Liquid Controls MA4 User Manual

Installation & Parts Manual

MA-4 Positive Displacement Meter for LPG Motor Fuel Dispensers

(Single & Dual Meter Versions)

Installation: M100-11

www.lcmeter.com

Table of Contents

Description Page Number

Safety Precautions ..............................................2

How LC Meters Work ..........................................3

Owner’s Information Packet ................................4

Installation Requirements....................................4-5

Installation ...........................................................6-9

Mounting Dimensions - Single Meter......6

Mounting Dimensions - Dual Meter ........7

Operation Requirements ........................8

Meter Installation ....................................8

Meter Start Up & Operation ....................9

Meter Maintenance .............................................10-11

Pulse Output Device 5 (POD5) ...........................12-14

Vapor Eliminator/Strainer Maintenance ...............15-16

Differential Valve Maintenance ............................17

Please have the following information available when you make inquiries, order replacement parts, or schedule service. If a specific meter accessory is involved, please provide the model and serial number of the meter in question (See Page 4).

Meter Serial Number____________________________ Full Service Distributor___________________________ Full Service Distributor Phone Number______________

Disassembling the Meter.....................................18-19

Removing the Non-Corroded Rotor Gears..........20

Removing Bearing Plates and Rotors .................20

Removing Corroded Rotor Gears........................21

Reassembling the Meter .....................................22-23

Timing the Rotor Gears .......................................24

Torque Chart .......................................................25

Wrench and Socket Size Chart ...........................25

Troubleshooting ................................................... 26

How to Order Replacement Parts .......................27

Meter Assembly Exploded View ..........................28

Strainer Assembly Exploded View.......................29

Differential Valve Exploded View.........................30

Optional Back Check Valve Assembly.................31

Publication Updates & Translations

The most current English versions of all Liquid Controls publications are available on our website, www.lcmeter.com. It is the responsibility of the Local Distributor to provide the most current version of LC Manuals, Instructions, and Specification Sheets in the required language of the country, or the language of the end user to which the products are shipping . If there are questions about the language of any LC Manuals, Instructions, or Specification Sheets, please cont act your Local Distributor.

WARNING WARNING

WARNING

WARNING WARNING

• Before using this product, read and understand the instructions.

• Save these instructions for future reference.

• All work must be performed by qualified personnel trained in the proper application, installation, and maintenance of equipment and/or systems in accordance with all applicable codes and ordinances.

• Failure to follow the instructions set forth in this publication could result in property damage, personal injury, or death from fire and/or explosion, or other hazards that may be associated with this type of equipment.

Safety Procedures

! WARNING

All internal pressures must be relieved before disassembly or inspection of the strainer, air eliminator , any valves in the system, the packing gland, and the front or rear covers. See “Relieving Internal Pressure” (Page 10).

Be Prepared

Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation and fire management.

Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department

and state and local codes to make sure that you are adequately prepared.

Read this manual as well as all the literature provided in your owner’s packet.

In the Event of a Gas Leak

In the event of a large gas leak: Evacuate the area

and notify the fire department.

In the event of a small, contained gas leak:

1. Stop the leak and prevent accidental ignition.

2. Prevent the entrance of gas into other portions of the buildings. Some gases, such as LPG , seek lower levels, while other gases seek higher levels.

3. Evacuate all people from the danger zone.

How LC Meters Work

4. See that the gas is dispersed before resuming business and operating motors. If in doubt, notify your local fire department.

In the Event of a Gas Fire

In the event of large fires or fires that are spreading:

Evacuate the building and notify your local fire

Liquid Controls meters are positive displacement meters. They are designed for liquid measurement in both custody transfer and process control applications. They can be installed in pump or gravity flow systems. Because of their simple design, they are easy to maintain, and easy to adapt to a variety of systems.

The meter housing (1) is designed with three cylindrical bores (2). Three rotors, the blocking rotor (3) and two displacement rotors (4, 5), turn in synchronized relationship within the bores. The three rotors are supported by bearing plates (6, 7). The ends of the rotors protrude through the bearing plates. Blocking rotor gear (8) is placed on the end of the blocking rotor. Displacement rotor gears (9, 10) are placed on the ends of the displacement rotors. These gears create the synchronized timed relationship between the three rotors.

As fluid moves through the meter housing, the rotor assembly turns. The liquid is broken into uniform sections by the turning rotors. Fluid displacement happens simultaneously. As fluid enters, another portion of the fluid is being partitioned and measured. At the same time, the fluid ahead of it is being displaced out of the meter and into the discharge line. Since the volume of the bores is known, and the same amount of fluid passes through the meter during each revolution of the blocking rotor, the exact volume of liquid that has p assed through the meter can be accurately determined.

