Pulse Output Device (POD) Installation & Parts

Introduction

This document provides installation and parts information for the Liquid Controls Pulse Output Device (POD).

Table of Contents

• Safety Procedures
• General Information
• POD Models
• Output Signal Resolutions
• Specifications
• Dimensions
• Regulatory Compliance Tag Markings
• Installation
• POD Installation
• POD Extension Kit Installation
• POD Wiring
• POD Wiring Schematics
• Bill of Materials

NOTICE: This manual provides warnings and procedures intended to inform the owner and/or operator of hazards present when using Liquid Controls Meters on LP-Gas and other products. Adherence to these warnings and avoidance of hazards is the responsibility of the owner-operators.

Publication Updates and Translations: Current English versions are available at www.lcmeter.com. Local distributors are responsible for providing current versions in the required language. Contact your local distributor for language inquiries.

Safety Procedures

Be Prepared

! WARNING:

• Read and understand all instructions before use.
• All work must be performed by qualified, trained personnel in accordance with applicable codes.
• Use proper Electrostatic Discharge (ESD) equipment and procedures when handling electronic components.
• Ensure all necessary safety precautions are taken.
• Provide for proper ventilation, temperature control, fire prevention, evacuation, and fire management.
• Ensure appropriate fire extinguishers are accessible.
• Consult local fire departments and codes for preparation.
• Read this manual and all provided literature.
• Save these instructions for future reference.
• Failure to follow instructions may result in property damage, personal injury, or death from fire, explosion, or other hazards.

Observe National and Local Codes

! WARNING:

North America: Installations must comply with the National Electrical Code (US) or Canadian Electrical Code for hazardous location ratings. For UL Listing, Class 2 power supply or an isolation power source with a 4 Amp max overcurrent protective device is required.

Avertissement: Pour être conforme aux exigences UL, une alimentation électrique de classe 2 ou une alimentation électrique isolée et comportant un dispositif de protection contre la surtension de 4 ampères ou moins sont requises pour l'installation.

Outside North America: Installations must comply with the local equivalent of IEC 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.

WARNING: Explosion Hazard - Substitution of components may impair suitability for hazardous area applications.

WARNING: Explosion Hazard - When in hazardous locations, turn power OFF before replacing or wiring modules.

WARNING: Explosion Hazard - Do NOT disconnect equipment unless power is OFF or the area is known to be Non-Hazardous.

Safely Evacuate Piping System

! WARNING: Before disassembly of any meter or accessory component:

• All internal pressures must be relieved and all liquid drained from the system in accordance with applicable procedures.
• Pressure must be 0 (zero).
• 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 from fire and/or explosion, or other hazards.

General Information

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

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

Check Each Shipment

Before installation, verify shipment against the packing list for missing parts. The packing list is included in the red information packet with the Installation and Operation Manuals.

Inside the electronics compartment, an optical shaft encoder converts rotary motion into a high-resolution, two-channel, quadrature square wave. Outputs are driven by field-effect transistors (FETs), switching from 0 volts ("ON") to the user's power supply voltage ("OFF"). The factory configuration includes a 2.2kΩ pull-up resistor on each output, which can be removed for 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 serves as a conduit junction box. The POD features an O-ring sealed, threaded cover. The standard wire entrance is a 1/2"-14 NPT female hub for threaded conduit or a cable gland. A removable, screw-type terminal block facilitates wiring. With the wiring entrance sealed and cover in place, the housing has a NEMA 4X weatherproof rating.

POD Models

Five POD models are available:

• 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)

Output Signal Resolutions

M & MA Series

Note: Multiply pulses/unit and max kHz by two for single channel, rising edge only. Multiply by four for LCR applications using both channels and rising/falling edge.

MS Series

Note: Multiply pulses/unit and max kHz by two for single channel, rising edge only. Multiply by four for LCR applications using both channels and rising/falling edge.

Specifications

Dimensions

Diagrams showing the front and side dimensions of the POD are present. Key dimensions include a 2.95" height, 3" width, and a 3.29" depth. The conduit hub is 1/2"-14 NPT threaded.

Regulatory Compliance Tag Markings

The POD carries various compliance markings:

• EU Explosive Atmospheres symbol:
• DNV 11 ATEX 01600X and IECEx DNV 11.0012X: Compliance with European Directive 94/9/EC (ATEX) and IECEx scheme. Special conditions for safe use include: 1) Use of Ex d certified cable glands only; 2) For ambient temperatures above 70°C, use field wiring rated 20°C above maximum ambient temperature.
• II 2 G Ex d IIB T6 Gb: Indicates suitability for surface installations (not mines), high protection against flammable gases/vapors/liquids (Zone 1), explosion protection via flameproof enclosure, gas group IIB (including ethylene, propane, methane), temperature class T6 (≤ 85°C), and equipment group Gb.
• -40°C ≤ Tamb ≤ 80°C: Safe ambient temperature limits.
• IP66: Dust tight and protected against powerful water jets.
• CE 0575: Compliance with applicable European Directives, with DNV as the Notified Body (registration number 0575).
• ULUS LISTED 2P46: Listed by UL for Canadian and US requirements for explosion-proof products in Class I, Division 1 & 2, Groups C & D environments. 2P46 is the UL listing control number.
• Type 4X: NEMA rating for indoor/outdoor use, protection against falling rain, splashing water, hose-directed water, ice formation, and corrosion resistance.
• DNV 12.0091 X: Explosive atmosphere certification for Brazil (INMETRO).
• CCE ID NO. P318018/1: Explosive atmosphere certification for India.

Note: IECEx approval does not apply to the POD5 model.

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 pressure before disassembly or inspection of the strainer, vapor eliminator, valves, packing gland, or covers.

Serious injury or death from fire or explosion could result from maintenance on an improperly depressurized system.

Relieving Internal Pressure Procedure from LPG and NH3 Meters:

1. Close the supply tank's belly valve.
2. Close the vapor return line valve.
3. Close the manual valve on the supply line inlet to the meter. Consult the truck manufacturer if no inlet valve exists.
4. Slowly open the valve/nozzle at the end of the supply line to bleed off product.
5. After product has bled off, close the valve/nozzle.
6. Slowly crack the fitting on top of the differential valve to relieve system product pressure; product will drain.
7. While product is draining, slowly reopen and close the discharge line valve/nozzle repeatedly until product stops draining from the differential valve and discharge line.
8. Leave the discharge line valve/nozzle open during system work.

Retrofit Installations

To Remove the Existing Hardware

1. Relieve pressure from the process piping to the meter.
2. Drain the meter by opening its drain plugs.
3. Remove the mechanical counter, adjuster, and adjuster drive shaft from the meter's front.
4. If a counter adapter bracket is bolted on, remove it. If integral, it cannot be removed, and a POD Pulser Extension will be required.
5. Remove packing gland mounting screws. Pull the packing gland out. Ensure the O-ring is removed from the packing gland well before installing the POD.

Visuals show removing packing gland mounting screws and a removed packing gland.

Installing the POD

To install the POD onto a flowmeter:

1. Verify the correct POD Model by comparing the driver tang on the POD to the removed packing gland's driver tang (blade type or fork type). Blade type packing glands require blade type PODs, and fork type require fork type PODs.
2. Determine the desired orientation of the conduit hub. The hub can be positioned in eight orientations (meters with two mounting screws are limited to four). For cable glands, any orientation is acceptable. For conduit, the hub should face down to allow moisture drainage away from the POD electronics.
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 until its mounting flange abuts the cover.
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.

Visuals show blade and fork style tangs, recommended conduit hub orientations, and the POD with O-ring and fork style tang.

POD Extension Kits

If a POD Extension Kit is required (for integral counter adapter brackets or high temperature applications), it must be installed prior to the POD. See Page 9.

Four POD Extension models are available. The POD Pulser must be a FORK drive pulser regardless of the extension used.

POD Extension Models:

• 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
• 49759: POD2, Blade Drive with Teflon O-Ring

POD Extension Kit Installation

After removing existing hardware (Page 4), install the POD Extension:

1. Verify the correct POD Extension Model by comparing its driver tang to the removed packing gland's driver tang (blade or fork type). Blade type packing glands require blade type POD Extensions, and fork type require fork type POD Extensions.
2. Install the POD Extension using the two provided screws. Align holes with the meter; use the 1.500" or 1.625" hole spacing as needed. Tighten screws to 21-25 inch-pounds.
3. Mount the POD to the POD Extension. Align the POD Fork Tang with the internal POD Extension Driver. Use the two provided screws to secure the POD to the extension, tightening to 21-25 inch-pounds.

Visuals show POD Extension Kit components and installation.

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, engaged five full threads into the hub. For Division 2 locations, rigid conduit, flexible conduit, or no conduit is permitted. If no conduit is used, a cable gland must seal the wiring to maintain NEMA 4X rating. Apply thread sealant to prevent moisture ingress.

Observe National and Local Codes

! WARNING:

North America: Comply with National Electrical Code (US) or Canadian Electrical Code for hazardous location ratings.

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

Wiring Cable

Multi-wire cable with overall shield is recommended. Individual wires should be in flexible metal conduit and not run with other cables. Use 16-20 AWG individual wires or 22 AWG shielded cable. Cable runs up to 5000 ft (1524 m) are possible, but runs over 1000 ft (304.8 m) require lower AWG wire to reduce voltage drop and capacitance. Long runs may need a lower pull-up resistor. Shielded cable with a metalized foil plastic shield and drain wire is preferred over woven shields for easier termination.

Terminal Block

The POD has a 4-position terminal block accessible after removing the cover. The block can be unplugged for easier wiring. Use a straight blade screwdriver with a tip less than 1/8" wide. Strip 1/4" of insulation from each wire. Open terminal slots by turning screws counterclockwise. Insert wires and tighten screws. Ensure the terminal block is properly oriented when re-plugging.

Wiring Configurations

Configuration depends on system needs (single channel or quadrature output). For unidirectional flow, use one channel (A or B). For bidirectional flow, use both channels (A and B) which are 90° out of phase. Channel A leads B in one direction, and B leads A in the reverse direction. Quadrature is typically required for Weights & Measures approved installations.

Conversion to Open Drain Output

The POD is factory supplied with a 2.2 kΩ pull-up resistor on each output transistor. To convert to true Open Drain outputs:

1. Turn off power and remove the cover.
2. Loosen and remove the circuit board assembly.
3. Using a small soldering iron, remove resistors R4 and R5. Apply heat to one pad, push the resistor off when solder melts, then repeat for the second resistor.
4. Reassemble the unit.

Signal Output

Diagrams illustrate the voltage output for clockwise rotation (Channel A leading Channel B) and counterclockwise rotation (Channel B leading Channel A). The quadrature channel output is 90° out of phase.

POD Wiring Schematics

Schematics are provided for PODs with Serial Number 04-24531 and higher.

Single Channel Applications (SP4000, SP3850, IT400)

Wiring Guide:

• Use metallic conduit with individual wires or 3-conductor, 22 AWG, shielded cable.
• Strip 1/2" off outer sheathing. Remove exposed shield and drain wire, then tape.
• Strip 1/4" insulation from each conductor and connect to terminal blocks.

Power Source Requirement: An isolation source and 5A max overcurrent protective device 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)

Visuals show wiring diagrams for single and dual channel applications.

Bill of Materials

POD Assemblies

POD Internal Components

Visuals show exploded views of POD assemblies and internal components.

POD Extension - FORK DRIVE (Models 49754 & 49756)

N/S = Not for Sale

Visuals show exploded views of POD Extension - Fork Drive components.

POD Extension - BLADE DRIVE (Models 49757 & 49759)

N/S = Not for Sale

Visuals show exploded views of POD Extension - Blade Drive components.

Contact Information

Liquid Controls
105 Albrecht Drive
Lake Bluff, IL 60044-2242
1.800.458.5262 • 847.295.1050
Fax: 847.295.1057
www.lcmeter.com

© 2003 Liquid Controls
Pub. No. 500003A (4/2014)

ISO 9001 and ISO 14001 certifications are noted.