Liquid Controls Pulse Output Device (POD)

Introduction

General Information

The Pulse Output Device (POD) converts the rotational movement of Liquid Controls Positive Displacement Meters into electronic pulses. This allows the meter to interface with a wide variety of electronic monitoring devices and control equipment. The POD operates in standard and bidirectional flow applications.

The POD attaches directly to the front cover of any Liquid Controls meter in place of the seal assembly. The meter's rotor motion for meter locking is magnetically coupled through a stainless steel wall to the POD's electronic housing. This eliminates the dynamic seal of the seal assembly and isolates the electronics from the meter's fluid process.

Within the electronic housing, a shaft-type optical encoder converts rotational motion into a high-resolution, dual-channel square wave. Both outputs are FET-driven and switch from zero voltage in the "ON" state to the user's supply voltage in the "OFF" state. As supplied from the factory, there is a 2.2K pull-up resistor on each output which can be removed in the field to produce a true "open collector" output. As open collector devices, the outputs can sink up to 100 mA in the "ON" state and withstand up to 30 VDC in the "OFF" state.

The electronic housing also serves as a conduit for the junction box. The POD has a threaded, O-Ring sealed cover. The standard wiring entry is a 1/2"-14 NPT female hub that accepts threaded conduit or cable connector. A removable, screw-type terminal block facilitates wiring of the unit to the circuit board. With the wiring entry sealed and the cover in place, the housing has a NEMA 4X rating for weather resistance.

POD Models

Five POD models are available:

• POD1: Fork-type mechanism with Buna-N O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD2: Fork-type mechanism with PTFE O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD3: Smooth-type mechanism with Buna-N O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD4: Smooth-type mechanism with PTFE O-Ring, 100 PPR Quad Pulser, 9 to 30VDC
• POD5: Fork-type mechanism with Buna-N O-Ring, 100 PPR Quad Pulser, 5 to 24VDC

Output Channel Resolutions

Output resolutions are provided for Series M & MA and Series MS meters.

Series M & MA

Series MS

If using both channels and the leading edge, multiply pulses per unit and maximum kHz by a factor of two. For RLC applications using both channels and the leading and trailing edges, multiply pulses per unit and maximum kHz by a factor of four.

Safety Procedures

General Safety Precautions

• Read and understand all instructions before use.
• Work must be performed by qualified personnel trained for the application, installation, and maintenance of the equipment and systems, adhering to all applicable codes and regulations.
• Always use appropriate Electrostatic Discharge (ESD) equipment when handling components and electronic boards, and follow proper procedures.
• Ensure all safety precautions have been taken.
• Provide adequate ventilation, temperature control, fire prevention and management, and evacuation plans.
• Ensure easy access for appropriate fire suppression personnel.
• Consult your local fire department and state/local codes for adequate preparation.
• Read this manual and any accompanying owner's literature.
• Keep these instructions for future reference.
• Failure to comply with these instructions may result in property damage, personal injury, or death from fire and/or explosion, or other risks associated with this type of equipment.

Observe National and Local Codes

North America

Installations must comply with the National Electrical Code (USA) or the Canadian Electrical Code for hazardous location ratings.

Outside North America

Installations must comply with EN 60079-14 for hazardous location ratings. Use only certified Ex d cable connectors. For ambient temperatures above 70°C, use field wiring rated for 20°C above the maximum ambient temperature.

⚠️ Explosion Risk

Replacing components may impair suitability for hazardous area applications.

⚠️ Explosion Risk

In hazardous locations, disconnect power before replacing or installing modules.

⚠️ Explosion Risk

DO NOT disconnect equipment unless power has been turned OFF or the area is non-hazardous.

Safe Evacuation of Piping System

⚠️ ATTENTION

Before disassembling any meter component or accessory:

• All internal pressures must be relieved and all liquid drained from the system according to all applicable procedures.
• Pressure must be at 0 (zero) psi.
• Close all liquid and vapor lines between the measured product and the liquid source.

Failure to comply with these instructions may result in property damage, personal injury, or death from fire and/or explosion, or other risks associated with this type of equipment.

Specifications

General

• Voltage: 9 to 30 VDC; POD5 is 5 VDC
• Maximum Supply Current: 50 mA
• Output Channel Resolution: 100 pulses per channel at each resolution, unscaled. Refer to table on page 4.
• Square Wave: Single channel output (Channel A or B); Quadrature channel output (Channel A and Channel B)
• Pulse Timing: Nominal 50% ON and 50% OFF
• Pulse Time Rise/Decay: <5 µs
• Output: Maximum 100 mA current sink in "ON" state; V+ supply @ 2.2 KΩ in "OFF" state. Optional FET Open Collector. FET (voltage generator collector) rating: 30 VDC maximum.
• Pulse Transmission Distance: 5,000 feet (1,524 meters)
• Pulse Output Fidelity: ISO 6551 Level A; API MPMS Section 5.5; Level A; OIML R117-1; Canada SVM-1 Measurement.

Construction Material

• Aluminum Alloy ADC12
• Powder Coat: Corro-Coat PE 74-141 Polyester

Cable Entry

1/2"-14 NPT

Operating Temperature Range

-40 to 176 °F (-40 to 80 °C)

Humidity Range

0-100% non-condensing

Shock

50 G for 10 ms

Vibration

1 G to 10-150 Hz

Electromagnetic Compatibility (EMI, RFI, etc.)

Lists various IEC standards for POD with PCB 84120 and 81999.

Dimensions

Front View Diagram Description: Shows a circular device with mounting holes, a conduit entry, and labels for dimensions (e.g., 3", 2.95", 0.65").

Lateral View Diagram Description: Shows a side profile of the device, indicating the conduit hub and overall length/depth dimensions (e.g., 3.29", 1.26").

Regulatory Compliance Markings

Liquid Controls company information and contact details are provided.

Various certification marks are displayed: UL Listed, CE, Ex markings (II 2 G Ex db IIB T6 Gb, temperature range, IP66), DNV, INMETRO.

EU Explosive Atmospheres Symbol

PRESAFE 18 ATEX 12438X and IECEx PRE 19.0072X: Explains compliance with ATEX Directive 2014/34/EU and IECEx Scheme. Details special conditions for use: use of certified Ex d cable glands/adapters, and field wiring requirements for ambient temperatures above 70°C.

Hazardous Location Ratings Explained

• II 2 G: Suitable for gas atmospheres.
• Ex db: Flameproof enclosure.
• IIB: Gas group including ethylene, propane, methane.
• T6: Temperature class (≤ 85°C).
• Gb: Equipment group.
• -40°C ≤ Tamb ≤ 80°C: Safe ambient temperature limits.
• IP66: Dust-tight and protected against powerful water jets.

CE 2460: Indicates conformity with European directives and the Notified Body (DNV) registration number.

CULUS LISTED: Listed by UL for explosion-proof products for use in Class I, Division 1 and 2, Groups C & D.

2P46: UL control number.

Type 4X: UL listing for indoor/outdoor use, protection against rain, splashing water, hose-directed water; not affected by icing; resists corrosion.

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

Installation

New Installations

When purchased with a flow meter, the POD is factory-installed and ready for wiring. Wiring instructions begin on page 10.

⚠️ ATTENTION: Internal Pressure Relief

All internal pressure must be relieved to zero before disassembling the filter, vapor eliminator, system valves, seal assembly, or front/rear covers. Improperly depressurized or evacuated systems can result in serious injury or death from fire or explosion.

Procedure for Releasing Internal Pressure (LPG and NH3 Meters)

• 1. Close the fill valve of the supply tank.
• 2. Close the vapor return line valve.
• 3. Close the manual feed line valve on the meter inlet side. If no manual valves are present, consult the truck manufacturer for system depressurization procedures.
• 4. Slowly open the valve/nozzle at the end of the feed line.
• 5. After product has drained, close the valve/nozzle at the end of the feed line.
• 6. Slowly break the fitting at the top of the differential valve to relieve product pressure in the system. Product will drain from the meter.
• 7. While product is draining from the differential valve, slowly reopen and close the valve/nozzle on the discharge line. Repeat until product stops draining from both the differential valve and the discharge line valve/nozzle.
• 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 its drain plugs.
• 3. Remove the mechanical counter, mechanical regulator, and regulator drive shaft from the front of the meter.
• 4. Some meters have a counter adapter bracket that is bolted on. If so, remove the bracket by removing its retaining screws. If the bracket is integral to the meter, it cannot be removed. In this case, one of the four POD Pulser Extensions will be needed.
• 5. Remove the seal assembly mounting screws. Pull the seal assembly out of the meter. If the O-Ring does not come out with the seal assembly, ensure it is removed from the seal assembly before installing the POD.

Diagram Description: Shows removal of seal assembly mounting screws and the removed seal assembly.

POD Installation

To install the POD into a flow meter:

• 1. Verify you have the correct POD Model by comparing the POD actuator terminal with the seal assembly actuator terminal removed in Step 5, Removing Existing Hardware, on Page 4. There are two types of seal assemblies/POD actuator terminals: smooth type and fork type. Smooth type seal assemblies must be replaced with smooth type PODs. Fork type seal assemblies must be replaced with fork type PODs.
• 2. Determine the desired orientation of the conduit hub. The hub can be positioned in one of eight possible orientations, as shown in the figure to the right. Meters with only two seal assembly mounting screws are limited to four orientations.
• Diagram Description: "Terminal Type Smooth (Left) and Terminal Type Fork (Right)" showing the two types of connectors.
• Diagram Description: "Recommended Orientations for POD Conduit Hub" showing various hub positions.
• Note on conduit hub orientation: When using a cable connector to seal the wire entry, any of the eight orientations can be used. However, when using conduit, the hub should be turned downward so that any accumulated moisture in the conduit drains away from the electronic POD.
• 3. Position the O-Ring onto the bottom of the POD, as shown to the right.
• 4. Align the fork-type or smooth-type actuator with the actuator mechanism on the meter and guide the POD into the opening in the meter cover. When properly aligned, the POD will seat until the mounting flange rests on the meter cover.
• 5. Rotate the POD to the desired position and align the mounting screws until snug. Using a 7/32" box wrench, tighten the screws and torque them to 21-25 inch-pounds.
• Diagram Description: Shows O-ring placement and alignment of fork-type terminal with mounting holes.

POD Extension Kits

If a POD Extension Kit is needed, it must be installed before the POD. Refer to Page 9.

POD Extension Kit Installation

The POD Extension is used when the meter has an integral bracket for the counter adapter or for high-temperature applications. The POD Extension is used to extend the connection beyond the meter. Four POD Extension models are available:

• 49754: POD1 or POD5, Fork-type mechanism with Buna-N O-Ring
• 49756: POD2, Fork-type mechanism with Teflon O-Ring
• 49757: POD1 or POD5, Smooth-type mechanism with Buna-N O-Ring
• 49759: POD2, Smooth-type mechanism with Teflon O-Ring

Once existing hardware is removed (Page 4), the POD Extension can be installed.

• 1. Verify you have the correct POD Extension Model by comparing the Extension's actuator terminal with the seal assembly actuator terminal removed in Step 5, Removing Existing Hardware, on Page 4. There are two types of Seal Assembly/Extension Actuator Terminals: smooth type and fork type. Smooth type seal assemblies must be replaced with smooth type POD Extensions. Fork type seal assemblies must be replaced with fork type POD Extensions.
• 2. Install the POD Extension using the two provided screws. There are two sets of holes on the POD Extension for these screws; one set is at 15/8" and the other is at 11/2". Align the holes with the meter to determine which set to use. Tighten the screws and torque them to 21-25 inch-pounds.
• 3. Once the POD Extension is positioned, the POD can be installed onto the POD Extension. Align the POD's Fork-type Terminal with the internal Actuator of the POD Extension. Use the two provided screws to mount the POD to the POD Extension using the threaded holes on the POD Extension. Using a 7/32" box wrench, tighten the screws and torque them to 21-25 inch-pounds.

Wiring

POD Wiring

WIRING CONDUIT SYSTEM

When wiring the POD, wires must enter through the POD's conduit hub. For explosion-proof systems (Class I, Div 1), wiring must be in rigid, explosion-proof conduit, or for high-vibration installations, use flexible, braided, explosion-proof conduit. The conduit must be secured by five (5) full threads into the POD's female hub to meet explosion-proof class requirements.

When installing in a Division 2 location, use rigid, flexible, or no conduit. If no conduit is used, the instrument cable must be brought into the POD's conduit hub using a cable connector to seal the wiring, to maintain the enclosure's NEMA 4X rating. Regardless of the connection type used, thread sealant must be applied to prevent moisture from entering the POD's electrical housing.

Observe National and Local Codes

North America

Installations must comply with the National Electrical Code (USA) or the Canadian Electrical Code for hazardous location ratings.

Outside North America

Installations must comply with EN 60079-14 for hazardous location ratings. Use only certified Ex d cable connectors. For ambient temperatures above 70°C, use field wiring rated for 20°C above the maximum ambient temperature.

WIRING

Multi-wire cable with overall shield is recommended for POD wiring. If individual wires are used, they must be in flexible metal conduit and not run with other wires and cables. Use individual wires between 16 and 20 AWG or shielded cables of no less than 22 AWG. Cables running up to 5000 feet (1524m) are possible, but for cables over 1000 feet (304.8m), use a smaller AWG cable to reduce IR voltage drop and capacitance between wires. Additionally, long-distance cables may require a lower pull-up resistor value due to additional cable capacitance that the pulser must drive. Cables with foil-backed plastic shielding with a drain wire are recommended over braided shielded cables, as they are easier to terminate than drain-wire type cables.

TERMINAL BLOCK

Removing the POD cover exposes a 4-position terminal block for connection to the user's electrical system. The terminal block can be unplugged from the board for easier wiring. Pull it up to remove.

Terminal block screws require a flat-blade screwdriver with a tip less than 1/8" wide. Before inserting wires into the terminal block, strip 1/4" of insulation from each wire. Turn each terminal screw counter-clockwise several times to ensure the wiring slot is fully open to accept the wire. Insert the stripped wire end and tighten the terminal screw. Plug the terminal block back into the board if it was removed. Ensure the four pins are in the correct orientation.

WIRING CONFIGURATIONS

Wiring configuration depends on system needs. Check electronic control input requirements to determine single-channel or quadrature channel output. The POD can be wired using only one of the two channels (Channel A or B) if the flow meter has flow in only one direction. To detect both forward and reverse flow, both channels, which are in quadrature to each other, can be used. Channel A leads Channel B by 90° in one flow direction, and Channel B leads Channel A in the reverse direction. Quadrature is required in most approved Weights & Measures installations.

CONVERSION FOR OPEN COLLECTOR OUTPUT

As supplied from the factory, the POD has a 2.2 KΩ pull-up resistor for positive supply to each transistor output. The unit can be field-modified to provide true Open Collector outputs if desired.

To modify the POD for Open Collector outputs:

• 1. Disconnect power to the unit and remove the cover by turning counter-clockwise.
• 2. Loosen the three circuit board mounting screws using a Phillips screwdriver. Remove the entire circuit board assembly from the POD housing.
• 3. With a small soldering iron tip, remove resistors R4 and R5.
• Diagram Description: Shows PCB layout with R4 and R5 resistors highlighted.
• 3a. Carefully apply heat to one of the resistor pads.
• 3b. When the solder melts, push the resistor out of the circuit board with the soldering iron tip.
• 3c. Remove the second resistor using the same method.
• 4. Reassemble the unit.

CHANNEL OUTPUT

The diagram below shows the voltage output for a clockwise rotation of the Pulse Output Device (POD) with Channel A leading Channel B. For reverse flow applications (counter-clockwise), Channel B leads Channel A.

Diagram Description: Shows a timing diagram with two channels (A and B) representing square wave outputs. Channel A leads Channel B by 90 degrees. Indicates "Clockwise Rotation of POD Voltage Output".

Wiring Diagrams

Single Channel Application (SP4000, SP3850, IT400)

Diagram Description: Shows a simplified wiring diagram for single-channel output, illustrating connections to Terminal J1 (POD) and terminals for SP4000, SP3850, IT400. Includes shielding, ground, DC common, pulse output A, and power supply connections.

Wiring Guide

• 1. Use metallic conduit with individual wires or use 3 conductor, shielded 22 AWG cables.
• 2. Strip 1/2" of the jacket. Remove the exposed shield and drain wire, then apply insulating tape.
• 3. Strip 1/4" of insulation from each conductor and connect to the terminal blocks.

Terminal Descriptions

Power Source Requirements

A 5A max isolation source and overvoltage protection device must be installed on the circuit voltage. If a 5A max isolation source and overvoltage protection device are not available, a Class 2 power source should be used.

Dual Channel Quadrature Application (LECTROCOUNT®, LCR®, LCR-II®, LC3, LCR 600)

Diagram Description: Shows a wiring diagram for dual-channel quadrature output, illustrating connections to Terminal J1 (POD) and terminals for LCR/LCR-II/LCR600 (J8) and LC3 (J3). Includes shielding, ground, DC common, pulse output A (quadrature), pulse output B, and power supply connections.

Terminal Descriptions

Parts List

POD Mountings

Diagram Description: Shows an exploded view of POD mounting hardware.

Internal POD Components

Diagram Description: Shows an exploded view of the internal components of the POD, with numbered parts corresponding to the table.

POD EXTENSION - FORK TYPE MECHANISM

MODELS 49754 & 49756

Diagram Description: Shows an exploded view of the POD Extension for Fork Type Mechanism.

N/S = Not Sold

POD EXTENSION - SMOOTH ACTUATOR

MODELS 49757 & 49759

Diagram Description: Shows an exploded view of the POD Extension for Smooth Actuator.

N/S = Not Sold

Further Information

For the latest publications in English, visit our website: www.lcmeter.com. Local distributors are responsible for providing the most current versions of manuals, instructions, and specification sheets in the requested language.