Published: 13.01.2019 Revision Date : 26.07.2019

*IPT reserves the right to change the construction and design of the products at any time without being obliged to change previous models accordingly.

AKARYAKIT MALZ. PETROL KIMYA SAN. ve TIC. LTD.STI.

ER 91 M/E A1013 FUEL METER

OPERATION AND MAINTENANCE MANUAL

DO NOT OPERATE OR MAINTENANCE THE METER BEFORE READING THIS MANUAL.

AT UYGUNLUK BEYANI EU DECLARATION OF CONFORMITY

ÜRETİCİ (The manufacturer) IPT Akaryakıt Malz. Petrol Kimya San. ve Tic. Ltd. Şti.

Merkez & Fabrika Adresi (Center &Factory Address)

1. Organize Sanayi Bölgesi Türkmenistan Cad. No:15 Sincan Ankara / TURKIYE

Telefon (Phone) +90 444 6 478 Web: http://www.ipt.com.tr/ We declare that the following products are in accordance with the following European Directives and the following harmonized European Standards, normative documents and guidelines have been applied… We also hereby declare that the production of above mentioned product meets MID directive Requirements as determined with EC type approval certificate

MODEL (Type)

AT Tip İnceleme Sertifika Numarası

(EC Type-examination Certificate number)

MODÜL D NO (ON A QUALITY

MANAGEMENT SYSTEM Annex D number)

Uygunluk Değerlendirmesini Yapan Kurumun Adı ve No

(Notified Body Identification Name and Number)

IPT SM ER 91 RO-2275-15263 RO-2275-15266 MRC 2275 AKARYAKIT SAYACI SERİ NO (Fuel meter serial number):

(…………………………………………………)

QMS approved and surveillance by MRC n.o. notified body 2275 Uygun Olduğu Yönetmelikler (Regulation as appropriate)

Referans No (Reference Num.)

Adı (Title)

2014/32/EU Ölçü Aletleri Yönetmeliği (Measuring instrument directive) 2014/34/EU ATEX Direktifi (ATEX Directive) 2014/30/EU EMC Direktifi (Electromagnetic Compatibility Directive) 2014/35/EU LVD Direktifi (The Low Voltage Directive) Uygun Olduğu Standartlar ve Uluslar arası Tavsiyeler Appropriate, the Standards and International Recommendations Referans No. (Reference num.)

Adı (Title)

OIML R 117-1 Dynamic measuring system for liquids other than water Part 1: Metrological and technical requirements

OIML R 117-2 Dynamic measuring systems for liquids other than water. Part 2: Metrological controls and performance tests

Bu uygunluk beyanı tamamen IPT’nin sorumluluğu altındadır. This decleration of conformity is issued under the sole responsibility of IPT. Seri numarası ve kullanıma sunulduğu tarih yazan ürünün yukarıdaki açıklamalara uygun olduğunu bildiririz. The serial number and made available by the date notified that the product according to the notes above. Üretim Yeri (Production Place): ANKARA IPT Adına İmza (Production site)

Beyan Tarihi (Date of declaration) (…………………………………………………)

(On behalf of Signature IPT) M.CEMİL ERDEM

PS08 T17 Rev. Date/NO:01/17.02.2017

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CONTENTS 1. INTRODUCTION ................................... 1

1.1 Warnings ......................................... 1 1.2 General Information ........................ 2 1.3 Harmonized Standards ................... 2 1.4 Definitions ....................................... 3 1.5 Technical Specifications ................. 3 1.6 Marking ........................................... 4 1.7 Meter Types and Intended Use ....... 4

2. SAFETY AND ENVIRONMENT ............ 5 2.1 General ........................................... 5 2.2 Users .............................................. 5 2.3 Safety Rules ................................... 5 2.4 Assembly, Maintenance and Repair 5 2.5 Environmentally .............................. 6

3. INSTALLATION ..................................... 6 3.1 Meter Equipments ............................ 6

3.1.1 Air Separator ....................... 6 3.1.2 Filter .................................... 6 3.1.3 Mechanic Counter Register 6 3.1.4 Electronic Counter Register 6

3.2 Flushing the Meter .......................... 6 3.3 Positioning And Connections .......... 6

3.3.1 Dimensions ........................ 6 3.3.2 Connection and Assembly . 7

Pump................................ 8 By-Pass Valve ................. 8

3.3.3 Piping Configuration ........... 8 3.3.4 Earthing ............................. 9

3.4 Paint ................................................ 9 4. OPERATION .......................................... 9

4.1 Control List .................................... 10 4.2 Operation Principle ........................ 10 4.3 Initial Start-up ................................ 11

Protecting Unknown Particles.... 11 4.4 Operation ....................................... 11

4.4.1 Mechanic Counter Reg. .... 11 4.4.2 Electronic Counter Reg. .... 12

5. TRANSPORTATION-STORING .......... 17 5.1 Transportation ............................... 17 5.2 Storing .......................................... 17

6. MAINTENANCE ................................... 18 6.1 Safety Seals ................................... 18 6.2 Calibration ...................................... 19

Accuracy Adjustment ................. 19 6.3 Filter ............................................... 20 6.4 Disassembly ................................. 21 6.5 Junk Meter ..................................... 26 6.6 Periyodic Maintenance .................. 26

7. TROUBLESHOOTING ......................... 27 8. GUARANTEE ...................................... 28 9. Product Test/Calibration Form .............. 29

1.INTRODUCTION

This manual includes important information about effective and reliable operation of the meter. To obey the operation instructions brings effective operation, long meter life and avoid of risks.

