction of a unit of volume (used for card/key systems).

19 WHITE/BLUE 18 Volume pulser positive input. Normally connected to the pulser power supply positive line (+30 volts maximum, DC only), and provides power to the volume pulser line.

Data Communication Lines9 PINK 18 Talk-to-pump. Connected to the appropriate terminal on the “TTP” terminal block of a

MCIU, and carries messages from the console to the pump.

10 TAN 18 Talk-to-console. Connected to the “TTC” terminal block of a MCIU and carries messages from the pump to the console.

16 GREEN 18 Data channel common. Connected to the “DCC” terminal block of MCIU.

17 WHITE / BROWN 18 RS-422 positive receive input.

4.3 MICON 500LN WIRING DIAGRAM

17

4.4

18

WIRING DETAIL: MICON 500LETABLE 10 - MICON 500LE 230 VAC (EUROPEAN) WIRING DESCRIPTION REFERENCE: 4.5 WIRING DIAGRAM

Wire No. 230 VAC Lines - (metric type shielded cable)YEL/GRN Earth. Connected internally to the casting and must be connected to the service ground.

1 230 VAC head power hot line. If power is interrupted on this line, the head will go into standby and power-fail modes.

2 Neutral for head power and main board authorize/authorize request circuit.

3 Motor Output.4 Motor/Solenoid Power5 Solenoid Output.6 Not Used7 Not Used8 Not Used19 Authorize output. When 230 VAC is applied to wire #20 and the handle switch is on, 230 VAC will be present

on this line. (3 Amp. maximum load)20 Authorize input. Application of 230 VAC will “authorize” the MICON to dispense product. If 230 VAC is not

present when the handle switch is turned on, the MICON applies a 14 Kn capacitive reactance between this line and wire #2 to serve as an authorize request load for Kraus Industries Self-Serve equipment.

Wire No. Low Voltage Lines9 Money pulser positive. Normally connected to the pulser power supply positive line (+30 volts maximum, DC

only) and provides power to the money and volume pulser lines.

10 Money pulser negative. The MICON will source a maximum of 100 mA from the pulser common (#9) to this line to form a pulse once for each penny of product dispensed. (Used with KRAUS MONITOR and MICRO consoles.)

11 Volume pulser negative. Provides a pulse (as described above for money pulser) for each specified fraction of a unit of volume. (Used for card or key systems.)

15 Not used.

16 Not used17 Not used18 Not used22 Volume pulser positive. Provides power to the volume pulser line.

Wire No. Micro 2, Concept 5000 & MCIU Data Communications Lines12 Data channel common. This line is connected to the “DCC” terminal block of a MCIU.

13 Talk-to-console. This line is connected to the “TTC” terminal block of a MCIU and carries messages from the pump to the console.

14 Talk-to-pump. This line is connected to the appropriate terminal on the “TTP” terminal block of a MCIU and carries messages from the console to the pump.

21 RS-422 positive input.

4.5 MICON 500LE WIRING DIAGRAM

19

4.6 COMMUNICATION INTERFACE CONNECTIONS

Tables 12 and 13 below describe communication interface connections for the following interface options:

• Tokheim Interface• Gilbarco Interface• Tatsuno Interface• RS-422 Interface• RS-232 Interface• Kraus MNET Interface

20

TABLE 11 – COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LN (NORTH AMERICAN)

TABLE 12 – COMMUNICATIONS INTERFACE CONNECTIONS FOR THE MICON 500LE (EUROPEAN)

Customer Harness Wire #

Tokheim Interface

Gilbarco 2-Wire

Interface

Tatsuno Interface

RS-422Interface

RS-232Interface

Kraus MNET

Interface

16 DCC Not used Not used OUT “+” Gnd DCC10 TTC 2-wire “+” “+” OUT “-” Tx TTC9 TTD 2-wire “-” “-” IN “-” Rx TTP

17 Not used Not used Not used IN “+” Not used Not used

Customer Cable Wire

#

Tokheim Interface

Gilbarco 2-Wire

Interface

Tatsuno Interface

RS-422Interface

RS-232Interface

Kraus MNET

Interface

12 DCC Not used Not used OUT “+” Gnd DCC13 TTC 2-wire “+” “+” OUT “-” Tx TTC14 TTD 2-wire “-” “-” IN “-” Rx TTP21 Not used Not used Not used IN “+” Not used Not used

4.7 PULSE OUTPUT CIRCUIT DIAGRAM

21

4.8 DUAL TWO PRODUCT DISPENSER WIRING DIAGRAM

22

4.9 DUAL SINGLE PRODUCT DISPENSER WIRING DIAGRAM

23

4.10 DUAL TWO PRODUCT/SINGLE PRODUCT DISPENSER WIRING DIAGRAM

24

FIGURE 10

PRICE SETTING USING THE MICON COMMUNICATOR

1. POST INSTALLATION CHECK

After completing the installation of the MICON and checking all wiring connections, correct operation should be verified as follows:

1. Enter a price, as described below (also described in section 6.2.2 – Setting Prices on a Single Tier Dispenser).

a) Go to breaker box and turn OFF AC power to MICON 500L electronic pumphead beingserviced. Caution: Ensure breaker box does not feed power to equipment whichshould remain ON.

MICON display should be flashing.

If display is not flashing, unit is in sleep mode. To correct this, turn handle ON and OFF. Display will start flashing.

b) Take the MICON hand held communicator and go to the front display of the MICON 500Lelectronic pumphead display.

c) Aim the communicator at the optical sensor (oval hole ) at right of price displayon MICON 500L.

d) To set prices:

• While aiming the communicator’s transmitter (located on the end of the unit) at theMICON 500L optical display sensor, press and hold the “SET” until the displayincrements to the desired number.

• Use the “SEL” key to select the next digit to be changed. Press and hold the “SET”key until the display increments to the desired number.

2. After entering a price, turn ON the 120 VAC (230 VAC European) MICON headpower.

3. Place the dispenser handle in the OFF position. Turn ON dispenser sequencingpower and ensure that no product can be dispensed.

4. If card lock equipment is being used, place the dispenser handle in the ONposition. Authorize the MICON. This is normally done by inserting the appropriatecard into the card terminal, then entering data (i.e., i.d. number, mileage, etc.) asrequired. The authorization signal received by the card terminal is sent to theMICON 500L head via input wire #14 (N. American) or #20 (European).

MICON hand held communicator


Aim end of communicator at optical sensor

25

5.0

26

POST INSTALLATION CHECK (CONT’D)

5. For stand alone operation, turn ON the dispenser handle. The authorization in thiscase is bypassed and the main board receives a direct signal. The display resetsand the main flow valve is signaled by the MICON to open and commence fuel flow.

6. When resetting, displays should flash to all 8’s momentarily, go blank, then return tozero. Now the solenoid valve controlling fuel flow should energize.

7. Dispense a convenient amount of product into a test can and check that the MICON500L displays the proper volume and dollars amount. For testing the MICON 500Lwith ATCTM option refer to section 8.

8. Place the dispenser handle in the OFF position and ensure that the pump motorand/or solenoid shuts off.

This completes the post installation check. If the unit does not function as described above, contact your factory or service representative.

1. MICON 500L OPERATION

2. CONSOLE ACCESSING FOR PRICE CHANGING: MCIU

The method used to set prices to MICON 500L electronic pumpheads is dependent upon the type of self serve consoles employed.

If you are using Kraus Global Inc. Monitor 4 Console Systems, refer to sections6.2.1- Reading Totalizers and 6.2.2 – Setting Prices, for information regarding pricechanges and reading of totalizers.

If you are using a Kraus Global Inc. Micon Communication Interface Unit(MCIU), MICON 500L totalizers and prices may be accessed through the console.Refer to owner’s manual for details.

If it is necessary to place the station in manual mode of operation, all of the affected dispensers must be “reset”:

1. Place the console Emergency switch in the Emergency position and wait forall MICON 500L registers to go blank.

2. Return the Emergency switch to the normal position and place the manualswitch in the manual position. The station may now be operated in the manualmode.

3. Manual mode switch switches AC power to line #14 (North American or line#20 (European: Authorize). In manual mode when emergency switch in position, AC power is removed from solenoid power line.

!ATTENTION

1. Ensure the dispenser handle is in the OFF position, and the 120 VAC (230 VACEuropean) MICON head power is turned ON.

2. Aim the communicator’s transmitter (located on the top of the unit) at the optical sensor located to the right of the MICON price display.

3. Depress and hold the “SEL” key on the communicator. The red indicator to ththe price display will flash as the MICON 500L receives the communicator’s signal.

4. Hold the “SEL” key until the dollar sales total is displayed. Dollars sale total uses tendigits of the dollars and volume displays preceded by the letters “d l”. Refer to Figure14.

5. To display volume total, depress and hold the “SEL” key until the display shows “V l”

followed by the ten digit volume total. Pressing the “SEL” key repeatedly or holding itdown will cause the display to switch back and forth between volume and dollarstotals.

FIGURE 11

DISPLAY DOLLAR AND VOLUME TOTALS

6.2 MICON 500L COMMUNICATOR OPERATION

The hand held communicator (part # MC 200D, available as an option) allows the reading of both dollar and volume totals, and price setting.

6.2.1 READING TOTALIZERS ON A SINGLE TIER DISPENSER

e left of

TOTAL DOLLAR SALES DISPLAY

THIS DISPLAY READS:

$782564.93

TOTAL UNIT SALES DISPLAY

THIS DISPLAY READS:

96154.823 UNITS

27

FIGURE 12

PRICE SETTING USING THE MICON COMMUNICATOR

6.2.2 SETTING PRICES ON A SINGLE TIER DISPENSER

1. Go to breaker box and turn OFF AC power to MICON 500L electronic pumpheadbeing serviced. Caution: Ensure breaker box does not feed power to equipmentwhich should remain ON.

MICON display should be flashing.

If display is OFF, unit is in sleep mode. To correct this, turn handle ON and OFF.Display will start flashing. The dollar (top) display on the MICON 500L displays thedollar amount and “Prc 1”.

2. Take the MICON hand held communicator and go to the front display of the MICON500L electronic pumphead.

3. Aim the communicator at the optical sensor (oval hole display on MICON 500L.

) at right of price

4. To set prices:

• While aiming the communicator’s transmitter (located on the end of the unit) atthe MICON 500L optical display sensor, press and hold the “SET” key until theMICON display increments to the desired number.

• Use the “SEL” key to select the next digit to be changed. Press and hold the“SET” key until the display increments to the desired number.

• When the correct price per unit has been entered, restore head power whilehandle switch remains in the OFF position.

MICON hand held communicator


Aim end of communicator at optical sensor

28

3. TWO TIER PRICE OPERATION

On MICON 500L units equipped with the two tier price option it is possible to make sales at twodifferent prices. For example, cardholders may receive a discount from the regular price whilefuel is dispensed to non-cardholders at full price. The unit maintains separate totalizers for eachprice of sales.

1. TWO TIER OPTION INSTALLATION

Two tier installation requires a connector (included with part #W392 - harness) and pricingpush-button switch (part #PWP 320) or key-switch (part #Y101). To order these optional partscontact your local service representative.

To install the two tier option:

Connect the push button switch between the blue and orange wires on the providedconnector. The push button switch can then be mounted in a 7/8” hole in the side ofthe dispenser.

An optional key-switch is available, which can be used instead of, or together with,the push-button. Wire the key-switch and push-button in series, not parallel.

2. SETTING PRICES ON A TWO TIER DISPENSER

Setting prices on a two tier dispenser is the same as on a single tier dispenser, except thatpressing the DISCOUNT button will change which price is being set.

1. To set “Prc 1”, which is the regular price, turn OFF AC head power at thebreaker box. The display should be flashing. The dollar display on the MICON 500Ldisplays the dollar amount and “Prc 1” at first.

Set this price by aiming the communicator’s transmitter (on top of unit) at the opticalsensor (oval hole ) at right of price display on MICON 500L.

Press the SEL key to select the digit to be changed, and press the SET key toincrement to the desired number.

2. To set “Prc 2”, which is the discounted price, press the DISCOUNT buttonlocated on the side of the dispenser. The dollar display on the MICON 500L will thendisplay the dollar amount and “Prc 2” at first. “Prc 2” indicates the discounted price.

Set this price by aiming the communicator at the optical sensor (oval hole )at right of price display on MICON 500L. Press the SEL key to select the digit to bechanged, and press the SET key to increment to the desired number.

29

6.3.3 MAKING DISCOUNT PRICE SALES ON A TWO TIER DISPENSER

1. To make a discount priced sale, simply press the DISCOUNT push button, locatedon the side of the dispenser, before turning the dispenser handle ON. When thebutton is pressed, the discount price will be displayed. The next sale will proceed atthe discount price.

If the DISCOUNT button is pressed by mistake and you do not wish to make adiscounted sale, simply press the DISCOUNT button again and the dispenser willrevert back to the regular price.

Pressing the DISCOUNT button while the dispenser handle is in the ON position hasno effect on the dispenser.

2. When the discounted sale is completed, turn the dispenser handle to the OFFposition. The regular price will again be displayed and subsequent sales will occurat the regular price.

The INFO-PAC used to monitor and program the MICON 500L pumpheads hasa setting intended for use when two tier (regular and discount) pricing is in

! effect: PRC RESTORE (price restore). When this setting is ON (defaultsetting), the MICON automatically reverts back to tier 1 (regular pricing) aftereach discounted transaction.

NOTE

It is possible to set PRC RESTORE OFF, in which case the price used for thecurrent sale is retained for the next sale. Refer to INFO-PAC MICON 500LProgramming Manual for details.

6.3.4 READING TOTALIZERS ON A TWO TIER DISPENSER

Reading volume and dollar totals on two tier dispenser totalizers is the same as on single tierdispensers totalizers, except that pressing the DISCOUNT button will change whichvolume/dollar setting (regular or discount) is being read.

The two tier dispenser contains two sets of totalizers:

volume and dollar totals for regular priced sales; volume and dollar totals for the discount priced sales.

To read the totalizers:

30

1. Proceed as on page 27 by ensuring the dispenser handle is in the OFF position,and the 120 VAC (230 VAC European) MICON head power is turned ON.Display should be flashing. Aim the communicator’s transmitter (on top of unit)at the optical sensor (oval hole ) at right of price display on MICON 500L. Press and hold the SEL key until the dollar sales total is displayed.

FIGURE 13

READING TOTALIZERS

6.3.4 READING TOTALIZERS ON A TWO TIER DISPENSER (CONT’D)

2. Display will show “d I” for regular dollar totals. Press the DISCOUNT button. Displaywill show “d I I” for discount dollar totals.

3. Press the SEL key until the display shows “v I” (regular priced volume total) or “v I I”

(discount priced volume total). Press the DISCOUNT button to switch back and forthbetween “v I” and “v I I”.

4. Press and hold the SEL to switch back and forth between dollar and volume total displays.

Manually adding regular and discount volume or dollar totals will yield grand sales totals.

6.4 ELECTRONIC AUDIT TRAILS

The MICON 500L is equipped with electronic audit trails in the form of non-resettable eventcounters. This feature is facilitated in software, and meets the current requirements ofMeasurement Canada regulations. The top display of the MICON 500L electronic pumpheadindicates the number of changes to device configuration parameters performed with the INFO-PAC, as shown in Fig. 3.

display reads$782564.93

REGULAR TOTAL DOLLAR SALES DISPLAY

DISCOUNT TOTAL DOLLAR SALES DISPLAY

display reads$704308.44

press DISCOUNT button on dispenser side to switch back and forth

display reads 96154.823units

display reads 86539.343units

REGULAR TOTAL VOLUME SALES DISPLAY

DISCOUNT TOTAL VOLUME SALES DISPLAY

press DISCOUNT button on dispenser side to switch back and forth

press SEL key on communicator to switch between dollar and volume displays

31

7.0 ELECTRONIC CALIBRATOR ADJUSTMENT

The MICON 500L is equipped with an electronic calibration feature. This feature provides theMICON 500L with the capability of electronically compensating for meter errors of +/-19.99%.The required calibration error is programmed into the MICON via the INFO-PAC hand heldprogramming device. The factory default is set for 0% calibration error. If the meter is correctlycalibrated, no further adjustment is necessary.

When the inspection switch (connected between P12-1 and P12-5) is turned ON, the MICONwill display calibration information or ATCTM (automatic temperature compensation) information(if ATCTM is installed). The display then indicates:

32

TOP DISPLAY temperature (ATCTM installed and ON)% calibration (ATCTM OFF)

CENTER DISPLAY uncompensated vol. (same as normal volume if ATCTM is OFF or not installed)

BOTTOM DISPLAY flow rate/status

Until flow begins, the product compensation type will be displayed for one of the following products:

GAS = GASOLINEProP = propanedESL = diesel fuelOFF = ATC turned OFF or not installed

If calibration adjustment is required, follow guidelines below:

1. To receive MICON 500L settings with the INFO-PAC, follow steps as outlined below:

To receive information from the MICON 500L:

1) Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON. The MICON 500L display should be flashing. If display is blank, unit is in sleep (i.e., battery save) mode. To correct this, turn handle ON and OFF. Display will start flashing.

2) Turn INFO-PAC ON by pressing left arrow key. Using up or down arrow key, scroll to INFO-PAC RX MICON option. Set RX MICON on by pressing left or right pointing arrow key.

3) Take INFO-PAC and go to the front display of the MICON 500L electronic pumphead. Locate optical sensor (oval “hole”) at right of price display on MICON 500L. Aim INFO-PAC receiver / transmitter (located behind red tinted filter at centre edge of INFO-PAC) at MICON 500L optical sensor. Red LED (light emitting diode) to left of MICON 500L price display flashes as INFO-PAC receives data from MICON 500L.

4) When INFO-PAC has received a copy of the MICON 500L setup information correctly, INFO-PAC display will show “Received Micon”. To view each setting, scroll with the up or down arrow key.

2. If MICON 500L is equipped with ATCTM, set INFO-PAC menu option ATC off.

7.0 ELECTRONIC CALIBRATOR ADJUSTMENT (CONT’D)

3. Set INFO-PAC calibration factor to C.FACTOR +00.00% (default).

4. Follow steps to transmit INFO-PAC settings to MICON 500L, outlined in the INFO-PAC MICON 500L Programming Manual and described below.

To transmit information to the MICON 500L:

1. Switch OFF the head power to the MICON 500L, by removing cover of explosion-proof MICON 500L housing andremoving fuse. The MICON 500L display should be flashing. This requires breaking of a Weights and Measures seal onthe cover, and removal of bolts. Flip switch inside MICON 500L to enable programming mode.

2. Scroll to INFO-PAC TRANSMIT option. Set TRANSMIT on.

Before transmitting settings from the INFO-PAC to the MICON 500L electronic pumphead, scroll carefullythrough all options displayed on the INFO-PAC, and ensure that each and every one is still on the desiredsetting, even if you have changed only a single setting.

Whenever programming with the INFO-PAC, ALL parameters are rewritten in the MICON 500L.

3. Locate optical sensor (oval “hole” ) at right of price display on MICON 500L.

4. Aim INFO-PAC transmitter/receiver (located in center behind red tinted filter on edge of INFO-PAC) at MICON 500L optical sensor.

Red LED to left of MICON 500L price display flashes as MICON receives data from INFO-PAC.

5. When MICON 500L has correctly received setup information, will show on MICON 500L price display.

Exit programming mode by flipping switch inside MICON 500L to DOWN (Normal position).

7. Switch the head power back ON and run the MICON 500L using the new settings.

8. Replace the cover of the explosion-proof MICON 500L housing and:

a) Install a suitable legal seal through the two adjacent drilled cover bolts to ensure the cover cannot be removed without breaking the seal.

b) Install a suitable legal handle seal through the handle shaft, behind the cotter pin, so that the handle coupler cannot be removed from the handle shaft.

5. Place MICON 500L handle switch in ON position. Observe MICON dollars and volume displays reset to zero.

6. Dispense a known volume of product and record the reading on the volume display.

33

7.0 ELECTRONIC CALIBRATOR ADJUSTMENT (CONT’D)

7. Use formula below to calculate percentage correction required:

% Correction = Actual Volume - Register Volume X 100Register Volume

8. Set calibration factor on INFO-PAC to the closest

setting available. Example

Product dispensed: 25.00 Litres Register reading: 26.360 Litres

% Correction = (25.000 – 26.360) X 100 = - 5.159%26.360

Set INFO-PAC calibration factor to C.FACTOR – 5.16%.

Place the programming switch into program mode and transmit the calibration factor tothe MICON with the TRANSMIT function. The dollars section of the MICON 500L displaywould show “-5.16” for the example given.

9. Repeat steps 5 and 6, to verify the calibration of the MICON 500L.

10. If ATCTM used at this installation, set ATCTM INFO-PAC menu option ATC on, and retransmit settings to MICON.



b) Install a suitable legal handle seal through the handle shaft, behind the cotter pin, so that the handle coupler cannot be removed from the handle shaft.

A.

B.

34

8.0 AUTOMATIC TEMPERATURE COMPENSATION

The MICON 500L is optionally available with automatic temperature compensation of the product dispensed.

To install the MICON 500L with the ATCTM feature, it will be necessary to install the temperature probe and a test well in the meter line.

It is a requirement of Measurement Canada, an agency of IndustryCanada, that a thermal well be provided next to the installedtemperature probe, for inspection purposes. The following guidelinesshould be observed when installing an inspection test well:

1. The thermal well must be positioned to retain thermally conductive fluid.The hole in the fuel line should be drilled (drill size Q) so that the well willbe at an angle within 45° of vertical when the well is installed and theassembly is reconnected.

2. Install a 1/8 inch NPT test well extension fitting (Kraus part # BC 546) ifneeded, into the hole which was drilled into the fuel line. The inside of the1/8 inch NPT fitting will be drilled out to accommodate the insertion of thetest well (Kraus part # BC 407).

• Test well and probe are to be as close together as practical and thetest well must be accessible to the inspector after installation. Fittingsare supplied with the MICON 500L (additional fittings available uponrequest).

• The fitting should provide easy access for the insertion of athermometer.

• The fitting should be placed in an appropriate location so as not tohinder reinstallation of the assembly.

3. Install the test well into the extension fitting and tighten into place.

4. Cover the test well assembly with the supplied protective plug.

FIGURE 14

THERMAL WELL LOCATION

TEMPERATURE PROBE

THERMAL TEST WELL

!ATTENTION

35

8.0 AUTOMATIC TEMPERATURE COMPENSATION (CONT’D)

If the connection is made with less than 5 threads fully engaged, it willbe necessary to solder the fitting into place. Connections which are inexcess of 5 full threads do not require soldering, but must make use ofa thread sealing compound suitable for use with the intended fuel type.

In addition to the test well and probe fitting, new installations will require two BC-256 labels("CORRECTED TO 15°C"). These labels must be attached to each faceplate of the dispenserand be visible to the customer. Labels are provided with MICON 500L and additional labels areavailable upon request.

The Automatic Temperature Compensator feature compensates the volume of productdelivered to the equivalent volume at 15 degrees Celsius (15oC default). In order to accuratelysense the temperature of the product, the probe must be directly immersed into the product asclose as possible to the meter. The following procedure should be used to verify the operationof the ATCTM:

1. Install and connect the temperature probe.

2. Turn the inspection switch to the ATCTM position.

3. Dispense a convenient volume of product into a test can and record the temperatureand volume of the product in the can.

4. The volume indicated on the display of the MICON 500L is the UNCOMPENSATEDvolume. This volume should agree directly with the volume measured in the test can.If it does not agree, the meter is out of calibration.

5. Calculate the compensated volume in the test can using the actual volume and thetemperature of the product in the test can and the appropriate correction tables. Thecalculated compensated volume should agree with the compensated volume shownwhen inspection switch in “normal” display position. If the values do not agree, aproblem exists in the MICON or its installation.

6. Return the inspection switch to the upwards position for "normal" display position.

This completes the testing of the ATCTM. If you encounter any difficulty please contact yourservice representative.

!ATTENTION

36

9.0 PULSER ASSEMBLY REPLACEMENT

If troubleshooting procedures indicate a defective pulser board and / or disk then the entire base assembly should be replaced as described in steps 1 to 6, as follows:

This does not apply to remote pulsers.

1. Remove the MICON face plates.

2. Unplug the harness that enters the pulser housing.

3. Remove any other necessary hardware in order to slide the base out from underthe explosion proof housing (it may be necessary to loosen the conduit couplingto lift the tub assembly).

4. Install the new base assembly.

5. Reassemble the MICON. Connect the wire harness.

Reverse polarity of the two signal lines: WHITE wire provides leading digitalsignal; YELLOW wire provides lagging digital signal. If polarity of pulser boardis not reversed, solenoid valve will shut OFF whenever flow is detected.

6. Test the dispenser for proper operation.

!NOTE

!NOTE

37

10.0 MICON DISPLAY FAULT CODES

Should an operational error occur while using the MICON 500L electronic register, a fault code will show in the bottom display.

Fault codes are interpreted as shown in Table 13.

38

TABLE 13 – MICON 500L FAULT CODES

DISPLAY CODE

DESCRIPTION OF FAULT

PROBABLE CAUSE RECOMMENDED ACTION TO CLEAR FAULT CONDITION

CO26 PULSER FAULT Missing or disconnected pulser.

Check customer harness lead electrical connections.

1. Correct source of error.

2. Turn handleswitch OFF, then ON.

CO27 PULSER BUFFER OVERFLOW FAULT

Input pulses comingin faster than MICON500L rated to handle.

Meter may be programmed for higher pulse per unit (ppu) number than MICON 500L rating.

Ensure meter and MICON 500L flow rates are compatible.

CO28 DISPLAY DISCONNECT FAULT

LCD (liquid crystal display) lost connection. Display disconnected or improperly connected.

Check connections. If connections are valid, display may require replacement.

CO29 EEPROM CHECKSUM FAULT

EEPROM corrupted. Reset pumphead by turning handle switch OFF, then ON.

If reset ineffective, reprogram the MICON, using the INFO-PAC.

If reset and reprogramming ineffective, internal processor may require replacing. Contact your service representative.

CO30 EXCESSIVE REVERSE COUNTS

Pulser connected backwards.

Ensure base is correct for meter direction.

CO31 TEMPERATURE PROBE

Probe circuit open. Check probe connections / replace probe.

CO32 TEMPERATURE PROBE

Probe circuit shorted. Check probe connections / replace probe.

10.0 MICON DISPLAY FAULT CODES (CONT’D)

Fault codes listed on previous page show in MICON 500L bottom display.

FIGURE 17 - FAULT CODE DISPLAYED BY MICON 500L ELECTRONIC REGISTER

39

11.0

40

Troubleshooting and Repair Guide

If, after installation, the dispenser does not operate as it is supposed to, the following tables should be consulted before calling your service representative.

Troubleshooting tables have been divided alphabetically into the following categories:

1. communicator

2. display

3. (MICON) pumphead power

4. pump motor and/or solenoid valve

5. registration

1. COMMUNICATOR

Problem Possible Cause Recommended Action

1.1 Unable to read totals or price setting with the communicator,

Defective optical reader on the display board.

Replace display board.

but it functions normally with other MICON heads.

Defective display wiring harness. Replace harness.

Defective KIL 463 control board Contact your service(M500L). representative to order new

board.

Older communicators may not Contact your service

work on newer MICONS, the representative for communicatorcommunicator may need to be upgrade or replacement.replaced or modified.

1.2 Communicator exhibits poor Optical reader is in direct Shade optical reader with hand.

range when attempting to set sunlight.prices or read totals on allMICON heads. Weak or dead battery in Unscrew back of communicator

communicator. and replace 9 volt transistorbattery.

11.0

41

Troubleshooting and Repair Guide (continued)

2. DISPLAY


2.1 Display blinks slowly on and off.

The breaker supplying power to wire #1 has been tripped.

No head power.

Blown fuse.

Defective KIL 463 control board (M500L).

Re-trip breaker.

Check 120 VAC (240 VACEuropean) supply to wire #1 (hot) and wire #2 (neutral).

Check and replace as needed.

Contact your service representative to order new board.

2.2 Displays immediately blank when 120 VAC head power is disconnected.

Battery low.


Handle shaft is in the wrong position.

It is a 6.0 VDC rechargeable battery with a 7.0 VDC charging circuit. If battery does not recharge, contact your service representative.

Contact your service representative to order new board

Position handle shaft flat side up (Normal handle off position).

2.3 Segment(s) on display board are staying ON all the time or missing entirely. One display window or all three windows reading 8’s. Other display board OK.

Defective display board.

Defective display wiring harness.


Unplug wire harness from MICON head and check connections.

2.4 Both display boards reading8’s or erroneous segments beingdisplayed.

Defective display board.

Defective display wiring harness.


Unplug display boards from the MICON head one at a time and observe display to isolate defective board.

Unplug wire harness from MICON head and check connections.


11.0

42


2. DISPLAY (cont’d)


2.5 MICON displays will not reset to zero when pump handle ON. Product is dispensed; previous sales are added onto first.

Switch S1 is not disengaging when the handle is turned OFF.

The pump handle is mechanically coupled to the electronic head, and actuates two internal switches. Verify correct operationof internal microswitches #1 and#2 as described in section 9.2.

2.6 MICON front display LED is flashing once per second while in battery back-up mode.

Low battery. These are 6 volt rechargeablebatteries with a 7 volt chargingcircuit. Check each.

3. MICON (PUMPHEAD) POWER


1.Fuse keeps blowing

2.MICON keeps tripping breaker.

Blown varistor.

Possible line short on wire #1 (underground).

Replace EMI filter/varistor (120V: part #V140LA10A; 240V: part#S14K275).

Have qualified personnel test for short; repair/replace wire as needed.

3.3 MICON shuts OFF during delivery.

Error Code

Authorize power loss.

Isolate and replace defective part. Move pump handle from OFF to ON position to reset dispenser.

Some CODE 26 problems can be solved by installing a unidirectional pulser base, providing slop in the meter coupling and in some cases, up/grading the software. Contact your service representative.

Check for authorize power loss on wire #14 (NA),#20 (EU)

11.0

43


3. MICON (PUMPHEAD) POWER (cont’d)


3.4 MICON shuts OFF at beginning of delivery.

Reversed pulser lines. (Observe the PPU (price per unit) display in the MICON. If fault code CO30 displays, problem is excessive reverse counts, caused by backward connected pulser.

No pulses being generated (pulser). (Observe the PPU [price per unit] display in the MICON. If fault code CO26 displays, problem is missing or disconnected pulser.)

Observe the PPU (price per unit) display in the MICON. If fault code CO27 displays, problem is pulser buffer overflow fault.

Locate the 4 wire harness between the pulser and the Micon. Connect WHITE wire where YELLOW located; connect YELLOW wire where WHITE located.

Check harness lead electrical connections.

Micro motion meter may be programmed for higher ppu than MICON rating. Ensure Micro-Motion meter and MICON flow rates are compatible.

INFO-PAC

MICON™ 500L/550L Programming Manual

Software Version 1.0

© 2000, Kraus Group Inc.

Publication Number: 206AY08.PRG R00

Printed in Canada

(i)

TABLE OF CONTENTSINTRODUCTION 1

KEY FUNCTIONS 1

1.0

2.0

1. Power On 22. Automatic Shut-Off 23. Service and Product Support - Canada 24. Set-Up Modes 3

3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS 4

Table 1 – Default Settings 4

1.CONFIG 42. TEST 43.PULSER 4 3.4 I.S. 45. IN COUNT 56. MULTIPLIER 57. CURRENCY 68. VOL DISP 79. SUPPRESS 710. CONV. 811. NO FLOW 812. VOL PPU 913. VOL PW 914. PENNY PW 915. W/M STANDARD 1016. CLEAR ZEROS 1017. CONSOLE 1018. BAUD 1019. PUMP ID 1120. GRADE 1121. DISPLAY 1122. TIER BUTTON 1223. C. FACTOR 1224. ATC 1325. COMP. TEMP 1326. PRODUCT 1327. PRC RESTORE 1328. VOL P. QUAD 1429. STOP&START 1430. SLOW FLOW 1431. START KEY 1532. STOP KEY 1533. PRESTART 1534. CUST. PRESET 1535. P. CODE 1536. TRANSMIT 1637. RX MICON 1738. CLEAR TOTALS 1839. TX TOTALS 1840. RX TOTALS 18

IMPORTANT REMINDER

Whenever programming with the INFO-PAC, all parameters are rewritten in the Micon 500/550L.Before transmitting settings from the INFO-PAC to the Micon 500/550L, electronic pump head, scroll carefully through all options displayed on the INFO-PAC, andensure that each and every one is still on the desired setting, even if you have onlychanged a single setting.

1.0 INTRODUCTION

The MICON MIP500L/550L INFO-PAC is a hand-held self-contained battery powered unitdesigned to monitor and program MICON electronic pumpheads. INFO-PAC modelMIP500L/550L is designed to configure MICON 500/550L pump computer heads used tocontrol liquid fuel flow from gasoline, diesel, propane or butane dispensers.