This true rotary motion is transmitted through the packing gland, the face gear, the adjuster drive shaft, and the adjuster to the register stack and counter. True rotary motion output means consistent accuracy since the register indication is in precise agreement with the actual volume throughput at any given instant.

At any position in the cycle, the meter body , the blocking rotor, and at least one of the displacement rotors form a continuous capillary seal between the un-metered

department. Stop the leakage only if you can safely reach the equipment.

In the event of small, contained fires that you can safely control: Stop the leakage if you can safely reach

the equipment. Then use the appropriate extinguisher: Class B fire extinguisher, water, fog, etc., depending on the materials. If in doubt, call your local fire department.

Meter Element Exploded View

upstream product and the metered downstream product. Capillary seals mean no metal-to-metal contact within

the metering element. This means no wear. No wear means no increase in slippage, and no increase in slippage means no deterioration in accuracy.

Throughout the metering element, the mating surfaces are either flat surfaces or cylindrical faces and sections that are accurately machined. These relatively simple machining operations, plus the fact that there is no oscillating or reciprocating motion within the device, permits extremely close and consistent tolerances within the LC meter.

The product flowing through the meter exerts a dynamic force that is at right angles to the faces of the displacement rotors. The meter is designed so that the rotor shafts are always in a horizontal plane. These two facts result in no axial thrust. Therefore, with no need for thrust washers or thrust bearings, the rotors automatically seek the center of the stream between the two bearing plates eliminating wear between the ends of the rotors and the bearing plates. Once again, no wear results in no metal fatigue and no friction.

The Liquid Controls meters are made of a variety of materials to suit a variety of products. Because of our no-wear design, capillary seals, and unique rotary metering, LC meters provide unequalled accuracy, long operating life, and unusual dependability.

Owner’s Information Packet

Is all your documentation included with your meter? LC meters come in many variations. The information sent to you depends on the accessories you have ordered with your meter. Make an inventory of your Owner’s Information Packet. First, find your LC packing slip with the computer printout. Locate the serial number and the meter model number on this printout. Cross-reference the packing slip with the actual meter serial numbers.

Included in your Owner’s Information Packet are the following:

• Installation and Parts Manual

• Bill of Materials

• SCAMP™ Installation and Operation Manual Record your meter serial number in the space provided

on the inside cover of this manual. The inside cover also provides a space for your full-service distributor’s name and telephone number, if applicable. Fill in this information and keep it handy. Y ou will always need your meter serial number and model number when calling for service or parts. See “How to Order Replacement Parts” on Page 27 in this manual.

Serial Number Plate (Side)

Serial Number Plate (Rear)

Installation Requirements

! WARNING

• Make sure that all necessary safety precautions have been taken. Provide for proper ventilation, temperature control, fire prevention, evacuation, and fire management.

• Provide easy access to the appropriate fire extinguishers for your product. Consult with your local fire department and state and local codes to make sure that you are adequately prepared.

• Read this manual as well as the literature provided in your Owner’s Information Packet. If you have any questions, consult with your full-service distributor or call the Service Department at Liquid Controls.

• Install the meter and accessories in conformance with all applicable federal, state, local, construction, electrical, and safety codes.

• Class 10 meters for LPG must be installed in accordance with the requirements of ANSI-NFPA 58 in addition to all other state and local codes.

• Under normal operation, do not expose any portion of the LP-Gas system to pressures in excess of rated working pressures without an automatic safety valve to vent the over pressure discharge to a place of safety away from the operator and other people. Failure to provide such a safety relief may result in leakage or rupture of one or more of the components in the system. This can result in injury or death from the gas, a fire, or pieces of flying debris from the rupture.

• Before shipment, protective thread caps were placed in all meter and accessory openings. They should remain in place until you are ready to attach piping.

• Prior to meter installation, the entire piping system should be thoroughly flushed of all debris, with a liquid that is compatible with the construction of the meter .

• Keep all external surfaces of the meter clean.

• Apply pipe compound to male threads only.

Installation & Operation Requirements

! WARNING

When a Back Check V alve is used, an automatic safety valve must be installed to prevent pressure build-up in excess of rated working pressure in the meter housing. One automatic safety valve should be installed in each meter. Remove the pipe plug from the front cover or rear cover and insert the appropriate automatic safety valve.

• The meter must always be securely bolted to a platform or supporting member, regardless of the mounting position of the meter. Never “hang” a meter on the connecting pipe.

Operation Requirements

The meter must remain full of product at all times. An easy way to accomplish this is to put the meter assembly in the line below the piping center-line (a sump position). This requires adding elbows and flanges prior to installing the meter. The meter should be installed in a bypass loop, below the pipe center-line, with block valves upstream and downstream. A block valve should be located in the mainstream, labeled as the bypass valve. A word of caution: any portion of pipe system that might isolate or block flow should be provided with a pressure relief to prevent damage from thermal expansion. There are excellent benefits to this type of installation. First, the meter is kept full. Second, this type of installation allows the meter to be isolated for servicing and calibration while continuing flow through the bypass valve.

