Liquid Controls Pulse Output Device (POD) Installation and Parts Manual

Resources in this Guide

This manual provides technical details on installation, hardware, setup, operation, and regulatory information for the Liquid Controls Pulse Output Device (POD). For convenience, a PDF edition can be downloaded. It is recommended to read the introductory and safety information before proceeding to the Installation chapter.

Publication Updates

The latest versions of Liquid Controls publications are available at www.LCmeter.com/resources/technical/manuals. For questions about LC manuals or specifications, contact your local distributor. For service, contact the Liquid Controls Service Team.

Liquid Controls Corporate Office:

• Phone: +1 847 295-1050
• Toll-free: 800 458 5262
• Address: Liquid Controls LLC, 105 Albrecht Drive, Lake Bluff, IL 60044 USA
• Website: www.LCmeter.com

Safety Procedures

BE PREPARED

• Read and understand all instructions before using the product.
• Work must be performed by qualified personnel trained in proper application, installation, and maintenance, adhering to all codes and ordinances.
• Use proper Electrostatic Discharge (ESD) equipment when handling electronic components.
• Ensure all necessary safety precautions are taken.
• Provide for proper ventilation, temperature control, fire prevention, evacuation, and fire management.
• Ensure access to appropriate fire extinguishers.
• Consult local fire departments and codes for adequate preparation.
• Read this manual and all provided literature.
• Save these instructions for future reference.
• Failure to follow instructions may result in personal injury, death, property damage, or other hazards.

SAFELY EVACUATE PIPING SYSTEM

⚠ WARNING: Before disassembling any meter or component, ALL INTERNAL PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE SYSTEM.

• Pressure must be 0 psi.
• Close all liquid and vapor lines between the meter and liquid source.

⚠ Failure to follow this warning could result in property damage, personal injury, or death.

Observe National & Local Codes

⚠ Power, input, and output (I/O) wiring must comply with area classification (Class I, Div 2). For North America, installations must follow the U.S. National Electrical Code (NFPA 70) or the Canadian Electrical Code for Class I, Division 2 ratings. Peripheral equipment must be suitable for the hazardous location.

WARNING: Explosion Hazard

In hazardous locations, turn power OFF before replacing or wiring modules. DO NOT disconnect equipment unless power is OFF or the area is known to be Non-Hazardous.

WARNING: Use 3.5 in·lb (0.4 N·m) torque when tightening terminal block screws.

General Information

The Liquid Controls Pulse Output Device (POD) converts the rotary motion of the Liquid Controls Positive Displacement Flowmeter into electronic pulses, enabling interface with various electronic monitoring and control equipment. It operates in standard and bidirectional flow applications.

Check Each Shipment

Before installation, verify the shipment against the packing list to ensure no parts are missing. The packing list is included with the Installation and Operation Manuals.

The POD mounts directly to the front cover of any Liquid Controls meter, replacing the packing gland. Magnetic coupling through a stainless steel wall transmits the meter's rotor motion to the POD's electronics compartment, eliminating dynamic seals and isolating electronics from process fluid.

Inside, an optical shaft encoder generates a high-resolution, two-channel, quadrature square wave. Outputs are driven by field-effect transistors (FETs), switching between 0V (ON) and power supply voltage (OFF). Factory configuration includes a 2.2kΩ pull-up resistor on each output, which can be removed from the circuit in the field to produce a true "open drain" output. As open drain devices, outputs can sink up to 100 mA (ON) and sustain up to 30 VDC (OFF).

The electronics compartment also functions as a conduit junction box. The POD features an o-ring sealed, threaded cover. Standard wire entrance is a ½-14 NPT female hub for conduit or cable glands. A screw-type, removable terminal block on the circuit board facilitates wiring. With the wiring entrance sealed and cover in place, the housing has a NEMA 4X weatherproof rating.

POD Models

Available POD models include:

• POD1 – Fork Drive with Buna-N O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD2 – Fork Drive with PTFE O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD3 – Blade Drive with Buna-N O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD4 – Blade Drive with PTFE O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD5 – Fork Drive with Buna-N O-Ring, 100 PPR Quad Pulser, 5 to 24VDC (POD5 is not IECEx approved)
• POD6 – Fork Drive with EPDM O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD7 – Blade Drive with EPDM O-Ring, 100 PPR Quad Pulser, 9 to 30VDC

Output Signal Resolutions

Approximate K-Factors and Volumetric Reference Data

K-Factor (Pulses/Unit) values are for reference only during initial calibration and not for final K-Factor use. Liquid Controls meter models listed assume a 400ppr pulser with a 1:1 Packing Gland/Face Gear ratio. For a 2:1 ratio, divide Pulses/Unit by 2.

Liquid Controls recommends using the 1:1 Ratio for the highest resolution with meter-mounted registers driven by the packing gland/face gear assembly. Maximum flow rates may vary based on meter class and regulatory approval.

Note: If using both channels and rising edge only, multiply pulses per unit and maximum kHz by a factor of two. For LCR applications using both channels and rising/falling edge, multiply pulses per unit and maximum kHz by a factor of four.

Specifications

Dimensions

FRONT View: The device is approximately 3 inches in diameter. The main body height is about 2 inches, with a 0.65-inch projection. It features the "LIQUID CONTROLS" logo and "CE" marking.

SIDE View: This view illustrates the POD attached to a meter. It includes a ½-14 NPT Threaded Conduit Hub for cable entry.

Regulatory Compliance Tag Markings

This equipment complies with the European Directive for Equipment For Potentially Explosive Atmospheres 2014/34/EU (ATEX) and the IECEx Certification Scheme. Certificates include Presafe 18 ATEX 12438X and IECEx DNV 11.0012X. Special Conditions for Safe Use include using only Ex d certified cable glands and thread adapters, and for ambient temperatures above 70°C, using field wiring suitable for 20°C above the maximum ambient temperature.

It also complies with UK Regulation for Equipment and Protective Systems Intended for use in Potentially Explosive Atmospheres, certified under DNV 22 UKEX 37237X.

• II: Suitable for surface (not mine) installations.
• 2G: High level of protection against flammable gases, vapors, or liquids.
• Ex db: Explosion protection via flameproof enclosure.
• T6: Temperature class for surface temperature limitations (≤ 85 °C).
• Gb: Equipment group per IEC 60079-0 and EN 60079-0.
• Temperature Range: -40 °C ≤ Tamb ≤ 80 °C (Safe limits of ambient temperature).

IP66: Ingress protection: dust tight and protected against powerful water jetting.

CE 2460: Complies with applicable European Directives. Quality Assurance Notification performed by DNV (EU Notified Body registration number 2460).

Type 4X: Enclosure evaluated by UL for outdoor use, providing protection against water, dust, and corrosion, and undamaged by ice formation. Listed by UL for explosion-proof products in Class I, Division 1 & 2, Groups C & D environments.

2P46: UL listing control number issued to Liquid Controls.

DNV 12.0091 X: Explosive atmosphere certification for Brazil (INMETRO).

Bill of Materials

Detailed lists of POD Assemblies and POD Internal Components are provided with item numbers, descriptions, and part numbers for various POD models.

POD Assemblies:

POD Internal Components:

POD Extension - FORK DRIVE (MODELS 49754 & 49756): Components include Pulser Extension Driver, Pulser Housing, Screws, Dowel Pin, O-Rings (Buna-N or Teflon), Mag Bearing, Fork Driver, and Fork Drive Shaft.

POD Extension - BLADE DRIVE (MODELS 49757 & 49759): Components include Pulser Extension Driver, Pulser Housing, Screws, Dowel Pin, O-Rings (Buna-N or Teflon), Mag Bearing, Blade Driver, Roll Pin, and Drive Blade.

Installation

POD Installation - New Installations

When ordered with the flowmeter, the POD is factory installed and ready for wiring. Wiring instructions begin on page 10.

RELIEVING INTERNAL PRESSURE

⚠ WARNING: All internal pressure must be relieved to zero before disassembly or inspection. Serious injury or death from fire or explosion could result from performing maintenance on an improperly depressurized system.

Follow these steps for Relieving Internal Pressure for LPG and NH3 Meters:

1. Close the belly valve of the supply tank.
2. Close the valve on the vapor return line.
3. Close the manual valve on the supply line inlet side of the meter. If no manual valve exists, consult the truck manufacturer for depressurization procedures.
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 system pressure. Product will drain from the meter system.
7. As product drains, slowly reopen and close the valve/nozzle on the discharge line until product stops draining.
8. Leave the discharge line valve/nozzle open while working on the system.

Retrofit Installations

To remove existing hardware:

1. Relieve pressure from the process piping to the meter.
2. Drain the meter by opening drain plugs.
3. Remove the mechanical counter, adjuster, and adjuster drive shaft from the meter front.
4. If a counter adapter bracket is present, remove it by unbolting it. If integral, it cannot be removed, requiring a POD Pulser Extension.
5. Remove packing gland mounting screws and pull the packing gland out. Ensure the O-Ring is removed from the gland well before installing the POD.

NOTE 1: Meters with two packing gland mounting screws are limited to four orientations.

NOTE 2: When using a cable gland, any of eight orientations can be used. When using conduit, the hub should face down to allow moisture to drain away from the POD electronics.

Installing the POD

POD Extension Kits

If a POD Extension Kit is needed, install it before the POD. See POD Extension Kit Installation (page 18).

To install the POD onto a flowmeter:

1. Verify the POD Model matches the driver tang on the removed packing gland (blade type with blade type, fork type with fork type).
2. Determine the desired orientation of the conduit hub (eight possible orientations shown in diagrams).
3. Position the O-Ring over the bottom of the POD.
4. Align the fork or blade style driver with the meter's drive mechanism and guide the POD into the meter cover opening. The mounting flange should abut the meter cover when aligned.
5. Rotate the POD to the desired orientation and thread in mounting screws until snug. Tighten screws to 21-25 inch-pounds using a 7/32" box end wrench.

POD Extension Kit Installation

The POD Extension is used for meters with integral counter adapter brackets or for high-temperature applications to extend the connection away from the meter.

Four POD Extension models are available: 49754 (POD1 or POD5 - Fork Drive with Buna-N O-Ring), 49756 (POD2 - Fork Drive with Teflon O-Ring), 49757 (POD1 or POD5 - Blade Drive with Buna-N O-Ring), and 49759 (POD2 - Blade Drive with Teflon O-Ring).

After removing existing hardware (as per Retrofit Installations), install the POD Extension. Note: The POD Pulser must be a FORK drive pulser regardless of the POD Extension used.

To install the POD Extension:

1. Verify the POD Extension Model's driver tang matches the packing gland's tang (blade type with blade type, fork type with fork type).
2. Install the POD Extension using the provided screws, aligning holes with the meter. Tighten screws to 21-25 inch-pounds.
3. Mount the POD onto the POD Extension, aligning the POD Fork Tang with the internal POD Extension Driver. Use two screws and tighten to 21-25 inch-pounds with a 7/32" box end wrench.

POD Wiring

WIRING CONDUIT SYSTEM

Wires must enter through the POD's conduit hub. For explosion-proof systems (Class I, Div 1), use explosion-proof rated rigid or braided flexible conduit. Conduit must engage five full threads into the female hub for explosion-proof requirements.

For Division 2 locations, rigid conduit, flexible conduit, or no conduit may be used. If no conduit is used, a cable gland must seal the instrument cable to maintain the NEMA 4X rating. Apply thread sealant to prevent moisture ingress.

OBSERVE NATIONAL & LOCAL CODES

North America: Installations must comply with the National Electrical Code (US) or Canadian Electrical Code for hazardous location ratings.

Outside North America: Installations must comply with EN 60079-14. Use Ex d certified cable glands only. For ambient temperatures above 70°C, use field wiring rated 20°C above the maximum ambient temperature.

WIRING CABLE

Multi-wire cable with an overall shield is recommended. Individual wires must be in flexible metal conduit. Use wires between 16 and 20 AWG or shielded cable no less than 22 AWG. Cable runs up to 5,000 ft (1,524 m) are possible; runs over 1,000 ft (304.8 m) may require lower AWG wire to reduce voltage drop and capacitance. Long runs might need a lower value pull-up resistor. Metalized foil plastic shield with a drain wire is recommended over woven shields.

TERMINAL BLOCK

The POD has a 4-position terminal block for electrical connections. The terminal block can be unplugged for easier wiring.

Wiring Configurations:

The wiring configuration depends on system needs. Check electronic control input requirements for single channel or quadrature output. For single direction flow, use one channel. For forward/reverse flow, use both channels (quadrature). Channel A leads Channel B by 90° in one direction, and B leads A in the reverse. Quadrature is required for most Weights & Measures approved installations.

CONVERSION TO OPEN DRAIN OUTPUT

The POD has a 2.2 kΩ pull-up resistor on each output transistor. This can be modified in the field for true Open Drain (Open Collector) outputs.

To modify to Open Drain outputs:

1. Turn off power and remove the cover.
2. Loosen circuit board mounting screws and remove the circuit board assembly.
3. Using a small soldering iron, remove R4 and R5 resistors.
4. Apply heat to one pad of the resistor, then push it off the board. Repeat for the second resistor.
5. Reassemble the unit.

SIGNAL OUTPUT

The diagram shows voltage output for clockwise rotation (Channel A leading Channel B) and counterclockwise rotation (Channel B leading Channel A). Quadrature channel voltage output is 90° out of phase with Channel B.

POD Wiring Schematics

Single Channel Applications – SP4000, SP3850, IT400

Wiring steps:

1. Use metallic conduit with individual wires or 3-conductor, 22 AWG, shielded cable.
2. Strip 1½" of outer sheathing. Remove exposed shield and drain wire, then tape.
3. Strip ½" insulation from each conductor and connect to terminal blocks.

Terminal Block Connections for SP4000, SP3850, IT400:

Power Source Requirement

An isolation source and overcurrent protective device rated 5A max must be installed. If not available, a Class 2 power source must be used.

Dual Channel Quadrature Applications LECTROCOUNT® LCR®, LCR-II®, LC³, LCR 600

Terminal Block Connections: