Fill-Rite 900D User Manual

Owners Installation, Operation, and Safety Manual

Digital Liquid Meter

Series 900D – High Flow

900DP, 900DP1.5, 900DPBSPT, 900DP1.5BPST

900DPX, 900D1.5DPX1.5, 900DPXBSPT, 900DPX1.5BSPT

Models

Tuthill Transfer Systems 8825 Aviation Drive Ft. Wayne, IN 46809 [phone] www.tuthill.com

Table of Contents

Owners Installation, Operation, and Safety Manual .............................................................. 1

Table of Contents .................................................................................................................. 2

Thank You! ............................................................................................................................ 2

About This Manual ................................................................................................................ 2

Safety Information ................................................................................................................. 3

Installation ............................................................................................................................. 3

Procedure for Meter Calibration ............................................................................................ 4

Operating Instructions ........................................................................................................... 5

Low Battery Warning ............................................................................................................. 6

Storage .................................................................................................................................. 7

Troubleshooting..................................................................................................................... 7

Fluid Compatibility ................................................................................................................. 7

Assembly and Disassembly .................................................................................................. 7

Illumination ............................................................................................................................ 8

Repair .................................................................................................................................... 8

Safety Testing Approvals ...................................................................................................... 8

Replacement Parts Information ............................................................................................. 9

Thank You!

Thank you for your purchase of the Fill-Rite® 900 Series Digital Meter! Your Fill-Rite product
comes with over 80 years of fluid transfer experience behind it, providing you the value that
comes with superior performance, user friendly design, long service life, and solid, simple
engineering. Experience that gives you peace of mind.

Excellence at Work! Excellence in Life!

About This Manual

From initial concept and design through its final production, your Fill-Rite meter is built to give
you years of trouble free use. To insure it provides that service, it i

this entire

familiar with the terms and diagrams, and pay close attention to the highlighted areas with the
following labels:

manual prior to attempting to install or operate your new meter. Become

s critical that you read

WARNING! Emphasizes an area in which personal injury or even death could

`

result from failure to follow instructions properly. Mechanical damage may also
occur.

IMPORTANT! These boxes contain information that illustrates a point that may
save time or may be key to proper operation, or clarifies a step.

CAUTION! Failure to observe a “Caution” can cause damage to the equipment.

At Fill-Rite, your satisfaction with our products is paramount to us. If you have questions or
need assistance with your product, please contact us at 1-800-634-2695 (M-F 8 AM–5 PM
ET).

2

Safety Information

p

WARNING! To insure safe and proper operation of your equipment, it is critical to
read and adhere to all of the following safety warnings and precautions. Improper
installation or use of this product can cause serious bodily injury or death!

1) NEVER smoke near the meter, or use the meter near open flames when
metering a flammable liquid! Fire can result!

2) A Fill-Rite Filter should be used on the meter outlet to insure no foreign
material is transferred to the fuel tank.

3) Threaded pipe joints and connections should be sealed with the appropriate
sealant or sealant tape to minimize the possibility of leaks.

4) Storage tanks should be securely anchored to prevent shifting or tipping
when full or empty.

5) To minimize static electricity build up, use only static wire conductive hose
when metering flammable fluids, and keep the fill nozzle in contact with the
container being filled during the filling process.

6) DO NOT exceed 50 psi/ 3.5 BARS line pressure.

7) DO NOT install additional foot valve or check valve without a pressure relief
valve; otherwise the meter may rupture.

WARNING! This product should not be used to transfer fluids any type of aviation
fuel.

WARNING! This product is not suited for use with fluids intended for human or
animal consumption or fluids containing water. Nickel plated meters are approved
for use with non-potable water, antifreeze, certain agricultural chemicals, and
other s

ecialized water applications.

Installation

Meters are furnished for horizontal piping; left to right flow. The
display can be rotated to any of four positions for horizontal or
vertical piping and for either direction of flow.

1. Determine direction for fluid to flow.

2. Install meter observing directional arrow on
casting on back of meter (circled). Liquid
MUST flow in the direction of the arrow for

proper operation.

3. Once the meter is plumbed into place,
remove four screws (circled) on corners of
meter face (Torx T25 bit required).

4. Rotate meter face assembly to desired
orientation.

5. Replace four screws.

6. Complete installation by making sure the
joints are properly sealed and meter is
positioned for easy viewing and use.

Flow Direction

CAUTION! Threaded pipe joints and connections should be sealed with the

appropriate sealant or sealant tape to minimize the possibility of leaks.

3

r

IMPORTANT! If you have purchased this meter as part of

a “Kit”, the meter flange base is drilled with 4 holes. This
allows the meter to be used with 300 and 700 series
pumps. Line the meter bracket up for installation and
insert the bolts in the two holes that align with the
corresponding holes on the pump outlet. Once the meter
bracket is bolted securely in place install the two plugs in
the holes that were not used to prevent moisture from
entering them.

Meter Calibration

Meter calibration is required upon installation, after disassembly, after significant wear, or
when dispensing a different viscosity fluid. Calibration must be done between 6 and 40 GPM
(23 and 151 LPM). Meter calibration can be easily changed by following the calibration
procedure. A container of KNOWN volume will be needed for the calibration procedure. For
the 900 series digital meter, a five gallon container or larger, or a 20 liter container or larger
should be used.

Procedure for Meter Calibration

Unit of measure and calibration is c onfigured using a 3-step process.

1. Select the desired unit of measure

2. Fill a container with a known volume using the desired fluid.

3. Enter the amount of fluid dispensed.

Prior to calibration, the unit must be placed in calibration mode. Press and hold the TOTAL
and CAL buttons for 5 seconds to enter Calibration Mode.

IMPORTANT! When calibrating, the totalizers will not increase in value.

1. The unit will default to the last unit
of measure used.

2. Press and release the TOTAL
button to toggle through the
available units of measure.

3. Press and hold the CAL button for 2
seconds to move to the next step.

4. If the meter is left untouched for 2
minutes or the RESET button is
pressed, the unit will automatically
exit Calibration Mode and ignore
any changes in volume.

IMPORTANT! Dispensing into a container with a known volume allows the unit
to automatically calculate the internal scaling value to compensate for fluid
viscosities and the system flow rate.

1. CAL 2 will be displayed.

2. Begin dispensing fluid into the container.

3. FILL will begin to blink after fluid flow is detected.

4. Dispense the desired amount fluid; stop flow as soon as desired level is reached.

5. Press and hold the CAL button

IMPORTANT! If left untouched for 2 minutes, or the RESET button is pressed,
the meter will exit Calibration Mode and any dispensed fluid will be ignored.

or 2 seconds to move to the next step.

f

Totalize

4

6. Pressing and holding the CAL
button for 2 seconds before
dispensing into a container will
cause the meter to skip a fill
operation and only change the
unit of measure.

IMPORTANT! For maximum
accuracy, try to get as close as
possible to the dispensed
volume without changing flow
rate.

7. The unit will default to a
measured value based on the last calibration performed.

8. The left-most digit will begin blinking.

9. Use the TOTAL button to scroll from 0 to 9 until the desired number has been selected.

10. Press and release the CAL button to move to the next digit.

11. Repeat Steps 3-4 until the amount
of dispensed fluid has been
entered.

12. If you make a mistake entering a
digit, press and release the
TOTAL button repeatedly until the
digit is active again.

13. Press and hold the CAL button for
2 seconds to complete the
calibration process regardless of
the current digit selected.

14. If at the last digit and the CAL
button is pressed for less than 2
seconds, the process should roll
back to the left-most digit, but retain the current value. This allows the user to edit an
incorrect value.

15. An error check for gross calibration errors (+/- 15%) will be performed unless USER units
are selected. If an error is detected, the meter will display Err0 until a button is pressed
and the calibration process is aborted.

16. If the meter is left untouched for 2 minutes or the RESET button is pressed, the unit will
automatically exit Calibration Mode and ignore any changes.

Operating Instructions

For accurate measurement and to prevent meter
damage, dispenser and piping m
with liquid and be free of air. The meter portion of
your dispenser should be calibrated per instructions
in this manual prior to its use.

The Fill-Rite 900 Series Digital Meter face
incorporates three buttons that control all the
operation and calibration functions.

To turn the display on, or wake the meter from
“Sleep” mode, simply press any button on the face.
The display will turn on and you can proceed with
the function you desire. Dispensing fluid will also
turn the meter display on.

ust always be filled

5

IMPORTANT! When the meter is in the “Deep Sleep” mode, dispensing fluid
will NOT turn the meter on. The meter will not display or accumulate any fluid
that is dispensed while in “Deep Sleep” mode.

• Pressing any button will turn the meter
on when in deep sleep mode. (Fluid flow
will not turn the unit on or cause it to exit
deep sleep mode).

• The last count and selected totalizer is
retained and displayed when the meter
is turned on.

• Pressing and releasing the TOTAL
button will switch between the resettable
and non-resettable totalizers. (The R
icon will be displayed when the
resettable total is displayed).

• Pressing and holding the RESET button
for 2 seconds will reset the counter.

• Pressing and holding the RESET button
and TOTAL buttons for 2 seconds will
reset the totalizer. The resettable

totalizer must be active in order to
reset it.

• Pressing and holding the RESET button
and CAL buttons for 2 seconds will display the software version for 2 seconds and then
perform a segment check for 3 seconds, and then restore the display.

• Pressing and holding the CAL button for 5 seconds will place the meter into a deep sleep
mode.

IMPORTANT! “Deep Sleep” mode is designed to maintain a status of
operational readiness while offering battery conservation. The meter should
be placed in this mode when:

• Flushing the unit so the dispensed volume is not counted.

• Traveling over rough surfaces (off-road) and does not want the unit to

count if fluid is being jostled.

• Extending battery life; there is no penalty for repeatedly placing it in
deep sleep.

• After 30 seconds of inactivity, the display will blank to conserve battery power.

• If the meter is connected to the external power source, the displa

forced into deep sleep mode.

• If external power is removed, the meter will revert to battery only operating
characteristics and vice-versa. Remain in deep sleep mode if active.

• The counter and totalizer 2 can be reset even if fluid flow is detected. The meter must
continue counting during the 2 second RESET button press, reset to 0 and resume
counting.

y will no

t blank unless

Low Battery Warning

The digital display includes a “Low Battery”
warning indicator. When the battery reaches a
level low enough to require replacement, the
display will show “BAT” as a reminder to change
the battery. When necessary, replace batteries
per procedure on page 8.

6

Storage

If your meter is to be stored for a period of time, clean it thoroughly. This will help protect the
meter from possible damage.

Troubleshooting

The following troubleshooting guide is designed to help you with basic diagnostics and repairs
if you should encounter abnormal service from your 900 series digital meter. We recommend you
use only genuine Fill-Rite parts. These parts, and additional service information is available
through your authorized Fill-Rite dealer.

Further troubleshooting information can be found in your pump manual. If you need additional
assistance, please contact us at 1-800-634-2695 (M-F 8 AM–5 PM ET).

Concern Possible Cause Recommended Repair

Counter inaccurate. Meter mis-calibrated. Check calibration and recalibrate as

Air in lines or metering
chamber.
Measuring gears or disc
are sticking.

Fluid leak at shaft seal. Dirty or damaged seal. Clean O-Ring seal and seat, replace
Low flow capacity. Clogged meter chamber. Clean meter chamber; clean or replace
Meter body cracks. Excess line pressure. Install pressure relief valve to allow

Nutating Disc Broken. Sudden high pressure

fluid hitting disc.

necessary (directions on page 4).
Check line seals and joints for
leakage; seal leaks appropriately.
Clean or replace internal metering
components as necessary.

seal as necessary.
screens and filters in piping.
high pressure to bleed back to the

tank. Replace meter.
Avoid surge flows by installing a shut­off valve on outlet of meter; install
meter as close to the pump as
possible, keep piping full of liquid.
Replace broken disc.

Fluid Compatibility

The 900 series digital meter IS compatible with the following fluids:

Diesel Fuel Bio-Diesel (up to B20) Gasoline Kerosene Mineral Spirits Heptane
Hexane

The 900 series digital meter IS NOT

Bleach Hydrochloric Acid Ink Sulfuric Acid Salt Water

CAUTION! If in doubt about compatibility of a specific fluid, contact supplier of
fluid to check for any adverse reactions to the following wetted materials:

Ryton® PPS Aluminum Stainless Steel Fluorocarbon
Buna N Polyester PTFE Nickel

compatible with the following fluids:

Assembly and Disassembly

The 900 series digital meter consist of a chamber housing, measuring chamber, drive shaft,
digital counter assembly, and cover. The design of the meter is such that it can be completely
disassembled without disturbing the piping (refer to diagram on page 9 for item number parts).

7

Accessing the Battery

For access to the batteries (2 AA cell
batteries) (figure 1):

1) Remove the four screws at the top
and bottom of the front bezel (Torx
#T25).

2) Lift bezel off. Batteries are located
on the back side of the display; use
a Phillips head screwdriver to remove the cover screws to access the batteries.

3) Reassemble by reversing this procedure.

Meter Chamber Assembly

The Meter Chamber consists of upper and lower chambers, a
nutating disc, and four screws (figure 2).

1) To expose the meter chamber assembly, gear train and
seal remove 4 screws.

2) The meter chamber can be dislodged by removing 4
screws.

Reassemble by reversing this procedure.

Figure 2

Figure 1

Illumination

Units equipped with the pulser / external power option offer illumination for the digital display.
To turn the light on, press and release the “CAL” button. The display will remain illuminated
for 10 seconds after turned on.

IMPORTANT! If replacing any components of the meter chamber, the
complete assembly must be replaced due to its precision method of
construction. This will assure a proper fit, and correct operation of the

chamber.

Repair

Meters needing repairs should be taken to an authorized repair facility. Meters MUST be
triple rinsed before taking them in for repairs.

Safety Testing Approvals

The Fill-Rite 900D series meters have been tested for compliance to the standards set forth
by Underwriters Laboratories (UL), UL Canada, ATEX, and other testing organizations. To

rmine which specific compliances apply to your particular meter, refer to the

dete
faceplate for information and compliance logos.

8

Replacement Parts Information

Replacement parts can be obtained through any authorized Fill-Rite dealer. Be sure to use
only genuine Fill-Rite replacement parts for your service and maintenance needs. For a list of
authorized dealers, please visit our web site at “www.fillrite.com”.

Models FR901, 901N, 9011.5 901MK300, 901MK300V, 901LMK300V, & 901MK4200

900DPMK300L Kit Meter w/ Pulser
900DMK300L Kit Meter w/o Pulser

900 Series Digital Meter Replacement Parts Kit

Kit Number # Description Qty

KIT 900DKY

9

3 laeS deriuqeR 1
4 srenetsaF deriuqeR 2
1 revirD citengaM 3
1 ylbmessA rebmahC 4

Repair Kits and Accessories

Kit # Description Contents

901DPMK300V

901DPLMK300V

900 Series Meter (gallons)

with Inlet Flange for FR300

& FR700 Pumps

900 Series Meter (liters)

with Inlet Flange for FR300

& FR700 Pumps

900 Series Meter (gallons)
Inlet Flange (4-hole)
Required O-rings
Required Fasteners
900 Series Meter (liters)
Inlet Flange (4-hole)
Required O-rings
Required Fasteners

900 Series Digital Meters w / Pulser

Certain 900 Series Digital Meters (model number suffix of DP) can be powered externally and
are equipped with an integral electronic pulser uni t for use with Fuel Management Systems.

The Fuel Management System must be configured for current sinking or contact closure types
of signals. The meter provides ten counts per unit of measure (in gallon, liter, and quart units of
measure only; pulser does not operate in ounce, pint, or user specific units of measure).

Electrical Installation Information

There are multiple electrical configurations for the 900D Series Digital Meter, featuring two
different power sources. It is critical that the meter be installed and wired correctly to ensure
correct, safe operation.

WARNING! Electrical wiring should be performed ONLY by a licensed electrician
in compliance with local, state, and national electrical codes (NEC/ANSI/NFPA 70,
NFPA30, and NFPA 30A in US installations for example), as appropriate to the
intended use of the meter. The barrier must be properly connected to an earth
grounded. Improper installation of this meter and barrier can result in equipment
failure or damage, serious bodily injury, or death!

CAUTION! For meter installations using external power, the power should come
from a dedicated circuit. No other equipment should be powered by this circuit.
Wiring must be of sufficient size to carry the correct current for the meter. Voltage
drop will vary with distance to meter and size of wire; refer to the National
Electrical Code (NEC), or local codes, for Voltage Drop Compensation to be sure
you are using the correct size wire for your application. Wiring between the
barrier and meter MUST NOT exceed 850’. Refer to “Typical Installation” wiring

information document DC000675-010 (included in the meter box) for details.

IMPORTANT! Explosion Proof versus Intrinsically Safe:

There is a distinct difference between a product that is “Explosion Proof” versus a
product that is “Intrinsically Safe”. Intrinsically Safe products are built so they do
not generate enough heat or energy to cause ignition or explosion. They are safe
to use in an explosive atmosphere (i.e.: around fuel tanks, etc. where explosive
vapors may be present). An Explosion Proof product is one that is designed to
contain an explosion internally if one should occur. Understanding the difference
between the two is critical when installing a new item to be certain the installation
is safe and to code.

10

Internal Power (Battery Power)

All 900D Series Digital Meters are battery powered. The battery tray is located behind the
faceplate on the circuit board (see illustration page 8). Power is supplied by two alkaline
“AA” batteries. With normal use, these batteries should provide 2 – 4 years of use.
digital display has an integral warning of low battery level (see page 6 for details)

WARNING! To reduce the risk of explosion DO NOT mix old batteries with
new batteries, or mix batteries of different manaufacturers.

WARNING! Batteries may ONLY be replaced with the following:
Duracell MN1500
Duracell MX1500
Energizer E91
Incorrect battery selection voids the UL certification.

If there are questions feel free to contact your Fill-Rite Customer Service Representative
at 1-800-634-2695 (M-F 8 AM to 5 PM ET).

External Power (AC Power)

900D Series Digital Meters equipped with an integral pulser for use with an Fuel Management
System can also use an auxiliary external AC power supply to operate. External power
sources can include (but are not limited to) transformers, universal power supplies, and direct
power from an applicable Fuel Management System power supply.

The following pages contain installation information on all of the typical installation
Additionally there are seperate wiring diagrams and detailed important

applications.
wiring information included in the box with your meter, but seperate from this manual.
It is critical that this additional information and diagrams be read and understood
by the installer prior to installation of the meter, and barrier where applicable.

The

900DP Battery and Wiring Access

Intrinsically Safe Barrier

11

WARNING! Substitution of components may impair intrinsic safety!

WARNING! To prevent ignition of combustible or flammable atmosphere,

disconnect power before servicing.

WARNING! To prevent ignition of flammable or combustible atmosphere,
do not use a volt meter or similar powered tools during live maintenance.

12

13

Technical Specifications and Information

Dimensions: 6.75” (H) x 8.46” (W) x 4.10” (D)
Accuracy: ± 1.25 %

Repeatability: ± 0.25% at calibrated flow rate.

Flow Rate: 6 to 40 GPM
Pressure Rating: 50 psi
Construction: Aluminum
Units of Measure: Ounces, pints, quarts, liters, gallons, 1 special “unit of measure” option.
Counter: 4 digit resettable counter; (.01 – 9999 units).

Totalizers: 7 digit non-resettable “Master” totalizer, 7- digit resettable secondary.
Mounting Options: Can be installed for vertical or horizontal mounting by rotating display

accordingly.

Approvals: UL / cUL / ATEX Listing (see page 8 for information on specific certifications).
Power Supply: 2 “AA” batteries* (Dura-cell MN1500, MX 1500, or Energizer E91 Alkaline

batteries only); optional external power supply on certain models.

Expected Battery Life: 2 – 4 years of normal use with standard Alkaline batteries.
Operating Temperature Range: -40⁰ to 140⁰ F (Pulser units have face heat for extended use

down to -40; note that display goes blank below -40 but meter and pulser will continue to
operate normally).

14

*Contact your Fill-Rite Customer Service Representative
for battery replacement information. Incorrect battery
selection may void UL listing certification.

Tuthill Product Warranty

Tuthill Transfer Systems (“Manufacturer”) warrants each consumer buyer of its Fill-Rite
products (“Buyer”) from the date of invoice or sales receipt, that goods of its manufacture
(“Goods”) shall be free from defects of materials and workmanship. Duration of the warranty
is as follows:

• Heavy Duty Products – Two Years

• Standard Duty Products – One Year

• Economy Duty Products – One Year

• Cabinet Meters, Parts, and Accessories – One Year

Manufacturers sole obligation under the foregoing warranties will be limited to either – at
Manufacturers option – repairing or replacing defective goods (subject to limitations
hereinafter provided) or refunding the purchase price for such Goods theretofore paid by the
buyer, and Buyers exclusive remedy for breach of any such warranties will be enforcement of
such obligations of the Manufacturer. If the Manufacturer so requests the return of such
Goods, the Goods will be redelivered to the manufacturer in accordance with Manufacturers
instructions FOB Factory. The remedies contained herein shall constitute the sole recourse of
the Buyer against the Manufacturer for breach of warranty. IN NO EVENT SHALL THE

MANUFACTURER’S LIABILITY FOR ANY CLAIM FOR DAMA
MANUFACTURE, SALE, DELIVERY, OR USE OF THE GOODS EXCEED THE PURCHASE
PRICE. The foregoing warranties will not extend to goods subject to misuse, neglect,

accident, improper installation or maintenance, or have been repaired by anyone other than
the Manufacturer or its authorized representative. THE FOREGOING WARRANTIES ARE

EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OF MERCHANTABILITY,
FITNESS FOR PURPOSE OF ANY OTHER TYPE, WHETHER EXPRESSED OR IMPLIED.

No person may vary the forgoing warranties or remedies, except in writing signed by a duly
authorized officer of the Manufacturer. The Buyer’s acceptance of delivery of the Goods
constitutes acceptance of the foregoing warranties and remedies, and all conditions and
limitations thereof.

Tuthill Corporation recommends you retain your sales receipt as proof of purchase.
The following space has been provided to record important information about your meter for

quick reference.

Model

Number

Manufacture

Date

Date of

Purchase

UPC Bar C

Serial Number

Purchase

ode

Location

ARISING OUT OF THE

GES

15

NOTES

16

DC001501-000