Upstream lines must be maintained full to prevent air from entering the meter. If the up stream or inlet lines are constructed in a manner which allows reverse flow, foot valves or back checks must be installed.

Position the meter with service in mind. Make sure there is ample work space. Removing the meter covers can be difficult when ample work space is not available. Always supply a platform or support for the meter mounting.

Every meter should be calibrated under actual service and installation conditions per the API Manual of Petroleum Measurement Standards:

Chapter 4 - Proving Systems Chapter 5 - Metering Chapter 6 - Metering Assemblies Chapter 11 Section 2.3 - Water Calibration of Volumetric Provers Chapter 12 Section 2 - Calculation of Petroleum Quantities

• Position the meter with service in mind. Provide ample work space. Removing covers can be difficult when work space is not available. Always supply a platform or support for the meter mounting.

• A meter is metallurgically designed to be physically compatible with a given type of liquid, as originally specified by the customer, and as indicated on the Serial Number Plate. A meter should not be used with a liquid different from the liquid originally specified, unless the physical characteristics and pH rating are similar and the application has been checked with Liquid Controls Sales or Engineering.

These chapters of the API Manual of Petroleum Measurement Standards supersede the API Standard

1101.

Provide a means of conveniently diverting liquid for calibration purposes.

Give careful attention to your system’s pumping equipment and piping because of their influence on liquid being measured as it enters the meter assembly. Systems should be made free of conditions that cause or introduce entrained air or vapor.

Follow the manufacturer’s recommendations fully when installing pumps. Give particular attention to factors like: use of foot valves, pipe size to the inlet and conformance to net positive suction head (NPSH) conditions when suction pumping is required. Following the manufacturer’s recommendations will minimize air and vapor elimination problems.

For liquids such as light hydrocarbons that tend to flash or vaporize easily at higher ambient temperatures, it is desirable to use flooded suctions and piping sized larger than the normal pump size.

Hydraulic shock is harmful to all components of an operating system including valves, the meter and the pump. In particular, meters must be afforded protection from shock because of their need to measure with high precision. Generally the best protection is prevention, which can be readily accomplished by adjusting valve closing rates in such a manner that shock does not occur.

Thermal expansion like hydraulic shock is a phenomenon that can easily damage meters and systems in general. Care should be taken in designing the system to include pressure relief valves in any portion or branch of the system that might be closed off by closure of operating valves or block valves.

Installation

Mounting Dimensions - Single Meter

NOTE: Always request up-to-date engineering approved dimensional drawings before starting any construction. Do

not rely on catalog pictures or drawings, which are for reference only. After receiving the prints, check to see that all equipment ordered is shown and that any extra pressure taps, plugs, etc. are noted and their size specified.

Mounting Dimensions - Dual Meter

Installation

NOTE: Always request up-to-date engineering approved dimensional drawings before starting any construction. Do

Installation

Theory of Operation

The Liquid Controls MA-4 LPG Meter combines a positive displacement meter, dif ferential valve, strainer, and vapor eliminator in one assembly.

The Liquid Controls vapor eliminator employs a sleevetype valve that permits a “leak” flow of approximately 0.2 GPM from the vapor vent back to the supply tank. A 200mesh strainer is incorporated in the vapor eliminator casting and is easily accessible by removing the strainer cover.

The Liquid Controls differential valve incorporates a piston-diaphragm type construction, with the piston moving away from its seat when at least 15 psi pressure (above product vapor pressure) is maintained at the meter outlet. The soft seat valve assures measurement accuracy by requiring 1) pump operation for delivery, 2) adequate back pressure to prevent product vaporization during measurement, and 3) blockage of flow when the vapor eliminator release valve opens.

Meter Installation

Meter:

Install the meter assembly in dispenser cabinet to a secure base, using the supplied bracket on the meter housing and the “feet” located on the strainer assembly base. Make inlet and outlet connections at the flanged surfaces on the strainer and differential valve, respectively.

Vent Line:

The vent line from the meter’s vapor vent to the vapor space on the supply tank should be 1/4 inch minimum inside diameter tube or pipe. A shut off valve must be installed in the vapor vent line to allow removal of the strainer or to service the meter. The vapor release vent line must be returned to the vapor space of the supply tank and normally should not be made common with the other vapor return lines or pump bypass lines. When properly installed, this line must permit free flow in either direction. If the valve in the vent line is closed the meter will not function. These instructions must be followed to maintain proper function of the differential valve.

Meter Start-up and Operation

Prior to meter start up, use extreme caution. Make sure that:

1. The meter is properly secured

2. All connections are tight

3. All valves are in the closed position Placing your meter in operation:

Check to determine that all fittings and flanges are tight and liquid lines are closed.

Open the vapor line to the meter. Using vapor pressure only, check each joint with a liquid soap solution to see that no leaks go undetected. When all joints have been checked, admit liquid SLOWLY to avoid operation on vapor at speeds greater than the minimum indicated on the serial number plate and to insure that cover cavities do not contain vapor which can be compressed. Proper slow filling can be done by throttling the system with a valve at the meter OUTLET or by allowing the system to fill by gravity.

With the valve(s) open between the tank and the meter, go to the valve located down stream of the meter. Open the down stream valve slowly until the meter’s register/ counter starts to move. Do not run the meter any faster than 25% of its maximum rated flow during start-up. Once the product is flowing out the end of your system, the outlet valve can be opened all the way provided that the system is designed not to exceed the flow rate marked on the meter.

Installation

Never operate the meter or system when partially filled with liquid, or with pockets of compressed air or vapor present. If these conditions cannot be avoided, air and vapor elimination systems may be required. If you cannot fill the meter slowly by gravity or by using a valve to throttle back the flow, consult the factory.

Do not operate the meter at a pressure exceeding that marked on the Serial Number Plate. Under any and all pressure producing circumstances, for instance, thermal expansion and hydraulic shock, the working pressure must not exceed the indicated maximum.

If the meter is operated at a rate greater than the maximum recommended GPM, excessive wear and premature failure may occur.

The meter can be calibrated for flows below minimum ratings if the flow remains constant and varies within narrow limits or if the product is viscous. A meter should never be run beyond the maximum flow rate determined for that class meter and/or liquid measured.

NOTE: If the valves are not manual, consult the valve manufacturer for slow flow start-up.

Filling the system with a pump: Consult the pump manufacturer for proper pump priming. Once the pump is primed with product, proceed.

CAUTION!

Make sure that your pump can operate against a dead head pressure. If NOT, consult the factory for assistance.

Meter Maintenance

! WARNING

Relieving Internal Pressure

All internal pressure must be relieved to zero pressure

before disassembly or inspection of the strainer, air eliminator any valves in the system,

the packing gland, and the front or rear covers.

Serious injury or death from fire or explosion could result from maintenance of an

WARNING

improperly depressurized and evacuated system.

Procedure for Non-LPG Meters

1. Turn off pump pressure to the system.

2. Close valves before and after the meter.

3. Remove pressure by removing the drain plugs and draining the meter.

Procedure for LPG Meters

1. Close the belly valve of the supply tank.

2. Close the valve on the vapor return line.

3. Close the manual valve in the supply line on the inlet side of the meter. If no manual valve exists on the inlet side, consult the truck manufacturer for procedures to depressurize the system.

Prevent pipe strain or stress from occurring when making meter or accessory repairs. Pipe strain and stress occur when the pipes are not supported or are not aligned correctly to the meter. The weight of the pipes must always be supported independent of the meter. This means that the meter and accessories can easily be removed without affecting the pipes or the pipe alignment. Never leave any of the pipes hanging.

Seasonal meter storage. If the meter is used for seasonal work, at the end of each season the meter should be removed from the system and thoroughly flushed with a compatible liquid. This includes removing the drain on the front and rear covers. Then flush the product from the front and rear covers. If flushing with water is preferred, extra care should be taken to drain the meter completely and to dry all internal parts. Immediate refilling with a compatible liquid (or oil misting) is essential to prevent corrosion as well as ice damage to parts from moisture that was overlooked after flushing and drying.

Do not mar or scratch any of the precision machined surfaces by prying or sanding parts.

4. Slowly open the valve/nozzle at the end of the supply line.

5. After product has bled off, close the valve/nozzle at the end of the supply line.

6. Slowly crack the fitting on top of the differential valve to relieve product pressure in the system. Product will drain from the meter system.

7. As product is bleeding from the differential valve, slowly reopen and close the valve/nozzle on the discharge line. Repeat this step until the product stops draining from the differential valve and discharge line valve/nozzle.

8. Leave the discharge line valve/nozzle open while working on the system.

Torque specifications. All fasteners such as screws and bolts should be torqued to proper specification. See the “Torque Chart” on Page 25 of this manual.

Stone the machined surfaces when reassembling the meter to assure that the machined surfaces are free of burrs and mars.

Repair pulled threads with threaded insert fasteners. These can be used in many instances. Contact your full-service distributor for advice if this occurs.

Coating threads. When removing and replacing bolts and castings in a meter, always coat the threads with anti-seize.

Removing flange seals. When removing the flange assembly , always carefully remove the O-ring seal. Make sure that the flange surface is clean. Discard and replace the old O-Ring seal if it is nicked or scratched in any way. If it is undamaged, it can be reused.

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Liquid Controls MA4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual