TCS 700-30 Owner's manual

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Installation, Operation &
Maintenance Manual
700-30/35
RotaryMeter

Page 2
Table of Contents
Warning Symbols
CAUTION
Follow the warning instructions within the fol-
lowing information to avoid equipment failure,
personal injury or death.
TURN POWER OFF
Before performing any maintenance, be sure to
turn system power off to avoid any potential
electric spark
FLAMMABLE
Flammable liquids and their vapors may cause a
fire or explosion if ignited.
EYE PROTECTION
Pressurized systems may cause hazardous leaks
and spray that may be dangerous for your eyes.
Always wear eye protection around pressurized
systems and its hazardous liquids.
INJURY
Wear gloves for protection from hazardous liq-
uids that may cause irritation or burns.
READ
Read and understand all related manuals thor-
oughly. The Engineering and OIM manuals will
provide the knowledge for all systems, mainte-
nance and operation procedures. If you have any
questions, please consult the factory.
Safety Warning Symbols 2
Receipt & Inspection 3
Notice 3
Meter Overview 4
Meter Specifications 5
Meter Types 5
Material of Construction 6
System Recommendations 6
System Recommendations (Continued) 7
System Recommendations (Continued) 8
Above Ground Storage System 9
Mobile Fueling System 10
Start Up Recommendations 11
Start Up Recommendations (Continued) 12
Direction of Flow 12
Meter Calibration 13
Meter Calibration (Continued) 14
Meter Calibration (Continued) 15
Calibration Adjustment 15
Split Compartment Testing 16
Split Compartment Testing (Continued) 17
Split Compartment Testing (Continued) 18
Maintenance 19
Maintenance (Continued) 20
Storage Instructions 20
Dimensions 21
Meter Assembly 22
Meter Assembly (Continued) 23
Air Eliminator Assembly 24
Air Eliminator Assembly (Continued) 25
Strainer Assembly 26
High Volume Strainer Assembly 27
Hydraulic Preset Valve Assembly 28
Hydraulic Preset Valve Assembly (Continued) 29
Air Check Valve Assembly 30
Back Pressure Check Valve Assembly 31
Torque Specifications 32
Drive Components 33
Disassembly of Meter 34
Disassembly of Meter (Continued) 35
Disassembly of Meter (Continued) 36
Inspection of Parts 37
Reassembly of Meter 38
Reassembly of Meter (Continued) 39
Reassembly of Meter (Continued) 40
Reassembly of Meter (Continued) 41
Disassembly of Strainer 42
Reassembly of Strainer 42
Disassembly of Air Eliminator 43
Reassembly of Air Eliminator 43
Disassembly of Hydraulic Preset Valve 44
Disassembly of Hydraulic Preset Valve (Continued) 45
Reassembly of Hydraulic Preset Valve 45
Disassembly of Air Check Valve 46
Reassembly of Air Check Valve 46
Meter Trouble Shooting 47
Air Eliminator Trouble Shooting 48
Hydraulic Preset Valve Trouble Shooting 49
Air Check Valve Trouble Shooting 49
Material Safety Data Sheet 50
MSDS (Continued) 51
MSDS (Continued) 52
MSDS (Continued) 53
Notes 54
Warranty 55

Page 3
Receipt & Inspection
Upon receipt of meter shipment, be sure to inspect the packaging and the flow meter assembly for any damage
before signing the receipt of the shipment. Notify the delivery company about possible damage and refuse re-
ceipt of the shipment.
Meters are individually boxed and are protected with packing material. Each package
is identified with the flow meter assembly part number, description, direction of flow
and serial number. Verify the meter model is the correct model, size, and configuration
as ordered. Contact your distributor if there is any discrepancy or question.
Meter assemblies should be handled with appropriate methods for the awkwardness of
size and weight involved. Appropriate clothing and shoes need to be utilized. Trans-
port the meter package to the installation site with appropriate transportation methods,
careful not to damage the flow meter.
Be careful of any loose or protruding staples from the packaging, as they can be very
sharp and may potentially cause injury.
If foam has been used to protect meter, carefully remove top foam layer before attempting to remove meter as-
sembly from box. Foam packaging maybe formed around the meter assembly making it difficult to remove. If
meter is bolted upon a wood pallet remove bolts while being careful not to let the meter tip over when the sup-
port has been removed. Do not lift the meter assembly by flex hoses, thermowells, wires, pulsers, or put objects
through meter. Removing meter assembly from packaging without adhering these warnings may cause serious
injury.
The wooden pallets and bases meet the ISPM 15; Guidelines for Regulating Wood Packaging Material in Inter-
national Trade through the Timber Products Inspection Company (TP #2134).
Every effort has been made to remove the calibration fluid before shipment. All TCS flow meters are plugged
and enclosed in a plastic bag. A Material Safety Data Sheet (MSDS) can be reviewed on PAGE 50. Appropri-
ate precautions should be taken regarding any personal, environmental and material compatibility with the end
use system.
Notice
Total Control Systems (TCS) shall not be liable for technical or editorial errors in this manual or omissions from
this manual. TCS makes no warranties, express or implied, including the implied warranties of merchantability and
fitness for a particular purpose with respect to this manual and, in no event, shall TCS be liable for special or conse-
quential damages including, but not limited to, loss of production, loss of profits, etc.
The contents of this publication are presented for informational purposes only, and while every effort has been
made to ensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, re-
garding the products or services described herein or their use or applicability. We reserve the right to modify or im-
prove the designs or specifications of such products at any time.
TCS does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper
selection, use and maintenance of any TCS product remains solely with the purchaser and end-user.
All rights reserved. No part of this work may be reproduced or copied in any form or by any means – graphic,
electronic or mechanical –without first receiving the written permission of Total Control Systems, Fort Wayne,
Indiana USA.
Flow Meter Identification Plate

Page 4
Meter Overview
The TCS Model 700 series flow meter is a simple and
efficient design. The meter consists of a single fluid
chamber that contains a single blocking rotor and two
displacement rotors whose rotation is synchronized
with mating gears. As the fluid enters the fluid cham-
ber, the blocking rotor is forced to rotate. The dis-
placement rotors, also rotating in conjunction with the
blocking rotor help direct the fluid flow through the
chamber and to the outlet. The linear flow of the fluid
is thus translated into rotary motion in the meter. The
output of the meter is picked up from the rotation of
the blocking rotor and transmitted to a register or
pulse transmitter.
The rotors in the meter are designed to operate at close tolerances to one another and the
wall of the fluid chamber. There are slight clearances between the rotors and the chamber
wall. Because of this, it is important that the meter be properly applied for the flow rate
and operating pressure of the system.
Because the fluid flowing through the meter is redirected only slightly from its natural
flow, there is very little pressure drop across the meter, unlike other meters that use multi-
ple measuring chambers.
The meter design uses high performance materials for the rotor bearings and journals.
Since there is no contact between the rotors and the fluid chamber wall, these critical com-
ponents have a long life expectancy.
Calibration of the meter involves adjusting the rotation of the output shaft relative to the
rotation of the internal rotors of the meter. This is accomplished by changing the settings
on an adjuster device. Calibration of the meter is discussed in detail in the section Meter
Calibration.
FLOW ILLUSTRATION

Page 5
Meter Specifications
Flange Connection: 3” NPT Flange Connection, 2” NPT Flange. Optional BSPT,
Slip Weld or ANSI flanges available upon request.
Flow Rate: 700-30 up to 200 GPM (760 LPM)
700-35 up to 300 GPM (1135 LPM); only for fluids under 225 SSU
Maximum Pressure: 150 PSI (10.5 BAR)
Working Temperature: -20 F to 160 F (-28.9 C to 71 C)
Meter Types
SP -Standard Petroleum
For metering refined petroleum products such as
Leaded and Unleaded Gasoline, Fuel Oils, Die-
sel, Bio-Diesel, Kerosene, Jet Fuels, Vegetable
Oils, Motor Oils, Ethylene Glycol (Antifreeze),
etc.
SPA -Standard Petroleum (Aviation)
For metering refined petroleum products such as
Aviation Gasoline, Fuel Oils, Jet Fuels, Gaso-
line, Diesel, Bio-Diesel, Kerosene, etc.
SPD -Standard Petroleum (Ductile Iron)
For metering refined petroleum products such as
Aviation Gasoline, Ethanol Blends, Methanol
Blends, Gasoline, Fuels Oils, Diesel, Bio-Diesel,
Kerosene, etc.
IC -Industrial Products (Carbon Bearings)
For metering Industrial Chemicals, General
Solvents, Water and other Non-lubricating
Liquids, such as Alcohol, Acetones, Ethanol,
Naptha, Xylene, MEK, Toluene, Deionized
Water, Demineralized Water, Potable Water,
etc.
IP -Industrial Products
For metering Industrial Chemicals, General
Solvents and many other liquids; such as Liquid
Sugars, Corn Syrup, Soy Bean Oil, Shortenings,
Latex Products, Adhesives, etc.
AF -All Ferrous
For metering Pesticides, Nitrogen Solutions,
Fertilizer, Chlorinated Solvents, Paints, Inks,
Alcohols, Adhesives, Motor Oils, Molasses,
Corn Syrup, Liquid Sugars, etc.

Viton®is a registered trademark of E.I. Dupont de Nemours & Co.
Simriz®is a registered trademark of Freudenberg-NOK.
Teflon®is a registered trademark of Dupont Dow Elastomers, L.L.C.
Page 6
Material of Construction
Description SP SPA SPD IP IC AF
Housing Hardcoat Anodized
Aluminum
Hardcoat
Anodized
Aluminum Ductile Iron Hardcoat
Anodized
Aluminum
Hardcoat
Anodized
Aluminum Ductile Iron
Rotors Hardcoat Anodized
Aluminum
Hardcoat
Anodized
Aluminum Ni-Resist Hardcoat
Anodized
Aluminum
Hardcoat
Anodized
Aluminum Ni-Resist
Rotor
Journals Plated SS Plated SS Plated SS Plated SS Plated SS Plated SS
Bearing Plates Ni-Resist Ni-Resist Ni-Resist Stainless
Steel Ni-Resist Ni-Resist
Bearing
Sleeves Ni-Resist Carbon Graphite Carbon Graphite Non-Galling SS Carbon Graphite Carbon Graphite
Timing Gears Stainless
Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
Packing Seal Viton® Viton® Simriz® Simriz® Simriz® Simriz®
Body
O-rings Viton® Viton® Teflon® Teflon® Teflon® Teflon®
Meter Selection
The flow meter must be carefully chosen from the Meter Selection factors in the Engineering Manual.
The meter must be selected based on the operating system and product characteristics. System variables
include flow rate, temperature and pressure. The product characteristics include the material compatibil-
ity, lubricity, viscosity, suspensions, pH, and whether the product can congeal, crystallize or leave a dry
film. Failure to select the correct flow meter may result in system failure or serious injury.
Air Elimination
In any system that the tank may be completely drained or multiple products manifold into one metering
system, the possibility of air being present increases. The solution is an air or vapor eliminator located
before the flow meter to vent the air or vapor from the system before it can be measured. Air or vapor
elimination is required for all weights and measures regulatory approvals in custody transfer applications.
System Recommendations

Page 7
System Recommendations (Continued)
Control Valves
Safety and isolation valves should be used throughout the metering system. In any pumping system where
there is one (1) pump and multiple flow meters, a digital or hydro-mechanical Rate-of-Flow control valve
must be used at each flow meter to prevent over speeding of the flow meters.
Best Plumbing Configuration
1). Flow meter must have secure mounting to a riser or foundation
2). The inlet and outlet piping must be securely supported, in a manner of not to allow pipe stress on flow
meter.
3). System should be designed to keep the flow meter full of liquid at all times.
4). System piping should have full 3” pipe diameter throughout the metering system to allow for minimal
pressure loss.
5). The pipe should be laid out as straight as possible to reduce pressure loss from flow restriction.
6). The meter and piping must be installed in such as way as to avoid accidental draining of the meter.
Meter inlet and outlet should be lower than the associated system plumbing (sump position).
7). It is not necessary for the air eliminator to be installed bolted directly to the meter. It can be installed
upstream from the meter. For effective operation of the air eliminator, it should be mounted between
the meter and any valves, tees or any other potential places where air may enter the system.
8). The metering system should include a means for calibration.
Protection From Debris
On new installations, care must be taken to protect the meter from damage during start-up. It is recom-
mended to put a strainer before the meter. Damage may result from the passage through the meter of dirt,
sand, welding slag or spatter, thread cuttings, rust, etc. The insertion of a spool (a flanged length of pipe
equal in length to the meter and accessories attached to the meter) in place of the meter until the system is
flushed, temporarily bypassing the plumbing around the meter, will also protect the meter from debris.
Once the system has run “clean” for a period of time the meter may be reinstalled or protective devices
removed.
Thermal Expansion
As with most liquids, they will expand and contract with temperature. In any system where there is a
chance for liquid to be captured between closed valves without relief, thermal expansion will likely occur
and create dangerously high pressures within the system. Care should be taken in designing the system in
which thermal shock may occur by implementing Pressure Relief Valves or Thermal Expansion Joints in
the system design.
When product is trapped within the system, the pressure will increase by 126 PSI (8.69 BAR) for every
one (1) temperature degree increase.

Page 8
Thermal Shock
The system operating temperature will expand or contract the metals within the flow meter. For systems that have
sudden or immediate temperature increases of 68 F (20 C) degrees or more, will require clearance rotors.
Clearance rotors will be necessary to eliminate the effect of immediate expansion of the rotors vs. meter
body, caused by thermal shock.
Hydraulic Shock (Water Hammer)
Hydraulic shock is a rise in pressure, which happens when an operating system has immediate change in
direction of flow such as a fast valve closure at a high operating flow rate. Hydraulic shock can damage
any item in the way of the product flow such as internal parts of the meter, valves, and pump. System de-
sign and improper operating procedures will elevate this problem. The use of 2-stage preset control
valves or surge suppressing bladders or risers will help reduce or eliminate this problem.
To compute the shock pressure when a valve is closed quickly (recommended to be less than 6 PSI):
Shock Pressure (PSI) = 63 x Velocity (FPS)
In order to eliminate hydraulic shock, you need to slow down the valve closure rate. The time required to
close the valve so that the line pressure will not exceed the normal pressure at no flow is:
Time (seconds) = 0.027 x L x V
N –F
V=Velocity in Feet/Seconds
L=Length of pipe before the valve in feet
N=Line pressure at no flow
F=Line pressure at full flow
Products that Dry/Congeal/Crystallize
There are many liquids that crystallize, harden and/or solidify on contact with air or with an increase in
temperature. A proper system design and a good understanding of the product being measured will help
to avoid the possibility of air entering into the system and the product being affected.
Calibration
The meter shall be tested and calibrated with the product it is intended to measure when installed. Total
Control Systems shall not be responsible for loss of product or any damages resulting from the end user’s
failure to test this meter to insure proper calibration. Every 700 series meter is tested and calibrated at the
factory to prove it is calibratable in your system. It is the owner’s responsibility to report this device to
the local Weights and Measures officials for their inspection before the meter is put to use.
System Recommendations (Continued)

Page 9

Page 10

Page 11
Start up Recommendations
Start-up instruction for new installations or after maintenance and repairs:
1). Only properly trained personal should design, install, or operate metering system.
2). Remove plastic threaded plugs placed in meter for shipping protection. They are not to be used in
meter system because of the PVC plugs low rated pressure, compatibility, and sealing issues.
3). Place the meter in an area with ample workspace, secure from vibration, and pipe line stress. Mount
and bolt down on to a fixed stand or platform. This prevents meter stress, which will cause leakage
and metal fatigue.
4). Apply thread sealing compound and gasket materials that are compatible with product.
5). Do not weld to meter or accessories. This will weaken housings and cause o-ring and casting leaks
and potentially distort the critical tolerances within the flow meter.
6). Always wear personal safety protection equipment such as goggles, steel toed shoes, gloves and full
body clothing.
7). Be sure to install a pressure relief valve or expansion joint in the system to protect against thermal
expansion.
8). Make sure all system components are properly secured and tightened.
9). All meter assembly bolts and connections are tight.
10). Air eliminator vapor release is properly vented and piped into a reservoir container or back to the
supply tank.
11). Electrical connections are properly installed and start/stop switches are off and locked-out.
12). Flooded suction to the Pump. Fluid is available to system and will not starve or cavitate pump.
13). Slow flooding of system
Start up system with all shut off valves in the closed position. When a pump is turned on and a
valve opened in a new, dry system, tremendous liquid and air pressure can be built up in the piping
and forced through the meter. The high pressure and volume of air causes the meter to operate more
quickly than normal. When product reaches the meter, there is an abrupt slowing of the meter rotors,
which could cause damage to the register, rotor shafts, packing gear and/or blade, timing gears and
other components. The recommended method of starting any system is to flood the piping gradually.
This allows product to slowly force the air from the entire system.
¡WARNING!
Test equipment should be grounded to prevent a possible spark. Test area should have no ignition source. Operators should
wear personal protection and prevent any product exposure and environmental issues.

Page 12
Start-Up Recommendations (CONTINUED)
Direction of Flow
The meter is set up at the factory for left to right flow. To change the meter to right to left flow, begin
by removing the screws (#9 on the Meter Assembly Breakdown) and the adjuster cover plate (#7) on the
front of the meter. Remove both the screws (#1), the drive shaft retainer (#10), the drive shaft (#3), the
e-ring (#4) and the face gear (#5). Reinstall the gear on the shaft with the gear teeth facing up. Snap the
e-ring back into place to hold the gear in place. Reinstall the shaft, mating the face gear with the drive
gear of the packing capsule assembly. Reinstall the screw and cover plate. The meter will now be set
up for right to left flow. See Page for a parts breakdown of entire meter assembly.
15). When operating the meter with accessories, valves should be opened slowly to avoid a pressure
surge that can damage the meter or air eliminator. System pressures should be maintained below
70 PSI (4.9 BAR).
16). Custody transfer metering systems must be calibrated by a regulatory agency before product can
be sold off the meter. Contact your local authorities for proper calibration.
17). Strainers should be cleaned frequently or have a maintenance schedule. This will ensure a clean
system and long service life.

Page 13
Meter Calibration
The method of proving should be selected, and necessary provisions made, during the design stage of the
installation. Of the most common used systems, portable provers have the advantage of more closely re-
producing the condition under which the product is normally delivered.
Use Accurate Prover
Scientifically designed provers are commercially available for proving meters, and no other kind should
be used. Even scientifically designed provers should be checked periodically for accuracy. Weights and
Measures officials have been very cooperative in giving assistance to checking privately owned volumet-
ric provers.
Recommended size of test measure:
The prover capacity should be equal to at least one minute’s flow through the meter at its maximum rate.
These provers are not merely truck compartments or drums, but are scientifically designed test measures,
having proper drainage means built into them, a calibration gauge glass neck, and protection against de-
formation (which causes volume changes).
A “homemade” prover, whether a drum or a tank is not likely to be satisfactory, and may cause expensive
errors due to inaccurate meter calibration.
Setting a Prover
The prover should be set level, using the levels provided on the prover, or separate ones. This insures con-
sistent results when moving the prover from meter to meter.
Where to Test a Meter
The best place to test is in its normal operating position, instead of a test stand. In this way, the correct-
ness of the installation and of the operation conditions will be verified by the test. Always test a meter
with the same liquid it is to measure, because a difference in viscosity, temperature and system plumbing
slightly affects meter accuracy.
Discharge Line from Meter
Where a portable prover is used, the liquid is generally discharged in to the prover in the same manner, as
a normal delivery would be made. Where a special test connection is used, the discharge line must be ar-
ranged to drain to the same point on each test. The meter flow rate and off/on is controlled at the end of
the discharge line.
Wetting the Prover
Reset the meter register to zero, and fill the prover to the zero or 100% marking of the scale. Disregard
the meter reading. Drain the prover, and reset the register. The reason for disregarding the first meter
reading is that the prover must be wetted, as its calibrated capacity is determined on its wet measure ca-
pacity by its manufacturer, and because the prover will be wet for the subsequent tests to be run.

Page 14
Meter Calibration (Continued)
After the prover has drained, allow a definitive time of a few minutes for drainage from the sides of the
tank. Total drainage time should be the same between all tests to insure uniform results. If a considerable
length of time is to elapse between tests, the wetting operation can be eliminated by allowing the prover to
remain full until the next test is to be run.
Making the Tests
The setup is now ready for accuracy the test. Reset the register to zero, and run the required test through
the meter. Do not exceed the maximum recommended rate of flow for the meter. Maximum and minimum
recommended rates of flow for various sizes and types of 700 series meters are marked on their identifica-
tion plates and maintenance manuals.
Determining Test Results
Run the meter to the mark on the dial corresponding to the prover capacity, and read the over or under de-
livery in cubic inches or percent on the calibrated plate on the neck of the prover. If the plate is calibrated
in cubic inches, the percentage error can readily be computed on the following basis:
(a) One gallon equals 231cu.in.
(b) A 100-gallon prover holds 23,100cu.in. Therefore, 23.1cu.in. represents 0.1% error.
The National Institute of Standards and Technology, in its NIST Handbook 44 specifies a tolerance of
plus or minus the following:
METER TOLERANCE
Acceptance tolerances apply to new meters and repaired meters after reconditioning.
Repeatability
When multiple tests are conducted at approximately the same flow rate and draft size, the range of test re-
sults for the flow rate shall not exceed 40% of the absolute value of the maintenance/normal tolerance and
the results of each test shall be within the applicable tolerance.
Changing Meter Calibration
Refer to meter literature for method of changing meter calibration. Any change in the meter calibration
adjustment will change the delivery in the same amount for all rates of flow. That is, the calibration curve
retains its shape, but is moved up or down. Therefore, if a meter tests satisfactorily at full flow, but drops
off too much at low flow, changing the calibration will not remedy this condition; it will bring the low
flow test to 100%, but it will also bring the full flow above 100% by the same amount that the low flow
was raised. A condition of this kind is caused either by the metering system, need for meter cleaning or
repairs, or because of an attempt to retain accuracy below the minimum recommended rate of flow for the
meter.
Indication of Device Acceptance Test Maintenance Test Special Test
Wholesale 0.2% 0.3% 0.5%
Vehicle 0.15% 0.3% 0.45%
Tolerance

Meter Calibration (Continued)
One complete turn of the adjuster barrel is equal to 1 gallon in 100 gallons or 1% of de-
livered volume. The adjuster body will show divisions of 1%, while the adjuster barrel
has divisions of 0.02%.
For volumes other than 100 gallons, the following formula may be used to calculate the
Adjuster percent to increase or decrease prover volume.
Volume on Prover minus Volume on Meter Counter
Volume on Meter Counter
Page 15
Calibration Adjustment
Temperature Correction
If the conditions of testing are such that there will be a change of more than a few degrees in the tempera-
ture of the liquids between the time it passes through the meter and the time the prover is read, it will be
advisable to make a temperature correction to the prover readings. To do this, it is necessary to install
thermowells; to take readings of the temperature of the liquids in the meter and in the prover; and to take
the degrees API of the liquid. Corrections can then be easily made by the use of the National Standard
API Tables.

Page 16
Split Compartment Test
Purpose: A product depletion test verifies the proper operation of air elimination when the storage tank for
the product being measured is pumped dry. This test is necessary for meters that may drain a tank com-
pletely, such as a vehicle tank meter.
Multiple-Compartment Test Procedure:
1). Begin the test from a compartment (ideally the largest compartment) containing an amount of fuel
equal to or less than one-half the nominal capacity of the prover being used. Operate the meter at the
normal full flow rate until the compartment is empty. There are several methods for determining that
the compartment is empty. There may be a significant change in the sound of the pump. There may
be visual evidence that the compartment has run dry. The meter may stop entirely or may begin to
move in jumps (pause, resume running, then pause, then run again.)
2). Continue the test until the meter indication stops entirely for at least 10 seconds. If the meter stops
for 10 seconds or more, proceed to step 3. If the meter indication fails to stop entirely for a period of
10 seconds, continue to operate the system for 3 minutes.
3). Close the valve from the empty compartment, and if top filling, then close the nozzle or valve at the
end of the delivery hose. Open the valve from another compartment containing the same product.
Carefully open the valve at the end of the delivery hose. Pockets of vapor or air may cause product to
splash out of the prover. The test results may not be valid if product is splashed out of prover.
Appropriate attire and protection is required, but caution is still necessary.
4). Continue delivering product at the normal full flow rate until the liquid level in the power reaches the
nominal capacity of the prover.
5). Close the delivery nozzle or valve, stop the meter. Allow any foam to settle, then read the prover
sight gauge.
6). Compare the meter indication with the actual delivered volume in the prover.
7). Calculate the meter error, apply Product Depletion test tolerance, and determine whether or not the
meter error is acceptable. Reference the NIST Handbook 44 for further information.

Page 17
Split Compartment Test (Continued)
Single Compartment Test Procedure:
The test of single-compartment tanks is easier to accomplish if there is a quick-connect hose coupling be-
tween the compartment valve and the pump that supplies product to the meter. If the system does not have
quick-connect couplings between the compartment and the meter, an additional source of sufficient prod-
uct at the test site is required.
Without a quick-connect coupling:
1). Begin the tests with the compartment containing an amount of fuel equal to or less than one-half the
nominal capacity of the prover being used. Operate the meter at the normal full flow rate until the
supply tank is empty. There are several methods for determining that the tank is empty. There may
be significant change in the sound of the pump. Someone may visually watch for the tank to run dry.
The meter may stop entirely or may begin to move in jumps (pause, resume running, the pause, then
run again).
2). Continue the test until the meter indication stop entirely for at east 10 seconds. If the meter stops for
at least 10 seconds, proceed to step 3. If the meter indication fails to stop entirely for at least 10
seconds, continue to operate the system for 3 minutes.
3). Close the compartment valve and the delivery nozzle or valve if top filling. Stop the pump and load
sufficient product from the alternate source into the supply compartment for the meter being tested.
Allow the product to stand in the compartment for a brief time to allow entrained vapor or air to
escape.
4). Open the compartment valve and restart the pump without pump resetting the meter to zero. Care
fully open the nozzle of valve at the end of the delivery hose. Pockets of vapor or air may cause
product to splash out of the prover. The test results may not be valid if product is splashed out of the
prover. Appropriate attire and protection is required, but caution is still necessary.
5). Continue delivery of product at the normal full flow rate until the liquid level in the prover reached
the nominal capacity of the prover.
6). Close the delivery nozzle or valve, stop the meter, and allow any foam to settle, then read prover
sight gauge.
7). Compare the meter indication with the actual delivered volume in the prover.
8). Calculate the meter error, apply Product Depletion test tolerance, and determine whether or not the
meter error is acceptable. Reference the NIST Handbook 44 for further information.

Page 18
Split Compartment Test (Continued)
With a quick-connect coupling:
1). During a normal full flow test run; close the compartment valve at approximately one-half of the
nominal prover capacity. Then slowly and carefully disconnect the quick-connect coupling,
allowing the pump to drain the supply line.
2). Continue the test until the meter indication stops entirely for at least 10 seconds. If the meter fails
to stop entirely for at least 10 seconds, continue to operate the system for 3 minutes.
3). If the meter stops for at least 10 second or after 3 minutes, close the delivery nozzle or valve at the
end of the delivery hose if top filling.
4). Disconnect and reconnect the quick-connect coupling and open the compartment valve.
5). Carefully open the nozzle or valve at the end of the delivery hose. Pockets of vapor or air may
cause product to splash out of the prover. The test results may not be valid if product is splashed
out of the prover. Appropriate attire and protection is required, but caution is still necessary.
6). Continue the delivery of product at the normal full flow rate until the liquid level in the prover
reaches the prover’s nominal capacity.
7). Close the delivery nozzle or valve, stop the meter, allow any foam to settle, then read the prover
sight gauge.
8). Compare the meter indication with the actual delivered volume in the prover.
9). Calculate the meter error, apply Product Depletion test tolerance, and determine whether or not the
meter error is acceptable.
Tolerance for Vehicle-Tank Meters
Meter size Maintenance and Acceptance
2” (50 mm) 137 cubic inches
3” (75 mm) and larger 229 cubic inches
The results of the product depletion test may fall outside of the applicable test tolerance as this is a
stand-alone test.
The test draft should be equal to at least the amount delivered by the device in 1 minute at its maxi
mum discharge rate, and in no case should it be less than 50 gallons.

Page 19
Maintenance
¡WARNING!
Test equipment should be grounded to prevent a possible spark. Test area should have no ignition source. Operators should
wear personal protection and prevent any product exposure and environmental issues.
1). Keeping accurate maintenance and calibration records can be an excellent tool in determining the
frequency of inspection or maintenance for a system. As the meter wears, the calibration will be af-
fected and require adjustment. A personality profile can be created for each meter to help guide in a
maintenance schedule.
2). Great care should be utilized in the maintenance of the metering system. Personal safety protection,
environmental hazards, and government regulations need to be the foremost priority. Only fully
trained personnel should be involved in maintenance. Failure to use original TCS replacement parts
will void any Weights & Measures approvals and risk damage to the meter system.
3). ALWAYS RELIEVE INTERNAL SYSTEM PRESSURE TO ZERO BEFORE DISASSEMBLY
OR INSPECTION.
4). SERIOUS INJURY OR DEATH FROM FIRE OR EXPLOSION COULD RESULT FROM MAIN-
TENANCE OF AN IMPROPERLY DEPRESSURIZED AND EVACUATED SYSTEM.
5). Total Control Systems flow meters and accessories are often used with petroleum, solvents, chemi-
cals, and other liquids that may be explosive, extremely flammable, very toxic, oxidizing, and corro-
sive. Severe injury or fatalities may arise if appropriate safety precautions are not followed.
6). Before replacing or cleaning filter/strainer screen, the electrical system must be turned off. Product
needs to be drained from system. Collect all product and return to storage or dispose of properly.
Replace all drain plugs that were removed. Personal safety protection must be warn at this time.
Make sure there is adequate ventilation in the area. The metering system will not completely drain
so make sure you collect extra product when you remove the strainer cover. Clean the screen once a
week, or more often if there is a lot of sediment in the system. Make sure there is no ignition source
and the system is grounded. Replace all plugs that were removed for drainage.
7). The metering system is heavy and awkward so take precaution to handle it properly.
8). Do not use force to disassemble or use a screwdriver to pry open any part of the metering system.
Have the proper tools available before trying to repair the meter system. Be careful of the parts as
they can be sharp and heavy. Do not drop housing or rotors as they can cause injury and can destroy
the parts. Be careful when inspecting and turning the timing gears and rotors as they can pinch
fingers, turn slowly to verify smooth operation.
9). When inspecting the spring loaded preset valves do not place anything inside the housing, as the
action of the valve will pinch this object when the valve closes.

Page 20
Maintenance (CONTINUED)
10). When removing gaskets or o-rings, carefully check for damage or corrosion. Cracked, rough,
worn, elongated, swollen o-rings need to be replaced. When replacing the o-rings place grease
along the inside of the races or completely around the o-ring to help the o-ring stay in the o-ring
grove during assembly. If o-ring is pinched or not in o-ring grove the meter system will leak and
cause serious problems to personal, environment, and equipment. Collect all replaced parts and
dispose of properly. Do not weld any part of the meter system or accessories as this will weaken
the part and allow for leaks
11). Coat with anti-seize and replace all bolts and screws, torque to TCS design specifications.
12). Recommended levels of maintenance and inspection will depend upon the products being meas
ured, their corrosiveness, system pressure requirements, government or company regulations, and
age of metering system. If hydrostatic testing is required pressure should not exceed 1.5 times the
marked meter pressure. It is not recommended to pneumatically test the meter system at anytime.
13). If any part of the meter system is removed from system it should be thoroughly flushed with a
compatible liquid. After this is done, immediately refill the meter or accessory with a compatible
liquid to prevent corrosion and water build up.
¡WARNING!
Test equipment should be grounded to prevent a possible spark. Test area should have no ignition source. Operators should
wear personal protection and prevent any product exposure and environmental issues.
Storage Instructions
Short periods of non-use of the meter (a week or less) will present no problem, provided that the meter re-
mains full of product. For long periods of non-use, such as winter storage, the following procedure is rec-
ommended. Before long-term storage, a good practice is calibration of the meter to determine that it is
functioning properly.
1). To store the meter when it is left in line, flush the system with clean water until 70-80 gallons of
water have gone through the meter.
2) Pump a 50% anti-freeze / 50% water solution through the entire system (100% RV antifreeze may
be used instead). With the pump running, shut off a valve downstream from the meter, making
sure that anti-freeze solution is present at that point. Then close an upstream valve, such that the
meter remains full of anti-freeze solution.
3) Remove the register from the meter, and lubricate the drive coupling shaft. After lubrication it,
replace the register onto the meter.
When starting the system after a period of storage, check the meter's calibration as detailed earlier in the
service manual.