Try to understand the contents,

Follow the instructions and directions complete and accurate,

Do not change the operation sequence,

Keep the manual and its copy near the meter in case the operator can use anytime.

1.1.Warnings

This manual includes the necessary information as operation, maintenance, transportation etc. about ER 91 M/E A1013 meter. Make the operator to pay the necessary attention to the manual and to keep the manual where he can access in any time.

This manual covers the operation and safety instructions have to be read before operating of the meter. IPT can not be hold responsible in case of improper use of the meter.

The meter was produced according to the technical safety rules. However it may harm for the operator and for the third person or can cause of any other damages.

The meter subject of this manual is composed of dynamic parts. Only the authorized persons must operate the meter.

Do not do any operation with the meter before reading the manual. Consult the IPT authorities in case of misunderstanding.

This product has to be used according to its intended use. IPT can not be hold responsible for the damage occured in case of misuse.

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The necessary technical information about the operation and maintenance of the meter given in the title 1.5 and 1.6. Do not run out of this values.

Physical deformation may come into being in the sudden temperature changes. Do not operate in different than the design temperature.

The subject of this manual, ER 91 M/E A1013 meter, just hand over as a meter machine and no controlling equipment will be given. The customer is responsible for supplying the connection and/or the controlling equipment.

The customer has to learn the specification and the harms of the liquid passing through the meter. Take the cautions to pouring of harmful liquid.

Always work proper to the human health safety and environmental laws, regulations and instructions.

Safety Signs

Hazardous liquid may result to dangereous health problems in case of spreading to hand, to face and to skin.

Hazardous liquid may result to breathing problems.

Situation may result to fire, explosion, property loss or death.

Moving parts may result to woundings or rupture organs.

1.2. General Information

ER 91 M/E A1013 (Plunger Type) meter is a positive replacement type, has a 1 ½” diameter of inlet/outlet dimensions and 180º inlet and outlet connections. The accuracy of the meter is certain in every pressure and flow rate. Inner mechanism consist of aluminium and polyamide parts. The meter has a low ignition temperature. All the dynamic seals/gaskets are used to materials made of FKM or teflon in order to give reliable performance in the high petroleum products.

1.3. Harmonized Standards

Every ER 91 M/E A1013 meter is designed and is being produced appropriate to the following standards. TS 6769-1 Metering pumps and dispensers to be installed at filling stations and used to dispense liquid fuel part 1:Specification for construction . TS 3380 EN 60079-1 Electrical apparatus for explosive gas atmospheres - Part 1: Flameproof enclosures ‘d’ TS 3033 EN 60529 Degrees of protection provided by enclosures (IP code) (For electrical equipments) TS EN 1127-1 Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and methodology TS EN 13463-1 Non-electrical equipment for potentially explosive atmospheres - Part 1: Basic method and requirements TS EN 13617-1 Petrol filling stations – Part 1: Safety requirements for construction and performance of

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metering pumps, dispensers and remote pumping units TS EN 13617-2 Petrol filling stations - Part 2: Safety requirements for construction and performance of safe breaks for use on metering pumps and dispensers TS EN 13617-4 Petrol filling stations - Part 4: Safety requirements for construction and performance of swivels for use on metering pumps and dispensers TS EN 13980 Potentially explosive atmospheres - Application of quality systems

1.4. Definitions

Meter Machine calculating the liquid being given or taken. Air Separator It is also known as air eliminator. It is the unit which seperates the air appears due to agitation of the fuel and put backs the air to the system in the outlet of the meter. Filter Equipment filtering the particles may exists in the liquid and may harm for the pump. Filter is coupled to the meter. Counter Register It is the unit displays the measurement of the meter in liters. It has two types as mechanical and electronic. Totatizator It is the meaning of the total measurements of the meter from the production date of it till the last measurement. Pump The machine which transfers the liquid from its original location to the meter with pressure. Discharge Tube It is the tube which carries the air from the air separator to the outlet of the meter.

Plunger Three parts in the casing which do the measure work by sucking and pushing the liquid. Measuring Chamber Three pieces of cylinders in the casing. The plungers measures the volume of the liquid by moving upwards and downwards in the cylinders. Etalon Scale The legal measuring cup which has scales on it shows the volume. Viscosity The resistance of the liquid to flow. Gasket The rubber material setting between two stable mechanical parts to prevent leakage and impermeability.

1.5. Technical Specifications

Type 90°c connecting positive displacement three plungers Flow Rate min : 20 lt/min. (5.28 gpm) max : 200 lt/min.(52.84 gpm) Operating Press. 1.5 bar Press. Loss 1 bar (max) Viscosity 430 cSt (without calibration change)

Operating Temp. -25 / +55C Accuracy % ±0.25 Mechanical Counter Register Momentary : 5 digits Totalizator : 8 digits Weight 34 kilos Dimensions 28x59x53 (W x L x H) Inlet / Outlet dimeters 1˝ - 1½˝ - ¾˝ Impermeability Material FKM (Viton)

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Material : Meter Casing : Cast Aluminium

(AlSi10Mg) Aır Separator Casing : Cast Aluminium

(AlSi10Mg) Mechanical Counter : Sheet metal Regist. Casing (St-37.2) Electronic Counter Register Type temperature compansation

Can be mounted on top of the measurement device or a distant place Electrical connection (AC or DC) Suitable for dual use

Operating Temp. -25 / +55C

Storing Temp. -40 / +65C Humidity %97 Display Momentary : 6 digits

Totalizator : 10 digits Weight 11 kg Dimensions (E x B x Y) 285x272x194 mm Cable Transition Ex-proof Glend Impermeability FKM (Viton) Material Power source 24v dc 25w Output Mechanical relay 10a 250vac/10a 30vdc Analog input 3 or 4 cable temp. probe Internal Battery lcd display 0.22f 5.5v Communication RS 232 Material : Display Policarbonate Glass Casing Cast Aluminium

(AlSi10Mg)

1.6.Marking

Table 1. Product Label

Model Definition: ER X1 X2 X3 X4X5X6X7 X1 : type (72-88-90-91) X2 : Counter Register Type (E: Electronic, M: Mechanical) X3 : Rotor Type (A:Piston, C:Tri-rotor, E:Rotary Vane ) X4 : Outlet Diameters (1: 1”/1 ½”, 2: 2” , 3: 3”) X5 : Configuration (0:Straight 1: 90º) X6 : Flange Class (1: 51 ANSI R.F) X7 : Construction (3: Aluminium, 4: Cast Iron)

Marking includes the type, working principle and serial number. In the reorder of meter or order of the spare parts, use the label information (type and serial no). If you need further information, please get in touch with IPT.

1.7. Meter Types and Intended Use

SP – Standard Petroleum (I) Leaded and unleaded gasoline, Fuel Oil, Diesel, Biodiesel, Kerosene, Jet Fuel, Vegetable oil, Lubricant oil, Ethylene glycole (Antifreeze) etc. rafined petroleum products.

AF – All Ferrous (II) Pesticides, Nitrogen Solutions, Fertilizer, Solvent, Paints, Ink, Alcohol, Adhesive Substances, Motor Oils, Molasses, Liquid Sugar, Frost-free Liquids etc.

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SS – Stainless Steel (III) All the liquids with SP and AF meters. Moreover Nitric, Phosphoric Iced Acetic Acid, Antifreeze Liquids, Vinegar, Fruit juice and other chemical substances.

IF IT IS NOT TOLD, A SP TYPE METER WILL BE SHIPPED. THE DAMAGES CAUSE OF DIFFERENT INTENDED USE

ARE NOT UNDER GUARANTEE!

2. SAFETY AND ENVIRONMENT

2.1. General

The ER 91 M/E A1013 meter you have bought was produced with high technology under the continuous quality control process. IPT can not be hold responsible for the damages and results occured in case of using out of its purpose. Not to obey the safety instructions means to endanger the human life, environment and the meter. Moreover the justs asking for the damage are being lost in case of not to obey the safety instructions. Not to obey the instructions may cause of the followings:

Damage or failure in main functions of the meter

Failure in the maintenance

Exposed of the human life to mechanical and chemical damages

Environmental damage due to hazardous liquid leakage.

Explosion

Special processes need special safety cautions. Ask IPT for advice in case of this kind of processes.

THE CUSTOMER IS RESPONSIBLE FOR OBEYING

THE LOCAL SAFETY LAWS AND COMPANY INSTRUCTIONS!

2.2. Users

The owner of the meter is responsible for ensuring that everyone who works with the meter has the necessary background. The operator shall explain the personnel’s responsibilities and authorities. If the operator troubles with some points, he/she can demand a course from the manufacturer firm. As a last word, the responsible personel must understand the operating instructions exactly.

2.3. Safety Rules

The meter designed with high care. The original parts and the equipments meet the safety regulations. Making changes in design or not using original spare parts means to endanger the safety.

BE SURE THE METER IS OPERATED IN THE

TECHNICAL SPECIFICATION LIMITS. ONLY IN THIS CASE

METER PERFORMANCE WILL BE GUARANTEED!

The signs and markings on the meter are the parts of safety conditions. These markings shall not be closed or unstitched. The markings shall be stay over the meter over the whole meter life. The markings outwear or getting older shall be changed with the new ones.

2.4. Assembly, Maintenance and Repair

All the assembly, maintenance and repair works must be done by the authorized personnel. Obey the local regulations.

WHILE DOING DRAINING, LEAKAGE REPAIR ETC.

WORK CAREFULLY CONSIDERING THE

ENVIRONMENTAL AND HUMAN HEALTH!

OBEY THE INSTRUCTIONS WRITTEN IN THE

INSTALLATION AND OPERATION SECTIONS WHEN OPERATING THE

METER AGAIN!

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2.5. Environmentally

The IPT fuel meters were designed to operate compatible to environment for all their lives. For this reason, use the biological oils in the maintenance. The operator is responsible for discharging of the liquid without given damage to the environment. Pay care when discarding an adr of the pumps of which working life finished.

CONSULT LOCAL GOVERNMENT

ASSOCIATIONS FOR THE WASTE MATERIALS AND

RECYCLING!

3. INSTALLATION

3.1.Meter Equipments

3.1.1.Air Separator

The meter equipped with the aluminum cased air separator in order to separate the air in the fuel. The air in the liquid is separated before entering in the measuring chamber and transferred to the outlet by the discharge tube.

3.1.2.Filter

The filter is coupled to the air separator body. It is produced to filtrate the unknown particles which may ocur in the liquid in order not to damage the meter. Cleaning and disassembling of the filter is simple.

3.1.3.Mechanical Counter Register

The mechanical counter register is a system displaying 5 digits momentary and 8 digits total volume transferred. The momentary volume digits can be reset by the reset button on the case. This reset operation can only be done when the meter is not operating. The totalizor is used to measure the volume of the liquid passed

through the meter from the production of the meter till the last measurement. The totalizator can not be reset, just it reset itself after all the numbers do one complete turn.

3.1.4.Electronic Counter Register

The electronic counter register is a system displaying 6 digits momentary and 8 digits total volume transferred. It is very dependable as its easy usage. If the electric current cuts off, the batteries in the counter register will keep the last transfer volume until the current is supplied. The totalizor is used to measure the volume of the liquid passed through the meter from the production of the meter till the last measurement. The totalizator can not be reset, it will reset itself after 99.999.999 liters.

3.2. Flushing The Meter

The meter was tested with diesel. If diesel may contaminate the liquid which will pass through the meter or if the diesel may react with the liquid, then flush the meter with the appropriate solvent completely. Read the instructions written in the ‘3.3.Positioning And Connections’ and ‘4.Operation’ sections.

3.3. Positioning and Connections

3.3.1. Dimensions

Figure 1. Front View of Meter

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Figure 2. Top View of Meter

Dim

ensi

on

s

(mm

)

A B C D E F G H I K L

28

0

15

5

33

0

54

5

38

0

27

0

35

22

5

53

0

53

5

28

0

Table 1. Meter Dimensions

Electronic Counter Register

Figure 4. Dimensions

3.3.2. Connection and Assembly

Figure 4. Bottom View of The Meter The connection of the meter to base is done from the bottom of the meter with three M10*20 screws.

Electronic Counter Register Wiring The electric couplings must be done according to the instructions and related regulations by a qualified electrician.

THE ELECTRIC COUPLINGS ARE ALWAYS DONE BY AUTHORIZED PEOPLE ACCORDING TO THE

STANDARDS AND REGULATIONS!

Electric connection: The electronic counter register needs 12-24v dc current. It can be operated by the tanker battery or an adaptor. Connect (+) and (-) wires to the “12-24v dc” socket in the back cover of the register (+ and – wires can be connected random). If you use with the adaptör, then use the CE approved one. Contact to IPT in case of malfunction even if obey the instructions.

Figure 5. Counter Register Wiring Diagram

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Motor Connection: On the connector group, there is a socket named “motor” which supplies energy to a contactor to start up an Electric motor. Solenoid Valve Connection: Solenoid valves are the equipment which can be connected to register on order and are used to control the fuel flow and allows the sale with preset. If a two stage solenoid valve is used, the transfer will be done gradually, so more controlled operation can be done. The register can be used both single stage and double stage solenoid valves. The valves are normally open (NO) type and they will turned into closed position at the beginning of the delivery. It must be remembered that the voltage of both solenoid valve and supply of the register shall be same. Single Stage Valve usage: “ROLE-H” socket is not going to be used. One of the energized cables of the bobbin will be connected to the “ROLE-Y” socket, while the other will be connected to the “COM-RET” socket. The yellow cable (earthing) from the bobbin will be connected to the truck’s chassis for earthing. A short circuit must be done between “12-24VDC” and “COM”. Double Stage Valve usage: There are two kinds of valves as shared cabled and separated cabled. For the shared cabled valve; the black cable is for the “COM-RET” socket, the blue cable is for the “ROLE-Y” socket and the brown cable is for the “ROLE-H” socket. The yellow cable (earthing) from the bobbin won’t be used. The yellow cable (earthing) from the bobbin will be connected to the truck’s chassis for earthing. A short circuit must be done between “12-24VDC” and “COM”. In case of slow and fast flow differencies can’t be seen, the places of blue and brown cables must be changed. For the separated cabled valve; both of the brown cables will be tied and connected to the “COM-RET” socket, one of the blue cables will be connected to “ROLE-Y” socket and the other blue will be connected to “ROLE-H” socket. The yellow cable (earthing) from the bobbin will be connected to the truck’s chassis for earthing. A short circuit must be done between “12-24VDC”

and “COM”. In case of slow and fast flow differencies can’t be seen, the places of the blue cables must be changed. For other connections, please consult IPT.

Pump The pumps has two connection points; inlet and outlet. The inlet is connected to the location of the liquid and the outlet is connected to the meter. Thereby the liquid transferred from its original place to the meter. The inlet and outlet of the pump must be determined prior to piping.

THE INLET PIPE CARRIES THE LIQUID WHICH WILL

ENTER THE METER MUST BE CONNECTED TO THE FILTER

COUPLED TO THE AIR SEPARATOR!

By-pass Vane

The meter is under high pressure when it is operating. At the moments when the liquid transfer is stopped, this pressure forces the vanes and causes of outwears and break downs. The designed by-pass valve system coupled to the pump casing can not be sufficient everytime. For this reason a by-pass valve must be set between the pump outlet and inlet. Thereby if there isn’t any liquid transfer, the pressure under the meter parts will be minimized.

3.3.3. Piping Configuration

The meter and the piping shall designed to prevent the flow of the liquid from the meter when the system is closed. One way to do this is to hold the inlet and outlet of the meter below the connected piping system (drainage position). At the same time it is prevented that the pipe system must not force the meter casing excessively. When setting up the meter, the inlet pipe is connected to the filter. It must set up in a cabinet or in a place where it can be protected from the outside influences. The connections must be tight. Loose connections, screws may cause of excessive vibration. Also from these points, liquid

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may leak and effects the accuracy of the measurement.

WHEN DOING INLET AND OUTLET CONNECTIONS, BE SURE THAT THE WELDING

SLAGS / METAL FILLINGS DO NOT ACCESS IN FRONT OF

THE METER!

The screws and nuts tightness must be done according to the following table. The excessive torque may cause of stripping of the screw or the inadequate torque may cause of leaking from the gaskets.

Connected Parts Figure

16 Poz No

Screw/Nut (radius*thread)

Torque (N*mt)

Meter cover / Meter casing 1.20 M10*1,5 33

Air separator cover-air separator casing

9.20 M8*1,25 33

Filter / inlet flange 9.9 M10*1,5 33

Filter / filter cover 9.9 M10*1,5 33

Meter casing / Outlet bracket

4 M10*1,5 33

Meter casing / air separator casing

8 M10*1,5 33

Meter cover / counter register

gear plate 1.22 M6*1 13

Air separator cover / aluminium tube

9.18 ¾” 90

Meter casing / aluminium tube

9.18 ¾” 90

Each end of aluminium tube

11 ½”-¾” 100

Table 3. Screw/Nut Torque Values

THE SCREWS/NUTS TIGHTEN UNSUFFICIENT

MAY CAUSE OF LEAKAGE FROM THE GASKETS. THE ACCUMULATING LIQUID MAY CAUSE OF FIRE OR

EXPLOSION!

3.3.4. Earthing

Earth the meter as shown below. Use copper wire having at least 1,5 mm² section. Fix the wire to the meter base using base screw. Insert the

other end of the wire to the ground no less than 5 cm.

Figure 6. Earthing

THE STATIC ELECTRIC ACCUMULATING ON THE METERS NOT EARTHED

MAY CAUSE OF EXPLOSION!

3.4. Paint

The paint used for the pumps is the Styrene alkid solvent based primer paint. The high water resistant paint protects the pump from corrosion.

THE PAINT USED CAN BE RESOLVED IN THE

PETROLEUM PRODUCTS. DO NOT EXPOSE THE METER’S

EXTERIOR SURFACE TO THIS KIND OF SUBSTANCES!

4. OPERATION

When working with hazardous liquids or maintaning the pump, wear protective clothes, use protective glasses or face mask.

The pump consists of rotating parts. To insert an organ like finger to these parts without taking safety precautions may cause of woundings or rupturing an organ.

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To get in touch with hazardous liquids, to swallow, splashing to eyes, to smudge of the body or breathing the vapours of them without taking appropriate precautions may cause of serious traumas or even death. Take the necessary safety precautions while working with the hazardous liquids.

To change the parts or accessories of the pump, to use outwear or damaged parts, to use liquids or chemical substances inappropriate to inner mechanism of the pump can damage the pump parts. In such a case the subjected liquid may pour, smudge to the body or splash to the eyes. According to the type of the liquid, this situation may cause of fire, explosion, thereby to loss of human life and property.

4.1. Control List

The following clauses must be controlled before operating of the meter;

1. That the meter should be earthed. 2. ER 91 M/E A1013 meters operate under

the principle of full hose system. Thereby the hose must be controlled prior to each measurement and must be filled completely.

3. That all isolating valves in the suction are fully open.

4. That all the equipments using after the meter such as vanes or guns must be opened.

5. That the counter register should be reset. 6. That there are no bends in any point of

the hose.

THE METER WORKS UNDER THE POSITIVE

DISPLACEMENT PRINCIPLE. BE SURE THAT THE HOSE IS

COMPLETELY FULL OF LIQUID!

7. The suggested properties of the hoses used with the meters are as follows;

Operation pressure 10 atu

Explosion pressure 30 atu

Swirl radius must be;

For 1” , 254 mm,

For 1¼” , 320 mm,

For 1½” , 380 mm,

For 2” , 510 mm. 8. The pump’s technical specifications (min -

max flow rate, pressure) must be chosen suitable for the meter.

9. There must be by-pass unit in the pump. After controlling all these clauses, the meter is ready for the measurement. While the measuring, the gun, valve etc. equipments after the meter must not be kept close long durations, so the meter must not be exposed to high pressures. After the measuring operation, the gun, valve etc. equipment must be closed and the pump must be shut down immediately.

4.2. Operation Principle

Figure 7. Operation Principle

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In meter, there are three plungers assembled to the measuring chambers (cylinders). The plungers are connected to the wobble plate from the upsides. The wobble plate also has the wobble plate shaft assembled under itself. The wobble plate shaft moves the slider which slides between the plungers by controlling the sequence when the liquid enters the meter. When the liquid enters the meter, first it flows from the upper cover into the casing. The slider is ready to open the measurement chambers. As soon as the pressure under it releases and the upper cover full of liquid, the plunger is forced to move to the bottom and by this, it pushes the liquid to the outlet. At that moment, another plunger moves from bottom to top. The slider is moved by the wobble plate to open an another measuring room entrance. While the plungers are moving to the top, the liquid flows from bottom to inside of the measuring rooms. This cycle continues with the incoming of the liquid. When the liquid flow stops, the pressure in the inlet and outlet becomes equal and the cycle stops.

4.3. Initial Start-Up

In a new and dry system, when the vanes open, there may be a high pressure in the piping system and this pressure pass through the meter by force. The high pressure and the air volume makes the meter operating faster. When the liquid reaches the meter, there will be a sudden acceleration at the rotor and the vanes. This may result to a damage in the counter register, in the gears or in the other components. The suggested start-up procedure for any system is overflowing the piping system gradually. This enables the meter to discard the air slowly from the piping.

Protecting Unknown Particles In new piping systems, attention must be paid to protect the meter in start-up. Welding slacks, corrosion, sludges may cause of damage in the meter. To protect the meter against these kind of damages, control the filters set up before the inlet of the meter.

4.4.Operation

By-pass Valve To protect the meter from the damage result to the high pressure created by the pump, the by-pass vane should be half-opened after resetting of the counter register. Turning the by-pass vane in the clockwise direction is close, counter-clockwise direction is open positions. (Open and closed positions are signified on the vane.)

WHILE THE METER IS OPERATING, THE BY-PASS

VANE SHOULD BE KEPT HALF OPEN!

4.4.1 With Mechanical Counter Register

Figure 8. Mechanical Counter Register

1. Start up the pump. 2. Be sure the system is in by-pass position. 3. Control the counter register whether it is

resetted.

ALL THE NUMBERS IN THE MOMENTARY DISPLAY MUST BE ZERO. OTHERWISE THE COUNTER REGISTER MAY

GET DAMAGE!

4. You can start to transfer the liquid. While

transferring the liquid, the counter register should be controlled.

5. For the new transfer, the resetting button (the button on the right of the counter casing) should be turned clockwise (arrow direction) in order to reset the counter register.

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NEVER TRY TO RESET THE COUNTER REGISTER WHILE

OPERATING!

The mechanical counter register can never be reset while in operation due to its gears. Otherwise the gears break down and the momentary display will be out of order. But even in this situation, the totalizator will work correctly.

4.4.2 With Electronical Counter Register

Figure 9. Electronic Counter Register

1. Be sure the register is supplied by electric. Press STOP button.

2. Define the volume by using P1, P2 or P3 buttons. P3 button is for 100 lt P2 buton is for 10 lt P1 button is for 1 lt (in case of pressing wrong buttons, press STOP button to restart preset value.) (This clause is only valid if a two stage valve is installed.)

3. Press START button after preset value is entered.

4. The register will be ready for delivery in two second time. The delivery will be cut off after preset value is given. (If solenoid valve is installed)

5. For new delivery, press STOP first and press START to reset the register.

Buttons P1 : 1 liter programming button P2 : 10 liters programming button P3 : 100 liters programming button

STOP : Deletes wrong preset and stops the device START: Starts the device Note : If the device related to an electronic cash register or an automation system, when pressing the START button, the device displays 88888888 until the approval signal receives from this system and only after this signal, the register

starts delivering fuel. The symbol will be seen on the screen. Sale Without Preset : Push START button, after the device reset itself, the sale starts. To finish the sale, use STOP button. Sale With Preset : Press START button after entering the desired volume by using P1/P2/P3 buttons while the device is in stop position. The device will shut down the fuel flow automatically when the desired volume is given. (with selenoid valve only) If the delivery is not started after the pre-defined “preset timeout duration”, the preset will be cancelled. Sale with preset can also be done by the automation system. To change the preset type as prive or volume, it is need to be pressed the PRESET button. After entering PRESET value and type, START button will be pressed. The preset value will be seen on the screen before delivery starts. Deleting Wrong Preset : Use the STOP button to delete the wrong preset value. Other Information for Electronic Register: Screen Symbols;

Delivery started

Register is in automation mode

ATC probe connected

13

Preset defined

Malfunction

Connected to Printer

THE SCREEN IS TURNED OFF IN CASE ELECTRIC IS

SUPPLIED. TO OPEN THE REGISTER, PRESS ONE OF

THE BUTTONS!

Menu The adjustment of the device can be seen under 4 menu titles as pump, administrator, service and factory. Administrator and service menus can be reached by their passwords. The min and max values can be accepted by the parametric adjustments are written in the menu. If a value excessed the min or max value, the “EXCESSIVE MIN/MAX VALUE” descriptive notice will be seen on screen with the value that the parameter can get most. Menu Arrangement Code All the titles under the menus have a arrangement number. This can be defined as following; Format : XYYZ X – Menu group number This is the main menu rank. YY – Choice Number The number of the parameter in the menu. Z – Fueling Number Dependent to operation type, it shows which fueling point, channel, nozzle or any other equipment is chosen. MENU To enter the menu, press MENU button while the device is not in operation mode. The stand-by duration in a menu without doing any adjustments (the delay without pressing any of the buttons) is 60 seconds. If this duration is passed over, it will automatically go back to main screen.

1 - Pump Menu:

This menu can be achieved directly and have the records related to fueling operatons and device information. 101 – Operation Total: Shows the operation information from volume, price and duration. 102 - Sale Record: The latest 100 deliveries’s information as sold volume, price, weight, operation duration, average flow rate, average temperature. The last operation is shown at first.

Volume (ATC) : Compansated (net) volume

Volume(gross) : The volume without ATC applied.

Price : Price of the sale. Weight : The weight of the sold volume. Average coefficient : The average of the

coefficients found due to temperature change which applied to calculation during the whole operation.1

Average Temperature : The average of the temperatures measured during the whole operation.1

Average Flow Rate : The averages of the flow rates measured during the whole operation.

Fueling Duration : The duration of the operation.

Suspend : The duration in an operation passed without delivery.

Pulse Amount : The total pulse amount generated by the pulsar card.

Time : The time and date of the operation. 1Valid for the liquids defined in the ATC parameter and can be calculated if ATC probe is installed. 103 – Case Report: The last 50 malfunctions met during operations, system information, the description of malfunction recorded with time information. Case name: the name of the case happened Time happened : The time of the case happened Case point: If the case is a malfunction, this is the fueling side and nozzle of the case happened. 104 – Information: The version number of the firmware, checksum number, production date, total operation duration etc are shown. Version: Version info of the firmware

14

Authorization: Information of if the device operates in manual or automation mode.

Operation duration: The total duration of the register while it remains open.

Total Delivery : Total number of deliveries Production : The production/revision date of the register

Calibration : The last calibration date of the register

Opening : The date/time info when the register was energized

Closing : The date/time info when the register was de-energized

Opening Amount : The total number of openings

CPUID : The serial number of cpu and equipment type

Checksum : Firmware checksum value CPU Frequency : The frequency of the cpu

2 – Administrative Menu: The administrator password must be entered

to gain access to menu. The password is set as "11111" by factory. If requested by the responsible person, the password can be changed from the options menu. 201 - Liter Preset: Format : 000.00 lt The values of the program button are set to preset selling in liters. Program button values can be changed by "P2" and "P3" buttons. The changed values will be recorded after pressing "MENU" button. If you wish to cancel the operation in the menu, "STOP" button should be pressed. Factory settings: P1 - 1 liter P2 - 10 liters P3 - 100 liters 202 - Price Preset: Format : 000.00 Tl The values of the program button are set to preset selling in currency. Program button values can be changed by "P2" and "P3" buttons. The changed values will be recorded after pressing "MENU" button. If you wish to cancel the operation in the menu, "STOP" button should be pressed. Factory settings: P1 - 1 Tl P2 - 10 Tl P3 - 100 Tl

203 - Unit Price : Format : TL 0000.00 The unit price of the fuel is adjusted manually. If the automation system is active, the unit price can be altered by the system. The value of the flashing digit can be changed by the buttons "P2" and "P3". The next digit is selected by pressing “P3”. The changed values will be recorded after pressing "MENU" button. If you wish to cancel the operation in the menu, "STOP" button should be pressed. Factory setting: 1 TL

204 - Currency: The country currency is adjusted. The adjusted currency is shown in the Menu. TL: Turkish lira EURO: European Currency Union DOLLAR : US dollar MANAT : Azerbaijan currency LARA : Georgia currency CAD : Canadian Dollar GHC : Ghana currency LEK : Albanian currency KM: Bosnia and Herzegovina currency LEVA : Bulgaria currency DINAR : Iraqi currency RSD : Serbian dinar RUB : Russian ruble LS: Lithuanian currency LL: Lebanese Pound DIRHAM : Morocco currency RIAL : Saudi Arabia currency Factory setting: Tl 205 - Large display: The major indicator type on the home screen is displayed. "Dependent to preset", "volume" and "price" values can be selected. Factory settings: Dependent to Preset 206 - Waiting Indication: The information is shown on the bottom row of the main screen while the register is energized but not delivering fuel. Company name: Manufacturer name of the register Date - Time: Current date and time information Factory settings: company name 207 - Filling Indicator: The information is shown on the bottom row of the main screen while the register is delivering fuel. The following information can be shown ; Flow rate (l/min)

15

Density (g/cm3) Ipt company logo Date/Time Factory setting: Flow 208 - Number of prints: If the printer is connected to register, how many receipts will be printed is defined in this title. Factory setting: 1 209 - Auto shutdown: The automatic shutdown duration of the device if it is energized but not in use. Factory settings: Open 210 - Auto shut-down time: This is the amount of the duration if the auto shut-down is “open”. Factory setting: 600 sec 211 - Date setting: Date setting is made. The format is as Day/Month/Year. 212 - Clock setting: The time setting is made over 24 hours. 213 - Language selection: Either in Turkish or English languages recorded in the device can be selected. Factory settings: Turkish 214 - Administrator password: To title where the password for the administrative menu can be changed. Factory setting: 11111

Error Codes:

The register checks many of the failures that may occur on the hardware and shows on the screen in order and gives an audible warning. Fault occurred are stored in memory with hour / date details. These records can be seen later from the event report in the pump menu.

