Liquid Controls POD1 User manual

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Table of Contents
Resources in this Guide .................................................................................................... 3
Publication Updates ........................................................................................................... 3
Safety Procedures .............................................................................................................. 4
General Information ........................................................................................................... 6
Specifications ..................................................................................................................... 9
Dimensions ....................................................................................................................... 10
Regulatory Compliance Tag Markings ............................................................................ 11
Bill of Materials ................................................................................................................ 13
Installation ........................................................................................................................ 15
POD Extension Kit Installation .................................................................................... 18
POD Wiring .................................................................................................................... 19
POD Wiring Schematics ............................................................................................... 22

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Pulse Output Device
Congratulations on ownership of a Liquid Controls Pulse Output Device. This manual provides
the technical details on installation, hardware, setup, operation, and regulatory information for
your meter.
Resources in this Guide
For convenience, you can easily download the PDF edition of this guide. Liquid Controls
recommends that you read through the introductory and safety information, and then proceed
to the Installation chapter.
NOTICE
This manual provides warnings and procedures that are intended to inform the owner and/or
operator of the hazards present when using the Liquid Controls Meter on LP gas and other
products. The reading of these warnings and the avoidance of such hazards is strictly in the
hands of the owner-operators of the equipment. Neglect of that responsibility is not within
the control of the manufacturer.
Publication Updates
The most current versions of all Liquid Controls publications are available on our web site,
www.LCmeter.com/resources/technical/manuals. If there are questions about the language or
interpretation of any LC manuals, instructions, or specification sheets, please first contact your
local distributor for help with your inquiry.
For service related issues that require further support from the Liquid Controls Service Team,
please call the number below.
Liquid Controls Corporate Office:
Phone: [phone]
Toll-free: 800 458 5262
Address: Liquid Controls LLC, 105 Albrecht Drive, Lake Bluff, IL 60044 USA
Website: www.LCmeter.com
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Safety Procedures
BE PREPARED
· Before using this product, read and understand the instructions.
· 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.
· When handling electronic components/boards, always use proper Electrostatic
Discharge (ESD)equipment and follow proper procedures.
· 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 appropriate fire extinguishers for your product.
· Consult with your local fire department, state, and local codes to ensure
adequate preparation.
· Read this manual and all the literature provided in your owner’s packet.
· Save these instructions for future reference.
· Failure to follow the instructions in this publication could result in, personal
injury, or death from fire and/or explosion, property damage, or other hazards
that may be associated with this type of equipment.
SAFELY EVACUATE PIPING SYSTEM
Before disassembly of any meter or accessory component: ALL INTERNAL
PRESSURES MUST BE RELIEVED AND ALL LIQUID DRAINED FROM THE
SYSTEM IN ACCORDANCE WITH ALL APPLICABLE PROCEDURES.
· Pressure must be 0 (zero) 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 from fire and/or explosion, or other hazards that may be
associated with this type of equipment.

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OBSERVE NATIONAL & LOCAL CODES
Power, input, and output (I/O) wiring must be in accordance with the area
classification for which it is used (Class I, Div 2). For North America, installations
must be per the U. S. National Electrical Code, NFPA 70, or the Canadian
Electrical Code in order to maintain Class I, Division 2 ratings. This may require
using connections or other adaptations in accordance with the requirements of the
authority having jurisdiction.
Peripheral equipment must be suitable for the hazardous location where it is
installed. (L'équipement périphérique doit être adapté à la zone dangereux où il est
installé.)
WARNING: Explosion Hazard
When in hazardous locations, turn power OFF before replacing or wiring modules.
(Lorsque dans des endroits dangereux, coupler le courant avant de remplacer ou
de câbler des modules.)
DO NOT disconnect equipment unless power has been switched OFF or the area
is known to be Non-Hazardous. (NE PAS déconnecter l'équipement san coupler
l'alimentation ou sans s'assurer que la zone est non dangereuse.)
WARNING: Use 3.5 in • lb (0.4 N • m) torque when tightening terminal block
screws.

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General Information
The Liquid Controls Pulse Output Device (POD) converts the rotary motion of the Liquid
Controls Positive Displacement Flowmeter 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.
Check Each Shipment
Before installation, check your shipment against the packing list and ensure that no parts are
missing. The packing list is inside the red information packet along with the Installation and
Operation Manuals.
The POD mounts directly to the front cover of any Liquid Controls meter in place of the
packing gland. The motion of the meter’s blocking rotor is magnetically coupled through a
stainless steel wall to the electronics compartment of the POD. This eliminates the dynamic
seal of the packing gland and isolates the electronics from the process fluid in the meter.
Inside the electronics compartment, an optical shaft encoder converts the rotary motion into a
high resolution, two-channel, quadrature square wave. Both outputs are driven by field effect
transistors (FETs) and switch from zero volts in the “ON” state to the power supply voltage in
the “OFF” state. As supplied from the factory, there is 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, the outputs can sink up to 100 mA in the “ON” state and sustain up to 30
VDC in the “OFF” state.
The electronics compartment also serves as a conduit junction box. The POD has an o-ring
sealed, threaded cover. The standard wire entrance is a ½-14 NPT female hub which accepts
threaded conduit or a cable gland. A screw-type, removable, terminal block on the circuit board
facilitates wiring of the unit. With the wiring entrance sealed and the cover in place, the
housing has a weatherproof rating of NEMA 4X.
POD Models
These are the available POD models:
· POD1 – Fork Drive with Buna-N O-Ring, 100 PPR Quad Pulser, 9 to 30VDC

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· 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 POD7 PPR Quad Pulser, 9 to 30VDC
· POD7 – BLADE DRIVE WITH EPDM O-RING, 100 PPR Quad Pulser, 9 to 30VDC

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Output Signal Resolutions
Approximate K-Factors and Volumetic Reference Data
When initially calibrating a specific meter model, the K-Factor (Pulses/Unit) values given below
are for reference only and are not to be used as a final K-Factor. NOTE: ll Liquid Controls
meter models listed below assume use of the 400ppr pulser with a 1:1 Packing Gland/Face
Gear ratio when calculating the Pulses/Unit. For 2:1 ratio, divide the Pulses/Unit by 2.

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Specifications
Voltage
· 9 to 30 VDC
· POD5 has a 5 VDC minimum but is not IECEx approved
Current Supply
maximum
· 50 mA
Output Signal
Resolution
· 100 pulses per channel per revolution, unscaled (see the Output
Signal Resolutions table in General Information )
Square Wave
· Single channel output – Channel A or channel B
· Quadrature channel output – Channel A and channel
Pulse Timing
· Nominal 50% on and 50% off
Rise/Fall Time of
Pulse
· < 5 µ s
Output
· Current sinking 100 mA maximum in “ON” state
· V+ supply @ 2.2 KΩ in “OFF” state.
· Optional open-drain FET (Field-Effect Transistor).
· FET rating (drain to source voltage) 30 VDC maximum
Pulse
Transmission
Distance
· 5,000 feet (1,524 meters)
Pulse Output
Fidelity
· ISO 6551 Level A
· API MPMS Chapter 5.5; Level A
· OIML R117-1
· Measurement Canada’s SVM-1
Materials of
Construction
· Aluminum Alloy ADC12
· Powder Coat: Corro-Coat PE 74-141 Polyester
Cable Entry
· ½"-14 NPT
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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 at 10-150 Hz
Electromagnetic
Compatibility
(EMI, RFI, etc.)
POD with PC Board 84120
· EU Directive 2004/108/EC
(EMC)
· IEC 61000-4-2
· IEC 61000-4-3
· IEC 61000-4-5
· IEC 61000-4-6
· IEC 61000-4-17
· IEC 61000-4-29
· IEC 61000-6-3
· ISO 7637-2
POD with PC Board 81999
· IEC 801 standard
Dimensions

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Regulatory Compliance Tag Markings
Explosive Atmospheres
· This equipment has been found to comply with the European Directive for Equipment For
Potentially Explosive Atmospheres 2014/34/EU (ATEX), and Certification Scheme for
Explosive Atmospheres of INTERNATIONAL ELECTROTECHNICAL COMMISSION
(IECEx). Evaluation was made in 2018 by DNV GL to the ATEX Directive with a certificate
number Presafe 18 ATEX 12438X and in 2011 to IECEx scheme with a certificate number
IECEx DNV 11.0012X, where X represents the following Special Conditions for Safe Use:
1) Only Ex d certified cable glands and thread adapters are to be used; and 2) For ambient
temperatures above 70 °C, use field wiring suitable for 20°C above maximum ambient
temperature.
· II – Suitable for use in surface (not mine) installations.
· 2G – High level of protection is provided against flammable gases, vapors, or liquids,
which may exist during normal operation.
· Ex d – Explosion protection is provided by a flameproof enclosure.
· T6
· Gb – Equipment group per IEC 60079-0 and EN 60079-0.
· Safe limits of ambient temperature.

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IP66
· Ingress protection: dust tight and protected against powerful water jetting.
CE 2460
Indicates conformity with all applicable Directives for products sold within the European
Economic Area.
Type 4X
· The enclosure has been evaluated by UL for outdoor use to provide protection against
water and dust and an increased level of protection against corrosion; and that will be
undamaged by the external formation of ice.
UL
Listed by UL to both the Canadian and US requirements for explosion proof products intended
for use in Class I, Division 1 & 2, Groups C & D environments as classified by the US and/or
Canadian Electrical Code.
2P46
UL listing control number issued to Liquid Controls.
DNV 12.0091 X
Explosive atmosphere certification for Brazil (INMETRO).
CCE ID NO. P318018/1
Explosive atmosphere certification for India.

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Bill of Materials

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Installation
POD Installation
New Installations
When ordered with the flowmeter, the POD comes factory
installed on the meter and ready for wiring. Wiring instructions
begins on page 10.
RELIEVING INTERNAL PRESSURE
All internal pressure must be relieved to zero pressure before disassembly or
inspection of the strainer, vapor 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 in
performing maintenance on an improperly depressurized and
evacuated system.
Strictly follow this procedure Relieving Internal Pressure Procedure 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 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.
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.

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Retrofit Installations
Follow these procedures to remove the existing hardware:
1. Relieve the pressure from the process piping to the
meter.
2. Drain the meter by opening the meter’s drain plugs.
NOTE 1: Meters with only two packing gland
mounting screws are limited to four orientations.
NOTE 2: When using a cable gland to seal the wire
entrance, any of the eight orientations can be used.
However, when using conduit, the hub should face
down so moisture that may accumulate in the
conduit will drain away from the POD electronics.
3. Remove the mechanical counter, adjuster, and
adjuster drive shaft from the front of the meter.
4. Some meters have a counter adapter bracket which
is bolted on. If this is the case, remove the counter
bracket by removing the bolts that hold it in place. If
the counter adapter bracket is integral to the meter,
it cannot be removed. In this case, one of four POD
Pulser Extensions will be required.
1. Remove the packing gland mounting screws. Pull the packing gland out of the meter. If
the O-Ring does not come out with the packing gland, be sure to remove it from the
packing gland well before installing the POD.

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Installing the POD
POD Extension Kits
If a POD Extension Kit is necessary, it must be installed prior to installation of the POD. See
POD Extension Kit Installation .
Follow these steps to install the POD onto a flowmeter:
1. Verify that the proper POD Model was
obtained by comparing the driver tang on
the POD to the driver tang on the
packing gland that was removed in Step
5 of the Retrofit Installations section
above. There are two types of packing
gland/POD driver tangs: blade type and
fork type. Blade type packing glands
must be replaced with blade type PODs.
Fork type packing glands 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.
3. Position the O-Ring over the bottom of
the POD as shown to the right.
4. Align the fork style or blade style driver
with the drive mechanism in the meter
and guide the POD into the opening in
the meter cover. When properly aligned,
the POD will go in until its mounting
flange abuts the meter cover.
5. Rotate the POD to the desired
orientation and thread in the mounting
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box end wrench, tighten the screws and
torque them to 21-25 inch-pounds.
POD Extension Kit Installation
The POD Extension is used when the meter has an
integral counter adapter bracket or for high temperature
applications. The POD Extension is used to extend the
connection away from the meter.
There are four POD Extension models 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
· 49759 POD2 – Blade Drive with Teflon O-Ring
Once the existing hardware has been removed as described in the Retrofit Installations
section of the Installation topic above, the POD Extension can be installed.
NOTE: Regardless of the POD Extension being used, the POD Pulser must be a FORK drive
pulser.
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Follow these steps to install the POD Extension:
1. Verify that the proper POD Extension Model was
obtained by comparing the driver tang on the POD
Extension to the driver tang on the packing gland
that was removed in Step 5 of the Retrofit
Installations section of the Installation topic
above. There are two types of Packing Gland/POD
Extension driver tangs: blade type and fork type.
Blade type packing glands must be replaced with
blade type POD Extensions. Fork type packing
glands must be replaced with fork type POD
Extensions.
2. Install the POD Extension using the two screws
provided. There are two sets of holes in the POD
and the other is 1½" apart. Line up 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 in place, the POD may
be installed onto the POD Extension. Align the
POD Fork Tang with the internal POD Extension
Driver. Use the two screws provided to mount the
POD to the POD Extension using two of the tapped
wrench, tighten the screws and torque them to 21-
25 inch-pounds.
POD Wiring
WIRING CONDUIT SYSTEM
When wiring the POD, the wires must enter through the POD’s conduit hub. For explosion-
proof rated systems (Class I, Div 1), the wiring must be in explosion-proof rated rigid conduit,
or–for high vibration installations–explosion-proof rated braided flexible conduit. The conduit
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must be engaged five (5) full threads into the female hub on the POD to meet explosion proof
requirements.
When installing in a Division 2 location, use either rigid conduit, flexible conduit, or no conduit.
When no conduit is used, the instrument cable must be brought into the POD conduit hub
using a cable gland to seal the wiring to maintain the Enclosure NEMA 4X rating. Regardless
of the type of connection used, thread sealant should be applied to prevent moisture from
getting into the POD electrical housing.
OBSERVE NATIONAL & LOCAL CODES
North America – Installations must be in full accordance with the National
Electrical Code (US) or the Canadian Electrical Code respectively to maintain the
hazardous location ratings on the product.
Outside of North America – Installations must be in full accordance with EN
60079-14 to maintain the hazardous location ratings on the product. Use Ex d
certified cable glands only. For ambient temperatures above 70ºC, use field
wiring rated 20ºC above the maximum ambient temperature.
WIRING CABLE
Multi-wire cable with an overall shield is recommended for POD wiring. If individual wires are
used, they must be in a flexible metal conduit and must not be run with any other cables or
wires. Use individual 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, however cable runs over 1,000 ft (304.8 m)
should use lower AWG wire to reduce the IR voltage drop and the inter-wire capacitance. In
addition, long runs may require a lower value pull-up resistor (due to the additional cable
capacitance that the pulser must drive). Cable that has a metalized foil plastic shield with a
drain wire is recommended over cable with woven shields because it is easier to terminate the
drain wire type cable.
TERMINAL BLOCK
Removing the cover of the POD will expose a 4–position terminal block for connection to an
electrical system. The terminal block can be unplugged from the board for ease of wiring. Pull
it straight up to remove.