The INFO-PAC is a transmitter and receiver. Programmable pumphead features can be set up inthe INFO-PAC memory, then transmitted to MICON heads. The INFO-PAC also receives anddisplays features already programmed to MICON pumpheads.

Setting configuration features in the MICON using the INFO-PAC requires breaking of two Weights& Measures seals on the MICON cover and the programming wire screw. See section(s) 3.36 and3.37.

2.0 KEY FUNCTIONS

This key is used to scroll upwards through the menu options.

This key is used to scroll downwards through the menu options.

This key is used to turn the INFO-PAC ON, and to scroll forward through the data items associated with each menu option.

This key is used to scroll backward through the data items associated with each menu option.

© Copyright 2000, 1998 Kraus Group Inc.All rights reserved.

Kraus Group Inc. assumes no liability or responsibility whatsoever pertaining to the accuracy or currency of theinformation supplied in this manual. Programming of MICON 500/550L electronic pumpheads in every case is the soleresponsibility of the installer performing the work. Kraus Group Inc. assumes no liability or responsibility whatsoeverresulting from any type of programming or installation, whether performed properly, improperly or in any other way. Theinformation supplied herein is a guide only.

MICON MIP500L/550LInfo-Pac

1

ON

2.2 AUTOMATIC SHUT-OFF

• INFO-PAC automatically shuts OFF after 30 seconds without keyboard activity.• INFO-PAC shuts OFF automatically after 10 minutes when TRANSMIT, TX TOTALS, RX

TOTALS or RX MICON is set to “on”.

2.3 SERVICE AND PRODUCT SUPPORT - CANADA

Should you experience any difficulties in system operation, customer assistance is available.

The procedure to receive such assistance is as follows:

1. Document the following information: 2. Call or Fax our Product Service line at:

2.1 POWER ON

The INFO-PAC is powered by a 9 volt battery.

1. Press key to power unit ON. LCD momentarily displays INFO-PAC model and

• system dysfunction• corrective measures taken• system model number• system serial number• purchase order information• date of installation• equipment location (i.e., city, address, etc.)

Software version number:

M500L/550L V 1.0

2. The display changes to show one of the following:

2

CONFIG default CONFIG custom

Company Service Number:

1-204-988-1234

Company Fax Number:

1-204-654-2881

11.0

44


4. PUMP MOTOR AND/OR SOLENOID VALVE


4.1 No reset cycle, pump motor and/or solenoid valve will not turn on when handle is placed in the ON position. Previous sale is not cleared when handle is turned ON.

Defective or inoperative linkage to MICON handle shaft (detent).

No authorize input voltage.

Defective internal microswitchand/or authorize relay on mainboard inside MICON head.

Replace linkage.

Check for 120 VAC on wire #14 or #15. (European: Check for 240 VAC on wire #20 or #19.)

Contact your service representative to order new microswitch or main board.

4.2 Pump motor and/or solenoid valve will not turn on when handle is placed in the ON position. Reset sequences displaying 8’s and clearing last sale.

If both pump motor and solenoid valve are not coming on, the problem could be a defective temperature probe (ATC only).

No power supplying the internal triacs.

Defective main board. One of the triacs in the control board (M500L: KIL 463) is burnt.

Check the PPU (price per unit) display in the MICON 500L. If fault code CO31 displays, problem is disconnected temperature probe. If fault code CO32 displays, problem is short circuited temperature probe circuit.

Check for 120 VAC (230 VAC European) on motor & solenoid input wire.Check output power on wire #6 (solenoid) or wire #8 (motor). European: Check output power on wire #5 (solenoid) or wire #3 (motor).

Check for an open circuit on either the motor, solenoid or dead man switch.

4.3 Pump motor is always ONwhen the handle is in the OFFposition (new installation).

If the motor is controlled by theMICON, the detent could be inthe wrong position.

Shorted triac.

Remove cotter pin and rotate detent to opposite position (Normally, handle OFF, battery on = Flat side UP.)

Find cause of short & replace main control board.

11.0 Troubleshooting and Repair Guide (continued)

After correcting source of error, always turn dispenser handle switch OFF, then ON.!

REMINDER

45

5. REGISTRATION


5.1 Product can be dispensed but it’s not registering on either the mechanical totalizer or electronic display.

Inoperative drive to MICON input shaft.

Stripped or loose gears on MICON base. This only occurs when direct drive meters are used (i.e., those that do not use a remote pulser).

Broken coupling between the meter and electronic register.

Repair drive.

Replace MICON base.

Replace coupling.

5.2 Product flow registering only on mechanical totalizer.

Defective MICON base (pulser). Replace MICON base.

5.3 MICON registering incorrectly (new installation or board replacement only).

Incorrect ATC (automatic temperature compensation) or programming of IN COUNT or MULTIPLIER setting

Consult INFO-PAC MICON 500LProgramming Manual (document number: 206KT00.PRG R00).

5.4 MICON is losing its price settings and totals.

Low battery. It is a 6.0 VDC rechargeable battery with a 7.0 VDC charging circuit. If battery does not recharge, contact your service representative.

5.5 MICON totals are jumping or the price is changing by itself.

Low battery.


It is a 6.0 VDC rechargeable battery with a 7.0 VDC charging circuit. If battery does not recharge, contact your service representative.


2.4 SET-UP MODESScrolling through each menu option should reveal settings as shown.Pictured to the right of each menu option below are factory default data items.

ON

M500L/550L V 1.0

POWER ON

Menuoptionsrepeat

o.

MULTIPLIER 1

CURRENCY dollars

VOL DISP 1.000

SUPPRESS 0.030

CONV. off

l .

.

2 .

e .

l .

8 .

a .

.

CONFIG default

S .

TEST off

PULSER .i.s

.I.S 1000

IN COUNT 1000

.

S .

l .

.

2 .

e .

l .

8 .

a .

S o .

S .

NO FLOW off

VOL PPU 10

VOL PW 4.0ms

PENNY PW 4.0MS

W/M STANDARD na

CLEAR ZEROS off

CONSOLE kraus

BAUD 9600

DISPLAY normal

GRADE 1

PUMP ID. not set

S S .

S .

S 2 .

S e .

S l .

S 8 .

S a .

l o .

l .

l S .

S l .

COMP. TEMP 15ºC

ATC on

C.FACTOR +00.00%

TIER BUTTON off

PRODUCT gas

PRC RESTORE on

VOL P. QUAD off

START KEY disab

SLOW FLOW 0.600

STOP&START disab

STOP KEY disab

PRESTART off

P. CODE 0000

TRANSMIT off

RX MICON off

CLEAR TOTALS off

TX TOTALS off

RX TOTALS off

l .

l e .

l l .

l 8 .

l a .

o .

CUST. PRESET off

l l

l 2 .

3

1. DESCRIPTION OF PROGRAMMABLE MENU OPTIONS

2. CONFIG

Used to set all menu options to default values.

CONFIG default

Indicates MICON 500/550L menu options are at their default values.

CONFIG custom

Indicates MICON 500/550L menu options have been modified from default values. Pressing either the

or keys will return options to default settings.

2. TEST

Used to put MICON 500L/550L into continuous display test mode.

TEST off (default)Indicates Micon 500L/550L should be in standard operating mode. Pressing either the or key will turn TEST mode ON.

TEST onIndicates MICON 500L/550L should continuously run through display test mode until INFO-PACis used to turn OFF test mode on the MICON.Pressing either the or key turns TEST mode OFF.

3. PULSER

Used to select pulser input source.

PULSER .i.s. (default)Indicates pulser input is through the I.S. circuit external wiring.

PULSER conduitIndicates pulser input is through conduit wiring.

3.4 .I.S.

In the Intrinsically Safe (.I.S.) pulse input mode, two different pulser types can be used.

.I.S. 1000Indicates the pulser has 62.5, 125, 250, 500, 1000, etc. pulses per revolution.

.I.S. 1024Indicates the pulser has 64, 128, 256, 512, 1024, etc. pulses per revolution.

4

TABLE 1 - DEFAULT SETTINGS

OPTION DEFAULT SETTINGS

1. CONFIG default2. TEST off3. PULSER .i.s.4. .I.S 10005. IN COUNT 10006. MULTIPLIER 17. CURRENCY dollars8. VOL DISP 1.0009. SUPPRESS 0.030

10. CONV. off11. NO FLOW off12. VOL PPU 1013. VOL PW 4.0ms14. PENNY PW 4.0ms15. W/M STANDARD na16. CLEAR ZEROS off17. CONSOLE kraus18. BAUD 960019. PUMP I.D. not set20. GRADE 121. DISPLAY normal22. TIER BUTTON off23. C. FACTOR +00.00%24. ATC on25. COMP. TEMP. 15oC26. PRODUCT gas27. PRC RESTORE on28. VOL P. QUAD off29. STOP&START disab30. SLOW FLOW 0.60031. START KEY disab32. STOP KEY disab33. PRESTART off34. CUST. PRESET off35. P. CODE 000036. TRANSMIT off37. RX MICON off38. CLEAR TOTALS off39. TX TOTALS off40. RX TOTALS off

3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS

EXAMPLE 1

E X Y I N b r E

EXAMPLE 2

3.5 IN COUNT

Works in conjunction with MULTIPLIER settings toindicate number of pulser edges which must becounted to register 1 unit volume of fuel flow.

Refers to number of edges that must be received onthe two incoming pulser lines (F1 and F2) to register1 unit of fuel flow. Indicates number of quadrature(input pulser) transitions per unit volume. This valueis equal to 4 times the number of pulses on anindividual pulser line.

Values for this option can be scrolled through using the or keys. Values are:

IN COUNT 1000 MULTIPLIER 1 = 1000 PULSER EDGES / 1 UNIT OF FUEL FLOW = 1000 EDGES / UNIT.001 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE)

IN COUNT 1000 MULTIPLIER 2 = 1000 PULSER EDGES / 2 UNITS FUEL FLOW = 500 EDGES / UNIT.002 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE)


IN COUNT 1000 MULTIPLIER 0.5 = 1000 PULSER EDGES / 0.5 UNITS FUEL FLOW = 2000 EDGES / UNIT.0005 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE)

IN COUNT 1000 MULTIPLIER 0.25 = 1000 PULSER EDGES / 0.25 UNITS FUEL FLOW = 4000 EDGES / UNIT.00025 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE)

IN COUNT 100 MULTIPLIER 1 = 100 PULSER EDGES / 1 UNIT FUEL FLOW = 100 EDGES / UNIT.01 REGISTERS ON MICON 500L/550L DISPLAY (PER EDGE)


3.6 MULTIPLIERWorks in conjunction with IN COUNT settings to indicate volume of fuel flow equal to 1 unit

Values for this option can be scrolledthrough using the or keys. Values are:

MULTIPLIER 1 (default)MULTIPLIER 2MULTIPLIER 4MULTIPLIER 0.5MULTIPLIER 0.25

ON

5

IN COUNT 1000 (default)

IN COUNT 100IN COUNT 10IN COUNT 1


money display

volume display

price display

3.7 CURRENCY

Used to select:

• Type of currency sales are registered in;• Number of decimal positions in money and price fields;• Character displayed before total money sales in totalizer display.

CURRENCY dollars (default)This setting uses 2 decimal positions in the money display field, 3 decimal positions inthe price field and d in the totalizer display.

CURRENCY Om,1p

This setting uses 0 decimal positions in the money display field, 1 decimal position in the price field and d in the totalizer display.

CURRENCY 2 dp

This setting uses 2 decimal positions in the money display field, 2 decimal positions in the price field and d in the totalizer display.

CURRENCY 1 dp

This setting uses 1 decimal position in the money display field, 1 decimal position in the price field and d in the totalizer display.

CURRENCY no dp


CURRENCY 1m,3p

This setting uses 1 decimal position in the money display field, 3 decimal positions in the price field and d in the totalizer display.

CURRENCY Om,2p


6


7. CURRENCY (cont’d)

CURRENCY 2m,1p


CURRENCY 3m,1p


8. VOL DISP

The value of this option determines the number of decimal positions to be displayed in the volume unit field of the MICON 500L/550L. The MICON 500L/550L cannot be set to display a more precise reading than the incoming pulses will allow, and cannot be set to display less precisely than to the nearest unit. Values are:

7

VOL DISPVOL DISPVOL DISPVOL DISP

1.000 (default)1.OO1.O1 (only available if IN COUNT setting is less than 1000)

3.9 SUPPRESS

This option determines whether or not unit suppression is used, and type of unit suppression used. Values are:

SUPPRESS 0.030 (default)For first 0.029 units of liquid fuel dispensed, MICON 500L/550L sale register display shows ZERO. For 0.030 units and over, the sale amounts are displayed.

SUPPRESS O.OO9

For first 0.008 units of liquid fuel dispensed, MICON 500L/550L sale register display shows ZERO. For 0.009 units and over, the sale amounts are displayed. (This is the maximum suppression allowed for sales registered in U.S. gallons.)

SUPPRESS O.OOO

MICON 500L/550L sale register display shows the sale amount. Suppression is turned OFF.


3.10 CONV.

This option converts volume units dispensed to volume display units. For example, for fuel dispensed in U.S. gallons, the MICON 500L/550L can convert the volume measurement displayed on the register to litres, using the INFO-PAC CONV. US gal-l setting.

Table 2 Conversion Settings

3.11 NO FLOW

This option controls length of time MICON 500L/550L keeps motor and solenoid valve ON if a sale is in progress but there is no product flow being registered. Anytime during the sale (before flow starts or after flow starts), when there has been no fuel flow for the “NO FLOW” timer interval the motor and valves will be shut OFF and the sale terminated.

No flow timer interval can be set from 15 seconds to 4 minutes, 15 seconds; in 15 second increments. (Previous model(s) permitted maximum timer value of 2 minutes.)

TABLE 3 – NO FLOW SETTINGS

8

INFO-PAC Option Fuel Dispensing Units

MICON 500L/550L Register Volume Display Units

Multiplication Factors Used for Conversion

CONV. OFF (default) N/A Volume dispensed not converted to litres.

N/A

CONV. us gal-l U.S. gallons litres (metric) U.S. gallons multiplied by3 51472/ = litres

65536

CONV. imp gal-l Imperial gallons litres (metric) Imperial gallons multiplied by4 35789/ = litres

65536

CONV. l-us gal litres (metric) U.S. gallons Litres multiplied by17314/ = U.S. gallons65536

INFO-PAC SETTING RESULT

NO FLOW off MICON 500L/550L will not shut down on a NO FLOW condition.

INFO-PAC SETTING Before flow starts OR after

15 seconds flow starts:30 seconds45 seconds Pump and valves shut OFF60 seconds75 seconds and sale is terminated after90 seconds NO FUEL FLOW occurs for105 seconds the number of seconds on120 seconds the INFO-PAC setting.135 seconds150 seconds165 seconds180 seconds195 seconds210 seconds225 seconds240 seconds255 seconds


3.12 VOL PPU

This option defines the number of output pulses per unit (PPU) transmitted on the Volume Out Pulse line of the MICON 500L/550L.

This value cannot be more than IN COUNT value set for the MICON 500L/550L.

A PPU less than 1 is not permitted by INFO-PAC. Values are:

3.13 VOL PW

This option sets the width of the Volume Pulse signal. This width is defined as the "on time" length of the pulse. Setting should be compatible with equipment used. Pulse width values are:

VOL PWVOL PWVOL PWVOL PWVOL PWVOL PWVOL PWVOL PW

0.5ms1.0ms2.0ms4.0ms (default)17.0ms19.0ms26.0ms150.0ms

3.14 PENNY PW

This option sets the width of the Penny Pulse signal. This width is defined as the "on time" length of the pulse. Setting should be compatible with equipment used. Pulse width values are:

PENNY PWPENNY PWPENNY PWPENNY PWPENNY PWPENNY PWPENNY PW

0.5ms1.0ms2.0ms4.0ms (default)17.0ms19.0ms26.0ms

Note: Setting VOL P.QUAD ON disables penny pulser output, since this line is used as second line of volume pulser. (Volume out pulser becomes a two channel quadrature pulser output, disabling the penny pulser option.)

Choose to have either:

• Penny pulser and volume pulser OR

• 2 channel volume pulser and no penny pulser.

9

VOL PPU 1

VOL PPU 10 (default)VOL PPU 50VOL PPU 100VOL PPU 1000


15. W/M STANDARD

This option sets up the allowable pulser errors to meet the na (North American) or eu (European) standards. Settings are:

W/M STANDARD na (default)W/M STANDARD eu

16. CLEAR ZEROS

This option sets the MICON 500L/550L register to display or suppress leading zeros on the current sale display. Settings are:

CLEAR ZEROS off (default)Displays leading zeros in current sale display.

CLEAR ZEROS onSuppresses leading zeros in current sale display.

17. CONSOLE

This option setting has no effect on the MICON 500L/550L. When the “RX MICON” option isused, this option will show which communications protocol is used on the serial communicationslines from the MICON 500L/550L to the console.

Compatible hardware interface boards, available as optional features of the MICON 500L/550L, must be installed. Communication protocols are:

CONSOLE kraus (default)MCIU’s (MICON communication interface units) manufactured by Kraus.

CONSOLE gilbarcoConsoles manufactured by Gilbarco.

CONSOLE tokheimConsoles manufactured by Tokheim.

CONSOLE tatsunoConsoles manufactured by Leif Dige.

CONSOLE Wayne DresserConsoles manufactured by Wayne Dresser

18. BAUD

This option is used to select the Baud rate.

BAUD 9600BAUD RATE 9,600 bits/second BAUD 19200BAUD RATE 19,200 bits/second

10


3.19 PUMP ID.

This option sets the pump address used during serial data channel communications.

Do not set pump address if MICON 500L/550L pump head is using Kraus MNET communications in conjunction with a MCIU or equivalent interface box. In this setup, pump address is set dynamically by the interface box. Values are:

PUMP ID. not set (default)PUMP ID. 01PUMP ID. 02PUMP ID. 03

PUMP ID. 24

20. GRADE

Functions for this option vary, depending on which type of console interface (i.e., Kraus, Gilbarco, Tokheim, Tatsuno) is used. Values are:

GRADE 1 (default)GRADE 2GRADE 3

For the Kraus (MNET) interface, setting GRADE to 2 disables the MICON 500L/550L’s “override console sales data collection” feature, when the MICON 500L/550L is authorizedmanually. Thus, if the console stops working, the operator can flip the switch controlling the console to manual override.

For the Tokheim interface, setting GRADE to 1 will transmit volume information to the console exactly as it is displayed. Setting GRADE to 2 will transmit volume information in the format ‘999.999’, regardless of the displayed format.

Gilbarco pumps have the capability of setting grades (e.g., regular or unleaded fuel) at the pump.

21. DISPLAY

This option sets the way the current sale amount display on the MICON 500L/550L is to be interpreted.

DISPLAY normal (default)Use this setting for computing registers.

DOLLAR

VOLUME

PRICE

11


3.21 DISPLAY (cont’d)

DISPLAY bulkDisplay shows net volume – gross volume – temperature. Use this setting when both temperature compensated and uncompensated volumes are desired.

DISPLAY non-compDisplay shows volume – volume –blank. Use this setting for non-computing dispenser(s).Faceplate may cover one of the volume displays.

22. TIER BUTTON

This option determines if a two tier button is being used.

TIER BUTTON onTwo prices are allowed to be set on the MICON and a preset keypad cannot be used.

TIER BUTTON offOnly one price can be set on the MICON. This is required when a keypad is connected.

23. C. FACTOR

This setting sets electronic calibration factor used to correct errors in the meter’s registering. This calibration factor can be set from -19.99% to +19.99%. Use to scroll to each digit position.Use to change value of each digit.

C.FACTOR -19.99%C.FACTOR +00.00% (default)C.FACTOR +19.99%

Temperature

Gross Volume

Net Volume

Net

Net

Blank

12


24. ATC

This setting enables/disables Automatic Temperature Compensation.

ATC on (default) ATC off

25. COMP. TEMP

This setting sets the temperature to which the ATC feature compensate the fuel volume. If 60ºF is used, the ATC inspection mode temperature will be in Fahrenheit instead of the default Celsius.

COMP. TEMP. 15ºC (default) COMP. TEMP. 60ºFCOMP. TEMP. 20ºC

26. PRODUCT

This setting is used to set the fuel type used for the ATC function. Each fuel type is associated with a density (see Table 4, below).

TABLE 4 – PRODUCT SELECTIONS

13

3.27 PRC RESTORE

This option is used when two tier pricing is in effect.

For example, a consumer who is a cardholder may receive a discount from regular sale price ofliquid fuel. If PRC RESTORE is set ON, MICON 500L/550L register reverts to regular sale price(tier 1) when dispenser handle returned to OFF position. Values are:

PRC RESTORE on (default)Price returns to the tier 1 price when the handle is returned to OFF position.

PRC RESTORE offPrice used for current sale is retained for next sale, unless explicitly changed by the user.

INFO-PAC SETTINGS FUEL DENSITIES VCF TABLE

REFERENCE

PRODUCT gas (default) 730 kg/m3 API 54BPRODUCT diesel 840 kg/m3 API 54BPRODUCT propane 510 kg/m3 ASTM-IP 54PRODUCT butane 580 kg/m3 ASTM-IP 54PRODUCT av gas (aviation gas) 710 kg/m3 API 54BPRODUCT jet a (jet kerosene, turbine fuel) 800 kg/m3 API 54BPRODUCT jet b (naptha) 760 kg/m3 API 54A

3.0 DESCRIPTION OF PROGRAMMABLE MENU OPTIONS (cont’d)

3.28 Vol. P. Quad

VOL P. QUAD off (default)Volume out pulser is single channel, with penny pulser option.

VOL P. QUAD onVolume out pulser becomes a two channel quadrature pulser output, disabling the penny pulser option.

29. STOP & START

This setting enables/disables the START and STOP option.

START & STOP disab (default)This setting does not allow the MICON to continue a sale after console authorization is disabled and enabled again.

START & STOP enabThis setting allows the MICON to continue a sale after console authorization is disabled and enabled again.

30. SLOW FLOW

For PRESET SALES this option sets when the fast flow valve is closed so that only the slow flowvalve is used. This option is set as the # OF VOLUME UNITS BEFORE THE PRESET AMOUNTIS REACHED. Use to scroll to each digit position. Use ON to change the value of each digit.

Example:

SLOW FLOW settings:

SLOW FLOW 0.000

SLOW FLOW 0.600 (default)

SLOW FLOW 9.999

If PRESET set to 30 litres, andSLOW FLOW set to 1 litre:

Fast flow valve closes at 29 litres. Last (30th) litre flows slowly.

Note: If the VOL DISP option is changed, the SLOW FLOW option must also be adjusted, since the decimal point will be shifted. IMPORTANT

REMINDER

14


31. START KEY

The START KEY is reserved for future expansion. This option should remain set at:

START KEY disab (default)

32. STOP KEY

The STOP KEY is reserved for future expansion. This option should remain set at:

STOP KEY disab (default)

33. PRESTART

PRESTART on (default)The motor will turn on as soon as the pump handle is turned on. The reset cycle is extended to a total of 5 seconds. After the reset cycle, the solenoid will turn on and pulse counting will be enabled. The Micon will ignore pulses during the reset cycle to ensure meter movement and resulting pulses at start up will not be registered or displayed. This feature is used with submersible systems with leak detectors and in propane systems where vapour can be a problem.

PRESTART offThe motor will not turn on until after the reset cycle.

34. CUST. PRESET

Reserved for custom setting. This option should remain set at:

CUST. PRESET off (default)

35. P.CODE

This option requires users responsible for setting fuel prices on the MICON 500L/550L to use a security code. User(s) may pick any 4 digit number as a personal identification code, to provide access to price changing.

P. CODE 0000 (default)

P. CODE 9999

15


36. TRANSMIT

This menu option is used to transmit the INFO-PAC settings to the MICON 500L/550L unit.

To transmit information to the MICON 500L/550L:

1. MICON 500L: Switch OFF the head power, by removing cover of explosion-proofMICON 500L housing and removing fuse. The MICON 500L display should be flashing.This requires breaking of a Weights and Measures seal on the cover, and removal ofbolts. Flip switch inside MICON 500L to enable programming mode.MICON 550L: Disconnect the program seal wire. Leave the AC power ON.

2. Scroll to INFO-PAC TRANSMIT option. Set TRANSMIT on.

3. Locate optical sensor (oval hole ) at right of price display on MICON 500L/550L.

4. Aim INFO-PAC transmitter/receiver (located in center behind red tinted filter on edge of INFO-PAC ) at MICON 500L/550L optical sensor.

Red LED to left of MICON 500L/550L price display flashes as MICON receives data from INFO-PAC.

5. When MICON 500L/550L has correctly received setup information, will show on the MICON 500L price display.

will show on the MICON 550L price display.

If it is not convenient to remove MICON 500L cover, there is an alternative method of shutting OFF head power, and permitting 1-time programming only:

1. Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON.

2. Remove cotter pin from handle shaft on the MICON 500L, and turn handle shaft DOWN to battery OFF position. This requires breaking of a Weights and Measures seal through the handle shaft, behind the cotter pin. Leave battery OFF for 30 seconds for a completely “cold start”.

ATTENTION

Before transmitting settings from the INFO-PAC to the MICON 500L/550L electronic pump head, scroll carefully through all options displayed on the INFO-PAC, and ensure that each and every one is still on the desired setting, even if you have changed only asingle setting.Whenever programming with the INFO-PAC, ALL parameters are rewritten in the MICON 500L/550L.

16


3.36 TRANSMIT (cont’d)

6. Exit programming mode by flipping switch inside MICON 500L to DOWN (Normal position). Reconnect the program seal wire.

7. Switch the head power back ON and run the MICON 500L using the new settings.



b) Install a suitable legal handle seal through the handle shaft, behind the cotter pin, so that the handle coupler cannot be removed from the handle shaft.On the MICON 550L, install seal wire through the 2 cover bolts and the program seal wire screw.

37. RX MICON

This menu option is used for INFO-PAC to receive MICON 500L/550L settings from units which have already been programmed.

To receive information from the MICON 500L/550L:

(STEP 1. applies only to the MICON 500L.)

1. Go to breaker box and turn power OFF. Caution: Ensure breaker box does not feed power to equipment which should remain ON.

Alternative: Switch OFF the head power to the MICON 500L, by removing cover ofexplosion-proof MICON 500L housing and removing fuse. This requires breaking of aWeights and Measures seal on the cover, and removal of bolts.

The MICON 500L display should be flashing.

2. Scroll to INFO-PAC RX MICON option. Set RX MICON on.

3. Locate optical sensor (oval hole ) at right of price display on MICON 500L/550L.

4. Aim INFO-PAC transmitter (located behind red tinted filter at the centre edge of INFO-PAC ) at MICON 500L/550L optical sensor.

Red LED to left of MICON 500L/550L price display flashes as INFO-PAC receives datafrom MICON 500L/550L.

3. When INFO-PAC has received a copy of the MICON 500L/550L setup information correctly, INFO-PAC display will show “Received Micon”.

This step is unnecessary ifprogram mode was enteredusing alternative method inStep 1 ( preceding page).

17


38. CLEAR TOTALS

This setting clears the total memory stored in the INFO-PAC

CLEAR TOTALS off (default)The totals are retained in the INFO-PAC

CLEAR TOTALS onWhen this setting is used, the totals in INFO-PAC memory will be erased.In order to clear totals in the MICON head, set CLEAR TOTALS to “on”. This sets the totals inthe INFO-PAC to zero. The zero totals can be transmitted to the MICON head using the TXTOTALS function.

39. TX TOTALS

TX TOTALS off (default)The INFO-PAC is not transmitting totals

TX TOTALS onThere are two situations where the TX TOTAL function is used:

1) Clearing totals of the MICON head to zero2) Transmitting previously stored totals

40. RX TOTALS

RX TOTALS off (default)The INFO-PAC is not receiving totals

RX TOTALS onThis setting receives totals from the MICON head.

18

OTHER COMPONENTS

1

PPootttteerr && BBrruummfifieellddGeneral PurposeHighPower PCBRelays

Figure 1

T92 Series Two-pole30APCBor Panel MountRelay

n 40A, 2 formA(NO) and2 formC(CO) switching capabilityn Designedto controlcompressorloads to3.5 tons,110LRA / 25.3FLAn Meets requirementsof UL508 andUL873 spacings - 8mm

throughair, 9.5mm over surfacen Meets requirementsof VDE8mmspacing,4kV dielectric coil-

to- contactn Meets requirementsof ULClassFconstructionn ULapprovedfor 600VACswitching (1.5HP)n Newscrewterminal version (consult factory for

availability, ratings)

Typical applicationsHVAC,residential / commercial appliances, industrial controls.

Contact ratings 1) (continued)ARI 780-86 Endurance Test (section 6.6):HVAC Definite Purpose Contactor StandardNormally Open ContactsSingle Phase/Two Pole (Both poles together switching a single load)

110 LRA, 25.3 FLA, 200K operations (DC Coil)

Single Phase Per Pole (Single load per pole)110 LRA, 18 FLA, 200K operations (DC Coil).60 LRA, 14 FLA, 200K operations (AC Coil).

L1 L2

Figure 2

1) Contact ratings at 25°C (unless otherwise noted) with relay properly vented.FLA, LRA ratings are compatible with 3.5 ton compressor applications.

Mechanical endurance 10x106 ops.

code voltage voltage voltage resistance powerVAC Hz VAC, 60Hz VAC, 60Hz Ω±10% VA

12 1224 24120 110/120240 220/240

6060

50/6050/60

9.619.296

192

1.22.4

1224

9.136.69503800

4444

277 250/277 50/60 222 28 5485 4 All figures are given for coil without preenergization, at ambient temperature +23°C.

ApprovalsUL E58304 (Recognized and Listed); CSA LR48471; VDE 40019600 Technical data of approved types on request.

Contact DataContact arrangement 2 form A (NO), 2 form C (CO)Rated voltageMax. switching voltage Rated currentLimiting continuous current Limiting making current

277VAC600VAC

30A NO; 3A NC40A NO; 3A NC40A NO; 3A NC

Limiting breaking current 40A NO; 3A NCContact material AgSnOInO, AgCdOMin. recommended contact load 500ma (NO)/ 100ma (NC), 12VACFrequency of operation, with load 360hrOperate/release time max., including bounce 25/25ms

Contact ratings 1)

Type Load CyclesUL508AgCdO NONO NO NO NO

40A, 277VAC, resistive30A, 120/277VAC, resistive10A, 600VAC, general purpose 1HP, 120VAC3HP, 240VAC

6x103

100x103

100x103

100x103

1x103

AgCdO, flange mount relaysNONCCO

20A, 400VAC3A, 400VAC20A NO / 3A NC, 400VAC

100x103

30x103

30x103

AgCdO, PC mount relaysNONCCO

30A, 400VAC3A, 400VAC30A NO / 3A NC, 400VAC

100x103

30x103

30x103

L1 L2

T1 T2

T1 T2

NO 1.5HP, 480 or 600VAC 100x103 Coil DataNONONONONONCNCNC

110LRA/25.3FLA, 240VAC (DC coil only)60LRA/14FLA, 240VAC (AC coilonly) 3A, 240VAC, pilot duty20A, 28VDC,resistive TV10,120VAC3A, 277VAC2A, 480VAC1A, 600VAC

100x103

100x103

100x103

100x103

100x103

100x103

100x103

100x103

Coil voltage range 5 to 110VDC; 12 to 240VACMax. coil power 1.7W; 4.0VA

Max. coil temperature 155°C

Coil insulation system according UL Class F

Coil versions, DC coil

Coil Rated Operate Release Coil Ratedcoil code voltage voltage voltage resistancepower

VDC VDC VDC Ω±10%W

AgSnOInO 6 6 4.5 0.6 221.7

NO 30A, 120/277VAC, resistive (DC coil only) 200x103 9 9 6.75 0.9 481.7

NO 30A, 120/277VAC, resistive (AC coil only) 100x103 12 12 9 1.2 861.7

NO 20A, 480VAC, resistive 100x103 18 18 13.5 1.8 1971.7

NO 1.5HP, 120VAC, 2 pole making/breaking (Fig.1) 100x103 24 24 18 2.4 3501.7

NO 3HP, 240VAC, 3 phase (DC coil only) 100x103 48 48 36 4.8 13901.7

NO NO

3HP, 480VAC, 3 phase (DC coilonly) 2HP, 600VAC, 3 phase (DCcoil only)

100x103

100x103110 110 82.5 11 7255

1.7 Coil versions, AC coil

VDE Coil Rated Frequency Operate Release Coil Ratedcoil

11-2012,Rev.1112www.te.com© 2012 TycoElectronicsCorporation,aTEConnectivityLtd. company.

Catalog andproductspecificationaccording to IEC61810-1 and to beused only togetherwith the‘Definitions’section.

Catalog and product data issubject to the terms of thedisclaimer and all chaptersof the ‘Definitions’ section,available at http://relays.te.com/definitions Catalog product data, ‘Definitions’ section,application notes and all specifications aresubject to change.

http://www.te.com/

http://relays.te.com/definitions

2


T92 Series Two-pole30APCBor Panel MountRelay (Continued)

Other DataMaterial compliance: EU RoHS/ELV, China RoHS, REACH, Halogen content

refer to the Product Compliance Support Center atwww.te.com/customersupport/rohssupportcenter

Ambient temperatureDC coil AC coil

Category of environmental protectionIEC 61810

-55ºC to 85ºC-55ºC to 65ºC

RTI - dust protected,RTII - flux proof, RTIII - wash tight

Vibration resistance (functional)Shock resistance (functional)Shock resistance (destructive)

1.65mm max excursions, 10-55 Hz10g for 11msec

100gTerminal type PCB-tht or quick connectWeight 86g Resistance to soldering heat THT

IEC 60068-2-20 250°C Packaging/unit tray/30 pcs., box/120 pcs.

Coil Data (continued)Ambient temperature vs. coil voltageAssumptions:1. Thermal resistance = 35°C per Watt (DC only.)2. Still air.3. Nominal coil resistance.4. Max. mean coil temperature = 155°C (change of resistance method).5. Coil temperature rise due to load = 6.3°C @30 amps.6. Curves are based on 1.7W at 25°C (DC only.).

Insulation DataInitial dielectric strength

between open contacts between contact and coil

1500Vrms

4000Vrms

between adjacent contact 2000Vrms

Initial surge withstand voltagebetween contact and coil 6kV

Initial insulation resistancebetween insulated elements 1x109Ω

Clearance/creepagebetween contact and coil 8mm clearance/9.5mm creepage

Dimensions

T92 – Mounting and termination code 1 T92 – Mounting and termination code 2, 3 and 4

120

100

80

60

40

20

070 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150

Applied Coil Voltage (% of Rated Nominal)

Max

.A

llow

able

Am

bien

tT

emp.

(°C

)

2.06 MAX.(52.32)

1.618 ± .020(41.10 ± .51) .047 TYP.

(1.19).585 ± .005 (14.86 ± .13) .309 ± .005

(7.85 ± .13)

1.36 MAX. (34.54)

1.21 MAX.(30.73)

.630 ± .005(16.00 ± .13)

.156(3.96)

.250 TYP.(6.35)

1.000 ± .010(25.40 ± .25)

.032 TYP.(0.81)

2.700 MAX.(68.58)

2.05 MAX.(52.07)

1.618 TYP.(41.10 ± .51).585 ± .005

(14.86 ± .13) .309 ± .005(7.85 ± .13)

1.36 MAX.(34.54)

1.04 MAX.(26.42)

.630 TYP.(16.00)

2.345 ± .005(59.56 ± .13)

.090 RAD.(2.29)

FOR #8 SCREW

1.495 MAX.(37.97)




http://www.te.com/customersupport/rohssupportcenter

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Contact material2 AgCdO 4 AgSnOInO

Coil voltageCoil code: please refer to coil versions table

3



Terminal assignmentBottom view on pins

2 form A 2 form C

Product code structure Typical product code T92 S 11

D 2 2 -24

TypeT92 Printed circuit board / panel mount power relay T92

EnclosureP S

Dust protected plastic caseWash-tight, tape sealed, plastic case (Mounting and termination code 1)Top sealed, not wash-tight, not tape sealed on bottom (Mounting and termination codes 2, 3 & 4)

Contact arrangement7

Coil InputA

2 form A (2 NO) 11 2 form C (2 CO)

AC voltage, 60Hz or 50/60 Hz (consult coil versions table) D DC voltageMounting and termination

12345

Printed circuit board mount; printed circuit board terminals.Panel mount via flanged cover; .250” (6.35mm) x .032” (.81mm) QC terminalPanel mount via flanged cover; .187” (4.75mm) x .032” (.81mm) QC terminals for coil and .250” (6.35mm) for contacts Panel mount via flanged cover, .187” (4.75mm) x .020” (.51mm) QC terminals for coil and .250” (6.35mm) for contacts. Panel mount via flanged cover, M4 screws w/ captive pressure plates. Requires Enclosure P and Contact arrangement 7.

Dimensions

T92 – Mounting and termination code 5

PCB layoutBottom view on pins

T92 - Mounting and termination code 1

An alternate PC board layout utilizes .076 ± .003 (1.93 ± .076) diameter holes on the samecenter-to-center spacing shown above. Use of the rectangular holes is recommended for improved solderability.

Only necessary terminals are present on single throw models. Consequently, some holeswill be unnecessary for single throw models.

2.700 MAX.(68.58)

2.345 ±.005(59.56 ± .13)

2.135 MAX.(54.23)

.913 MAX.(23.19)

2.010 MAX.(51.05)

1.431 MAX.(36.34)

1.36 MAX.(34.54)

.090 (2.29)RAD. FOR#8 SCREW

2 4

6 8

0

1

2 4 3

6 8 7

0

1

1.618(41.10).585

(14.86).309(7.85)

.630(16.00)

.203 TYP.(5.16) .052 TYP.

(1.32).072 TYP.

(1.83)

1.000(25.40)

.162(4.12)

.365(9.27)

.185(4.70)




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4






Product Code Enclosure Contacts Coil Mounting Contact Material Coil Part NumberT92P7A22-24 Plastic dust cover 2 form A, 2 NO AC Panel mount + quick connect AgCdO 24 VAC 6-1393211-0T92P7A22-120 120 VAC 5-1393211-7T92P7A22-240 240 VAC 6-1393211-2T92P7A22-277 277 VAC 6-1393211-3T92P7A24-240 AgSnOInO 240 VAC 3-1423008-3T92P7A52-120 Panel mount + screw terminals AgCdO 120 VAC 1423008-8T92P7A52-240 240 VAC 1-1423008-2T92P7D12-12 DC PCB terminals 12 VDC 6-1393211-5T92P7D12-24 24 VDC 6-1393211-6T92P7D22-12 Panel mount + quick connect 12VDC 6-1393211-9T92P7D22-24 24 VDC 7-1393211-1T92P7D22-48 48 VDC 7-1393211-2T92P7D24-12 AgSnOInO 12VDC 2-1423008-2T92P7D24-24 24 VDC 1423008-9T92P7D42-24 AgCdO 7-1393211-5T92P7D52-12 Panel mount + screw terminals 12 VDC 1-1423008-0T92P7D52-24 24 VDC 1423967-1T92P11A12-120 2 form C, 2 CO AC PCB terminals 120 VAC 3-1393211-8T92P11A22-12 Panel mount + quick connect 12 VAC 3-1393211-9T92P11A22-24 24 VAC 4-1393211-3T92P11A22-120 120 VAC 4-1393211-0T92P11A22-240 240 VAC 4-1393211-4T92P11A22-277 277 VAC 4-1393211-6T92P11A24-240 AgSnOInO 240 VAC 3-1423008-7T92P11A42-120 AgCdO 120VAC 4-1393211-8T92P11D12-12 DC PCB terminals 12 VDC 5-1393211-0T92P11D22-12 Panel mount + quick connect 5-1393211-3T92P11D22-24 24 VDC 5-1393211-4T92P11D24-12 AgSnOInO 12 VDC 3-1423008-5T92P11D24-24 24 VDC 3-1423008-6T92S7A12-24 Wash tight 2 form A, 2 NO AC PCB terminals AgCdO 24 VAC 9-1393211-8T92S7A12-120 120 VAC 9-1393211-7T92S7A12-240 240 VAC 9-1393211-9T92S7A22-24 Top sealed Panel mount + quick connect 24 VAC 1393212-4T92S7A22-120 120 VAC 1393212-2T92S7A22-240 240 VAC 1393212-5T92S7D12-12 Wash tight DC PCB terminals 12 VDC 1393212-8T92S7D12-24 24 VDC 1-1393212-0T92S7D12-48 48 VDC 1-1393212-1T92S7D12-110 110 VDC 1393212-7T92S7D14-24 AgSnOInO 24 VDC 1-1423008-8T92S7D22-12 Top sealed Panel mount + quick connect AgCdO 12 VDC 1-1393212-4T92S7D22-18 18 VDC 1-1393212-5T92S7D22-24 24 VDC 1-1393212-7T92S7D22-110 110 VDC 1-1393212-3T92S11A12-24 Wash tight 2 form C, 2 CO AC PCB terminals 24 VAC 8-1393211-1T92S11A12-120 120 VAC 8-1393211-0T92S11A12-240 240 VAC 8-1393211-2T92S11A22-12 Top sealed Panel mount + quick connect 12 VAC 8-1393211-3T92S11A22-24 24 VAC 8-1393211-6T92S11A22-120 120 VAC 8-1393211-4T92S11A22-240 240 VAC 8-1393211-7T92S11D12-12 Wash tight DC PCB terminals 12 VDC 8-1393211-9T92S11D12-24 24 VDC 9-1393211-0T92S11D12-48 48 VDC 9-1393211-1T92S11D12-110 110 VDC 8-1393211-8T92S11D22-12 Top sealed Panel mount + quick connect 12 VDC 9-1393211-3T92S11D22-24 24 VDC 9-1393211-4

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®

Operating and Maintenance For Petroleum Meters

M203Rev. BP.D. Oscillating Piston Flowmeters:

11⁄4 Type 4 Petroleum11⁄2 Type 4 Petroleum

TABLE OF CONTENTS

Installation 1

Operation 3

PresetModels 3

Printer Register Models 4

Calibration 4

Register Maintenance 5

11⁄4 Preset Models with Auto Stop Valve 6

11⁄2 Preset Models with Auto Stop Valve 7

Measuring Chamber Maintenance 10

Gear Train Maintenance 12

Air Release Maintenance 12

General Maintenance 14

Troubleshooting 15

INSTALLATIONUse pipe thread cement on the outside of male threads only.

The flowmeter may be located at any convenient point on the discharge line from the pump. OnPreset Models the base of the flowmeter casing is above the bottom of the valve. Do not clamp it inposition without using the spacers provided or making a hole for the valve.

Be sure to allow room for the removal of the strainer basket, register, and air release mecha-nism. (See Figure 15.)

The piping on the outlet side of the flowmeter should be arranged so as to eliminate the possi-bility of draining the measuring chamber.

All piping connected to the flowmeter must be firmly secured to prevent strain on the flowmetercasing.The use of flexible connections to the pump or tank is recommended.

There must be no bypass connection around the flowmeter. Experience has shown that thevalve in this line will eventually leak, work open or be accidentally left open.

In order to obtain a maximum rate of delivery, the compartment outlets and the piping should beas large as practical and the number of elbows should be reduced to a minimum. Sweep elbowsshould be used wherever possible.

Blowing The Hose: As it is impossible to blow all the liquid from the hose, the amount of liquid leftin the lines on the discharge side of the flowmeter will not be the same before and after everydelivery. It is therefore recommended that provision be made to keep the hose and outlet piping fullof liquid at all times. For this purpose a hose nozzle with a check valve should be used.

Pumping Out Underground Tanks: In making provisions for pumping out underground tanks, DONOT provide any connection between the outlet of the flowmeter and the compartments or manifold.A valve in this line which is leaky or carelessly left open will allow part of the metered liquid to bediverted.

Air Vent Line: The vent pipe from the air release should be 3⁄4 pipe or 1⁄2 inside diameter tubing.Care should be taken to prevent any possible obstruction to the free flow of air through this line.

It should either be connected to the top of one of the compartments or run into a container ofabout 5 gallons capacity to collect any liquid discharged with the air.

INSTALLATION

Piping

Page 1

FIGURE 1TRUCK INSTALLATION – PETROLEUM

CAUTIONCONTAINERS EMPLOYED TO COLLECT VAPOR OR LIQUID DISCHARGED FROM THE METER VAPOR RELEASESHOULD BE OF SUFFICIENT SIZE TO PREVENT ANY LIQUID ESCAPE DURING NORMAL OPERATION, AND SHOULDHAVE A SUITABLE FLAME ARRESTOR VENT. ALL VENT LINES AND FITTINGS SHOULD BE OF METAL CONSTRUC-TION, AND ALL VALVES SHOULD BE DESIGNED SO THAT NORMAL VIBRATION DOES NOT CAUSE ACCIDENTALOPENING.

Interlocking Of Compartment Or Manifold Valves

When Installing

After Installing

Cleaning The Strainer

Interlocking of Compartment or Manifold Valves

If the valve of an empty compartment or auxiliary suction connection is open even slightly, whileanother compartment is being emptied, air drawn in through this valve will be churned up with theliquid to such an extent in the pump that some of it may be carried through the air release and causeover-registration on the flowmeter.

Either the compartment or the manifold valves should be interlocked so that delivery can bemade from only one compartment at a time. Compartment valves are ordinarily interlocked by meansof a selector lever in the can box.

Manifold valves may be of the 2-way 3-port lubricated plug type so arranged as to achieve thesame purpose.

FIGURE 2MANIFOLD VALVE INTERLOCKING

WARNINGWhen Installing

The connecting piping should be firmly secured to prevent strain on the flowmeter casing.Care should be taken that there is provision for expansion due to change in temperature.

All piping on the inlet side of the flowmeter should be very thoroughly cleaned out. Wheneverpossible, place a spool in the place of the flowmeter and flush out all lines thoroughly before theflowmeter is installed. The majority of service calls on new installations would be eliminatedif these directions were followed.

Inlet and/or outlet are marked on flowmeter; do not install backwards.

After Installing

Pass sufficient liquid to clear the lines of air. Check the rate of flow. It should not exceed therated capacity of the flowmeter. The bypass of the pump should be regulated to deliver the maximumpractical rate of flow for the least amount of pressure. Pressure on the flowmeter should not exceed125 psi. Do not try to increase the flow through undersized pipes and fittings by means of excessivepressures which will cause leaking gaskets and collapsed air release floats.

Temperature of the liquid should not exceed 140F.

All flowmeters are tested and calibrated at the factory and adjustment should not be necessary. If registration appears to be in error, the flowmeter registration should be checked using a calibrated volumetric prover. The prover must be of sufficient capacity to permit a full flow delivery for at least one minute. Do not base calibration upon assumed volume of ordinary con-tainers or “dip stick” measurement.

If the registration is not in agreement refer to the section on “Flowmeter Calibration.”

Cleaning The Strainer

While the installation is still new, the strainer, if used, should be cleaned very frequently. Afterthe system has been thoroughly flushed of foreign material, only periodic maintenance of the unit isrecommended.

Page 2

OPERATION

To Operate the Flowmeter

PRESET MODELS

To Stop In Emergency

To Adjust Tripping Point

FIGURE 3PRESET 800 SERIES PRINTER REGISTER

Page 3

OPERATIONTo Operate The Flowmeter

1. Reset register to zero by turning operating knob to the rear stop. On Printer models, first insert ticket.

2. On Preset models, set the Preset wheels to the desired quantity.3. Start pump — open Auto Stop valve (if used).4. Open hose nozzle and make delivery.5. After completing of delivery on Printer models, stamp final reading on ticket by turning oper-

ating knob to the front stop and remove ticket.

PRESET MODELSTo set the Preset mechanism press the setting buttons inward until the desired quantity is noted

on the Preset wheels.

To Stop In Emergency

Pushing the red emergency stop button will trip the valve. After it has been used either thedelivery may be completed automatically as originally set by reopening the valve or the mechanismmay be set for a new figure. The accuracy of delivery in either case is not affected.

To Adjust Tripping Point

Registers are shipped from the factory with the Preset mechanism adjusted to trip correctly atthe normal rates of flow. If, due to a change in the speed of closing of the valve or for other reasons, the Preset does not trip at the correct point, the trip point may be adjusted as follows:

If the valve is closing “off the mark,” either late (over-delivery) or early (under-delivery), adjustthe two connecting link nuts to bring the trip point to the zero mark. For right-hand assembly turn thenuts to lengthen the connecting link when the trip point is early, or turn to shorten if the trip point islate. For left-hand assemblies turn in the opposite direction. Continue this procedure until the finaltrip is on or close to the zero mark. On double trip valves, the intermediate flow rate will be satisfac-tory when the final trip is adjusted, as described.

Further adjustment of the trip point is possible, but is not recommended for normal applications.The following procedure should be used only when very exact settings of the final trip are necessary.

Adjust the connecting link nut as described above, and proceed as follows:

Remove the trip adjusting screw located in the lower right corner of the register front housing.Insert a narrow blade (3⁄16) screwdriver until it engages the slotted head of the adjusting screw. Oneturn of this screw will change the tripping point about one-quarter of one-tenth gallon.

If the Preset trips before reaching the zero mark(early), turn the adjusting screw clockwise.

If the Preset trips after reaching the zero mark (late),turn counterclockwise.

Do not turn the adjusting screw more than 11⁄2 turns in either direction from the initial position or pass a point where a resistance to further turning of the screw is felt.

If the trip point is not on zero after 11⁄2 turns, returnthe adjusting screw to its original position and turn theconnecting link nut a half turn in the appropriate direc-tion. Then repeat the trip screw adjustment procedure.

Gear shifter supplied as standard on 833 and 834models. Optional on 831 and 832 models.

DUST BAR

CLAMPSCREW PRESET BUTTONS

OPERATING KNOB

TRIP ADJUSTING SCREW COVER

EMERGENCY STOP BUTTON

STOP PINS

CLAMP SCREWS LETTERWHEELS

FIGURE 4PRINT UNIT ADJUSTMENTS

PRINTER REGISTER MODELS

To Insert and Remove Tickets

To Adjust Ticket Guides

To Change Setting of “Letter”Wheels

To Change Position of the Register(Non-Preset Models)

CALIBRATION

Page 4

PRINTER REGISTER MODELS

To Insert and Remove Tickets

To insert a ticket be sure that the operating knob is turned forward to a stop. Then depress the dust bar and insert the ticket in the ticket slot under it, either “face down bottom end first” or “face up top end first,” as noted on the instruction plate. Turn the operating knob backward to the stop. This resets the visible wheels to zero, locks the ticket in place and prints the initial reading on the ticket.

Upon completion of delivery, turn the operating knob forward to the stop. This operating prints the final reading and releases the ticket. It is now possible to remove the ticket.

To Adjust Ticket Guides

The Printer registers are shipped from the factory with the ticket guides adjusted for a standard (41⁄8) width ticket. If for any reason it is necessary to reposition the ticket, proceed as follows:

1. Remove top cover.

2. Insert a ticket into the printer. Loosen the clamp screwson the rear of the ticket guides. Move the guides to theright or left as required. Tighten clamp screws. The ticketmust slide freely between the guides. If the ticket bendsat the forward end of the guide, remove the guide andrebend the tail of the guide.

3. If it is necessary to raise or lower the printing, push thetwo stop pins to the front or rear with the end of a screw-driver.

4. Replace the top cover and reseal.

To Change Setting of “Letter Wheels

1. With the top plate removed, the “letter” wheels are vis-ible (see Figure 4).

2. By means of a screwdriver or similar tool, turn the wheelsuntil the desired letters appear at the top where they are in position to print.

To Change Position Of The Register(Non-Preset Models)

Remove the register from the flowmeter. Two studs and two threaded holes will be seen on theflowmeter cover. Turn register 180 and tighten the screws in front of the register. For conveniencethe operating knob may be moved to the opposite side of the register. If the register is to be turned90 transfer the studs to the two empty holes.

Gear shifter standard on 833 and 834 models. Optional (extra charge) on models 831 and 832.

CALIBRATIONTest all flowmeters with 50-gallon or larger test measures. Do not base calibration upon truck

compartments.

Preset flowmeters should first be tested and adjusted without the Preset (set the register formore than the test quantity), then tested with the Preset. If the Preset mechanism does not tripcorrectly, see instructions on page 3 “To Adjust the Tripping Point.” Rerun the test, and then if thedelivery is not correct, a service man should be called.

Erratic Registration

Erratic registration is an indication of trouble in the system caused by air or dirt in the measuringchamber. Do not try to correct this by recalibration of the flowmeter, but first check over the piping forair leaks, clean the strainer and then, if the trouble has not been found, clean the flowmeter asdirected on pages 10 and 11. If this does not correct the trouble, check for faulty installation.

Over-registration is an indication of air, whereas under-registration is generally caused by dirt orpipe scale in the measuring chamber, or the liquid bypassing the flowmeter in some manner.

Consistent Over or Under-Registration

When the flowmeter registers consistently either more or less than is delivered, the calibrationmay be corrected in the following manner:

1. Remove four screws holding top cover and remove cover.

2. Lift and turn the change gear shifter (see Figure 5) in the direction indicated on the top of the shifter.

3. There is a series of holes, marked A to H, in the plateinto which the guide pin enters at different settings.Altering the setting by one hole changes the calibra-tion approximately 17 cubic inches in 50 gallons.

Example: Suppose the flowmeter consistently gives 34cubic inches too much when it registers 50 gallons. After re-moving the cover plate move the gear shifter 2 spaces to theright (from position E to position C) to decrease the deliveryabout 34 cubic inches in 50 gallons.

After changing the calibration always replace top cover,making sure that the sheet steel housing on the sides andback fits into the groove in the bottom edge of cover. Run asmall amount of liquid through the flowmeter before testing.To prevent tampering, always reseal after calibration.

Note: For broader change gear requirements, refer to form TSG-310.

REGISTER MAINTENANCERegister parts are such that only minor field repairs are advisable. When a register is in need of

repair or service other than that for which instruction is given here, it should be returned to an autho-rized Red Seal Measurement distributor for service.

To Remove Register From Flowmeter

Loosen the two clamp screws on lower front of the register. Lift the register off. On PresetModels the valve linkage must first be disconnected. (Remove cotter pin and washer at valve end.)

When one register is removed and another substituted,(1) Check the number of teeth on the change gears (seeFigure 6). They must be the same as the gears on the oldregister and on the same respective spindles. The num-ber of teeth is stamped on each gear. To remove these gears,close the split end of the spindle with a pair of pliers and pulloff the gear. After putting on a gear, spread the end of thespindle slightly. (2) Make sure the position of the “Gear Shifter”

is the same on the new register as on the old one — eachhole is lettered for convenience.

CHANGE GEAR “S” To Clean Register Mask

The Register mask is made of plastic and requires spe-cial treatment.Instructions for cleaningare given on next page:

Erratic Registration

Consistent Over or Under-Registration

REGISTER MAINTENANCE

To Remove Register From Flowmeter

To Clean Register Mask

Page 5

FIGURE 6CHANGE GEAR ARRANGEMENT

CHANGE GEAR “R”(ON “STD”SPINDLE)

GEAR SHIFTER

FIGURE 5GEAR SHIFTER ADJUSTMENTS

N

OG

E

D

B

C

TO OPENTO OPEN

G

E

D

B

C

N

O

To Rotate Register

When the flowmeter is assembled as a Left Hand assembly and it is desired to change it to a Right Hand assembly, or vice versa, proceed as follows:

1. Remove cotter pins (E) from valve linkage.

2. Unscrew the outside register link lock nut (P) and remove connecting rod (G).

3. Remove register link (N), rotate 1/2 turn and reassemble onto register as described in appro-priate valve adjustment instructions.

4. Loosen two clamp screws on lower front of register, lift register up and turn register 180.

5. Remove four handle housing assembly hex screws (C) and remove handle housing assem-bly from valve.

6. Remove valve handle set screw (B) and slide handle off bushing. Remove two cam retainingscrews (not shown). Remove shaft seal plug (D). Disassemble valve operating shaft andvalve operating cam. Reassemble valve operating shaft and install valve operating cam inthe reverse direction. Reinstall two cam retaining screws and shaft seal plug. Reinstall hous-ing assembly with valve operating cam acting on pilot rod. Secure with four hex screws (C).Reassemble valve handle (A) on knurled knob in position as shown for specific assembly.

After completing the above instructions, the valve linkage must be adjusted in accordance with the procedure for the specific type valve as outlined on the following pages.

LEFT HAND ASSEMBLY RIGHT HAND ASSEMBLY

M

PAA

M

P

11⁄4 PRESET MODEL WITH AUTO-STOP VALVETo Rotate Register

FIGURE 7VIEW LOOKING AT BACK OF REGISTER

Page 6

If the mask becomes soiled with grease and oil, solvents for these substances, such as kero-sene or naptha, may be used to remove dirt. However, sprays that are commonly employed in clean-ing glass windshields must not be used as cleaners, since they contain solvents.

A water solution of nonabrasive soap is recommended for washing grease, oil, or dirt from themask. It is then cleansed by rubbing gently with a soft cloth, in a manner similar to cleaning windowglass, rinsing the plastic in clean water, and finally drying.

Scouring cleanser and similar material must not be used in cleaning the mask, since they con-tain abrasives that scratch the surface.

The use of solvents, such as acetone, ethyl acetate, benzene, and ethylene dichloride to brightenthe surface is never recommended since these substances soften the surface of the plastic.

11⁄4 PRESET MODELS WITH AUTO STOP VALVE

To Adjust Linkage Valve

To Adjust The Tripping Point

11⁄2 PRESET MODEL WITH DOUBLE TRIP VALVETo Rotate Register

right-hand assembly, or vice versa, proceed as follows:

Page 7

To Adjust Linkage Valve

Note: Before any adjustment of the Auto-StopValve is made, be sure that the Auto-Stop settingwheels indicate a quantity other than zero to ensure that the trip mechanism of the register is in proper position.

1. Depress the emergency stop button on the register and turn the shaft (O) clockwise (asviewed from rear of register).

2. Assemble register arm (N) on knurled knob in position as shown for specific assembly. (SeeFig. 7 ). Arm should move an equal distance each side of vertical center line (M) (Angle x=x).

3. Assemble one nut (P) on connecting rod (G) and the other end of the connecting rod to thecenter hole in handle (A) using washers and cotter pins (E).

4. Open valve all the way. Turn shaft (O) counter clockwise to latch up mechanism. With valveheld open tighten nut (P) against register arm link. Then assemble and tighten second nut at(P).

5. Depress the emergency stop button and allow the valve to close. At this point the leakagebetween the valve and the register must be free. If it is not, the above adjustments must berechecked.

6. Set the register to deliver the minimum quantity and open the valve to run product throughthe flowmeter.

7. After the initial trip occurs the valve should close to the intermediate flow position. This ratewill vary depending on product metered. If the valve closes too far, or all the way, adjust nuts(P) to provide additional rod length.

8. It is sometimes necessary to change the position of the handle. This can be done by loosen-ing handle screw (B) and repositioning the handle as follows: if the register mechanism willnot latch up, position the handle further toward the register. If the valve will not close, thehandle may be positioned away from the register. Fine adjustments may be made by chang-ing the effective length of connecting rod (G) utilizing nuts (P). Effective length of connectingrod (G) may also be varied by positioning the end of the rod in the upper or lower holes in thevalve handle.

9. The Auto-Stop trip adjusting screw should be near its mid-position.

To Adjust The Tripping Point

The flowmeter is shipped from the factory with Auto-Stop mechanism adjusted to trip correctlyat maximum rates of flow while the flowmeter is measuring a non-viscous liquid. Trip adjustment after final installation may be necessary due to differing flow rate and/or viscosity.

If the Auto-Stop does not trip off at the correct mark due to a change in the speed of closing ofthe valve, different rates of flow, or any other reason, the adjustment is made as follows:

Remove the screw located in the lower right corner of the front housing. Insert a medium-sizedscrewdriver into this hole until it engages the slotted head of an adjusting screw. One turn of thisscrew will change the tripping point about one-quarter of one graduation of the first wheel.

If the Auto-Stop trips before reaching the zero mark, turn the adjusting screw in a clockwisedirection.

If the Auto-Stop trips after the zero mark, turn the adjusting screw in a counterclockwise direction.

11⁄2 Preset Model With Double Trip Valve

To Rotate Register

When the flowmeter is assembled as a left-hand assembly and it is desired to change it to a

Adjustment of Auto-Stop Valve

To Adjust Valve Linkage

1. Depress the emergency stop button on the register and turn the shaft (O) clockwise.

2. Assemble register arm (N) on knurled knob in position as shown for specific assembly. (SeeFig.8). Arm should move an equal distance each side of vertical center line (M) (Angle x = x).

3. Assemble valve arm (H) as shown for specific assembly. On the right hand assembly theremust be one notch between the cast mark (K) on the valve arm and the cast mark (J) on thestop plate (J above K). On the left hand assembly these cast marks must be in line.

4. Assemble one nut (P) on connecting rod (G) and assemble clevis to the other end of theconnecting rod a distance of 1.

5. Insert end of connecting rod through register arm link and assemble clevis (F) to valve arm(H) using upper hole. (See Figure 8). Insert clevis pin (E).

6. Open valve all the way. The opening of the valve is stopped by the set screw (B) which shouldproject approximately 1⁄8 below the lug holding it. Turn shaft (O) counterclockwise to latch upmechanism. With valve held open, tighten nut (P) against register arm link. Then assembleand tighten second nut at (P).

7. Depress the emergency stop button and allow the valve to close. At this point the linkagebetween the valve and the register must be free. If it is not, the above adjustments must berechecked.

Page 8

1. Remove clevis pin (E) from valve linkage.

2. Unscrew the outside register link lock nut (P) and remove connecting rod (G) and clevis (F) as a unit.

3. Remove register link (N), rotate 1/2 turn and reassemble onto register as described in ap-propriate valve adjustment instructions.

4. Loosen two clamp screws on lower front of register, lift register up and turn register 180.

5. Remove operating shaft cap screw (C) on both sides.

6. Interchange connecting rod arm (H) and valve operating handle (A). The connecting rod armmust be assembled with notches (J and K) in specific relationship. (See item 3 of valveadjustment instructions for details regarding position of notches.)

7. Reassemble operating shaft cap screws (C).

8. Remove valve handle stop set screw (B) and screw into hole on opposite side of valve.

FIGURE 8VIEW LOOKING AT BACK OF REGISTER

After completing the above instructions, the valve linkage must be adjusted in accordance with the following procedure:

Adjustment Of Auto-Stop Valve

Before any adjustment of the valve is made, be sure that the Preset setting wheels indi-cate a quantity other than zero to insure that the trip mechanism of the register is in proper position.

To Adjust Valve Linkage

M

O

N

PX X

G

TO OPEN

F E

A B

DIRECTION OF FLOW

YH

JK

C

DOUTLET

RIGHT HAND ASSEMBLY

MPN

O

X X

GTO OPEN

E F

A B

DIRECTION OF FLOW

Y

J

K

C

D

H

OUTLET

LEFT HAND ASSEMBLY

DOUBLE TRIP MAINTENANCE

To Disassemble and Assemble Double Trip Valve

7. Place other end of spring over boss in cylinder (C) and press cylinder down over piston (F). Back of cylinders should be below flange face for proper assembly.

8. Hold cylinder in place, place “O” ring in body recess and attach retaining ring (B) with two screws (A).

9 Open valve as far as possible — make sure that valve is not being stopped by set screw (L).

Page 9

8. Set the register to deliver the minimum quantity and open the valve to run product throughthe flowmeter.

9. After the initial trip occurs the valve should close to the intermediate flow position. This rateshould be approximately 15 to 20 gpm. If the valve closes too far, or all the way, unscrewclevis (F) on rod (G) to hold valve open further. If the rate of flow is too fast during theintermediate position, turn the clevis onto the rod to allow the valve to close further. Itshould not be necessary to turn more than one turn in either direction.

10. It is sometimes necessary to change the position of set screw (B) if the clevis has beenreadjusted. If the register mechanism will not latch up, unscrew the set screw to allow thevalve to open further. If the connection rod (G) is under compression, when the valve is heldall the way open, turn the set screw down to relieve the pressure on the register.

11. The Auto-Stop trip adjusting screw should be near its mid-position. If a small adjustment ofthis screw will not permit the register to shut off “on the mark” it is usually possible to correctthis by a slight adjustment of the clevis (F). This will move the main valve nearer to or furtheraway from its seat during the intermediate flow and thereby change the amount of timeneeded for the valve to fully close at the last trip (Also see To Adjust The Tripping Point.)

NOTE: If it is difficult to obtain proper rate of flow during intermediate trip position and still haveregular latch up fully. Check Auto-Stop valve to insure that it is opening all the way. Check valve byremoving set screw (B) and clevis (F) from valve arm; open valve as far as possible. The distancebetween lug on arm and lug on stop plate must not be more than 1⁄4.

DOUBLE TRIP MAINTENANCE

To Disassemble and Assemble Double Trip Valve

1. Remove valve from flowmeter.

2. Remove two screws (A) holding retaining ring (B) at inlet of valve. (Caution: End plate shouldbe held by hand when removing screws because of spring tension beneath the plate.) Allinternal parts of the valve can now be removed with the exception of the operating shaftmechanism. The removal of the internal parts from the valve body may be assisted by oper-ating the valve handle as when operating the valve.

3. Disassemble piston and throttling ring assembly (items F to K). Inspect valve seats, “O” ringgaskets, piston ring (D), and cylinder (C) for damaged surfaces. Replace all defective partswith new parts.

4. Reassemble piston and throttlingring assembly. Apply Loctite BlackMax 380 to bond the disc (G) tothe piston (F), and allow 24 hoursto cure before placing in service.Apply Loctite Threadlocker 242under heads of three piston as-sembly screws (H).

5. Assemble pilot valve (E) on pilotvalve rod (J). Place assembly intovalve body.

6. Place one end of spring over pilot valve boss.

FIGURE 9 VALVE ASSEMBLY

To Adjust Rate of Closing of Valve

To Inspect OperatingShaft Seals of PresetValves

MEASURING CHAMBER MAINTENANCE

To Remove And Disassemble

Page 10

To Adjust Rate of Closing Of Valve

Variations in the viscosity of the liquids being measured will cause changes in the rate of closingof the valve from its full open position to its intermediate position. (Valve should reach its intermedi-ate position with approximately 4 gallons remaining on Preset setting wheels.)

Setting of orifice plate is indicated on tag attached to valve.

The rate of closing can be adjusted by changing the position of orifice plate which is readilyaccessible through inlet of valve. (Valve does not have to be disassembled.)

(Figure 10) View of valve inlet showing position of orificeplate for gasoline and other low viscosity liquids. Note that ori-fice opening is completely covered. (Photo shows 11⁄2 valve.)

The normal position of orifice plate in valve to be used withgasoline or other low viscosity liquids will be set with orifice open-ing covered. If valve closes too slowly with this setting, turn platecounterclockwise to expose either small, medium or large holeas required.

To Inspect Operating Shaft Seals of Preset Valve

The following steps should be followed if it becomes neces-sary to disassemble the operating shafts because of leakage.Shaft seal cannot be corrected by tightening of the bearingbracket screws. In this case new “O” rings are usually required. (See parts list for 2 Type 1A Double Trip Preset Valve.)

1. Remove the valve handle (A), connectingrod arm (I), two stop plates (B and H), andtwo roll pins (C). Remove eight screws andpry off two shaft bearing brackets (D). Donot damage gaskets (G).

2. The two “O” ring seals (E) can be inspectedfor damaged surfaces. Replace any defec-tive “O” rings.

3. To remove the operating shaft (J) and twoshaft bearings (D), first remove the twoscrews in the valve operating cam (K). In-spect the shaft for score marks and replaceif necessary. New “O” ring seals are worth-less if used with a badly scored shaft.

4. Remove retainer (F), replace “O” rings (G) and reinstall shaft bearings (D).

5. Reassemble the operating shaft and cam.

6. Replace rings, flat gaskets, two roll pins, two stop plates, connecting rod arm and valve handle.

MEASURING CHAMBER MAINTENANCE

To Remove and Disassemble

This operation is not difficult and may be performed by any competent mechanic. No specialtools are required. No trouble need be expected, if these few simple, but important, directions arefollowed. Do not open the flowmeter until you have checked over all other possible causes of erraticregistration.

FIGURE 11 SHAFT ASSEMBLY

FIGURE 10 VALVE ORIFICE PLATE

FIGURE 13 CHECKING THE

PISTON MOVEMENT

Page 11

1. Prepare a clean surface on which to place the parts as they are removed. The parts aremachined to close tolerances and should be handled with care. Have a replacement gasketready before opening the flowmeter.

2. Loosen the two clamp screws on the lower front of the register. Lift the register off. On PresetModels the valve linkage must first be disconnected. (Remove cotter pin and washer at valveend.)

3. Remove the flowmeter cover taking care not to damage the gasket.

4. Lift the measuring chamber from the flowmeter casing.

5. Remove the upper cylinder head by inserting a screwdriver in one of the slots provided andprying it off. Be careful not to scratch or nick any part of the chamber.

6. Lift out the piston by its spindle. If care is taken to draw it straight, it should come out easily.Do not force it.

7. Remove the control roller and the diaphragm from the lower cylinder head.

8. The seal pin may be removed (for replacement only) by pulling upward, using pliers if neces-sary.

To Clean The Measuring Chamber

The parts may be most easily cleaned of scale, etc., by means of a good, coarse, stiff bristle(not wire) brush and gasoline. All foreign matter, except deeply embedded chips or heavy corrosiondue to water, may be removed in this manner. Do not use abrasives, such as emery cloth or sandpa-per. When the piston is badly corroded, the whole chamber should be replaced.

FIGURE 12MEASURING CHAMBER COMPONENTS

The parts of the measuring chamber which may show wear after long periods of service are thediaphragm and the control roller. These parts will not require replacement until the accuracy beginsto fall off at low rates of flow. To change these parts, merely substitute the new for the old when theflowmeter has been taken down for cleaning.

Experience has shown that the sliding surfaces between the chamber and piston take on aburnished finish and wear little if any.

To Reassemble The Chamber In The Flowmeter

Before reassembling the flowmeter, rinse all parts in gasoline. If possible, flush out the flowme-ter body. Assemble the parts carefully; they should slide together easily without hammering or forc-ing. It is essential that all contact surfaces between the cover and chamber, or between the measur-ing chamber and its seat in the casing, be clean and free from nicks.

To Clean The Measuring Chamber

To Reassemble The ChamberIn The Flowmeter

1. Assemble diaphragm and seal pin in chamber if replacement was necessary.

2. Place the control roller on its pin and see that it will rotate freely.

3. Replace the piston and oscillate it carefully by hand; it should move easily without binding. Ifit sticks, do not force it, but remove and locate the cause. Do not file down the roller as thiswill impair the accuracy of the flowmeter.

4. Replace the upper cylinder head and again oscillate the piston to make sure that is free.

5. When replacing the measuring chamber in the casing, be sure that the seat is clean and freefrom nicks. Make sure the dowel pin in the main casing enters the slot in the chamber bottomproperly and allows the chamber to rest on its seat.

6. Before replacing the cover, first be sure the chamber is properly seated and inspect thegasket.Then set the arm of the gear train so that it will not come down on the piston spindle.

7. Make sure the cover is down on its seat before tightening the bolts.

GEAR TRAIN MAINTENANCE

To Repair Leaking “U” Cup Seal Stuffing Box

Keep dirt out of register and avoid injury to gasket.

Remove the register. If tightening the stuffing box nut with thefingers does not stop this leak, replace “U” cup shaft seal. It mayalso be necessary to replace “U” cup shaft seal and to replace thegear train.

1. Remove the register.

2. Remove the star connection (1), using a No.8 Allen wrench.

3. Unscrew the stuffing box nut (2).

4. Remove shaft seal (3). Inspect upper end of spindle to besure it is free of nicks or burrs which might damage thenew shaft seal when it is placed on spindle. Remove theclamp nut (6); gear train assembly can be removed fromunderside of flowmeter cover.

5. Replace shaft seal with new part. Be sure expander (4) and spring (5) are in position before inserting new seal.

6. Assemble nut and tighten down all the way.

To Replace The Gear Train

1. Remove the register (see page 5).

2. Remove the star connection (1), using a No.8 Allen wrench.

3. Remove the flowmeter cover, with gear train assembly attached. Keep dirt out of flowmeter and avoid injury to the cover gasket.

4. Unscrew the stuffing box nut (2).

5. Remove clamp nut (6); gear train assembly can be removed from underside of flowmeter cover.

AIR RELEASE MAINTENANCE

General Note — “O” Ring Gaskets

1. The groove in which the “O” ring is located must be free of dirt.

Page 12

GEAR TRAIN MAINTENANCE

To Repair Leaking “U”

Cup Seal Stuffing Box

To Replace The Gear Train

AIR RELEASE MAINTENANCEGeneral Note –

“O” Ring Gaskets

FIGURE 14GEAR TRAIN ASSEMBLY

To Clean The Strainer

Air Release Valve Troubles

To Inspect Air Release Unit

2. The flat face against which the “O” ring seats must be clean and free of nicks or dents which will allow the pressure to leak between the gasket and the metal.

To Clean The Strainer

Remove the strainer cover and pull out the screen. Blow the dirt off screen with compressed air and rinse in gasoline or kerosene.

FIGURE 15AIR RELEASE COMPONENTS

Air Release Valve Troubles

Troubles with this unit may arise from:

a) Collapsed ball float allowing vent to remain open.

b) Dirty or worn valve seat.

c) Improper position of float.

d) Sticking back pressure valve.

To Inspect Air Release Unit

1. Remove the Strainer (see Fig. 15).

2. Uncouple the Vent Connection.

3. Remove the cap screws on the air release cover and lift out the mechanism.

4. If the float is damaged, remove by taking out the hinge pins and replace with a new one.

5. If the valve is leaky,

a. Remove the air release unit from the underside of the cover by unscrewing three small screws.

b. Take off the sleeve with piston seal.

c. Move the ball in the direction of the valve housing as far as possible and remove valve disc assembly.

d. Inspect piston seal for any obvious deterioration.

e. The valve disc assembly should be taken apart to inspect for dirt or defective pilot valve seat. A pair of fine nose pliers is needed for this. Replace valve if seats are defective.

f. When reassembling, make sure the piston seal is properly positioned and that the valve disc assembly moves freely in sleeve.

6. To avoid possible mechanical interference, the support bracket and float linkage should ap-pear as shown above. If this is not as shown, the framework has been bent out of shape. Toadjust, bend metals back in the direction required.

To Remove Back Pressure Valve

1. Remove Air Release and Strainer from the line by unbolting at inletflange and flowmeter inlet.

2. Remove strainer sleeves and air release valve.

3. Remove drain plug.

4. Hold block of wood (13⁄4 diam.) against back pressure valve andknock valve out of housing by means of 1⁄2 diameter rod insertedthrough drain plug hole.

GENERAL MAINTENANCEIn the maintenance of the accuracy of Neptune Flowmeters,

little is necessary other than to see that the proper conditions of operation are preserved. Theseconditions, once the flowmeter has been properly installed, consist merely in guarding against for-eign matter, such as air, sediment and water, entering the measuring chamber.

The liquid passing through the measuring chamber must be free of grit and other forms ofsediment in order to prevent unnecessary friction and the scoring of the piston and chamber walls.Evidence of trouble from this source is under-registration of the flowmeter.

Periodic cleaning of the strainer at the inlet of the flowmeter will help to insure against thistrouble. In the design of this unit, particular care has been taken to make this operation as simple aspossible. See page 13.

Being an instrument which measures by volume, a flowmeter will record the passage of air aswell as the liquid being measured. Over-registration is the result. The air release valve is intended toprevent this condition by venting this air before it passes through the measuring chamber.

Incidental water will cause no damage to the flowmeter. Trouble from this source may be ex-pected only when water is allowed to stand in the flowmeter for considerable periods of time.

When washing trucks, care should be taken to cover the register. Water in the register will causetrouble particularly in cold weather when ice may form and cause sticking.

Test with 50-gallon or larger test measures. Do not base calibration upon truck compartments oron 5-gallon measures. Instructions for calibration will be found on page 5.

Preset Flowmeters should first be tested and adjusted without the Preset (set the register formore than the test quantity); then test with the Preset. If the Preset mechanism does not trip cor-rectly see instructions on “To Adjust the Tripping Point,” page 3.

Before a flowmeter is put in storage the measuring chamber must be flushed with a light lubri-cating oil to prevent condensation damage.

To Remove Back Pressure Valve

GENERAL MAINTENANCE

Sediment

Air

Water

Testing

Storage

FIGURE 16 BACK PRESSURE

VALVE

TROUBLESHOOTINGTROUBLESHOOTING1. Register Not Working When Liquid is Flowing

a) Bypass around flowmeter not shut off.b) Frozen condensation inside register.c) Register in need of repair.d) Sheared key on “Change Gear” — caused by ice in register.

2. Leakage at the Stuffing BoxLoose stuffing box nut or worn spindle.

3. Chronic Leakage at the Main Case Gasketa) Excessive line or shock pressure.b) Broken gasket or loose bolts.

4. Reduction in the Rate or Complete Stoppage of Dischargea) Pump bypass stuck open.b) Air release valve fails to close allowing the liquid to escape through air vent.c) An open valve in the piping allowing liquid to circulate around the pump.d) Worn pump.e) Blocked strainer due to sediment or frost.f) Piston in flowmeter stuck, caused by dirt. Check strainer and clean measuring chamber.

5. Over-Registration — Erratica) Leaking valve in empty compartment causing an emulsion of air and oil.b) Air release valve jamming allowing air to pass through the flowmeterc) Spring in back pressure valve broken or valve stuck open.d) Vent line from the air release valve plugged causing air to pass through the flowmeter.e) Leaks in the suction line such as at valve stems, pump packing, or flange gaskets.f) Air pockets in closed-end piping in the suction line.g) Manifold or compartment valves only partly open causing excessive suction.h) Suction piping too small causing excessive suction.

6. Under-Registration — Erratica) Dirt in the measuring chamber.b) Badly worn control roller or diaphragm.c) Main casing distorted or damaged.d) Dirt under the seat of the measuring chamber at the outlet port (after cleaning).e) Leakage around the flowmeter due to partly open valve.

7. Consistent Over- or Under-RegistrationFlowmeter in need of calibration.

8. Liquid Leaking Out the Air Release Venta) Improper operation.b) Worn, damaged or defective valve unit.

9. Printing Not Clear in Cold WeatherTicket carbon not suitable for cold weather use.

PRESET MODELS

10. Cut Off is Not AccurateTrip Adjustment

11⁄4TYPE 4 WITH 1 A/S VALVE 800 SERIES REGISTER

11⁄2 ST’D PIPE THREAD27⁄8

61⁄8

43⁄4

83⁄4

71⁄2 CLEARANCE FOR REMOVING STRAINER 1 NPT THREAD

83⁄4

411⁄165⁄8 63⁄4

5 CLEARANCE FOR REMOVING FLOAT

4 5

21⁄2

11⁄16 DIA. (2) HOLES

31⁄2

153⁄4

137⁄8

91⁄4

115⁄16

93⁄8

21⁄8

4

53⁄8

5 ⁄1 4

1 PIPE THREAD

33⁄8

3 CLEARANCE FOR REMOVING REGISTER

13⁄8

3⁄8 - 16 TAP (3) HOLES EQUALLY SPACED ON 47⁄8 DIA B.C. 3⁄4 DIA.

2 PIPE THREAD

Page 17

11⁄2TYPE 4 WITH 2 A/S VALVE 800 SERIES REGISTER

11⁄2 ST’D PIPE THREAD27⁄8

61⁄8

43⁄4

83⁄4

1 NPT THREAD

227⁄8

5⁄8 43⁄4

93⁄8

4 5

21⁄2

137⁄8

91⁄4

17⁄8

115⁄16

153⁄4

23⁄8

65⁄8

51⁄4 33⁄8

3 CLEARANCE FOR REMOVING REGISTER

13⁄8

3⁄8 - 16 TAP (3) HOLES EQUALLY SPACED ON 47⁄8 DIA B.C. 3⁄4 DIA.

73⁄8

15 CLEARANCE FORREMOVING FLOAT

71⁄2 CLEARANCE FOR REMOVING STRAINER

U.S.A./International1310 Emerald RoadGreenwood, SC 29646-9558Tel.: Toll-Free (800) 833-3357

(864) 223-1212Fax: (864) 223-0341

© 2013

Specifications subject to change without prior notification.

O M - 0 1 1 6 6 - 0 2January 21, 1981

Rev. C 06‐05‐2013

B C

T H E GORMAN‐RUPP CO M PANY • MANSFIELD, OHIOwww.grpumps.com

GORMAN‐RUPP O F CANADA LIMITED • S T. THOMAS, ONTARIO, CANADA

©1981 The Gorman‐Rupp Company

Printed in U.S.A.

INSTALL ATION, O P E R ATION,

AND MAINTENANCE MANUA LWITH PA R T S L I ST

0 SERIES PUMP

MODEL

0 2 K 3 - X 2 1P

http://www.grpumps.com/

i

TA B L E O F C O N T E N T S

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA G E I - 1

S A F E T Y - S EC T I O N A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA G E A - 1

INSTALLATION - S EC T I O N B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA G E B - 1

Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POSITIONING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Lines In Sumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction Line Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DISCHARGE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Siphoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bypass Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE B - 1

PAGE B - 2

PAGE B - 2

PAGE B - 2

PAGE B - 2

PAGE B - 2

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 3

PAGE B - 4

PAGE B - 4

PAGE B - 4

PAGE B - 4

PAGE B - 5

PAGE B - 5

O P E R ATION - S EC T I O N C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA G E C - 1

PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines With a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lines Without a Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strainer Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Vacuum Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE C - 1

PAGE C - 1

PAGE C - 1

PAGE C - 1

PAGE C - 2

PAGE C - 2

PAGE C - 2

PAGE C - 2

PAGE C - 2

PAGE C - 3

PAGE C - 3

T ROUBLESHOOT IN G - S EC T I O N D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA G E D - 1

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE D - 3

PUMP MAINTENANCE AND R E PAIR - S EC T I O N E . . . . . . . . . . . . . . . . PA G E E - 1

PERFORMANCE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST:

PAGE E - 1

ii

TA B L E O F C O N T E N T S(continued)

Pump Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE E - 3

PAGE E - 4

PAGE E - 4

PAGE E - 4

PAGE E - 5

PAGE E - 5

PAGE E - 6

PAGE E - 7

PAGE E - 7

PAGE E - 7

PAGE E - 7

0 S E R I E S OM-011 6 6

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump.

Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so

could result in personal injury or damage to the

pump.

This Installation, Operation, and Maintenance

manual is designed to help you achieve the best

performance and longest life from your Gorman‐

Rupp pump.

This pump is an 0 Series, enclosed impeller, self‐

priming centrifugal model with straight‐in suction,

without a suction check valve and close‐coupled to

an explosion‐proof electric motor. The pump is de

signed for handling clean liquids that do not con

tain large entrained solids. The basic material of

construction is gray iron, with bronze impeller and

stainless steel impeller shaft.

If there are any questions regarding the pump or

its application which are not covered in this man

ual or in other literature accompanying this unit,

please contact your Gorman‐Rupp distributor, or:

The Gorman‐Rupp CompanyP.O. Box 1217

Mansfield, Ohio 44901-1217

Phone: (419) 755-1 0 1 1or:

Gorman‐Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631-2 8 7 0

For information or technical assistance on the mo

tor, contact the motor manufacturer's local dealer

or representative.

This manual will alert personnel to known proce

dures which require special attention, to those

which could damage equipment, and to those

which could be dangerous to personnel. However,

this manual cannot possibly anticipate and provide

detailed precautions for every situation that might

occur during maintenance of the unit. Therefore, it

is the responsibility of the owner/maintenance per

sonnel to ensure that only safe, established main

tenance procedures are used, and that any proce

dures not addressed in this manual are performed

only after establishing that neither personal safety

nor pump integrity are compromised by such prac

tices.

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL result insevere personal injury or death. Theseinstructions describe the procedure required and the injury which will resultfrom failure to follow the procedure.

Hazards or unsafe practiceswhich CO U L D result in severe personalinjury or death. These instructionsdescribe the procedure required andthe injury which could result fromfailure to follow the procedure.

Hazards or unsafe practices which COULDresult in minor personal injury or productor property damage. These instructionsdescribe the requirements and the possible damage which could result fromfailureto follow the procedure.

NOT EInstructions to aid in installation, operation, and

maintenance or which clarify a procedure.

INTRODUCTION PA G E I - 1

0 S E R I E S OM-011 6 6

S A F E T Y - S EC T I O N A

This information applies to 0Series electric motor driven pumps.Refer to the manual accompanyingthe motor before attempting to beginoperation.

This manual will alert personnelto known procedures which requirespe cial attention, to those whichcould damag e equipment, and to thosewhich could be dangerous topersonnel. How ever, this manualcannot possibly pro vide detailedinstructions and precau tions for eachspecific application or for everysituation that might occur duringmaintenance of the unit. Therefore, it isthe responsibility of the owner, installerand/or maintenance personnel to ensure that applications and/or maintenance procedures not addressed in thismanual are performed only after establishing that neither personal safety norpump integrity are compromised bysuch applications or procedures.

Before attempting to open or service thepump:

1 . Familiarize yourself with this man

ual.

2. Disconnect the incoming power to

the motor and lock it out to ensure

that the pump will remain inopera

tive.

3. Allow the pump to completely cool

if overheated.

4 . Check the temperature before

opening any covers, plates, or

plugs.

5. Close the suction and discharge

valves.

6. Vent the pump

tiously.

7. Drain the pump.

slowly and cau

This pump is designed to handle petroleum products or other industrial liquids that do not contain large entrainedsolids. Do not attempt to pump volatile,corrosive, or flammable materials whichmay damage the pump or endanger personnel as a result of pump failure.

This pump is designed to handle petroleum products or other industrial liquids that do not contain large entrainedsolids. All controls must meet industrystandards and codes for use in an explosive atmosphere. Do not attempt topump liquids for which the pump and/orcontrols have not been approved, orwhich may damage the pump or endanger personnel as a result of pump failure.

Be certain proper safety practices arefollowed before operating or servicingthe pump. Provide adequate ventilation,prohibit smoking, wear static‐resistantclothing and shoes. Clean up all fuelspil ls immediately after occurrence.

Do not install and operate a non‐explosion proof motor in an explosive atmosphere. Install, connect, and operatethe motor in accordance with the National Electric Code and all local codes.If there is a conflict between the instructions in the manual accompanying theunit and the National Electric Code or

S A F ET Y PA G E A - 1

0 S E R I E SOM-011 6 6

the applicable local code, the Nationalor local code shall take precedence.

Because this pump is designed to handle volatile and/or flammable liquids,overheating may produce dangerousfumes. Take precautions to ensure thearea surrounding the pump is adequately ventilated. Allow the pump tocool and use extreme caution whenventing the pump, or when removingcovers, plates, plugs, or fittings.

After the pump has been positioned,make certain that the pump and all piping connections are tight, properly supported and secure before operation.

Do not remove plates, covers, gauges,pipe plugs, or fittings from an overheated pump. Vapor pressure within thepump can cause parts being disengaged to be ejected with g reat force. Allow the pump to cool before servicing.

Do not operate the pump againsta closed discharge valve for longperiods of time. If operated against aclosed dis charge valve, pumpcomponents will deteriorate, and theliquid could come to a boil, buildpressure, and cause the pump casingto rupture or explode.

Overheated pumps can cause severeburns and injuries. If overheating of thepump occurs:

1. Stop the pump immediately.2. Ventilate the area.3. Allow the pump to completely cool.4 . Check the temperature before

opening any covers, plates,gauges, or plugs.

5. Vent the pump slowly and cautiously.

6. Refer to instructions in this manualbefore restarting the pump.

The electrical power used to operatethis pump is high enough to cause injury or death. Obtain the services of a qualified electrician to troubleshoot, testand/or service the electrical components of this pump.

Use lifting and moving equipmentin good repair and with adequatecapacity to prevent injuries topersonnel or dam age to equipment.Suction and dis charge hoses andpiping must be re moved from thepump before lifting.

Pumps and related equipment must be installed and operated according to all national, local and industry standards.

PA G E A - 2 S A F ET Y

OM-011 6 60 S E R I E S

INSTALLATION - S EC T I O N B

Review all S A F ET Y information in Section A.

Since pump installations are seldom identical, this

section offers only general recommendations and

practices required to inspect, position, and ar

range the pump and piping.

Most of the information pertains to a standard

static lift application where the pump is posi

tioned above the free level of liquid to be pumped.

If installed in a flooded suction application where

the liquid is supplied to the pump under pressure,

some of the information such as mounting, line

configuration, and priming must be tailored to the

specific application. Since the pressure supplied

to the pump is critical to performance and safety,

be sure to limit the incoming pressure to 50% of

the maximum permissible operating pressure as

shown on the pump performance curve.

For further assistance, contact your Gorman‐Rupp

distributor or the Gorman‐Rupp Company.

Pump Dimensions

See Figure 1for the approximate physical dimen

sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Models 0 2 K 3 - X 2 1P

INSTALLATION PA G E B - 1

OM-011 6 6 0 S E R I E S

P R E I N STALLATION INSPECT ION

The pump assembly was inspected and tested be

fore shipment from the factory. Before installation,

inspect the pump for damage which may have oc

curred during shipment. Check as follows:

a. Inspect the pump and motor for cracks,

dents, damaged threads, and other obvious

damage.

b. Check for and tighten loose attaching hard

ware. Since gaskets tend to shrink after dry

ing, check for loose hardware at mating sur

faces.

c. Carefully read all warnings and cautions con

tained in this manual or affixed to the pump,

and perform all duties indicated. Note the di

rection of rotation indicated on the pump.

Check that the pump shaft rotates counter

clockwise when facing the impeller.

Only operate this pump in the direction indicated by the arrow on the pump bodyand on the accompanying decal. Refer toR O TATION in O P E R ATION, Section C.

d. Check levels and lubricate as necessary. Re

fer to L UBRIC A TION in the MAINTENANCE

AND R E PAIR section of this manual and per

form duties as instructed.

e. If the pump and motor have been stored for

more than 12 months, some of the compo

nents or lubricants may have exceeded their

maximum shelf life. These must be inspected

or replaced to ensure maximum pump serv

ice.

If the maximum shelf life has been exceeded, or if

anything appears to be abnormal, contact your

Gorman‐Rupp distributor or the factory to deter

mine the repair or updating policy. Do not put the

pump into service until appropriate action has

been taken.

The electrical power used to operatethis pump is high enough to cause injury or death. Obtain the services of a qualified electrician to troubleshoot, testand/or service the electrical components of this pump.

POSITIONING PUMP

Lifting

Pump unit weights will vary depending on the

mounting and drive provided. Check the shipping

tag on the unit packaging for the actual weight, and

use lifting equipment with appropriate capacity.

Drain the pump and remove all customer‐installed

equipment such as suction and discharge hoses

or piping before attempting to lift existing, installed

units.

The pump assembly can be seriouslydamaged if the cables or chains used to liftand move the unit are improperly wrappedaround the pump.

PA G E B - 2 INSTALLATION

Mounting

Locate the pump in an accessible place as close as

practical to the liquid being pumped. Level mount

ing is essential for proper operation.

The intermediate is equipped with mounting foot

holes for mounting the pump to a base.

SUCTION AND D I S C H A R G E PIPING

Pump performance is adversely effected by in

creased suction lift, discharge elevation, and fric

tion losses. See the performance curve and oper

ating range shown on Page E‐1 to be sure your

overall application allows pump to operate within

the safe operation range.

OM-011 6 60 S E R I E S

Materials


Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

compatible with the liquid being pumped. If hose is

used in suction lines, it must be the rigid‐wall, rein

forced type to prevent collapse under suction. Us

ing piping couplings in suction lines is not recom

mended.

Line Configuration

Keep suction and discharge lines as straight as

possible to minimize friction losses. Make mini

mum use of elbows and fittings, which substan

tially increase friction loss. If elbows are necessary,

use the long‐radius type to minimize friction loss.

Connections to Pump

Before tightening a connecting flange, align it ex

actly with the pump port. Never pull a pipe line into

place by tightening the flange bolts and/or cou

plings.

Lines near the pump must be independently sup

ported to avoid strain on the pump which could

cause excessive vibration, decreased bearing life,

and increased shaft and seal wear. If hose‐type

lines are used, they should have adequate support

to secure them when filled with liquid and under

pressure.

Gauges

Most pumps are drilled and tapped for installing

discharge pressure and vacuum suction gauges.

If these gauges are desired for pumps that are not

tapped, drill and tap the suction and discharge

lines not less than 18 inches (457,2 mm) from the

suction and discharge ports and install the lines.

Installation closer to the pump may result in erratic

readings.

SUCTION L I N ES

To avoid air pockets which could affect pump prim

ing, the suction line must be as short and direct as

possible. When operation involves a suction lift, the

line must always slope upward to the pump from

the source of the liquid being pumped; if the line

slopes down to the pump at any point along the

suction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pump

inlet. If reducers are used in suction lines, they

should be the eccentric type, and should be in

stalled with the flat part of the reducers uppermost

to avoid creating air pockets. Valves are not nor

mally used in suction lines, but if a valve is used,

install it with the stem horizontal to avoid air pock

ets.

Strainers

If a strainer is furnished with the pump, be certain

to use it; any spherical solids which pass through a

strainer furnished with the pump will also pass

through the pump itself.

If a strainer is not furnished with the pump, but is

installed by the pump user, make certain that the

total area of the openings in the strainer is at least

three or four times the cross section of the suction

line, and that the openings will not permit passage

of solids larger than the solids handling capability

of the pump.

This pump is designed to handle up to 3/8‐inch

(9,5 mm) diameter spherical solids.

Sealing

Since even a slight leak will affect priming, head,

and capacity, especially when operating with a

high suction lift, all connections in the suction line

should be sealed with pipe dope to ensure an air

tight seal. Follow the sealant manufacturer's rec

ommendations when selecting and applying the

pipe dope. The pipe dope should be compatible

with the liquid being pumped.

Suction Lines In Sum ps

If a single suction line is installed in a sump, it

should be positioned away from the wall of the

sump at a distance equal to 1 1/2 times the diame

ter of the suction line.

OM-011 6 6 0 S E R I E S

If there is a liquid flow from an open pipe into the

sump, the flow should be kept away from the suc

tion inlet because the inflow will carry air down into

the sump, and air entering the suction line will re

duce pump efficiency.

If it is necessary to position inflow close to the suc

tion inlet, install a baffle between the inflow and the

suction inlet at a distance 1 1/2times the diameter

of the suction pipe. The baffle will allow entrained

air to escape from the liquid before it is drawn into

the suction inlet.

If two suction lines are installed in a single sump,

the flow paths may interact, reducing the efficiency

of one or both pumps. To avoid this, position the

suction inlets so that they are separated by a dis

tance equal to at least 3 times the diameter of the

suction pipe.

Suction Line Positioning

The depth of submergence of the suction line is

critical to efficient pump operation. Figure 2 shows

recommended minimum submergence vs. veloc

ity.

NOT EThe pipe submergence required may be reduced

by installing a standard pipe increaser fitting at the

end of the suction line. The larger opening size will

reduce the inlet velocity. Calculate the required

submergence using the following formula based

on the increased opening size (area or diameter).

Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity

PA G E B - 4 INSTALLATION

D I S C H A R G E L I N ES

Siphoning

Do not terminate the discharge line at a level lower

than that of the liquid being pumped unless a si

phon breaker is used in the line. Otherwise, a si

phoning action causing damage to the pump

could result.

Valves

If a throttling valve is desired in the discharge line,

use a valve as large as the largest pipe to minimize

friction losses. Never install a throttling valve in a

suction line.

OM-011 6 60 S E R I E S

A check valve in the discharge line is normally rec

ommended, but it is not necessary in low dis

charge head applications.

With high discharge heads, it is recommended that

a throttling valve and a system check valve be in

stalled in the discharge line to protect the pump

from excessive shock pressure and reverse rota

tion when it is stopped.

If the application involves a high dischargehead, gradually close the dischargethrottling valve before stopping the pump.

Bypass Lines

If it is necessary to permit the escape of air to atmo

sphere on initial priming or during the repriming

cycle, install an air bypass line ‐ sized so that it will

not affect the pump discharge capacity ‐ between

the pump and the discharge check valve. Since

this pump does not use a suction check valve, the

discharge end of the bypass line must be sub

merged in the liquid being pumped in order to

maintain suction.

NOT EThe bypass line may clog frequently if the liquid

contains solids and the valve remains closed. If this

condition occurs, either use a larger bypass line or

leave the shut‐off valve open during pumping.

E L E C T R I C A L CO N N EC T I O N S

This pump is driven by an electric motor. Check

that the electrical service available matches the

motor requirements stamped on the motor name

plate before connecting the motor to the incoming

power.

The electrical power used to operate thepump is high enough to cause injury ordeath. Obtain the services of a qualifiedelectrician to make all electrical connections.

Do not install and operate a non‐explosion proof motor in an explosive atmosphere. Install, connect, and operatethe motor in accordance with The National Electric Code and all local codes.If there is a conflict between the instructions in the manual accompanying theunit and The National Electric Code orthe applicable local code, The Nationalor local code shall take precedence.

Refer to the following motor data before making

electrical connections.

GROUNDING

Because this pump is used to handle volatile or

flammable liquids, the unit must be grounded by

attaching a ground wire assembly to a ground rod

in order to eliminate electrostatic build‐up by the

liquid being pumped. Install the ground rod in ac

cordance with the National Electrical Codes and all

local codes. Be sure the fastening device makes a

tight electrical connection with the rod and the

pump.

Inspect and test the ground wire assemblyfor conductivity. Replace a broken orfrayed wire before resuming operation.


MODEL VOLTAGE PHASE HP Hz RPM F.L. AMPS

02K3-X2 1P 115/230 1 2 60 3450 19.8/9.9

0 S E R I E S OM-011 6 6

O P E R ATION - S EC T I O N C


Follow the instructions on all tags, labels and

decals attached to the pump.

This pump is designed to handle petroleum products and other industrial liquids that do not contain large entrainedsolids. Do not attempt to pump volatile,corrosive, or flammable liquids whichmay damage the pump or endanger personnel as a result of pump failure.

Pump speed and operating conditionsmust be within the performance rangeshown on page E‐1.

PRIMINGS TARTING

Install the pump and piping as described in IN

S TAL LATION . Make sure that the piping connec

tions are tight, and that the pump is securely

mounted. Check that the pump is properly lubri

cated (see L UBRIC A TION in MAINTENANCE

AND R E PAIR ).

This pump is self‐priming, but the pump should

never be operated unless there is liquid in the

pump casing.

Never operate this pump unless there isliquid in the pump casing. The pump willnotprime when dry. extended operation of

Add liquid to the pump casing when:

1. The pump is being put into service for the

first time.

2. The pump has not been used for a consider

able length of time.

3. The liquid in the pump casing has evapo

rated.

Once the pump casing has been filled, the pump

will prime and reprime as necessary.

After filling the pump casing, reinstalland tighten the fill plug. Do not attemptto operate the pump unless all connecting piping is securely installed. Otherwise, liquid in the pump forced outunder pressure could cause injury topersonnel.

To fill the pump, remove the pump casing fill cover

or fill plug in the top of the casing, and add clean

liquid until the casing is filled. Replace the fill cover

or fill plug before operating the pump.

a dry pump will destroy the seal assembly.

O P ER ATION

valve.

PA G E C - 1

Consult the operations manual furnished with the

motor.

O P E R ATION

Lines With a Bypass

Since this pump does not have a suction check

valve, the discharge end of the bypass line must be

submerged in order to maintain suction.

Close the throttling valve in the discharge line and

open the shut‐off valve in the bypass line so that

the pump will not have to prime against the weight

of the liquid in the discharge line. Start the motor.

When the pump has primed and liquid is flowing

steadily through the bypass line, close the bypass

shut‐off valve and open the discharge throttling

0 S E R I E SOM-011 6 6

Lines Without a Bypass

Open all valves in the discharge line and start the

power source. Priming is indicated by a positive

reading on the discharge pressure gauge or by a

quieter operation. The pump may not prime imme

diately because the suction line must first fill with

liquid. If the pump fails to prime within five minutes,

stop it and check the suction line for leaks.

After the pump has been primed, partially close the

discharge line throttling valve in order to fill the line

slowly and guard against excessive shock pres

sure which could damage pipe ends, gaskets,

sprinkler heads, and any other fixtures connected

to the line. When the discharge line is completely

filled, adjust the throttling valve to the required flow

rate.

Do not operate the pump againsta closed discharge throttling valvefor long periods of time. If operatedagainst a closed discharge throttlingvalve, pump components willdeteriorate, and the liquid could cometo a boil, build pressure, and causethe pump casing to rupture or explode.

Leakage

No leakage should be visible at pump mating sur

faces, or at pump connections or fittings. Keep all

line connections and fittings tight to maintain maxi

mum pump efficiency.

Liquid Temperature And Overheating

The maximum liquid temperature for this pump is

160° F (71° C). Do not apply it at a higher operat

ing temperature.

Overheating can occur if operated with the valves

in the suction or discharge lines closed. Operating

against closed valves could bring the liquid to a

boil, build pressure, and cause the pump to rup

ture or explode. If overheating occurs, stop the

pump and allow it to cool before servicing it. Refill

Allow an over‐heated pump to completely cool before servicing . Do not remove plates, covers, gauges, or fittingsfrom an over‐heated pump. Liquid within the pump can reach boiling temperatures, and vapor pressure within thepump can cause parts being disengaged to be ejected with great force. After the pump completely cools, drain theliquid from the pump by removing thecasing drain plug. Use caution when removing the plug to prevent injury to personnel from hot liquid.

the pump casing with cool liquid. falls off rapidly after stabilization, an air leak exists.

PA G E C - 2 O P ER ATION

Strainer Check

If a suction strainer has been shipped with the

pump or installed by the user, check the strainer

regularly, and clean it as necessary. The strainer

should also be checked if pump flow rate begins to

drop. If a vacuum suction gauge has been in

stalled, monitor and record the readings regularly

to detect strainer blockage.

Never introduce air or steam pressure into the

pump casing or piping to remove a blockage. This

could result in personal injury or damage to the

equipment. If backflushing is absolutely neces

sary, liquid pressure must be limited to 50% of the

maximum permissible operating pressure shown

on the pump performance curve.

Pump Vacuum Check

With the pump inoperative, install a vacuum gauge

in the system, using pipe dope on the threads.

Block the suction line and start the pump. At oper

ating speed the pump should pull a vacuum of 20

inches (508,0 mm) or more of mercury. If it does

not, check for air leaks in the seal, gasket, or dis

charge valve.

Open the suction line, and read the vacuum gauge

with the pump primed and at operation speed.

Shut off the pump. The vacuum gauge reading will

immediately drop proportionate to static suction

lift, and should then stabilize. If the vacuum reading

0 S E R I E S OM-011 6 6

Before checking for the source of the leak, check

the point of installation of the vacuum gauge.

STO P P I N G

After stopping the pump, disconnect the incoming

power to the motor and lock it out to ensure that the

pump will remain inoperative.

Do not operate the pump againsta closed discharge throttling valvefor long periods of time. If operatedagainst a closed discharge throttlingvalve,

O P ER ATION PA G E C - 3

pump components will deteriorate, andthe liquid could come to a boil, buildpressure, and cause the pump casing torupture or explode.

Cold Weather Preservation

In below freezing conditions, drain the pump to

prevent damage from freezing. Also, clean out any

solids by flushing with a hose. Operate the pump

for approximately one minute; this will remove any

remaining liquid that could freeze the pump rotat

ing parts. If the pump will be idle for more than a

few hours, drain the pump, and flush it thoroughly

with clean liquid. Operate the pump during the

draining process.

0 S E R I E S OM-011 6 6

TROUBLESHOOTIN G - SEC TIO N D


Before attempting to open or service the

pump:

1 . Familiarize yourself with this manual.2. Disconnect the incoming power to

the motor and lock it out to ensurethat the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

4 . Check the temperature before opening any covers, plates, or plugs.

5. Close the suction and dischargevalves.

6. Vent the pump slowly and cautiously.7. Drain the pump.

TROUBLES H O O TI NG PA G E D - 1

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO PRIME

Not enough liquid in casing.

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump

gasket.

Suction lift or discharge head toohigh.

Strainer clogged.

Add liquid to casing. See PRIM

ING.

Correct leak.

Replace suction hose.

Check pump vacuum.

Replace leaking or worn seal

or gasket.

Check piping installation and

in stall bypass line if needed.

See INSTALLATION.

Check strainer and clean if

neces sary.

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE

Air leak in suction line.

Lining of suction hose collapsed.

Leaking or worn seal or pump

gasket.

Correct leak.

Replace suction hose.

Check pump vacuum.

Replace leaking or worn seal or

gasket.

OM-011 6 6 0 S E R I E S

PA G E D - 2 TROUBLES H O O TI NG

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)

Strainer clogged.

Suction intake not submerged at

Check strainer and clean if

neces sary.

Check installation and correctsub

proper level or sump too small. mergence as needed.

Impeller or other wearing parts worn Replace worn or damaged parts.

or damaged. Check that impeller is properlycentered and rotates freely.

Impeller clogged. Free impeller of debris.

Suction lift or discharge head toohigh.

Check piping installation andinstallbypass line if needed. See INSTAL

LATION.

Low or incorrect voltage. Measure control box voltage,bothwhen pump is running and whenshut off.

No voltage at line side of circuit

Check power source for blownfuse,

breaker. open circuit breaker or controlbox,broken lead, or looseconnection.

PUMP REQUIRES TOO MUCH POWER

Discharge head too

low. Liquid solution

too thick.

Adjust discharge

valve. Dilute if

possible.

PUMP CLOGS FREQUENTLY Liquid solution too

thick. Discharge flow

too slow.

Dilute if possible.

Open discharge valve fully to

in crease flow rate, and run

power source at maximum

governed speed.

EXCESSIVE NOISE Cavitation in pump.

Pumping entrained air.

Pump or drive not securely

mounted. Impeller clogged or

damaged.

Reduce suction lift and/or

friction losses in suction line.

Record vac uum and pressure

gauge readings and consult

local representative or factory.

Locate and eliminate source of

air bubble.

Secure mounting hardware.

Clean out debris; replace

dam aged parts.

0 S E R I E S OM-011 6 6

PREVENTIVE MAINTENANCE

TROUBLES H O O TI NG PA G E D - 3

Since pump applications are seldom identical, and

pump wear is directly affected by such things as

the abrasive qualities, pressure and temperature

of the liquid being pumped, this section is intended

only to provide general recommendations and

practices for preventive maintenance. Regardless

of the application however, following a routine pre

ventive maintenance schedule will help assure

trouble‐free performance and long life from your

Gorman‐Rupp pump. For specific questions con

cerning your application, contact your Gorman‐

Rupp distributor or the Gorman‐Rupp Company.

Record keeping is an essential component of a

good preventive maintenance program. Changes

in suction and discharge gauge readings (if so

equipped) between regularly scheduled inspec

tions can indicate problems that can be corrected

before system damage or catastrophic failure oc

curs. The appearance of wearing parts should also

be documented at each inspection for comparison

as well. Also, if records indicate that a certain part

(such as the seal) fails at approximately the same

duty cycle, the part can be checked and replaced

before failure occurs, reducing unscheduled down

time.

For new applications, a first inspection of wearing

parts at250 hours will give insight into the wear rate

for your particular application. Subsequent inspec

tions should be performed at the intervals shown

on the chart below. Critical applications should be

inspected more frequently.

Preventive Maintenance Schedule

Item Service Interval*

Daily Weekly Monthly Semi‐ Annually

Annually

General Condition (Temperature, Unusual I I I CII

R

Noises or Vibrations, Cracks, Leaks,Loose Hardware, Etc.)

Pump Performance (Gauges, Speed, Flow) IBearing LubricationSeal Lubrication (And Packing Adjustment,

If So Equipped) I RV‐Belts (If So Equipped)Air Release Valve Plunger Rod (If SoEquipped)

I

Front Impeller Clearance (Wear Plate)Rear Impeller Clearance (Seal Plate)Check Valve IPressure Relief Valve (If So Equipped) CPump and Driver Alignment IShaft Deflection IBearings IBearing Housing IPiping IDriver Lubrication - See Mfgr's Literature

Legend:I = Inspect, Clean, Adjust, Repair or Replace asNecessary C = CleanR = Replace

* Service interval based on an intermittent duty cycle equal to approximately 4000 hoursannually. Adjust schedule as required for lower or higher duty cycles or extremeoperating conditions.

OM-011 6 60 S E R I E S

PUMP MAINTENANCE AND R E PAIR - SEC TIO N E

MAINTENANCE AND R E PAIR O F T H E WEARING PA R T S O F T H E PUMP WILL MAINTAIN P E A K

O P ER ATING PERFORM AN C E.

S TANDARD P ER F O R M A N C E F O R PUMP M O D EL S 0 2 K 3 - X 2 1P

Based on 70° F (21° C) clear water (corrected to

.80 specific gravity) at sea level with minimum suc

tion lift. Since pump installations are seldom identi

cal, your performance may be different due to such

factors as viscosity, specific gravity, elevation, tem

perature, and impeller trim.

If your pump serial number is followed by an “N”,

your pump is NOT a standard production model.

Contact the Gorman‐Rupp Company to verify per

formance or part numbers.

Pump speed and operating conditionpoints must be within the continuous performance range shown on the curve.

MAINTENANCE & R E PAIR PA G E E - 1

OM-011 6 6 0 S E R I E S

S EC T I O N DRAWING

Figure 1. Pump Models 0 2 K 3 - X 2 1P

PA G E E - 2 MAINTENANCE & R E PAIR

OM-011 6 60 S E R I E S

PA R T S L I ST

Pump Models 0 2 K 3 - X 2 1P(FromS/N 312560 Up)

If your pump serial number is followedby an “N”, your pump is NOT a standard production model. Contactthe Gorman‐Rupp Company to verify part numbers.

ITEM PART MAT'L

NOT SHOWN:

G‐R DECAL

WARNING DECAL

ROTATION DECAL

INSTRUCTION TAG

SUCTION STICKER

PRIMING STICKER

DISCHARGE STICKER

GR-03

2613FF

2613M

38817-027

6588AG

6588AH

6588BJ

- - -

- - -

- - -

- - -

- - -

- - -

- - -

1

1

1

1

1

1

1

INDICATES PARTS RECOMMENDED FOR STOCK

u INCLUDED WITH REPAIR PUMP CASING ASSY


46471-213 - - - 1

u NO.

1

PART NAME

PUMP CASING

NUMBER

See Note Below

CODE QTY

2 IMPELLER 10205 14000 1

3 MECHANICAL SEAL 25271-821 --- 1

u 4 FILL PLUG ASSY 48271-060 --- 1

5 RD HD MACH SCREW X0402 14990 1

6 RD HD MACH SCREW X0405 14990 1

7 CASING GASKET 2958GB 20000 1

u 8 STUD C0606 15991 8

9 HEX NUT D06 15991 8

10 INTERMEDIATE BRACKET 6367C 10010 1

11 STUD C0606 15991 4

12 HEX NUT D06 15991 4

13 LOCK WASHER J06 15991 4

14 1 PHASE MOTOR M33 --- 1

15 REDUCER COUPLING AE1612 15079 1

16 PIPE NIPPLE THA1206 15079 1

17 CONDUIT BOX 27144-124 --- 1

18 IMPELLER ADJUSTING SHIM SET 5889 17000 1

u 19 CASING DRAIN PLUG P08 15079 1

20 VANE PLATE 10204 10010 1

u 21 PIPE PLUG P04 15079 1

22 IMPELLER JAM NUT AT07S 15991 1

23 NAME PLATE 38818-020 13990 1

24 DRIVE SCREW BM#04-03 17000 4

25 VANE PLATE O‐RING S1487 --- 1

OM-011 6 6 0 S E R I E S

PUMP AND S E A L D I SA S S E M B LY

AND R E A S S E M B LY


Follow the instructions on all tags, label and decals

attached to the pump.

This pump requires little service due to its rugged,

minimum‐maintenance design. However, if it be

comes necessary to inspect or replace the wearing

parts, follow these instructions which are keyed to

the sectional view (see Figure 1) and the accompa

nying parts list.

This manual will alert personnel to known proce

dures which require special attention, to those

which could damage equipment, and to those

which could be dangerous to personnel. However,

this manual cannot possibly anticipate and provide

detailed precautions for every situation that might

occur during maintenance of the unit. Therefore, it

is the responsibility of the owner/maintenance per

sonnel to ensure that only safe, established main

tenance procedures are used, and that any proce

dures not addressed in this manual are performed

only after establishing that neither personal safety

nor pump integrity are compromised by such prac

tices.

Before attempting to service the pump, disconnect

the incoming power to the motor and lock it out to

ensure that the pump will remain inoperative.

Close all valves in the suction and discharge lines.

For motor disassembly and repair, consult the liter

ature supplied with the motor, or contact your local

motor representative.

Before attempting to open or service thepump:

1 . Familiarize yourself with this manual.

2. Disconnect the incoming power tothe motor and lock it out to ensurethat the pump will remain inoperative.

3. Allow the pump to completely coolif overheated.

4. Check the temperature beforeopening any covers, plates,or plugs.

5. Close the suction and dischargevalves.

6. Vent the pump slowly and cautiously.

7. Drain the pump.

Use lifting and moving equipmentin good repair and with adequatecapacity to prevent injuries topersonnel or dam age to equipment.

Be certain proper safety practices arefollowed before operating or servicingthe pump. Provide adequate ventilation,prohibit smoking, wear static‐resistantclothing and shoes. Clean up all fuelspil ls immediately after occurrence.

Pump Disassembly

Before attempting to service the pump, remove the

pump casing drain plug (19) and drain the pump.

Clean and reinstall the drain plug.

To service the impeller (2), seal assembly (3), or va

ne plate (20), the pump housing (1) must be sepa

rated from the intermediate (10).

Remove the suction and discharge lines. Remove

the nuts (9) and use a suitable hoist and sling to

separate the pump casing and gasket (7) from the

intermediate. Remove the vane plate O‐ring (25).

Use lifting and moving equipmentin good repair and with adequatecapacity to prevent injuries topersonnel or dam age to equipment.Suction and dis


OM-011 6 60 S E R I E S

charge hoses and piping must be removed from the pump before lifting.

Impeller Removal

For access to the impeller (2), disengage the

screws (5 and 6) and remove the vane plate (20).

Immobilize the impeller by inserting a bar between

the impeller vanes, being careful not to damage

the vanes. Disengage the impeller nut (22).

Immobilize the motor shaft by inserting a large flat

head screwdriver into the slot in the end of the shaft

in the front end of the motor.

Unscrew the impeller from the shaft. Use caution

when removing the impeller; tension on the seal

spring will be released as the impeller is removed.

Remove the impeller adjusting shims (18). Tie and

tag the shims or measure and record their thick

ness for ease of reassembly.

Seal Removal and Disassembly

Remove the spring retainer and spring. Apply oil to

the shaft and work it up under the rubber bellows.

Slide the rotating portion of the seal off the shaft.

Remove the hardware (12 and 13) securing the in

termediate (10) to the motor (14). Slide the inter

mediate off the shaft and use a suitably sized dowel

to press the seal stationary element and seat out of

the intermediate from the back side.

Seal Reassembly and Installation

Clean the seal cavity and shaft with a cloth soaked

in fresh cleaning solvent.

Most cleaning solvents are toxic andflammable. Us e them only in a well ventilated area free from excessive heat,sparks, and flame. Read and follow allprecautions printed on solvent containers.

The seal is not normally reused because wear pat

terns on the finished faces cannot be realigned

during reassembly. This could result in premature

failure. If necessary to reuse an old seal in an emer

gency, carefully wash all metallic parts in fresh

cleaning solvent and allow to dry thoroughly.


Handle the seal parts with extreme care to prevent

damage. Be careful not to contaminate precision

finished faces; even fingerprints on the faces can

shorten seal life. If necessary, clean the faces with a

non‐oil based solvent and a clean, lint‐free tissue.

Wipe lightly in a concentric pattern to avoid

scratching the faces.

Inspect the seal components for wear, scoring,

grooves, and other damage that might cause leak

age. If any components are worn, replace the com

plete seal; never mix old and new seal parts.

If a replacement seal is being used, remove it from

the container and inspect the precision finished

faces to ensure that they are free of any foreign

matter.

To ease installation of the seal, lubricate the bel

lows with water or a very small amount of light lu

bricating oil, and apply a drop of light lubricating oil

on the finished faces. Assemble the seal as follows

(see Figure 2).

OM-011 6 6 0 S E R I E S

S E A L PLAT E

IMPELLER S H A F T

B E L LOWS

S TATIONARYS E A T

DRIVE BANDR O TATINGELEMEN T

I M P EL L ERS TATIONARY

ELEMEN T

IMPELLER SHIMS

S P R I N GR E TAINER

SPRING R E TAINER

Figure 2. Seal Assembly

This seal is not designed for operation attemperatures above 160°F (71°C). Do notuse at higher operating temperatures.


Lay the intermediate (10) on a flat surface with the

impeller side facing up. Subassemble the station

ary element into the stationary seat and use even

pressure to press this subassembly into the inter

mediate until it seats squarely against the shoulder

bore.

Carefully slide the assembled intermediate and

stationary portion of the seal over the motor shaft.

Secure the intermediate to the motor with the hard

ware (12 and 13).

Subassemble the rotating element into the retainer

and bellows. Lubricate the I.D. of the bellows with

water and slide this subassembly onto the shaft

until the polished faces contact. Install the seal

spring and spring retainer.

Impeller Installation

Inspect the impeller and replace it if cracked or

badly worn.

For maximum pump efficiency, the impeller should

be centered within the vane plate scroll.

To verify the impeller positioning, measure the

vane plate and impeller as shown in Figure 3. Use

these measurements to calculate the required im

peller location (dimension E). Add or remove im

peller adjusting shims (18) until dimension E is ob

tained.

OM-011 6 60 S E R I E S

D

2

B2

A B

C D

E

Step 2Step 1 Step 3

A + B C + D2 2

= E-

Figure 3. Centering Impeller Within Vane Plate Scroll

Install the correct thickness of impeller shims (18)

and screw the impeller onto the shaft until fully

seated.

Apply “Loctite Threadlocker No. 242” or equivalent

compound to the impeller shaft threads. Immobi

lize the motor shaft by inserting a large flat head

screwdriver into the slot in the end of the shaft in

the front end of the motor. Secure the impeller with

the impeller jam nut (22). Torque the nut to 15 ft.

lbs. (180 in lbs. or 2,07 m. kg.).

Clean all of the old adhesive from the vane plate

and its mating surface on the intermediate. Apply a

thin filmof “3M Gasket Adhesive No. 847” or equiv

alent compound to the vane plate and secure the

vane plate to the intermediate bracket using the

machine screws (5 and 6).

NOT EAfter the vane plate has been installed, check for

free shaft rotation. Correct any scraping binding

before further reassembly.

Pump Reassembly


Install the vane plate O‐ring (25) onto the vane

plate shoulder. Install the casing gasket (7). Ease

the pump casing over the vane plate. Be careful

not to damage the O‐ring. Secure the casing to the

intermediate bracket with the nuts (9).

Final Pump Assembly

Install the suction and discharge lines and open all

valves. Make certain that all piping connections are

tight, properly supported and secure.

Fill the pump casing with clean liquid. Reinstall the

fill plug (4) and tighten it.

Refer to O P ER ATION , Section C, before putting

the pump back into service.

LUBRIC ATION

Seal Assembly

The seal assembly is lubricated by the medium be

ing pumped and no additional lubrication is re

quired.

Read this Book

For new books, visit out web page at: www.BennettPump.com

For Part Pricing, please visit the parts pricing section under the Literature Tab on our website.

116146 Rev A 2-18-11

Bennett 1218 E. Pontaluna Road, Spring Lake, MI 49456 USA 800-235-7618 ~ Outside USA 231-798-1310

[email protected] ~ www.bennettpump.com

Bennett Pump Company

SB-100 Meters

Operation, Service & Parts ManualOnly Trained Personnel May Work on This Equipment

For more information, please contact:

Jim Biesecker, Component Sales

1218 E. Pontaluna RoadSpring Lake, Michigan USA

Tel: 800-235-7618 (USA)Tel: 231-798-1310 (International)Tel: 231-799-6262 (Sales)

Fax: 231-799-6200

Email: [email protected]: [email protected]: [email protected]

http://www.BennettPump.com/

mailto:[email protected]

http://www.bennettpump.com/




Table of Contents

Introduction 3

Technical Specifications 3

Dimensions & Mounting 4

Theory of Operation 5

General Description 6

Features & Construction 6

Basic Concept 7

Accuracy & Calibration 8

Troubleshooting & Repair 9

Parts List 12

116146 Rev A 2-18-112

Introduction

The SB-100 meter is the standard product for Bennett Dispensers. It can drive mechanical andelectronic computers at any flow used in a basic gasoline dispenser.

The SB-100 meter is a precision device built to maintain .3% accuracy for flow rates from 1.5 GPM (5LPM) to 26 GPM (100 LPM). The SB-100 is a volumetric meter employing four pistons with seals andassociated chambers. During the first year of use, the SB-100 meter's calibration should be checkedupon installation, after 90 days and after 180 days in order to insure accurate measurement. After thebreak-in period, semi-annual calibration checks are all that is required.

It is a compact, lightweight unit built with the following main objectives: Excellent accuracy over a wide range of flows Approvals: USA - Weights & Measures, Underwriters

Laboratories Canada - Weights & Measures, CSAEurope - OIML (International Organization for Legal Metrology) as a component in an approved system

Very good durability of performance and life up to 2 million gallons (7,500,000 liters) under laboratory conditions

Flexible mounting capability for layout in the dispenser: several product outlet positions Minimal numbers of internal components to assemble or repair Concept takes care of potential requirements for a meter:

Adaptable to temperature compensation system Electronic calibration available Compatible with alternate fuels with up to 15% additives. Models available for

higher fuel blends, contact factory for details.

The positive displacement meter uses the general principle of four horizontal, single effect pistonsequipped with "cup seals" moving in stainless steel sleeved cylinders and driving a vertical crankshaft.The crankshaft also of stainless steel is fitted with stainless steel connecting rod rollers and selflubricated bearings throughout for minimum friction and maximum corrosion resistance.

The patented SB-100 meter, patent number 5094106, is compatible with the Bennett T-75 PumpingUnit and is used in all of our electronic and mechanical dispensers sold worldwide and offers advancedfeatures. At Bennett we consider the meter the key to accurate product measurement and thefundamental source of information for the marketer’s inventory systems. The SB-100 is designed toprovide years of accurate and reliable service starting with the first liter!

Technical Specifications

116146 Rev A 2-18-113

Volume per Revolution 0.5 liter 0.125 gallonOutlet Shaft Diameter 10 mm 0.394 in.Rotation Direction of Outlet Shaft (Top View ClockwiseExternal Dimensions

HorizontalVertical (Including Drive)

200x220 mm 197 mm

7.87x8.66 in.7.45 in.

Cylinder Diameter 72.4 mm 2.85 in.Crankshaft Eccentricity 14.93 mm 0.558 in.Stroke (Pistons 1 & 4) Adjustable

BetweenAnd

28.35 mm31.39 mm

1.056 in.1.176 in.

Minimum Mechanical Adjusting Device Increment 0.05% 0.05%Working Pressure 3.5 Bars 50 PSIFlow Rate Capacity Within +/- 0.3% Accuracy

Minimum FlowMaximum Flow (Objective)

5 lpm100 lpm

1.3 gpm26.4 gpm

7.75 in. (197 mm)

Electronic Calibration Mechanical Calibration

Top View - Electronic Top View -Mechanical

Bottom View - Electronic Bottom View - Mechanical

Side View - Mechanical

Front/Side View - Electronic Front View -Mechanical

7.75 in. (197 mm)

Dimensions & Mounting

116146 Rev A 2-18-114

WEIGHT: 4.7 kg(10 lbs)

Back View Mechanical or Electronic

Theory of Operation

The meter body (1) is cast aluminum with agasketed flange at the base for rigid mountingwith other components using four to six screws.The cylinder covers (2,3) are also castaluminum with an O-ring seal and each issecured to the body by four screws. Thecalibrator cover (3) has a threaded shaftextending through it that limits the piston stroketo effect calibration. The shaft is sealed with anO-ring (NOTE: Electronic calibration meters donot have the calibrator cover (3).

Fastened to the top of the meter body is a castaluminum collector housing (4), which can beassembled in several outlet positions. An O-ring and four screws make the seal andconnection. Extending through the top of thecollector is the output of the crankshaft which issealed against leakage by a lip seal (5) held inplace by a retainer (6) and three screws. (Referto Figure for numbers in parenthesis).

Mechanical Meter Shown.

PRODUCT INLET

116146 Rev A 2-18-115

PRODUCT OUTLET

The meter is a positive displacement, fourpiston device featuring a rotary distributor valveand "cup seal" pistons. Because of thesefeatures the meter shows superior accuracyand repeatability by eliminating internal productslippage. The composition of the "cup seal"piston is such as to provide long life and lowcalibration drift.

The SB-100 Meter features improved linearityallowing the calibration to remain withintolerance from 1.3 gpm (5 Ipm) flow rate to 27gpm (100 Ipm). Mechanical Calibration hasbeen simplified by placing the calibration dialwheel on the piston cover face, out where it iseasily accessible.

The minimum mechanical adjustment is 0.05%.

calibration

Currently the standard SB-100 Meter is compatible with methanol/gasoline mixtures to15% methanol. The SB-100 can bemanufactured of materials which arecompatible with M85 and 100% methanol. The SB-100 is fully compatible with MTBE (methyltertiary butyl ether) additives to 15%concentrations.

The SB-100 weighs only 10 pounds (4.7 kg)making service, installation and handling veryeasy. The SB-100 Meter is the result of sevenyears of product development.

Features and Constructions

116146 Rev A 2-18-116

Basic Concept

1

8

2

3

4

5

7

6

8

116146 Rev A 2-18-117

Each cylinder is closed with cover (6), one ofthem being fitted with a calibrating device (7mechanical only) that allows adjustment of thestroke of the corresponding piston to get theexact value of the volume per revolutiondispensed by the meter.

The crankshaft and connecting rods aresupported by self lubricating bearings tominimize the wear and make the moving partsrun smoothly. The crankshaft may drive amechanical computer or an electronic pulserthat can be fixed directly to the collector (8)which forms the upper part of the meter.

The liquid to be measured enters the bottompart of the meter body (1) and pressure sealsthe rotating distributor (2) down on its matingsurface through a diaphragm (3) and acountervalve (3).

The pressure differential on the two sides ofpistons 1 and 2 pulls the connecting rods (4)and makes the crankshaft (5) turn clockwise(top view). The crankshaft drives the distributorwhich changes the distribution of liquid; piston2 and 3 become active, then 3 and 4 and finally4 and 1 before the cycle starts again.

Accuracy & Calibration

The accompanying Meter Accuracy Curve is typical of the SB-100; 0.3% accuracy from 1.3 gpm (5 lpm)to 27 gpm (100 lpm).

Calibration is achieved by adjustment of the dial and screw assembly on the cover attached to cylinderNo. 1. A clockwise adjustment decreases delivery while counterclockwise increases delivery. Totaladjustment is +/- 15 cubic inches (+/- 240 ml) in minimum increments of 0.05%. Once the meter isadjusted to zero, a pin is inserted through the dial and into the cover and wire sealed through a crossdrilled hole in the pin. See Figure 4.

Figure 4

-0.3

Flow Rate (gpm)

Typical Meter Accuracy Curve

-0.2

-0.1

0

0.1

0.2

0.3

0 5 10 15 20 25 30

Ten

ths

of

1%D

evia

tio

n

Based on metering gasoline with an approximate viscosity of 30 SSU

116146 Rev A 2-18-118

Figure 4

Troubleshooting & Repair

116146 Rev A 2-18-119

Problem Cause Solution

1. Over delivery and out oftolerance difference betweenfast and slow delivery.

A. Dirty or gummed pistons and/ or piston chambers.

B. Damage or worn piston seals.

A. Remove cylinder covers.Remove screw holding pistonto connecting rod. Using visegrips, secure the center hubof the piston and pull straightout. Clean piston seal andpiston chamber using mineralspirits. Reassembly inreverse order.

B. Replace all Pistons. Usepiston repair kit KR043601.

2. Leakage at the output shaft. A. Top lip seal is damaged. A. Replace top lip seal. 107694s

3. Large over delivery amount. A. Damaged distributor and/or diaphragm.

A. Use distributor/diaphragm kit KR044601

SB100 Mechanical Meter

116146 Rev A 2-18-1110

SB100 Electronic Meter

116146 Rev A 2-18-1111

SB100 Meter Parts List

116146 Rev A 2-18-1112

Item Part Number Description Comment1 N/A Lead Seal Wire Please Call 231-798-1310 for details2 N/A Universal Link Please Call 231-798-1310 for details3 H651203 Half Coupling Unthreaded See Kit List4 H650402 Half Coupling Threaded5 H650501 Screw6 A480001 Screw, Flat Head M3.5 - 0.6 X 8 mm7 N666401 Shaft Seal Retainer8 107694S Shaft Seal9 A586901 Screw, Hex Head M6 - 1.0 X 20 mm9 N840401 Screw, Hex Head M6 - 1.0 X 20 mm with Seal Hole

10 A247018 O-Ring, Square Section11 N646502 Collector Cover High Alcohol11 103044 Collector Cover12 A247019 O-Ring, Square Section13 N673201 Gasket14 103077 Spring15 A631901 Screw, Fil Head M4 - 0.7 X 10 mm Stainless Steel16 N685901 Inner Diaphragm Retainer17 100081 Diaphragm18 N673101 Gasket19 N902501 Counter Valve20 101183 Counter Valve Assembly21 N685801 Outer Diaphragm Retainer22 A586801 Screw, Pan Head M5 - 0.8 X 12 mm23 101184 Collector Cover Assembly High Alcohol23 103048 Collector Cover Assembly24 N672601 Drive Pin25 N891601 Distributor26 A579901 Retaining Ring27 A584001 Washer Crankshaft Support28 101185 Meter Body Assembly High Alcohol28 103049 Meter Body Assembly29 N903701 Roller & Bearing Assembly30 A631801 Washer31 A239401 Lock Nut32 N903801 Crank Shaft Assembly Gallons32 N903802 Crank Shaft Assembly Liters33 114149 Pin Cylinder Cover Gallons33 114444 Pin Cylinder Cover Liters33 114442 Pin Cylinder Cover High Alcohol Gallons33 114445 Pin Cylinder Cover High Alcohol Liters33 N659201 Cylinder Cover (Non Pin)34 A247010 O-Ring, Square Section35 N792201 Piston Screw, Hex Head With Nylon Patch (also use with High Alcohol)36 N701502 Piston Assembly High Alcohol36 103046 Piston Assembly38 N654801 Connecting Rod39 A586401 Retaining Ring40 N683701 Calibrating Cover High Alcohol40 103043 Calibrating Cover41 111787 O-Ring42 N701601 Calibrating Dial & Screw Assembly43 N675801 Seal Pin44 N779601 Calibration Cover Assembly44 103047 Calibration Cover Assembly High Alcohol45 100535 Gasket, Meter Inlet Not Shown46 N902401S Valve Plate Not Shown47 A586601 Screw, Valve Plate Not Shown48 A578404 DU Bearing, Meter Body Not Shown, for meters built since 199549 N906501 DU Bearing and Retainer, Meter Body Not Shown, for meters built before 1995

Kit List

116146 Rev A 2-18-1113

These two kits are for SB100 meters built since 1995

These two kits are for SB100 meters built before 1995

Part Number Description Comment100965 Kit, SB100, V'Plate/C'Valve Replacement Includes 1 each of items 8, 10, 12, 13, 14, 20, 25 & 46

KR043601 Kit, SB-100 Piston Retail, 4 Per Includes 4 of items 34, 35, & 36, 1 each of 10 & 45112343 Kit, SB-100 Piston Retail, Alcohol Meters Includes 4 of items 34, 35, & 36, 1 each of 10 & 45107170 Kit, Crankshaft Bearing Replacement Includes 2 of item 29, 1 ea. of 10, 31 & 45112246 Kit, Lower Hydraulic Gallon SB-100 Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & 48112347 Kit Lower Hydraulic Gallon SB-100 Alcohol Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & 48112247 Kit Lower Hydraulic Liter SB-100 Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & 48112348 Kit Lower Hydraulic Liter SB-100 Alcohol Includes 4 of items 34, 35, & 36, 1 ea. of 8, 10, 12, 26, 32, 45 & 48

KR044601 Kit, SB-100 Diaphragm/Distributor Includes 4 of item 15, 1 ea. of 8, 10, 12, 13, 14, 17, 25 & 45112651 Kit, SB-100 Meter Coupling Includes items 3, 4 & 5103490 Kit, Tools for Du Bearing Replacement112248 Field Du Bearing Install/Removal Tool114377 Kit, Meter Gallon Pin Covers M-Calibration Includes 3 of items 33 & 34, 2 ea. of 29, 1 ea. of 10, 8, 38, 48, 45

114400 Kit, Meter Gallon Pin Covers E-Calibration Includes 4 of items 33 & 34, 2 ea. of 29, 38, 1 ea. of 10, 8, 45, 48

114446 Kit, Meter Liter Pin Covers M-Calibration Includes 3 of items 33 & 34, 2 ea. of 29, 1 ea. of 10, 8, 38, 48, 45

114447 Kit, Meter Liter Pin Covers E-Calibration Includes 4 of items 33 & 34, 2 ea. of 29, 38, 1 ea. of 10, 8, 45, 48

KR044703 Kit, SB-100 Meter, Crankshaft, Gallons Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 48KR044704 Kit, SB-100 Meter, Crankshaft, Liters Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 48

KR044701 Kit, SB-100 Meter, Crankshaft, Gallons Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 49KR044702 Kit, SB-100 Meter, Crankshaft, Liters Includes 4 of item 34, 1 ea. of 8, 10, 12, 26, 32, 45 & 49

14 116146 Rev A 2-18-11





Read this Book

For new books, visit out web page at: www.BennettPump.com

For Part Pricing, please visit the parts pricing section under the Literature Tab on our website.

107072 Rev D 02/21/11



Bennett Pump Company

T-75 Hydraulic Pumping Units

Operation, Service & Parts ManualOnly Trained Personnel May Work on This Equipment

For more information, please contact:

Jim Biesecker, Component Sales

1218 E. Pontaluna RoadSpring Lake, Michigan USA

Tel: 800-235-7618 (USA)Tel: 231-798-1310 (International)

Tel: 800-423-6638 (Tech Support - USA) Tel: 231-799-6262 (Sales)Fax: 231-799-6200

Email: [email protected]: [email protected]: [email protected]

http://www.BennettPump.com/






Table of Contents

Introduction 4

Specification Sheet 5

Technical Specifications 6Pump Curve U.S. Market 7Pump Curve European Market 8Overall Dimensions 9

Theory of Operations 11

Hydraulic Schematics & Principle 13

How to Correct Problems on Pumping Units 15

Parts List 18

Appendices

A. European Approval 22B. European Approval 25C. Dimensions and Mounting 29D. Installation Piping for Type 75 Pump Dispenser 31

3107072 Rev D 02/21/11

Introduction

The Type 75 pumping unit is the standard product produced by Bennett Pump Company. It is used inmany countries and has proven its ability to work properly even in the toughest conditions.

It is a compact, lightweight unit built with the following functions:

Filtering

Pumping

Air elimination

By-Pass (adjustable as an option)

Outlet Control Valve

The same unit is used to achieve the two standard flows of 13 gpm (3m3/h) or 22 gpm (5m3/h). Thisfeature is achieved by:

U.S. Market — 60Hz power:Using two sizes of pump chamber initially assembled into the housing. The 13 gpm pump requires a 250 Watt 1/3 hp motor, the 22 gpm pump uses a 560 Watt 3/4 hp motor.

Europeon Market — 50Hz power:Running the 22 gpm pump at different speeds, just by changing the pump pulley

This unit uses a rotary vane pump with carbon blades that produces very good suction (power) evenwhen the pump is dry (at start). The rotor is supported at each end by self lubricated insert bearings thatare field replaceable.

Air elimination is achieved within extreme standards through a patented fully static device using a vortexeffect.

Filtration is achieved with three different filter means (10 micron cloth filter, 35 micron pleated paper filterand 70 micron Nylon strainer), according to the conditions of use. The T-75 Pumping Unit is fullycompatible with the SB-100 Meter.

For further information, please contact the Bennett Technical Service Department at 1-800-423-6638.

4107072 Rev D 02/21/11

5

Specification Sheet

Standard Fuels (up to 15% alcohol) or Alcohol Fuels (E85 typical)

Standard Flow (13 GPM) or High Flow (22 GPM)

Ultra High (50 psi), High Pressure (45 psi), Normal Pressure (35 psi) or Low Pressure (25 psi) By-Pass Valve Spring (nominal pressures w/adjustable bypass screwed in)

Adjustable or Non-Adjustable By-Pass Valve Settings

Low Pressure (4.3 psi) or Standard Pressure (6 psi) Control Valve Spring

Meter Outlet Flange or Tube Style Outlet

W/Tube outlet - offer a Motor Mount Option on Atmospheric Cover

100 or 70 Micron Metal Strainer Basket or 35 Micron Paper Element Filter with or without Fabric Integral Inlet check valve

107072 Rev D 02/21/11

Technical SpecificationsU.S. Market

Technical SpecificationsEuropean Market

6107072 Rev D 02/21/11

Maximum Flow (gpm) 13 22Noise Level (dB) 68 72Bypass Pressure (psi) 25 25Motor Power (hp) 1/3 3/4Minimum Dry Suction (in. Hg) 10 12Minimum Wet Suction (in. Hg) 21 21Air Elimination According to OIML, CEE 77.313 RegulationMicron Filter (µ) 10,35,70 according to conditions of usePump Curve See Figure 1 See Figure 2

Maximum Flow (m3/h) 3 5Minimum Flow (m3/h) 0.3 0.5Noise Level (dB) 68 72Bypass Pressure (b) 1.8 (Adjustable 1.2 - 2.5) 2.0 (Adjustable 1.2 - 2.5)Motor Power (Kw) .37 .55Minimum Dry Suction (mb Hg) 450Minimum Wet Suction (mb Hg) 700Air Elimination According to OIML, CEE 77.313 RegulationMicron Filter (µ) 10,35,70 according to conditions of usePump Curve See Figure 3Approval Documents (See Appendices

Ministère de I’Industrie et du Commerce - FRANCE#85.0.01.462.2.3 (July 1, 1985)#87.0.04.462.2.3 (Dec. 31, 1987)

10 15Flow Rate (gpm)

T-75 Pump (3/4 hp) PerformanceU.S. Market

0

5

15

10

20

25

30

35

0 5 20 25

Pu

mp

Pre

ssu

re (p

si)

Pump Speed 700 rpm

Test Conditions:1. Tested on Stoddard Solvent

* 30 SSU Viscosity* 0.78 Specific Gravity

2. 12 inches Hg operating vacuum3. Fixed bypass cover

Figure 2

T-75 Pump (1/3 hp) PerformanceU.S. Market

Figure 1

0

Test Conditions:10 1. Tested on Stoddard Solvent


2. 12 inches Hg operating vacuum3. Fixed bypass cover

5

15

25

Pump Speed 700 rpm

20

30

0 2 4 6 8Flow Rate (gpm)

10

12

14

16

Pu

mp

Pre

ssu

re(p

si)

Pump CurvesU.S. Market

7107072 Rev D 02/21/11

T-75 Pump PerformanceEuropean Market

Figure 3

0

0.5

1

1.5

2

2.5

0 10 20 30 40 50Flow Rate (lpm)

60 70 80 90

Pu

mp

Pre

ssu

re(b

ars)

Pag e15

Pump CurvesEuropean Market

8107072 Rev D 02/21/11

Note:Adjustable bypass can vary pump pressures from posted curve values by +/- 20 % from 0 to 80% of fast flow

Pump Speed 700 rpm0.55 Kw motor

Pump Speed 450 rpm

0.37 Kw motor

Tes t Conditions:1. Tested on Stoddard Solvent


2. 400 mb Hg operating vacuum

Overall DimensionsT75 with Meter Outlet

Side View

Top View

Front ViewBack View

2.69”

0: 1.63”

0:[40mm]

Bottom View

9107072 Rev D 02/21/11

Overall DimensionsT75 with Tube Outlet

Side View

Top View

Front ViewBack View

2.69”

0: 1.63”

0:[40mm]

Bottom View

10107072 Rev D 02/21/11

Figure 7

Theory of Operation

Detailed Description

11107072 Rev D 02/21/11

Theory of Operation

The pump assembly has the following main components: (See Figure 7 for numbers in parenthesis.)

a body (1) of cast aluminum

The inlet is designed to accept a triangular inlet flange with a 3-hole bolt pattern.

a cover (2)

outlet flanged for direct meter mounting

tubular outlet for remote meter mounting (as shown on page 6)

a filter (3) in the horizontal position. The filter cover includes a pipe plug to drain the pump.

An optional inlet checkvalve (19) is available to hold product in the suctionline when the pump is turned off. This is an environmentally friendly devicethat maintains a vacuum in the line preventing fuel from leaking through aloose joint into the ground.

a rotating pump (4) with radial carbon blades

Throwout rings (5) maintain contact of the blades to the stator.

The stator (6) is made of cast iron and is tightly fitted in the pump body.

The rotor (7) is made of cast iron with a chrome plated shaft.

Self lubricated bearings (21) prevent seizure when tank is pumped dry.

The cover (8), also of cast iron, encapsulates the rotor and the stator.

an air elimination assembly (9), a patented fully static device, uses a vortex effect.

The insert (10) starts spinning the fluid.

The foam and the air pass through the tube (11) and evacuated through the orifice (12).

a drain line eliminator (13) or atmospheric chamber of 1.2 gallon (4.5 liter) capacity.

The float valve assembly (14) provides for the recovery of liquid from the chamber, while air is evacuated through the vent tube (15).

A non return float (20) seals the atmospheric chamber when the pump is turned off to prevent flooding and spilling out onto the driveway.

a bypass valve (16) limiting the maximum working pressure.

its cover includes a device to adjust the bypass pressure (optional in USA)

a control valve assembly (17) assures that all downstream hydraulic components are filled with liquid. This valve has a relief valve (18) to relieve excess pressure.

NOTE: A diaphragm operated preset valve is available as an option.

12107072 Rev D 02/21/11

Figure 8

Figure 9

Hydraulic Schematics & Principle

13107072 Rev D 02/21/11

Hydraulic Schematics & Principle

(See Figure 8 for numbers in parenthesis.)

The product is drawn from the underground storage tank through the strainer screen of filter (1).

The rotary van pumping unit (2) pressurizes the fluid.

Product enters the centrifugal air separator assembly (3). Any air present is forced out the air tubealong with a small amount of liquid into the atmospheric chamber (4).

Product collected in the atmospheric chamber is returned to the pump intake across the non return floatwhen the liquid level in the chamber lifts the float and valve assembly from its seat (5). Any air is thenvented to the atmosphere through the vent tube.

Air free product leaving the air separator opens the control valve (6) and is pumped to the meter. Thecontrol valve includes a built-in relief valve (7) which relieves excess pressure caused by hot weatherexpansion.

Product passes through the meter where it is accurately measured, then through the hose and nozzleinto the vehicle being fueled.

Whenever the nozzle is not fully opened, some liquid is relieved into the pump intake through the bypassvalve (8).

14107072 Rev D 02/21/11

How to Correct Problems on Pumping Units

15107072 Rev D 02/21/11

Problem Cause Action

1. The motor starts but the pump does not deliver fuel.

a. The fuel supply is below the suction stub in the storage tank.

a. Fill the storage tank.

b. The vent pipe is plugged in the storage tank.

b. Clean the vent pipe.

c. The strainer screen or filter assembly has an obstruction.

c. Remove obstructions from the screen or filter assembly.

d. The bypass valve is not seating properly due to wear or obstruction.

d. Check the valve for an obstruction causing the valve to stay open, and/or replace the bypass valve.

e. The v-belt is loose or broken. e. Adjust or replace the v-belt.

f. There is an obstruction in the atmospheric float valve.

f. Clean the float and valve area.Check for swelling and bindingin the linkage.

g. The pump is out of prime. All fuel drained out of suction line due o fault line check or foot valve.

g. Check for a faulty foot valve in the storage tank or a faulty check valve in the suction line.

h. The suction line is leaking. h. Start the pump and open the nozzle. If bursts of air are felt while holding a finger on the vent tube, the suction line is damaged. Repair or replace.

i. The intake line, foot valve, angle check valve, or vertical check valve have an obstruction.

i. Connect a vacuum gauge to the 1/4” plug on the filter cover. Turnthe pump on and open the nozzle. A reading of 15 or more inches of mercury with no flow indicates a complete blockage inthe suction line. Clean the lineor replace.

j. The suction stub in the storage tank is on the bottom of the tank.

j. Make sure there is a three inch clearance.

k. The control valve has an obstruction.

k. Clean the control valve. It must slide freely in the valve cavity.

l. The nozzle is not working. l. Replace the nozzle.

m. *Two pumps are connected to one storage tank with one suction line. There is a faulty check valve in one of the supply lines.

*Not recommended.

m. Disconnect the vent tube on theidle pump. Install a short coppertube. Place the end of thecopper tube in a container of liquid. If the liquid is drawn out of the container when the opposite pump is operated with an open nozzle, the line check valve is faulty. Replace the check valve.


16107072 Rev D 02/21/11


2. The pump runs, but delivery is slow.

a. The fuel supply level is low. a. Fill the storage tank.

b. The storage tank vent pipe is partially obstructed.

b. Clean the vent pipe.

c. The strainer screen is partially plugged.

c. Remove obstructions from the screen or filter assembly.

d. The pump bypass valve is not seated properly.

d. Remove and clean the strainer screen.

e. The v-belt is loose. e. Adjust the v-belt.

f. The motor voltage is too low. f. Check the power supply voltage. Check for too many pieces of equipment on one electrical line.

g. A blade or blades in the pump are worn or broken.

g. Check the blades and replace if necessary.

h. An automatic nozzle has been installed.

h. Delivery speed will be reduced by 10-25%. If maximum speed is desired, replace with a manual nozzle.

i. The motor is defective. i. Inspect the motor for loose connections. If no loose connections are found, the motor is defective. Repair or replace.

j. There is a slow leak in the suction line.

j. Start the pump and open the nozzle. If bursts of air are felt while holding a finger on the vent tube, the suction line is damaged. Repair or replace.

k. The suction line is obstructed or the foot valve, angle or vertical check valve is partially stuck andwill not open fully.

k. Connect a vacuum gauge to the 1/4” plug on the filter cover. Turn the pump on and open the nozzle. A reading of 11 to 13 inches of mercury indicates a partial obstruction in the suction line. Clean or replace the suction line components.

l. The pump control valve is partially stuck and will not open fully.

l. Remove the valve and clean thoroughly.

m. The nozzle check valve is sticking.

m. Clean or replace the nozzle check valve.

n. The hose is defective (flattened).

n. Replace the hose.


17107072 Rev D 02/21/11


3. Inaccurate Delivery. a. Control valve stuck open. a. Remove 4-bolt control valve cover and free control valve.

b. Vent tube from air eliminator to atmosphere plugged.

b. Clear any obstructions.

4. Fuel Runs out Vent Tube When Pump is Operating.

a. Float valve stuck in a closed position.

a. Clean the float and valve area. Check for swelling and binding in the linkage.

b. Flooded suction chamber. Directional flow valve missing.

b. Storage tank level must be lower than pumping unit. Make sure 2 or more pumps are not using same suction line.

5. The computer jumps when the pump is turned on.

a. Control valve not seated properly.

a. Remove valve cover & inspect for dirt or nicks in O-ring.

b. Expansion relief Dill valve in control valve stuck open.

b. Remove and inspect for foreign matter. Pull spring loaded seat for better view. Reinstall.

Type 75 Pumping Unit

19107072 Rev D 02/21/11

Type 75 Pumping Unit Parts List

20107072 Rev D 02/21/11

Item Part Number Description Comment1 A479902 Bolt M8-1.25 X 25 mm (Use N840502 for Seal Wire Bolt)2 N152902 Meter Inlet Adaptor With Tap

105588 Meter Inlet Adaptor High Alcohol3 N162801 Gasket, Meter Inlet Adaptor4 111874 Housing, Air Valve Float Assembly5 108737 Gasket9 108734 Float10 111537 Retainer Ring11 110211 ID Tag12 N152801 Cover, Atmospheric Chamber Meter Mount Style

105787 Cover, Atmospheric Chamber Meter Mount Style - High Alcohol13 N347901 Cover, Atmospheric Chamber Pipe Outlet with Motor Mount Ears

103055 Cover, Atmospheric Chamber Pipe Outlet with Motor Mount Ears - High Alcohol108945 Cover, Atmospheric Chamber GPU109582 Cover, Atmospheric Chamber GPU - High Alcohol

17 N162901 Gasket - Atmospheric Cover18 A480101 Bolt - Round Head M6-0.7 X 20 mm19 N888301 Non-Reversing Float20 111788 O-Ring #O17 Also used with High Alcohol21 109892 Atmospheric Float Assembly22 N162901 Gasket - Atmospheric Cover23 113078

113079One Piece Air Separator Body One Piece Air Separator Body

High Alcohol

24 N162501 Gasket, Inlet Separator25 N162601 Gasket, Outlet Separator26 N190201 Insert - Air Separator Inlet27 108727 Tube - Air Separator28 108730 Piston OIML Only29 108725 Spring30 108728 End Cap31 N225301 Tube - Air Separator

32 109668 Screw - Air Test Valve33 109666 Adaptor - Air Test Valve34 110430 Pipe Plug 1/4 - 18NPT35 N154801

103053Cover, Control Valve Cover, Control Valve

High Alcohol

36 N162301 Gasket37 E008001 Spring Standard Delivery Pump 12 GPM

J325201 Spring Heavy Duty Delivery Pump 22 GPM38 113022 Control Valve Assembly Aluminum Body Version with Hard Coat39 A321901 Pressure Relief Valve40 111790 O-Ring #210 Also used with High Alcohol41 N150602 Pump Body High Alcohol

103052 Pump BodyN150603 Pump Body Side Inlet Version109735 Pump Body Side Inlet High Alcohol

42 N160301 Filter Insert43 100070 Strainer Standard Production

A311901 Filter Paper Filter 35 MicronStrainer Special - Used with Sack

N347301 Cloth Sack 10 Micron

Type 75 Pumping Unit Parts List

21107072 Rev D 02/21/11

Item Part Number Description Comment44 N905001 Filter Spring45 N162201 Gasket46 N154701

103054Filter Cover Filter Cover

High Alcohol

47 N154901 105585

Bypass Cover Bypass Cover

Non-AdjustableHigh Alcohol

48 N162401 Gasket49 N481201

N481202N481203

Bypass ValveBypass ValveBypass Valve

Standard - Silver Spring Low Pressure Standard - Green Spring Medium Pressure Standard - Copper Spring High Pressure

50 111791 O-Ring #229 Also used with High Alcohol51 A620801 Cap Nut52 A620901 Seal Ring53 N873001 Disc54 N872801 Adaptor Not Sold Separately - See Item #6055 A620101 Retaining Ring56 N872901 Check Valve Body57 N873201 Spring58 N873101 Washer59 N872701 Shaft60 N873301

KR044102Check Valve Assembly Check Valve Assembly

With out RingIncludes Item #50 & Item #60

61 N308301 Cap62 N308201 Adjustment Screw63 A507901 Washer64 N308101 Cover - Adjustable Bypass65 A479903 Screw M8 - 1.25 X 20 mm66 A000301 Lock Washer67 A028101 Flat Washer68 N106901

100040Pulley - Single Groove Pulley - Dual Groove

69 N155901 Clamping Ring70 N162701 Gasket71 J682702 Rotor Cover Assembly72 A480001 Flat Head Screw73 H352101 Shaft Seal Retainer74 A323702 Shaft Seal (with insertion tool) 109711 Shaft Seal Kit - Includes #74 & 75 with install plug75 A247014 Square Seal76 N103801 Rotor Cover77 N650401

N238101Throw Out Ring Throw Out Ring

Standard Delivery Pump Heavy Duty Pump

78 A199501 Woodruff Key79 A263101 Retaining Ring80 N238301

*KR0420xxRotor & Shaft Assembly*Rotor Replacement Kit

Standard 6 Blade RotorIncludes #70, 74, 75, (2) 77, 80, (6) 81 xx=“01” Std Delivery

“02” Heavy Duty81 110704 Rotor Blade82 N156401

N159501Stator Stator

Standard Delivery Pump Heavy Duty Pump

KR036604 Gasket Set for Pumping Unit Complete Set of Gaskets, Seals, and O-Rings for P/U

Appendix A

22107072 Rev D 02/21/11

BULLETIN OFFICIEL DES INSTRUMENTS DE MESURECERTIFICAT D'APPROBATION C.E.E. DE MODELES

n° 87.0.04.462.2.3 du 31 décembre 1987

modifiant le certificat C.E.E. n° 85.0.01.462.2.3 du fer juillet 1985 (f)

Groupes de pompage el de dégazage SATAM modèles EPZ 75/3 et EPZ 75/5

Le présent certificat est établi en application de la directive 71/316/CEE du 26 juillet 1971, modifiée parla directive 83/575/CEE du 26 octobre 1983, relative aux dispositions communes aux instruments demesurage et aux méthodes de contrôle métrologique, de la directive 71/319/CEE du 5 juillet 1971,relative aux coupleurs de liquides autres que l’eau el de la directive 77/313/CEE du 5 avril 1977,modifiée par la directive 82/625/CEE du l'er juillet 1982, relative aux ensembles de mesurage deliquides autres que l’eau. Du décret n° 73-788 du 4 août 1973, modifié par le décret n° 84-1107 du 6décembre 1984, portant application des prescriptions de la Communauté économique européennerelatives aux dispositions communes aux instruments de mesurage et aux méthodes de contrôlemétrologique et du décret n° 73-791 du 4 août 1973 relatif a l'application des prescriptions de laCommunauté économique européenne au contrôle des compteurs volumétriques de liquides autresque l’eau et de leurs dispositifs complémentaires.

Fabricant:SATAM Industries, 63, Avenue du General. Leclerc, B.P. 100. 93123 La Courneuve. Paris, France.

Objet:Le présent certificat CEE modifie le certificat CEE n° 85.1.01.462.2.3 du l'er juillet 1985 (1).

Caractéristiques:Les groupes de pompage et de dégazage SATAM, modèles EPZ 75/3 et EPZ 75/5, faisant l’objet du présent certificat CEE différent des modèles approuvés par le certificat CEE précité par:

Le remplacement sure le couvercle des groupes de pompage et de dégazage d’un clapet tare parun orifice protège par une bride rivetée : cet orifice assure l'évacuation des vapeurs et des gaz dela cuve de purge dans le cas ou le tube de mise a l'atmosphère est obstrue.

La modification du groupe de pompage du modèle EPZ 75/3 : il est identique a celui du modèleEPZ 75/5 mais la vitesse de rotation de l’axe des palettes dans la chambre d’aspiration estréduite. La pression maximale de fonctionnement, identique pour les deux modèles, est égale à 2bar.

Les autres caractéristiques, les indications complémentaires, le signe d’approbation CEE, le principe de fonctionnement et le plan de scellement ne sont pas modifies.

Les ensembles de mesurage routiers approuves antérieurement avec un groupe de pompage et dedégazage SATAM, modèle EPZ 75/3 ou EPZ 75/5, objet du certificat CEE n° 85.1.01.462.2.3 précitépeuvent être équipes d’un groupe de pompage et de dégazage objet du présent certificat.

(1) Revue de Métrologie, juillet 1985, page 509.

Revue de Métrologie, t. 65, n° 12, décembre 1987 1403

Appendix A

1404 Revue de Métrologie, t. 65, n° 12, décembre 1987

23107072 Rev D 02/21/11

BULLETIN OFFICIEL DES INSTRUMENTS DE MESURE

Signe d’approbation de modèle:

F85

01.462

Dépôt de modèles:

Les plans et schémas ont été déposés au siège de la direction régionale de l’industrie et de la recherche d’Ile-de-France et à la sous direction de la métrologie.

Validité du présent certificat CEE:

Le présent certificat CEE est valable jusqu’en juillet 1995.

Annexe:

Dessin n° 4858.

Pour le ministre et par délégation:

Par empêchement du directeur général de l’industrie:

L’Ingénieur général des Mines,A.C. Lacoste.

Appendix A

BULLETIN OFFICIEL DES INSTRUMENTS DE MESURE

N° 4858

Groupes de pompage et de dégazage SATAM EPZ 75/3 et EPZ 75/5

Vue en coupe du couvercle

Revue de Métrologie, t. 65, n° 12, décembre 1987 1405

tube do mise a

l’atmosphère

rivets bride couvercle sortie vers le mesureur

orifice

cuve de purge

24107072 Rev D 02/21/11

Appendix B

25107072 Rev D 02/21/11

BULLETIN DES INSTRUMENTS DE MESURE JUILLET 1985

CERTIFICAT D'APPROBATION C.E.E. DE MODELESn° 85.0.01.462.2.3 du fer juillet 1985

Groupes de pompage el de dégazage SATAM modèles EPZ 75/3 et EPZ 75/5

(Précision commerciale)

Le présent certificat est établi en application de la directive 71/316/CEE du 26 juillet 1971, relative auxdispositions communes aux instruments de mesurage et aux méthodes de contrôle métrologique, dela directive 71/319/CEE du 26 juillet 1971, relative aux coupleurs de liquides autres que l’eau Dudécret n° 73-788 du 4 août 1973 portant application des prescriptions de la CEE relatives auxdispositions communes aux instruments de mesurage et aux méthodes de contrôle métrologique dudécret n° 73-791 du 4 août 1973 relatif à l'application des prescriptions de la CEE au contrôle descompteurs volumétriques de liquides autres que l’eau et de leurs dispositifs complémentaires et del’arrêté du8 novembre 1973 relatif aux modales d’application de certaines dispositions du décret n°73-788 du 4 août 1973, de l’arrêté du 20 novembre 1973 portant application du décret n° 73-791 di 4aout 1973 et de l’arrêté du 19 juin 1978 relatif à l'application des prescriptions de la CEE au contrôledes ensembles de mesurage à computeur columetrique destines à determines le volume des liquidesoutres que l’eau.

Fabricant:SATAM Industries, 63, Avenue du General. Leclerc, B.P. 100. 93123 La Courneuve. Paris, France.

Caractéristiques:Les groupes de pompage et de dégazage SATAM, modèles EPZ 75/3 et EPZ 75/5, sont destines au mesurage de l’essence, do supercarburant et du gazole.

Ils sont composes des éléments suivants:

Un filtre avec couvercle amovible.

Une pompe rotative a six palettes radiales.

Un séparateur de gaz statique a effet VORTEX.

Une cuve de purge.

Un clapet de bipasse.

Un clapet anti-retour.

Un orifice de refoulement vers le mesureur.

Ces deux modèles différent par la cylindrée do la chambre d’aspiration de la pompe. En outre, le modèle EPZ 75/7 comporte une bague de guidage des palettes.

Appendix B

BULLETIN DES INSTRUMENTS DE MESURE JUILLET 1985

Leurs caractéristiques métrologiques sont les suivantes:

Indication complémentaire:

Lorsque le groupe de pompage et de dégazage SATAM, modèle EPZ 75/5 est incorporé dans unensemble de mesurage routier destiné au mesurage de gazole, un indicateur de gaz doit êtredispose en amont du flexible de l’ensemble.

Signe d’approbation de modèle:

F85

01.462

Dépôt de modèles:

Les plans et schémas ont été déposés au service de la métrologie.

Validité du présent certificat CEE:

Jusqu’au ler juillet 1995.

Annexe:

Notice descriptive. Dessins n° 4490-1 et 2

Pour le ministre et par délégation:

Par empêchement du Directeur de la qualité et de la sécurité industrielles:

Le Chef du service de la Métrologie,P, Bertran.

26107072 Rev D 02/21/11

510 B-2

Modèle EPZ 75/3 EPZ 75/5

Débit maximal 3 m3/h 5 m3/h

Pression maximale de fonctionnement 1.7 bar 2 bar

Pression minimale de fonctionnement 0.6 bar 0.6 bar

No 4490-1

12

21

19

20

23

4 3 7 56

9

10 118

Liquide dégazeLiquide

mousse

Section AA

18

22

exit

Appendix B

BULLETIN DES INSTRUMENTS DE MESURE

entrance 17 1615

27107072 Rev D 02/21/11

JUILLET 1985Groupe pompe dégazeur SATAM EPZ 75/3

No 4490-1

9

6 4 3 7 5

Section AA

exit mou

18

8 10 11

1222 Liquide Liquide dégaze

21

19

20

23

moussssee

No 4490-2

12

21

19

20

23

4 3 7 56

9

10 118

Liquide dégazeLiquide

Section AA

18

22

exit

24

Appendix B

BULLETIN DES INSTRUMENTS DE MESURE

entrance 17 1615

28107072 Rev D 02/21/11

JUILLET 1985Groupe pompe dégazeur SATAM EPZ 75/5

Figure 5 - Meter Flange Outlet Option

Appendix CInlet & Mounting Dimensions

29107072 Rev D 02/21/11

Figure 6 - Tubular Outlet/Motor Mount Option

Appendix CInlet & Mounting Dimensions

30107072 Rev D 02/21/11

Appendix DInstallation Piping for Type 75 Pump Dispenser

To obtain maximum flow rates on a self-contained pump, follow these guidelines:1. The total length of horizontal piping between the pump and tank must be no longer than 60 feet.2. Piping specifications:

a. Use new 1-1/2” galvanized or approved non-metallic pipe for 10-15 GPM pumps. Use new2” galvanized or approved non-metallic pipe for 20-24 GPM pumps.

b. All horizontal piping must be buried a MINIMUM of 18” below the finishing grade.c. The pipe from the tank must slope up to the pump (approximately 1-1/2” to 2” per 10 feet).

The pipe MUST be straight. The pipe must be supported continuously to prevent sagging.d. All piping must hold a 50 PSI pressure test for 10 minutes.e. To absorb ground movement from settling of the tank, front heaving of the ground pump or

pump island settling, a swing joint must be used in the supply line at the tank and directlyunderneath the dispenser. Three additional directional changes using elbows are permitted.

f. Only one pumping unit is permitted for each underground pipe. Do not use a tee toconnect two pumps off one line.

3. Static lift on self contained units must not exceed 10 feet (vertical distance between product level inthe storage tank and the center of the pumping unit).

31107072 Rev D 02/21/11

2/2SERIES

8210

Features• Wide range of pressure ratings, sizes, and resilient

materials provide long service life and lowinternal leakage

• High Flow Valves for liquid, corrosive, and air/inertgas service

• Industrial applications include:- Car wash- Air compressors- Pumps

- Laundry equipment- Industrial water control

Pilot Operated

General Service Solenoid ValvesBrass or Stainless Steel Bodies

3/8" to 2 1/2" NPT

NC

NO

Solenoid EnclosuresStandard: RedHat II - Watertight, Types 1, 2, 3, 3S, 4, and 4X; RedHat - Type I.Optional: RedHat II - Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, 6P, 7, and 9; Red-Hat - Explosionproof and Watertight, Types 3, 4, 4X, 7, and 9. (Toorder, add prefix “EF” to catalog number, except Catalog Numbers 8210B057,8210B058,and8210B059,whicharenot available withExplosionproofenclosures.)SeeOptional FeaturesSection for other availableoptions.

Electrical

Nominal Ambient Temp. RangesRedHat II/RedHat

RedHat II RedHat

AC: 32 F to 125 F (0˚C to 52˚C)

DC: 32 F to 104 F (0˚C to 40˚C)

DC: 32 F to 77 F (0˚C to 25˚C)

(104˚F/40˚C occasionally)

8210G227 AC:32 F to 130 F (0˚C to 54˚C)

DC:32 F to 90 F (0˚C to 32˚C)

Refer to Engineering Section for details.

ApprovalsUL listed as indicated. CSAcertified.RedHat II meets applicableCEdirectives.Refer to Engineering Section for details.

Construction

4

2- WA

Y

11

^ % )

*Catalog Numbers 8210G127, 8210G129, 8210G132, 8210G133 have 316L Stainless Steel bodies.

Valve Parts in Contact with Fluids

Body Brass 304 Stainless Steel*

Seals and Discs NBR or PTFE

Disc-Holder PA

Core Tube 305 Stainless Steel

Core and Plugnut 430F Stainless Steel

Springs 302 Stainless Steel

Shading Coil Copper Silver

Standard CoilandClass ofInsulation

Watt Rating andPower Consumption

Spare Coil Part Number

DCWatts

AC GeneralPurpose

Explosionproof

Watts VAHolding

VAInrush

AC DC AC DC

F - 6.1 16 40 238210 - 238214 -

F 11.6 10.1 25 70 238610 238710 238614 238714

F 16.8 16.1 35 180 272610 97617 272614 97617

F - 17.1 40 93 238610 - 238614 -

F - 20 43 240 99257 - 99257 -

F - 20.1 48 240 272610 - 272614 -

H 30.6 - - - - 74073 - 74073

H 40.6 - - - - 238910 - 238914

Standard Voltages: 24, 120, 240, 480 volts AC, 60 Hz (or 110, 220 volts AC,50Hz). 6, 12, 24, 120, 240 volts DC. Must be specified whenordering. Other voltages available when required.

2/2SERIES

8210 4

2-WA

Y

12

Specifications (English units)PipeSize(in)

Orifice Size (in)

Cv Flow Facto

r

Operating Pressure Differential (psi) Max.Fluid Temp. ˚F

Brass Body Stainless Steel Body WattRating/Class ofCoilInsulation➆

Min. Max. AC Max. DC

Air-Inert Gas

Water Light Oil@ 300SSU

Air-Inert Gas


AC DC Catalog Number

Const. Ref.➃

UL➄Listing

Catalog Number

Const. Ref.➃

UL➄Listing

AC DC

NORMALLY CLOSED (Closed when de-energized), NBR or PTFE➁ Seating

3/8 3/8 1.5 ➀ 150 125 - 40 40 - 180 150 8210G073 ➂ 1P 8210G036➂

1P 6.1/F 11.6/F

3/8 5/8 3 0 150 150 - 40 40 - 180 150 8210G093 5D - - - 10.1/F 11.6/F

3/8 5/8 3 5 200 150 135 125 100 100 180 150 8210G001 6D - - - 6.1/F 11.6/F

3/8 5/8 3 5 300 300 300 - - - 175 - 8210G006 5D - - - 17.1/F -

1/2 7/16 2.2 ➀ 150 125 - 40 40 - 180 150 8210G015 ➂ 2P 8210G037➂

2P 6.1/F 11.6/F

1/2 5/8 4 0 150 150 - 40 40 - 180 150 8210G094 5D - - - 10.1/F 11.6/F

1/2 5/8 4 0 150 150 125 40 40 - 175 150 - - - 8210G087 7D 17.1/F 11.6/F

1/2 5/8 4 5 200 150 135 125 100 100 180 150 8210G002 6D - - - 6.1/F 11.6/F

1/2 5/8 4 5 300 300 300 - - - 175 - 8210G007 5D - - - 17.1/F -

1/2 3/4 4 5 - 300 - - 300 - 130 90 8210G227 5D - - - 17.1/F 40.6/H

3/4 5/8 4.5 0 150 150 125 40 40 - 175 150 - - - 8210G088 7D 17.1/F 11.6/F

3/4 3/4 5 5 125 125 125 100 90 75 180 150 8210G009 9D - - - 6.1/F 11.6/F

3/4 3/4 5 0 150 150 - 40 40 - 180 150 8210G095 8D - - - 10.1/F 11.6/F

3/4 3/4 6.5 5 250 150 100 125 125 125 180 150 8210G003 11D - - - 6.1/F 11.6/F

3/4 3/4 6 0 - - - 200 180 180 - 77 8210B026 ➁ ‡ 10P - - - - - 30.6/H

3/4 3/4 6 0 350 300 200 - - - 200 - 8210G026 ➁ ‡ 40P - - - 16.1F -

1 1 13 0 - - - 100 100 80 - 77 8210B054 ‡ 31D - 8210D089 15D - - 30.6/H

1 1 13 0 150 125 125 - - - 180 - 8210G054 41D 8210G089 45D 16.1/F -

1 1 13 5 150 150 100 125 125 125 180 150 8210G004 12D - - - 6.1/F 11.6/F

1 1 13.5 0 300 225 115 - - - 200 - 8210G027 ‡ 42P - - - 20.1/F -

1 1 13.5 10 300 300 300 - - - 175 - 8210G078 ➁ 13P - - - - 17.1/F -

1 1/4 1 1/8 15 0 - - - 100 100 80 - 77 8210B055 ‡ 32D - - - - - 30.6/H

1 1/4 1 1/8 15 0 150 125 125 - - - 180 - 8210G055 43D - - - 16.1/F -

1 1/4 1 1/8 15 5 150 150 100 125 125 125 180 150 8210G008 16D - - - 6.1/F 11.6/F

1 1/2 1 1/4 22.5 0 - - - 100 100 80 - 77 8210B056 ‡ 33D - - - - - 30.6/H

1 1/2 1 1/4 22.5 0 150 125 125 - - - 180 - 8210G056 44D - - - 16.1/F -

1 1/2 1 1/4 22.5 5 150 150 100 125 125 125 180 150 8210G022 18D 8210G127 - - 6.1/F 11.6/F

2 1 3/4 43 5 150 125 90 50 50 50 180 150 8210G100 20P 8210G129 - - 6.1/F 11.6/F

2 1/2 1 3/4 45 5 150 125 90 50 50 50 180 150 8210G101 21P - - - 6.1/F 11.6/F

NORMALLY OPEN (Open when de-energized), NBR Seating (PA Disc-Holder, except as noted)

3/8 5/8 3 0 150 150 125 125 125 80 180 150 8210G033 23D - - - 10.1/F 11.6/F

3/8 5/8 3 5 250 200 200 250 200 200 180 180 8210G011 ➇➈

39D - - - 10.1/F 11.6/F

1/2 5/8 4 0 150 150 125 125 125 80 180 150 8210G034 23D - - - 10.1/F 11.6/F

1/2 5/8 3 0 150 150 100 125 125 80 180 150 - - - 8210G030 37D 10.1/F 11.6/F

1/2 5/8 4 5 250 200 200 250 200 200 180 180 8210G012 ➇➈

39D - - - 10.1/F 11.6/F

3/4 3/4 5.5 0 150 150 125 125 125 80 180 150 8210G035 25D - - - 10.1/F 11.6/F

3/4 5/8 3 0 150 150 100 125 125 80 180 150 - - - 8210G038 38D 10.1/F 11.6/F

3/4 3/4 6.5 5 - - - 250 200 200 - 180 8210C013 24D - - - - 16.8/F

3/4 3/4 6.5 5 250 200 200 - - - 180 - 8210G013 46D - - - 16.1/F -

1 1 13 0 125 125 125 - - - 180 - 8210B057 ➅➉

34D - - - 20/F -

1 1 13 5 - - - 125 125 125 - 180 8210D014 26D - - - - 16.8/F

1 1 13 5 150 150 125 - - - 180 - 8210G014 47D - - - 16.1/F -

1 1/4 1 1/8 15 0 125 125 125 - - - 180 - 8210B058 ➅➉

35D - - - 20/F -

1 1/4 1 1/8 15 5 - - - 125 125 125 - 180 8210D018 28D - - - - 16.8/F

1 1/4 1 1/8 15 5 150 150 125 - - - 180 - 8210G018 48D - - - 16.1/F -

1 1/2 1 1/4 22.5 0 125 125 125 - - - 180 - 8210B059 ➅➉

36D - - - 20/F -

1 1/2 1 1/4 22.5 5 - - - 125 125 125 - 180 8210D032 29D - - - - 16.8/F

1 1/2 1 1/4 22.5 5 150 150 125 - - - 180 - 8210G032 49D 8210G132 - - 16.1/F -

2 1 3/4 43 5 - - - 125 125 125 - 150 8210 103 30P - - - - 16.8/F

2 1 3/4 43 5 125 125 125 - - - 180 - 8210G103 50P 8210G133 - - 16.1/F -

2 1/2 1 3/4 45 5 - - - 125 125 125 - 150 8210 104 27P - - - - 16.8/F

2 1/2 1 3/4 45 5 125 125 125 - - - 180 - 8210G104 51P - 16.1/F -

➀ 5 psi on Air; 1 psi on Water. ➅ Valves not available with Explosionproof enclosures. UL listed for fire protection systems per UL429A.➁ Valve provided with PTFE main disc. ➆ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts. ‡ Must have solenoid mounted vertical and upright.➂ Valve includes UItem (G.E. trademark) piston. ➇ AC construction also has PA seating.➃ Letter “D” denotes diaphragm construction; “P” denotes piston construction. ➈ No disc-holder.➄ Safety Shutoff Valve; General Purpose Valve. ➉ Stainless steel disc-holder.

2/2SERIES

82104 2- WA

Y

13

Specifications (Metric units)PipeSize(in)

Orifice Size (mm)

KvFlow

Factor (m3/hr)

Operating Pressure Differential (bar) Max. Fluid Temp.

˚C

Brass Body Stainless Steel Body WattRating/Class ofCoilInsulation➆

Min. Max. AC Max. DC

Air-Inert Gas


Air-Inert Gas


AC DC Catalog Number

Const. Ref.➃

UL➄Listing

Catalog Number

Const. Ref.➃

UL➄Listing

AC DC

NORMALLY CLOSED (Closed when de-energized), NBR or PTFE➁ Seating

3/8 10 1.3 ➀ 10 9 - 3 3 - 82 65 8210G073 ➂ 1P 8210G036➂

1P 6.1/F 11.6/F

3/8 16 2.6 0 10 10 - 3 3 - 82 65 8210G093 5D - - - 10.1/F 11.6/F

3/8 16 2.6 0.3 14 10 9 9 7 7 82 65 8210G001 6D - - - 6.1/F 11.6/F

3/8 16 2.6 0.3 21 21 21 - - - 79 - 8210G006 5D - - - 17.1/F -

1/2 11 1.9 ➀ 10 9 - 3 3 - 82 65 8210G015 ➂ 2P 8210G037➂

2P 6.1/F 11.6/F

1/2 16 3.4 0 10 10 - 3 3 - 82 65 8210G094 5D - - - 10.1/F 11.6/F

1/2 16 3.4 0 10 10 9 3 3 - 79 65 - - - 8210G087 7D 17.1/F 11.6/F

1/2 16 3.4 0.3 14 10 9 9 7 7 82 65 8210G002 6D - - - 6.1/F 11.6/F

1/2 16 3.4 0.3 21 21 21 - - - 79 - 8210G007 5D - - - 17.1/F -

1/2 19 3.4 0.3 - 21 - - 21 - 54 32 8210G227 5D - - - 17.1/F 40.6H

3/4 16 3.9 0 10 10 9 3 3 - 79 65 - - - 8210G088 7D 17.1/F 11.6/F

3/4 19 4.3 0.3 9 9 9 7 6 5 82 65 8210G009 9D - - - 6.1/F 11.6/F

3/4 19 4.3 0 10 10 - 3 3 - 82 65 8210G095 8D - - - 10.1/F 11.6/F

3/4 19 5.6 0.3 17 10 7 9 9 9 82 65 8210G003 11D - - - 6.1/F 11.6/F

3/4 19 5.1 0 - - - 14 12 12 - 25 8210B026 ➁‡

10P - - - - - 30.6/H

3/4 19 5.1 0 24 21 14 - - - 93 - 8210G026 ➁‡

40P - - - 16.1F -

1 25 11 0 - - - 7 7 6 - 25 8210B054 ‡ 31D - 8210D089 15D - - 30.6/H

1 25 11 0 10 9 9 - - - 82 - 8210G054 41D 8210G089 45D 16.1/F -

1 25 11 0.3 10 10 7 9 9 9 82 65 8210G004 12D - - - 6.1/F 11.6/F

1 25 11.5 0 21 16 8 - - - 93 - 8210G027 ‡ 42P - - - 20.1/F -

1 25 11.5 0.7 21 21 21 - - - 79 - 8210G078 ➁ 13P - - - - 17.1/F -

1 1/4 29 13 0 - - - 7 7 6 - 25 8210B055 ‡ 32D - - - - - 30.6/H

1 1/4 29 13 0 10 9 9 - - - 82 - 8210G055 43D - - - 16.1/F -

1 1/4 29 13 0.3 10 10 7 9 9 9 82 65 8210G008 16D - - - 6.1/F 11.6/F

1 1/2 32 19.5 0 - - - 7 7 6 - 25 8210B056 ‡ 33D - - - - - 30.6/H

1 1/2 32 19.5 0 10 9 9 - - - 82 - 8210G056 44D - - - 16.1/F -

1 1/2 32 19.5 0.3 10 10 7 9 9 9 82 65 8210G022 18D 8210G127 - - 6.1/F 11.6/F

2 44 37 0.3 10 9 6 3 3 3 82 65 8210G100 20P 8210G129 - - 6.1/F 11.6/F

2 1/2 44 39 0.3 10 9 6 3 3 3 82 65 8210G101 21P - - - 6.1/F 11.6/F

NORMALLY OPEN (Open when de-energized), NBR Seating (PA Disc-Holder, except as noted)

3/8 16 2.6 0.0 10 10 9 9 9 6 82 65 8210G033 23D - - - 10.1/F 11.6/F

3/8 16 2.6 0.3 17 14 14 17 14 14 82 82 8210G011 ➇➈

39D - - - 10.1/F 11.6/F

1/2 16 3.4 0 10 10 9 9 9 6 82 65 8210G034 23D - - - 10.1/F 11.6/F

1/2 16 2.6 0 10 10 7 9 9 6 82 65 - - - 8210G030 37D 10.1/F 11.6/F

1/2 16 3.4 0.3 17 14 14 17 14 14 82 82 8210G012 ➇➈

39D - - - 10.1/F 11.6/F

3/4 19 4.7 0 10 10 9 9 9 6 82 65 8210G035 25D - - - 10.1/F 11.6/F

3/4 16 2.6 0 10 10 7 9 9 6 82 65 - - - 8210G038 38D 10.1/F 11.6/F

3/4 19 5.6 0.3 - - - 17 14 14 - 82 8210C013 24D - - - - 16.8/F

3/4 19 5.6 0.3 17 14 14 - - - 82 - 8210G013 46D - - - 16.1/F -

1 25 11 0 9 9 9 - - - 82 - 8210B057 ➅➉

34D - - - 20/F -

1 25 11 0.3 - - - 9 9 9 - 82 8210D014 26D - - - - 16.8/F

1 25 11 0.3 10 10 9 - - - 82 - 8210G014 47D - - - 16.1/F -

1 1/4 29 13 0 9 9 9 - - - 82 - 8210B058 ➅➉

35D - - - 20/F -

1 1/4 29 13 0.3 - - - 9 9 9 - 82 8210D018 28D - - - - 16.8/F

1 1/4 29 13 0.3 10 10 9 - - - 82 - 8210G018 48D - - - 16.1/F -

1 1/2 32 19.5 0 9 9 9 - - - 82 - 8210B059 ➅➉

36D - - - 20/F -

1 1/2 32 19.5 0.3 - - - 9 9 9 - 82 8210D032 29D - - - - 16.8/F

1 1/2 32 19.5 0.3 10 10 9 - - - 82 - 8210G032 49D 8210G132 - - 16.1/F -

2 44 37 0.3 - - - 9 9 9 - 65 8210 103 30P - - - - 16.8/F

2 44 37 0.3 9 9 9 - - - 82 - 8210G103 50P 8210G133 - - 16.1/F -

2 1/2 44 39 0.3 - - - 9 9 9 - 65 8210 104 27P - - - - 16.8/F

2 1/2 44 39 0.3 9 9 9 - - - 82 - 8210G104 51P - - - 16.1/F -

➀ 0.3 bar on Air; 0.0 bar on Water.➁ Valve provided with PTFE main disc.➂ Valve includes UItem (G.E. trademark) piston.➃ Letter “D” denotes diaphragm construction; “P” denotes piston construction.➄ Safety Shutoff Valve; General Purpose Valve.

➅ Valves not available with Explosionproof enclosures.➆ On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts.➇ AC construction also has PA seating.➈ No disc-holder.➉ Stainless steel disc-holder.

UL listed for fire protection systems per UL429A.‡ Must have solenoid mounted vertical and upright.

2/2SERIES

8210 4

2-WA

Y

14

Dimensions: inches (mm)

Const. Ref. 1, 2

KP

H

NPT BOTH ENDS

L

W

1/2 NPT

R .12 [3.2]4 PLACES

.59 [15]

.69 [18] .86 [22]

Ø.266 [6.8] .88 [22]

BOTTOM VIEW SHOWINGMOUNTING BRACKET HOLES

(OPTIONAL)FLOW

1.656 [42]

.281 [7.1] DIA2 MOUNTING HOLES

OPTIONAL MOUNTING BRACKET

FLOW

L

K

P

H

NPTBOTH ENDS

W

1/2 NPT

1.625 [41.3]

Const. Ref. 5-9, 11, 23 , 25, 37,38, 40-46

Const. Ref. 13

L

W

P

K

H

NPTBOTH ENDS

FLOW

Const. Ref.

H K L P W

1* in 3.85 3.00 1.91 3.41 1.69mm 98 76 49 87 43

2* in 4.17 3.25 2.28 3.63 1.69mm 106 83 58 92 43

5 in 3.84 2.31 2.75 3.28 2.28mm 98 59 70 83 58

6* in 3.38 1.94 2.75 2.80 2.28mm 86 49 70 71 58

7 in 4.19 2.50 2.81 3.47 2.39mm 106 64 71 88 61

8 in 4.13 2.47 2.81 3.44 2.29mm 105 63 71 87 58

9* in 3.66 2.10 2.81 2.96 2.28mm 93 53 71 75 58

10* in 5.25 X 2.81 4.59 2.31mm 133 X 71 117 59

11* in 4.16 2.66 3.84 3.52 2.75mm 106 68 98 89 70

12 in 5.64 3.15 3.75 4.01 3.36mm 143 80 95 102 85

13 in 4.44 3.22 3.75 4.19 5.81mm 113 82 95 106 147

15* in 5.34 X 3.75 4.47 3.84mm 136 X 95 114 98

16 in 5.64 3.15 3.66 4.01 3.56mm 143 80 93 102 90

18* in 6.11 3.30 4.38 4.16 3.92mm 155 84 111 106 100

20* in 7.33 3.71 5.06 4.57 4.87mm 186 94 129 116 124

21* in 7.33 3.71 5.50 4.57 4.87mm 186 94 140 116 124

23 in 4.35 2.65 2.75 3.79 2.28mm 110 67 70 96 58

24 in 5.06 X 3.78 4.44 2.75mm 129 X 96 113 70

25 in 4.64 2.81 2.81 3.94 2.28mm 118 71 71 100 58

26 in 6.53 X 3.75 4.91 3.19mm 166 X 95 125 81

27 in 8.22 X 5.50 5.47 4.87mm 209 X 140 139 124

28 in 6.53 X 3.66 4.91 3.19mm 166 X 93 125 81

29 in 7.03 X 4.38 5.06 4.40mm 179 X 111 129 112

* DC dimensions slightly larger.IMPORTANT: Valves may be mounted in any position, except as noted in specificationstable.

2/2SERIES

82104 2- WA

Y

15


Const. Ref. 10, 15, 24, 31-36

K

P

H

L

FLOW

NPTBOTH ENDS

7/8 DIA.HOLE FOR1/2 CONDUIT CONN.

1.625 [41.3]

W

1.656 [42]

.281 [7.1] DIA.2 MOUNTING HOLES

OPTIONAL MOUNTING BRACKET

L

P

K

H

W

NPTBOTH ENDS

1/2 NPT

FLOW

IN

Const. Ref. 12, 16, 26, 28, 47, 48

Const. Ref.

H K L P W

30 in 8.22 X 5.06 5.47 4.87

mm 209 X 129 139 124

31 in 5.25 X 3.75 4.44 3.25

mm 133 X 95 113 83

32 in 5.69 X 3.66 4.69 3.25

mm 145 X 93 119 83

33 in 6.06 X 4.38 4.94 3.91

mm 154 X 111 125 99

34 in 6.91 X 3.75 6.09 3.25

mm 176 X 95 155 83

35 in 7.34 X 3.66 6.34 3.25

mm 186 X 93 161 83

36 in 7.66 X 4.38 6.56 3.91

mm 1.95 X 111 167 99

37 in 4.61 2.75 2.81 3.89 2.39

mm 117 70 71 99 61

38 in 4.61 2.75 2.81 3.89 2.39

mm 117 70 71 99 61

39 in 5.42 2.31 2.75 4.86 3.80

mm 138 59 70 123 97

40 in 5.20 3.29 2.81 4.50 2.28

mm 132 83 71 114 58

41 in 5.13 3.10 3.75 4.32 3.25

mm 130 79 95 110 83

42 in 6.43 4.40 3.93 5.62 3.25

mm 163 112 100 143 83

43 in 5.57 3.35 3.66 4.57 3.25

mm 142 85 93 116 83

44 in 5.90 3.57 4.38 4.79 3.91

mm 150 91 111 122 99

45 in 5.26 3.17 3.75 4.38 3.84

mm 134 81 95 111 98

46 in 4.95 3.10 3.84 4.31 2.75

mm 126 79 98 110 70

47 in 6.43 3.59 3.75 4.81 3.52

mm 163 91 95 122 90

48 in 6.43 3.59 3.66 4.81 3.73

mm 163 91 93 122 95

49 in 6.91 3.75 4.38 4.96 4.40

mm 176 95 111 126 112

50 in 8.13 4.15 5.06 5.37 4.87

mm 207 105 129 136 124

51 in 8.13 4.15 5.50 5.37 5.18

mm 207 105 140 136 132

IMPORTANT: Valves may be mounted in any position, except as noted in specificationstable.

2/2SERIES

8210 4

2-WA

Y

16


Const. Ref. 39

NPTBOTH ENDS

K

1/2 NPTH

P

L

FLOW

.281 [7.1] DIA.2 MOUNTING HOLES

1.66 [42]

SHOWING MOUNTING

BRACKET ONLY

Const. Ref. 18, 29, 49

1/2 NPT

W

H

P

K

L

(BOLT PATTERN MAY VARY)

W

NPTBOTH ENDS

Const. Ref. 20, 21, 27, 30, 50, 51

1/2 NPT

K

L W

NPTBOTH ENDSP

H

V6 With Tee

Cold Water - Factory Installed TeeApproximate actuation/deactuation low RatesGPM upper, M3/HR lower

Air-Factory Installed TeeApproximate actuation/deactuation flow ratesSCFM upper, NM3/M lower

V6 Low Flow, Field AdjustableCold Water - Low Flow ModelsApproximate actuation/deactuation flow ratesGPM upper, M3/HR lower

Air - Low Flow ModelsApproximate actuation/deactuation flow ratesSCFM upper, NM3/M lower

EC-Type Certificate, IECEx and KC Installation Instructions:

Cable ConnectionThe cable entry device shall be certified in type of explosion protection flameproofenclosure “d”, suitable for conditions of use and correctly installed. For Ta ≥ 65°Ccable and cable gland rated ≥ 90°C shall be used.

Conduit ConnectionAn Ex d certified sealing device such as a conduit seal with setting compound shallbe provided immediately to the entrance of the valve housing. For Ta ≥ 65°C wiringand setting compound, in the conduit seal, rated ≥ 90°C shall be used.

Note: ATEX, IECEx and KC units only: The temperature class is determined by themaximum ambient and or process temperature. Units are intended to be used inambient of -20°C≤ Tamb ≤75°C. Units may be used in process temperatures up to105°C providing the enclosure and switch body temperature do not exceed 75°C.The standard Temperature Class is T6 Process Temp ≤75°C. AlternateTemperature Class of T5 Process Temp ≤90°C and 115°C (T4) Process Temp≤105°C are available consult factory.

Refer to Certificate No: IECEx DEK 11.0039 for conditions of safe use for IECExcompliant units.

All wiring, conduit and enclosures must meet applicable codes for hazardousareas. Conduits and enclosures must be properly sealed. For outdoor or otherlocations where temperatures vary widely, precautions should be taken to preventcondensation inside switch or enclosure. Electrical components must be kept dryat all times.

CAUTION: To prevent ignition of hazardous atmospheres, disconnect the devicefrom the supply circuit before opening. Keep assembly tightly closed when in use.

MAINTENANCEInspect and clean wetted parts at regular intervals. The cover should be in placeat all times to protect, the internal components from dirt, dust and weather and tomaintain hazardous location ratings. Disconnect device from the supply circuitbefore opening to prevent ignition of hazardous atmosphere. Repairs to be con-ducted by Dwyer Instruments, Inc. Units in need of repair should be returned to thefactory prepaid.

* Options that do not have ATEX, IECEx or KC.Attention: Units without the “AT” suffix are not Directive 94/9/EC (ATEX) compliant. These units are not intended for use in potentially hazardousatmospheres in the EU. These units may be CE marked for other Directives of the EU.

1/2˝ NPT 3/4˝ NPT 1˝ NPT 1-1/4˝ NPT 1-1/2˝ NPT 2˝ NPT1.5 1.00.34 0.23

2.0 1.250.45 0.28

3.0 1.750.68 0.40

4.0 3.00.91 0.68

6.0 5.01.36 1.14

10.0 8.52.27 1.93

1/2˝ NPT 3/4˝ NPT 1˝ NPT 1-1/4˝ NPT 1-1/2˝ NPT 2˝ NPT6.5 5.0.18 .14

10.0 8.0.28 .23

14 12.40 .34

21 18.59 .51

33 30.93 .85

43 361.19 1.02

Minimum Maximum.04 .03.009 .007

.75 0.600.17 0.14

Minimum Maximum.18 .15.005 .004

2.70 2.0.08 .06

Example V6 EP B B S 2 B MT V6EPB-B-S-2-B-MT flow switch; brass upper housing, brass lower housing, brasstee with 3/4˝ NPT connections, SPDT snap switch, and high temperature option

Series V6 Series V6 flow switchConstruction EP Explosion Proof and WeatherproofUpperBody Material

BS

Brass303 Stainless Steel

LowerBody Material

BS

Brass303 Stainless Steel

Circuit (Switch)Type

SD

SPDTDPDT

ProcessConnectionSize

123456LF

1/2˝ NPT3/4˝ NPT1˝ NPT1-1/4˝ NPT1-1/2˝ NPT2˝ NPTLow Flow Model (1/2˝ NPT connections)

ProcessConnectionType

0B FSMIPVCPVCSWSS150

No Tee, Male NPT Connection, Field Trimmable VaneBrass TeeForged Steel TeeIron TeePVC Tee with NPT*PVC Tee with sweat joints*304 Stainless Steel Tee304 Stainless Steel 150# Tee(For LF Model no tee material chosen, tee material matches lower housing choice)

Switch Options MVMT

Gold Contacts on snap switch for dry circuits (see specifications for ratings)High Temperature switch rated 400°F (205°C) (see specifications for ratings)*

Options ATCSAIECKCCVFTRGLIDJCTLHORFBORFSRVTBCVIT018020022022A031

ATEX approved construction (weatherproof and explosion-proof junction box)CSA approved construction (weatherproof and explosion-proof junction box)*IECEx approved construction (weatherproof and explosion-proof junction box)Korean certified (KC) approved construction (with JCT option standard)Custom VaneFlow Test ReportGround Lead*Customer Information on standard nameplateWeatherproof and explosion-proof junction box, left sideOrifice BrassOrifice Stainless SteelReinforced VaneTerminal Block Connector*Viton® O-rings in place of Buna-N on low flow models.018 Spring.020 Spring.022 Spring.022 Spring with Alnico® magnet.031 Spring

V6 With Field Trimmable VaneCold Water - Brass or Cast Iron Reducing TeeApproximate actuation/deactuation flow ratesGPM upper, M3/HR lower

Cold Water - Stainless or Forged Steel Straight Tee and BushingApproximate actuation/deactuation flow ratesGPM upper, M3/HR lower

Air - Stainless or Forged Steel Straight Tee and BushingApproximate actuation/deactuation flow ratesSCFM upper, NM3/M lower

Air - Brass or Cast Iron Reducing TeeApproximate actuation/deactuation flow ratesSCFM upper, NM3/M lower

Vane 1/2˝ NPT 3/4˝ NPT 1˝ NPT 1-1/4˝ NPT 1-1/2˝ NPT 2˝ NPT 1/2˝ NPT 3/4˝ NPT 1˝ NPT 1-1/4˝ NPT 1-1/2˝ NPT 2˝ NPTFullSize

9.0 8.52.0 1.9

39.0 37.01.10 1.05

a 9.5 9.02.2 2.0

40.0 38.01.13 1.08

b 10.0 9.32.3 2.1

42.0 40.01.19 1.13

c 11.0 10.02.5 2.3

50.0 44.01.42 1.25

d 6.2 5.5 12.0 10.01.4 1.2 2.7 2.3

27.0 25.0 55.0 46.00.76 0.71 1.56 1.30

e 7.0 6.5 13.0 11.01.6 1.5 3.0 2.5

30.0 28.00.85 0.79

f 4.3 3.9 7.6 7.1 14.0 12.01.0 0.9 1.7 1.6 3.2 2.7

20.0 18.0 32.0 30.00.57 0.51 0.91 0.85

g 4.9 4.4 8.0 7.31.1 1.0 1.8 1.7

21.0 19.0 34.0 32.00.59 0.54 0.96 0.91

h 5.5 5.0 9.0 8.21.2 1.1 2.0 1.9

23.0 21.0 37.0 34.00.65 0.59 1.05 0.96

i 3.5 3.1 6.0 5.6 10.0 9.00.8 0.7 1.4 1.3 2.3 2.0

16.0 15.0 24.0 22.0 39.0 36.00.45 0.42 0.68 0.62 1.10 1.02

j 4.0 3.5 7.0 6.6 13.0 11.00.9 0.8 1.6 1.5 3.0 2.5

18.0 16.0 28.0 25.0 51.0 45.00.51 0.45 0.79 0.71 1.44 1.27

k 4.6 4.2 8.0 7.6 15.0 13.01.04 0.95 1.8 1.7 3.4 3.0

19.0 17.0 33.0 30.0 69.0 57.00.54 0.48 0.93 0.85 1.95 1.61

l 2.6 2.3 5.6 5.2 10.0 9.00.6 0.5 1.3 1.2 2.3 2.0

13.0 12.0 22.0 20.0 38.0 35.00.37 0.34 0.62 0.57 1.08 0.99

m 1.6 1.3 3.5 3.1 6.3 6.1 12.0 10.00.4 0.3 0.8 0.7 1.43 1.39 2.7 2.3

6.4 3.8 15.0 14.0 25.0 23.0 45.0 42.00.18 0.11 0.42 0.40 0.71 0.65 1.27 1.19

n 2.2 1.8 4.3 3.8 8.0 7.50.5 0.4 1.0 0.9 1.8 1.7

10.0 7.0 20.0 16.0 32.0 28.00.28 0.20 0.57 0.45 0.91 0.79

o 3.0 2.40.7 0.5

12.0 9.00.34 0.25

Vane 1/2˝ NPT 3/4˝ NPT 1˝ NPT 1-1/4˝ NPT 1-1/2˝ NPT 2˝ NPT 1/2˝ NPT 3/4˝ NPT 1˝ NPT 1-1/4˝ NPT 1-1/2˝ NPT 2˝ NPT

FullSize

5.0 4.5 8.5 7.81.1 1.0 1.9 1.8

21.0 18.0 33.0 30.00.59 0.51 0.93 0.85

a 5.5 5.0 9.2 8.61.2 1.1 2.1 2.0

22.0 20.0 39.0 36.00.62 0.57 1.10 1.02

b 6.2 5.7 9.8 9.01.4 1.3 2.2 2.0

24.0 22.0 42.0 38.00.68 0.62 1.19 1.08

c 6.8 6.3 12.0 10.01.5 1.4 2.7 2.3

28.0 26.0 51.0 46.00.79 0.74 1.44 1.30

d 2.8 2.4 8.5 7.8 13.0 11.00.6 0.5 1.9 1.8 3.0 2.5

12.0 10.0 33.0 30.0 55.0 50.00.34 0.28 0.93 0.85 1.56 1.42

e 3.4 3.0 10.0 9.20.8 0.7 2.3 2.1

14.0 12.0 37.0 34.00.40 0.34 1.05 0.96

f 4.0 3.6 12.0 10.00.91 0.82 2.7 2.3

16.0 14.0 43.0 40.00.45 0.40 1.22 1.13

g 2.0 1.5 5.0 4.50.5 0.3 1.1 1.0

8.0 6.5 19.0 17.00.23 0.18 0.54 0.48

h 2.5 2.0 6.5 6.10.6 0.5 1.48 1.39

11.0 10.0 26.0 24.00.31 0.28 0.74 0.68

i 3.5 3.0 9.0 8.20.8 0.7 2.0 1.9

14.0 13.0 32.0 30.00.40 0.37 0.91 0.85

j 7.0 5.51.6 1.2

27.0 24.00.76 0.68

k 10.0 8.02.3 1.8

39.0 36.01.10 1.02

The Series V6 FLOTECT® Flow Switch is an inexpensive, explosion-proof flowswitch for use on air, water or other compatible gases and liquids. Three configu-rations are available - 1. Factory installed in a tee. 2. With a trimmable vane forfield adjustment and installation in a suitable tee. 3. Low flow models with an inte-gral tee and adjustable valve. All are available with an optional enclosure which isUL and CSA listed, or Directive 94/9/EC (ATEX) compliant for

II 2 G Ex d IIC T6 GbProcess Temp≤75°C or IECEx compliant for Ex d IIC T6 Gb Process Temp ≤ 75°C.

Bulletin E-22

Series V6 FLOTECT® Flow Switch

For units supplied with both internal ground and external bonding terminals, theground screw inside the housing must be used to ground the control. The externalbonding screw is for supplementary bonding when allowed or required by localcode. When external bonding conductor is required, conductor must be wrapped aminimum of 180° about the external bonding screw. See below. Some CSA listedmodels are furnished with a separate green ground wire. Such units must beequipped with a junction box, not supplied but available on special order.

W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC.P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A.

Specifications - Installation and Operating InstructionsSPECIFICATIONSService: Gases or liquids compatible with wetted materials.Wetted Materials: Standard V6 Models: Vane: 301 SS; Lower Body: brass or 303SS; Magnet: ceramic; Other: 301, 302 SS; Tee: brass, iron, forged steel, or 304 SS.V6 Low Flow Models: Lower Body: brass or 303 SS; Tee: brass or 304 SS; Magnet:ceramic; O-ring: Buna-N standard, Fluoroelastomer optional; Other: 301, 302 SS.Temperature Limits: -4 to 220°F (-20 to 105°C) Standard, MT high temperatureoption 400°F (205°C) (MT not UL, CSA, ATEX, IECEx or KC) ATEX Compliant AT,IECEx IEC Option and KC (KC Option), Ambient Temperature -4 to 167°F (-20 to75°C) Process Temperature: -4 to 220°F (-20 to 105°C).Pressure Limit: Brass lower body with no tee models 1000 psig (69 bar), 303 SSlower body with no tee models 2000 psig (138 bar). Brass tee models 250 psi (17.2bar), iron tee models 1000 psi (69 bar), forged and stainless steel tee models 2000psi (138 bar), low flow models 1450 psi (100 bar).Enclosure Rating: Weatherproof and Explosion-proof. Listed with UL and CSA forClass I, Groups A, B, C and D; Class II, Groups E, F, and G. (Group A on stainlesssteel body models only).

0518 II 2 G Ex d IIC T6 Gb Process Temp≤75°C Alternate Temperature ClassT5 Process Temp≤90°C, 115°C (T4) Process Temp ≤105°C consult factory. EC-typeCertificate No.: KEMA 04ATEX2128.ATEX Standards: EN 60079-0: 2009; EN 60079-1: 2007.IECEx Certified: For Ex d IIC T6 Gb Process Temp≤75°C Alternate TemperatureClass T5 Process Temp≤90°C, 115°C (T4) Process Temp≤105°C consult factory.IECEx Certificate of Conformity: IECEx DEK 11.0039;

IECEx Standards: IEC 60079-0: 2007; IEC 60079-1: 2007;Korean Certified (KC) for: Ex d IIC T6 Gb Process Temp≤75°C;KTL Certificate Number: 2012-2454-75.

Switch Type: SPDT snap switch standard, DPDT snap switch optional. ElectricalRating: UL models: 5A @125/250 VAC. CSA, ATEX and IECEx models: 5A @125/250 VAC (V~); 5A res., 3A ind. @ 30 VDC (V ). MV option: .1A @ 125 VAC(V~). MT option: 5A @125/250 VAC (V~). [MT option not UL, CSA, ATEX orIECEx].Electrical Connections: UL models: 18 AWG, 18˝ (460 mm) long. ATEX/CSA/IECEx models: terminal block.Upper Body: Brass or 303 stainless steel.Conduit Connections: 3/4˝ male NPT standard, 3/4˝ female NPT on junction boxmodels.

ELECTRICAL CONNECTIONSConnect wire leads in accordance with local electrical codes and switch actionrequired. N.O. contacts will close and N.C. contacts will open when flow increasesto the actuation point. They will return to “normal” condition when flow decreasesto the deactuation point. Black = Common, Blue = Normally Open and Red =Normally Closed.

Phone: 219/879-8000Fax: 219/872-9057

www.dwyer-inst.come-mail: [email protected]

Process Connection: 1/2˝ male NPT on models without a tee.Mounting Orientation: Switch can be installed in any position but the actuation/de-actuation flow rates in the charts are based on horizontal pipe runs and are nomi-nal values.Set Point Adjustment: Standard V6 models none. Without tee models vane is trim-mable. Low flow models are field adjustable in the range shown. See set pointcharts on opposite page.Weight: 2 to 6 lb (.9 to 2.7 kg) depending on construction.Options not Shown: Custom calibration, bushings, PVC tee, reinforced vane,DPDT relays.

INSTALLATIONUnpack and remove any packing material found inside lower housing or tee.

Switch can be installed in any position but the actuation/deactuation flow rates inthe charts are based on horizontal pipe runs and are nominal values. For more pre-cise settings, units can be factory calibrated to specific flow rates.

V6 Models with Tee are supplied in 1/2˝ - 2˝ NPT sizes. Install in piping with arrowpointing in direction of flow.

V6 Low Flow Models have 1/2˝ NPT connections and are field adjustable. Installin piping with arrow pointing in direction of flow. To adjust, loosen the four sockethead cap screws on bottom. The adjustment valve rotates 90° between “O” (open)and “C” (closed). See flow charts for approximate ranges. Tighten screws once therequired flow rate has been set.

V6 with Field Trimmable Vane. These models enable the installer to chooseapproximate actuation/deactuation points by trimming the full size vane at appro-priate letter-designated marks on a removable template. Flows are defined in thefollowing charts. Note that the charts are based on either brass or cast iron reduc-ing tees or stainless or forged steel straight tees with bushings where necessary.Install in piping with arrow pointing in direction of flow.

When bushings are used, they must be back drilled to allow proper clearance forunrestricted vane travel. Bore the I.D. to 13/16˝ (20 mm) on 1/2˝ x 3/4˝ bushings or1˝ (25 mm) on larger bushings. The depth of the bore must leave internal threads9/16˝ (14 mm) high for proper engagement between the lower housing of theswitch and the bushing. Check for proper vane travel and switch operation afterinstallation.

FRONTVIEW DETAIL SIDE VIEW DETAIL

CLAMP

SCREW

LOCKWASHER CONDUCTOR

http://www.dwyer-inst.com/


3-3/8 [85.72] DIA.

13/16 [20.63]

3/4 FEMALENPT

9-1/4[235.0]

3/4˝ NPT

"B"

"B"

"A"

4-1/2[114.3]

3-15/16[100.0]

INLET1/2˝ FEMALE

NPT3-5/8 [92.07]

3/4˝ NPT

1-1/8 SQ. [28.57]

OUTLET1/2˝ FEMALE

NPT

3-3/8 [85.72] DIA.

8-5/8[219.1]

7.250[184.2]

INLET1/2˝ FEMALENPT 3-5/8 [92.07]

OUTLET1/2˝ FEMALE

NPT

6-1/8[155.5]

1-1/8 SQ. [28.57]

13/16 [20.63]

EXTERNAL GROUND

3/4˝ FEMALENPT

5-3/8[136.5]

"A"

.625[15.87]

1.875[47.62]

W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC.P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A.

Phone: 219/879-8000Fax: 219/872-9057

www.dwyer-inst.come-mail: [email protected]

DIMENSIONSSeries V6 FLOTECT® Flow Switch

V6 Low Flow V6 Low Flow with CSA,ATEX Conduit Enclosure

V6 with TeeV6 with Tee and CSA,

ATEX Conduit Enclosure

Trimmable Vane

V6 with FieldTrimmable Vane

6-5/16[160.34]

LOCKINGCOLLARASSEMBLY

3/4NPTUPPERHOUSINGSWITCHSUPPORTS

SPDT(ORDPDT)SNAPSWITCH

MAGNETLEVERPIN

MAGNETLEVERASSEMBLY

MAGNETS

LOWERHOUSING– BRASSORSTAINLESSSTEEL

VANESPRING

VANEPIVOTPIN

VANEPIVOTBRACKET

SNAPRING

1/2NPTSTAINLESS STEELVANE

OVERALL LENGTH WITH1-1/4 TEECONNECTIONAPPROXIMATELY 8

SPDT

DPDT

Terminal ConnectionsCSA, ATEX Enclosures

©Copyright 2014 Dwyer Instruments, Inc. Printed in U.S.A. 9/14 FR# 82-440805-00 Rev. 10

PipeSize

Brass/Ductile Iron Forged/Stainless Steel Malleable IronDim. A Dim. B Dim. A Dim. B Dim. A Dim. B

1/2˝3/4˝1˝1-1/4˝1-1/2˝2˝

2-1/4 (57)2-3/8 (60)2-1/2 (64)2-5/8 (67)2-7/8 (73)3 (76)

1-1/8 (29)1-1/4 (32)1-3/8 (35)1-1/2 (38)1-5/8 (41)1-7/8 (48)

2-1/4 (57)2-5/8 (67)3 (76)3-1/2 (89)4 (102)4-3/4 (121)

1-1/8 (29)1-7/8 (47)2-1/8 (54)2-1/2 (64)2-3/4 (70)3-1/8 (79)

2-1/2 (64)2-5/8 (67)2-7/8 (73)3 (76)3-1/4 (83)3-1/2 (89)

1-1/4 (32)1-3/8 (35)1-1/2 (38)1-3/4 (44)1-7/8 (48)2-1/8 (54)

http://www.dwyer-inst.com/


MICRO SWITCH™

Hazardous Location SwitchesEX Series

Datasheet

2 sensing.honeywell.com

What makesour switchesbetter?Honeywell has over 80 years of switch manufacturing experiencecovering most environment types

Proven technology plus superior quality and service are offeredworld-wide. The EX Series holds multiple agency approvals,including CE, IEC Ex, UL, CSA, and ATEX directives

Multiple actuator options make the EX Series a good choice for indoor explosion-proof applications

Smallest UL-listed, power-load carrying switch available for use inhazardous locations

MICRO SWITCH™ EX Series Hazardous Location Limit SwitchesMICRO SWITCH™ EX Series switches feature the smallest UL-listed housings available for use in hazardous locations. The EXSeries switch cavity is designed to cool expanding gases below the ignition temperature of the surrounding explosive atmosphere.The EXSeries is capable of switching up to 20 amps while providing ample wiring space for ease of installation. Single and doubleconduit openings are available. Dual conduit openings may allow for through wiring of multiple switches. The EXSeries can bemounted from any of the switch’s four sides.

FLEXIBILITY IN MOUNTINGRELIABILITY • ACTUATION VARIETY

Manufactured for harshandexplosive environme

nts

3sensing.honeywell.com

Features and Benefits

COMPACT AND RUGGED HOUSINGOften used in applications where space is at a premium, MICRO SWITCH™ EXSeries switches feature ample wiring space that eases installation time. Thefour-sided mounting with optional mounting bracket simplifies installation in most applications. The EX Series offers dual conduit openings on select models that allow for through wiring making it easier to wire multiple switches in a single circuit.

WIDE VARIETY OF PRODUCT OFFERINGS AND VARIATIONSBroad range of actuator styles available in pin plunger and rotary configurations.Switching capacity from 1 A for low energy loads, up to 20 A for most industrial electrical loads.

DESIGN FLEXIBILITYRotary actuators are field adjustable for quick set up and application adaptability. Roller lever actuators are adjustable through 360° of rotation. 1EX and 2EX listingshave dual conduit openings enabling “wire through” or allowing the user to split the wiring of a double pole switch with one pole exiting each side.

Potential Applications

INDUSTRIAL PAINT BOOTHSPosition detecting in automated paint booths used by indoor industrial paintingcompanies

Automotive paint booth door position detection assures the door is closed beforepaint can be applied

PETROLEUM AND CHEMICAL PLANTSValve position in indoor potentially explosive environments in petroleum refineriesand chemical plants

PROCESSING FACILITIESPosition sensing indoors at grain handling and processing plants, pulp and paperprocessing, lumber and other types of facilities where dust and other fine particlesin the atmosphere may create the potential for explosions

International approvals for use around the world


EX Series

Table 1. Specifications

1 Refer to order guide2 Most models, refer to individual specifications for selected catalog listings

Table 2. Agency Approvals and Standards

*Most models, refer to individual specifications for selected catalog listings

Characteristic Parameter

Product type MICRO SWITCH™ hazardous location limit switches

Actuators overtravel top plunger side roller lever one-way roller leveradjustable roller lever rod lever manually activated paddle adjustable rod lever with one-inch nylon roller

Circuitry SPDT, DPDT

Electrical 1 A, 3 A, 5 A, 10 A, 15 A, and 20 A

Housing material Aluminum die-cast

Termination types 1/2-14 NPT conduit, preleaded

Sealing NEMA 1, 7, and 9, UL listed, and CSA certified: Class I, Div.1 & 2, Groups B*, C, and D [*Group B - only as noted in order

guide] Class II, Div.1 & 2, Groups E, F, and G

Operating temperature1 -40 °C to 71 °C [-40 °F to 160 °F]*High temp models available up to 204 °C [400 °F] (refer to order guide on pages 6 and 7)

Agency approvals and standards IEC Ex, ATEX (CE), UL, CSA

UL listed #E14274

CSA certified #LR57324

ATEX directive2 KEMA 04ATEX2312X

IEC Ex certified KEM 08.0012X

UNSPSC code 302119

UNSPSC commodity 302119 Switches and controls and relays

UL, CE/ATEX, CSA, IEC Ex, INMETRO Standards & Designations

UL listed #E14274 UL 1203

CSA certified #LR57324 C22.2 No. 25 and No. 30

ATEX directive * KEMA 04ATEX2312X II 2 G Ex d IIB + H2 T6 Gb (EX) II 2 G Ex d IIB + H2 T2 Gb (EXHT)

EN60079-0 and EN60079-1IEC Ex certified * KEM 08.0027X II 2 G Ex d IIB + H2 T6 Gb

(EX) II 2 G Ex d IIB + H2 T2 Gb (EXHT)

IEC60079-0 and IEC60079-1INMETRO certified * In process IEC60079-0 and IEC60079-1


MICRO SWITCH™ Hazardous Location Limit Switches

Table 3. Circuitry and Electrical Ratings Table 4. Hazardous Location ClassificationsRating

Circuitry Electrical ratingcode

A SPDT UL/CSA Rating:15 A, 125, 250, or 480 Vac

1/8 HP, 125 Vac; 1/4 HP, 250 Vac0.5 A, 125 Vdc; 0.25 A 250 Vdc

B SPDT UL/CSA Rating:20 A, 125, 250, or 480 Vac

10 A, 125 Vac “L”

1 HP, 125 Vac; 2 HP, 250 Vac0.5 A, 125 Vdc; 0.25 A, 250 Vdc

C DPDT UL/CSA Rating: 10 A, 125 or 250 Vac

0.3 A, 125 Vac; 0.15 A 250 VdcD SPDT UL/CSA Rating:

10 A, 125, 250, or 480 Vac0.5 A, 125 Vdc; 0.25 A 250 Vdc

E SPDT UL Rating: 1 A, 125 Vac

F SPDT UL/CSA Rating:3 A, 125 or 250 Vac

1/10 HP, 125 Vac; 1/6 HP, 250 Vac

G SPDT UL/CSA Rating:5 A, 125, 250, or 480 Vac;

0.50 A, 125 Vdc; 0.25 A, 250 Vac

RatingClassification

code

1 Explosion Proof-UL listed for Hazardous Locations NEMA 7, Class I, Groups B, C, and D NEMA 9, Class II, Groups E, F, and G

2 Explosion Proof-UL listed for Hazardous Locations NEMA 7, Class I, Groups C and D

NEMA 9, Class II, Groups E, F, and G3 European Hazardous Locations

Designation: Ex dIIB + H2 T6 Category II 2 G

4 European Hazardous Locations Designation: Ex dIIB + H2 T2 Category II 2 G

Series Code ATEX Temperature Rating

EX T6 -40 °C to 70 °C [-40 °F to 158 °F]

EXHT T2 -40 °C to 204 °C [-40 °F to 400 °F]


EX SeriesMICRO SWITCH™ EX SERIES ORDER GUIDE

*Note: CW (Clockwise) and CCW (Counter-Clockwise) when looking at nameplate. EX Series switches are not sealed against liquids and are not intended to be used in liquid splash environments or outdoor use without protection. NEMA 1, 7, 9 only.

Cat

alo

g

Lis

tin

g

Act

uat

ion

Cir

cuit

ry

Ele

ctri

cal

Rat

ing

UL

/CE

Haz

. Lo

ca-

tio

n C

od

e

Op

erat

ing

F

orc

e

Pre

trav

el

max

. mm

[i

n]

Ove

rtra

vel

max

.

Diff

. Tra

vel

max

.m

m [

in]

No

tes

EX-AR CW* SPDT 15 A (A)

2, 3 2,22 N to 5,56 N[8 oz to 20 oz]

5,56[0.219]

(8°)

90° 0,18[0.007](0.25°)

EX-AR141 CW* SPDT 15 A (A)

2, 3 2,22 N to 5,56 N[8 oz to 20 oz]

5,56[0.219]

(8°)

90° 0,18[0.007](0.25°)

No mounting bracket

EXA-AR CW* SPDT 20 A (B)

2, 3 3,34 N to 8,90 N[12 oz to 32 oz]

5,56[0.219]

(8°)

25° 0,304[0.012]

EXA-AR20 CW* SPDT 15 A (B)

2, 3 – 5,56[0.219]

(8°)

25° – No lever furnished (order separately)

EX-AR16 CW or CCW*

SPDT 15 A (A)

2, 3 0,56 N [2 oz]max.

5,56[0.219]

(8°)

90° 0,18[0.007](0.25°)

Low O.F.(no return spring) without mounting

bracket

EX-AR1613

CW* SPDT 15 A (A)

2, 3 0,56 N [2 oz]max.

16° ± 2° 40° min. – 0.125 in x 5.28 inaluminum lever(no mountingbracket)


2, 3 3,81 N to 9,53 N[12.5 oz to31.25 oz]

5,56[0.219]

(8°)

90° 0,18[0.007](0.25°)

No lever furnished (order separately)

EX-AR230 CCW* SPDT 15 A (A)

2, 3 0,45 Nm[4.0 in-lb]

1,65[0.065]

25° 0,18[0.007](0.25°)

No lever furnished (order separately)

EX-AR471-3

CW* SPDT 15 A (A)

2, 3 3,34 N to 7,32 N[12 oz to 24 oz]

5,56[0.219]

(8°)

90° 0,533[0.021](0.75°)

36 inch leadwire

EX-AR50 Manual

opera-tion

SPDT 15 A (A)

2, 3 11,12 N [40 oz] – 3,18[0.125]

min.

0,077[0.003]approx.

Large 3 in x 3.5 in paddle


MICRO SWITCH™ Hazardous Location Limit SwitchesMICRO SWITCH™ EX SERIES ORDER GUIDE, CONTINUED

*Note: CW (Clockwise) and CCW (Counter-Clockwise) when looking at nameplate. EX Series switches are not sealed against liquids and are not intended to be used in liquid splash environments or outdoor use without protection. NEMA 1, 7, 9 only.

Cat

alo

g

Lis

tin

g

Act

uat

ion

Cir

cuit

ry

Ele

ctri

cal

Rat

ing

UL

/CE

Haz

. Lo

ca-

tio

n C

od

e

Op

erat

ing

F

orc

e

Pre

trav

el

max

. mm

[i

n]

Ove

rtra

vel

max

.

Diff

. Tra

vel

max

.m

m [

in]

No

tes


2, 3 2,22 N to 5,56 N[8 oz to 20 oz]

5,56[0.219]

(8°)

90° 0,18[0.007](0.25°)

One-way roller lever

EXD-AR-3 CW* DPDT 10 A 1, 3 2,44 N to 7,32 N 6,35 25° 2,77 36 inch wire leads

(C) [8 oz to 24 oz] [0.25] [0.109]

EXA-N Plunger SPDT 20 A (B)

2, 3 15,57 N [56 oz] 2,77[0.109]

3,18[0.125]

min.

0,229[0.009]

With seal boot

EXA-Q Plunger SPDT 20 A (B)

2, 3 8,90 N [32 oz] 1,27[0.05]

3,18[0.125]

min.

0,229[0.009]

EXHT-Q Plunger SPDT 3 A (F)

1, 4 8,90 N [32 oz] 1,27[0.05]

3,18[0.125]

min.

0,229[0.009]

400° high temperature

EX-Q400 Plunger SPDT 5 A 1 13,34 N [48 oz] 1,98 4,78 0,102 400° high temperature

(G) [0.078] [0.188] [0.004] intermittent exposure

EXHT-AR CW* SPDT 3 A (F)

1, 4 3,34 N to 8,90 N[12 oz to 32 oz]

5,56[0.219]

(8°)

25° 0,406[0.016]

400° high temperature

1EX1 CW* SPDT 15 A (A)

2, 3 2,22 N to 5,56 N[8 oz to 20 oz]

5,56[0.219]

(8°)

90° 0,18[0.007](0.25°)

Dual conduit openings

2EX1 CW* DPDT 20 A (B)

2, 3 3,34 N to 8,90 N[12 oz to 32 oz]

5,56[0.219]

(8°)

25° 0,305[0.012](0.5°)

Dual conduit openings


EX Series

DIMENSIONAL DRAWINGS mm [in]Figure 1. MICRO SWITCH™ EX Series, no lever

Figure 2. MICRO SWITCH™ EX Series, side rotary

Figure 3. MICRO SWITCH™ EX Series, side rotary with twoconduit openings

Figure 7. MICRO SWITCH™ EX Series, boot sealed

Figure 4. MICRO SWITCH™ EX Series, one-way lever

Figure 6. MICRO SWITCH™ EX Series, top pin plunger

Figure 5. MICRO SWITCH™ EX Series, rod lever

Figure 8. MICRO SWITCH™ EX Series, manually actuated


MICRO SWITCH™ Hazardous Location Limit Switches

Table 5. Replacement Catalog Listings

Double Conduit

* Order levers separately

Table 6. Actuator Order CodesGROUNDING SCREW ASSEMBLY(for equipped models only)

Pan-head Phillips screwwith external lock washer

Metal clamp

Adapter screw

Washer

EX Series Part Number Internal Switching Element/ Basic Switch

Actuator Internal Springs

EXA-AR BA-2R-P4 6PA5-EX 33PA6-EX

EXA-Q BZ-2R-P4 8PA15-EX –

EX-AR BZ-2R-P4 6PA5-EX 33PA7-EX

EX- AR128 BZ-2R-P4 6PA130-EX 33PA7-EX

EX-AR16 BZ-2RW88-P5 6PA5-EX –

EX-AR1613 BZ-2RW88-P5 6PA136-EX –

EX-AR20* BZ-2R-P4 * 33PA7-EX

EX-AR30 BZ-2R-P4 6PA5-EX 33PA5-EX

EX-AR50 BZ-2R-P4 6PA134-OP 33PA7-EX

EX-AR800 BZ-2R-P4 6PA5-EX 33PA7-EX

EXD-AR-3 DT-2R4-A7 6PA5-EX 33PA6-EX

EXD-AR30-3 DT-2R711-A7 6PA5-EX 33PA5-EX

EXD-Q-3 DT-2R-A7 8PA77-EX –

EXH-AR3 4HS202 6PA5-EX 33PA6-EX

EXH-AR33 4HS203 6PA5-EX 33PA6-EX

EX-N15 BZ-2R15-P4 8PA12-EX –

EX-Q BZ-2R-P4 8PA15-EX –

EX-Q800 BZ-2R-P4 8PA15-EX –

1EX1 BZ-2R-P4 6PA5-EX 33PA6-EX

2EX1 BZ-2R-P4 6PA5-EX 33PA6-EX

4EX1-3 DT-2R4-A7 6PA5-EX 33PA6-EX

Type Part Number

One-way roller lever (for CW actuation)

6PA130-EX(bronze roller)

One-way roller lever (for CCW actuation)

6PA142-EX(bronze roller)

Adjustable length roller

lever

43 mm to 76 mm[1.7 in to 3 in]

6PA138-EX(nylon roller)

Rod lever 134 mm [5.28 in]

6PA136-EX(aluminum rod)

Adjustable length 317,5 mm [12.5

in]max. rod lever

with 25,4 mm [1 in]

nylon roller

6PA204-EX

Roller lever 6PA5-EX(bronze roller)

6PA127-EX

(nylon roller)


EX Series

This datasheet supports the following MICRO SWITCH™ EX Series Hazardous Location Limit Switches

Table 7. Mounting Brackets

1EX1 EX-AR1613 EX-AR800 EXH-AR3 EX-Q173 6PA130-EX

2EX1 EX-AR1620 EX-AR830 EXH-AR33 EX-Q19 6PA136-EX4EX1-3 EX-AR-1621 EX-AR87 EXH-AR7 EX-Q22 6PA138-EX4EX5-3 EX-AR182 EXD-AR20-3 EXH-AR7-R1 EX-Q400 6PA142-EXEXA-AR EX-AR20 EXD-AR-3 EXH-N EX-Q62 6PA204-EXEXA-AR20 EX-AR230 EXD-AR30-3 EXH-Q26-2 EX-Q800 6PA5-EXEXA-AR62 EX-AR30 EXD-AR30-6 EXHT-AR 15PA85-EX 8PA12-EXEXA-N EX-AR400 EXD-AR62-3 EXHT-AR403 19PA4-EX 8PA15-EXEXA-Q EX-AR420 EXD-AR87-3 EXHT-Q 33PA1-EX 8PA77-EXEX-AR EX-AR471-15 EXD-N-3 EX-N15 33PA5-EX EX-XR3EX-AR128 EX-AR471-3 EXD-Q26-2 EX-N152 33PA6-EX EX-XR9EXAR-141 EX-AR50 EXD-Q-3 EX-Q 33PA7-EX EX-YQ-3EX-AR16 EX-AR68 EXD-Q62-3 EX-Q1 6PA126-EX

EX-AR8 EXH-AR2 EX-Q171 6PA127-EX

15PA85-EX (for side rotary) 15PA86-EX (for top plunger)

used for top, bottom, back, or end mounting. It is furnished with each switch, except where noted in the order guides.

ordered separately for top mounting of plunger switches. EX switches may also be direct mounted, using 10-32 UNF screws.


MICRO SWITCH™ Hazardous Location Limit SwitchesTable 8. Additional Available EX Lstings

Double Conduit

Listing CW CCW Plunger SPDT DPDT 2-CKT DB

1 A 10 A 15 A 20 A Class 1 Group

B

Pre-leaded

EXA-AR62 ü ü

EXA-N ü ü ü

EX-AR1620 ü ü

EX-AR-1621 ü ü

EX-AR182 ü ü ü

EX-AR30 ü ü ü

EX-AR400 ü ü 5 A

EX-AR420 ü ü 5 A

EX-AR471-15 ü ü ü 15 ft

EX-AR471-3 ü ü ü 3 ft

EX-AR68 ü ü ü

EX-AR8 ü ü ü

EX-AR800 ü ü ü ü

EX-AR830 ü ü ü

EX-AR87 ü ü ü

EXD-AR20-3 ü ü ü ü 3 ft

EXD-AR-3 ü ü ü ü 3 ft





EXD-N-3 ü ü ü ü 3 ft

EXD-Q26-2 ü ü ü ü 3 ft

EXD-Q-3 ü ü ü ü 2 ft

EXD-Q62-3 ü ü ü ü 3 ft

EXH-AR2 ü ü ü ü

EXH-AR3 ü ü ü ü 10.5 ft

EXH-AR33 ü ü ü ü 10.5 ft

EXH-AR7 ü ü ü ü 3 ft

EXH-AR7-R1 ü ü ü ü

EXH-N ü ü ü ü

EXH-Q26-2 ü ü ü ü

EXHT-AR403 ü ü 3 A

EX-N15 ü ü ü

EX-N152 ü SPNO ü

EX-Q ü ü ü

EX-Q1 ü SPNO ü

EX-Q171 ü ü

EX-Q173 ü ü

EX-Q19 ü ü

EX-Q22 ü ü

EX-Q62 ü ü

EX-Q800 ü ü ü ü

4EX1-3 ü ü ü 3 ft

4EX5-3 ü ü ü 3 ft


EX Series

ADDITIONAL INFORMATIONThe following associated literature is available on the Honeywell web site at sensing.honeywell.com:

• Product installation instructions

• Product range guide

• Hazardous location switches product brochure

• Product application-specific information

– Applicaiton note: Electronic sensors and electromechanicalswitches in valves and flow meters

– Application note: Industrial waste water treatment

– Application note: Sensors and switches for industrial manualprocess valves

– Sensors and switches in oil rig applications

WARNINGPERSONAL INJURYDO NOT USE these products as safety or emergency stop devices or in any other application where failure of the productcould result in personal injury.

Failure to comply with these instructions could result indeath or serious injury.

WARNINGMISUSE OF DOCUMENTATION• The information presented in this product sheet is for

reference only. Do not use this document as a productinstallation guide.

• Complete installation, operation, and maintenanceinformation is provided in the instructions supplied with each product.

Failure to comply with these instructions could result indeath or serious injury.

WARRANTY/REMEDYHoneywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Honeywell’s standardproduct warranty applies unless agreed to otherwise by Honeywellin writing; please refer to your order acknowledgement or consultyour local sales office for specific warranty details. If warrantedgoods are returned to Honeywell during the period of coverage,Honeywell will repair or replace, at its option, without charge thoseitems it finds defective. The foregoing is buyer’s sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particu-lar purpose. In no event shall Honeywell be liable for conse-quential, special, or indirect damages.

While we provide application assistance personally, through ourliterature and the Honeywell website, it is up to the customer todetermine the suitability of the product in the application.

Specifications may change without notice. The information wesupply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

WARRANTY

P.D. McLAREN LIMITED warrants all parts of new RDR equipment of its own or RDR Mfg. Ltd.'s (considered to be of P.D. McLAREN LIMITED's manufacture) manufacture for one year from the date of installation or 15 months from the date of shipment, whichever comes first. Installation report required to activate one year warranty period.

During the first 90 days after installation, P.D. McLAREN LIMITED will furnish replacement parts and on site labor to repair defective equipment. Maximum travel distance allowed under this warranty is 90 KM radius from the nearthest Authorized Service Contractor. All travel expenses beyond the 90 KM radius are the full responsibility of the purchaser.

Thereafter, during the remainder of the one year warranty, P.D. McLAREN LIMITED's obligation will be restricted to replacement, F.O.B. factory, of defective parts, freight charges prepaid. P.D. McLAREN LIMITED's obligation under this warranty is limited to repair or replacement of defective parts for the 24 months stated above.

Any unauthorized alteration of, or addition to equipment of P.D. McLAREN LIMITED's manufacture voids this warranty. P.D. McLAREN LIMITED's liability is that exclusively stated herein, and P.D. McLAREN LIMITED shall not be liable for any indirect or consequential damages or loss of product.

Any changes in design or improvements added to the equipment line, shall not create any obligation to install same on equipment previous sold.

To the extent permitted by law, this warranty is given in lieu of all other warranties express or implied, andP.D. McLAREN LIMITED neither assumes nor authorizes any person to assume for it any liability beyond that stated herein. This warranty does not cover damage caused by accident, abuse, acts of God, faulty installation, improper maintenance, nor any indirect, special or consequential damages to include, but not limited to loss of product, loss of profits, or litigation fees.

The warranty validation form delivered with your RDR equipment must be completed and returned before a warranty claim can be processed.

WARRANTY CLAIMS MUST BE SUBMITTED WITHIN 30 DAYS FROM THE DATE OF THE WORK BEING COMPLETED. ALL REPLACEMENT PARTS WILL BE INVOICED WITH INVOICE CREDIT ISSUED UPON RETURN AND DETERMINATION OF DEFECT FAULT. RETURNED PARTS MUSTBE ACCOMPANIED BY A COPY OF THE REPLACEMENT PART(S) PACKING SLIP AND ACOMPLETED SERVICE REPORT. ALL WARRANTY PARTS MUST BE RETURNED WITHIN 30DAYS OF FAILURE.

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Since 1924

P.D. McLAREN LIMITED