E00: NO ELECTRIC SUPPLY E01: ATC FAULT The temperature probe was not installed or probe malfunction E02: NO PULSE

The pulse generator was not installed or generator malfunction. The 3rd party hardware system may not be detected by cpu(see E18)*. E03: NO SCREEN E04: NO AUTOMATION COMMUNICATION Communication cable is disconnected or wires are connected in reverse position, the automation parameters may incorrect, automation system is defective or communication module may be faulty. E05: NO MASS METER Communication cable is disconnected or wires are connected in reverse position, mass flow system parameters are incorrect, mass measuring system is faulty or communication module may be faulty. E06: PULSAR TURNS WRONG DIRECTION Pulsar is turning i the wrong direction. The places of the wires of the pulsar must be changed. E07: LOW TEMPERATURE ATC probe measures a temperature below the setted bottom temperature. E08: HIGH TEMPERATURE ATC probe measures a temperature above the setted top temperature. E09: VALVE LEAKS While not delivering fuel, continuous pulse coming from generator. The solenoid valve may be leaking. E10: FILLING TIMEOUT

No fuel was given from pressind “START” button until the defined timeout duration ended. E11: NOZZLE OPEN The nozlle is not in its place when the register first energized. E12: LOW FLOW The delivery flow rate is lower than the adjusted minimum flow rate level. E13: HIGH FLOW The delivery flow rate is higher than the adjusted maximum flow rate level. E14: AUTHORIZATION TIMEOUT If an authorization signal received from the authorization system but the delivery was not

16

started until the defined duration passed, the authorization cancelled by the system. E15: INVALID UNIT PRICE The unit price is not recorded. E16 RTC ERROR System time malfunction. E17: MEMORY ERROR Failure occurred in system memory. E18: HARDWARE INCOMPATIBLE A different manufacturer’s pulsars may incompatible with the cpu. Connect the pulsar ends with 4.7Kohm and connect + and - supply terminals with 470 ohms. Solenoid Valve (Optional):

Delivery control is performed by relay outputs on the register card which are connected to the solenoid. Some controls as malfunction, temperature compansation etc. is done at the very beginning od the delivery. If any malfunctions meet at the beginnig, the bobbins of the solenoid will be energized and the delivery is started. If any malfunctions are met while delivery, the bobbins will be de-energized, so the delivery will be cut-off immediately and the related error code/description will be appeared on the screen. “STOP” button will be pressed to cancel the delivery. Electronic register cut-off the energy of the solenoid valve when the presetted volume given, so the delivery will be stopped.

Figure 10. Solenoid Valve

THE REGISTERS WITHOUT CONNECTION TO A

SOLENOID VALVE CAN NOT CUT OFF THE DELIVERY AUTOMATICALLY. THE

DELIVERY VOLUME MUST BE CONTROLLED FROM THE

DISPLAY!

By the two stage solenoid valve;

- Slow flow delivery start

- Slow down the delivery and fast delivery

- Prediction of cut off can be done.

SINGLE STAGE VALVES MUST BE USED FOR START AND CUT

OFF OPERATIONS. PRESET VALUES CAN BE ACHIEVED

SUCCESSFULLY BY THE TWO STAGE VALVES!

The control of the system can be done by automation system as externally or a solenoid valve can not be used in the system (manual mode). The filling process is normally started by pressing "START" button, as well as it can be started by "Smart Flow Wake Up " feature. If "START" button is not pressed intentianally or in case of it forgotten, the register will automatically bring itself to operation status by noticing the movement in pulsar. Thus, it is prevented to deliver fuel without measuring. ATC Probe (Optional) The electronic counter register is able to do the temperature compansation of the following products. For this, a probe must be connected to the register. Please consult IPT for the probe installation. Printer (Optional) After transferring the desired volume, the volume of fuel can be printed on a bill. Just pushing the STOP button after the transfer, the volume seen on the display is printed.

17

5. TRANSPORTATION-STORING

5.1. Transportation

While transporting and carrying, pay attention for the safety of the meter. Especially be careful for the counter register. The seals must be prevented in order to break off and the transportation must be done with the meter’s package.

Figure 11. Packaging

Use double layered corrugated card board.

The product is folded with the balloon nylon to protect against dust, moist and impacts, surrounded by the adhesive band.

The folded product put to a box.

The banded box is reinforced by a plastic strap.

The strapped product is ready for the transportation.

That put in the car with care not to fall over or not any materials to fall off above it.

Use the figure below to carry the pump after putting out of the box. Always carry the pump lifting it under the casing. Use a nylon rope at least 50 kg tensile force.

Figure 12. Lifting of Meter

5.2. Storing

When stored for a long periods of time, the meter must be inspected after no more than six months – depending on the storage conditions. Avoid storage: in an environment containing chloride on foundations with continuous vibrations, as the bearings/bushings might be damaged in unventilated rooms Recommended storage: indoors in a dry, dust-free, non-aggressive atmosphere in a well-ventilated room to prevent condensation flanges and pipe couplings closed using plastic plugs meter packed if necessary in plastic film and with moisture-absorbing Silica Gel bags Preservation procedure: Make sure that the meter does not corrode or dry out, as drying out between the sliding surfaces of the bearings/bushings may cause damage when the meter is put into operation. Preservation of the meter is necessary on untreated surfaces – both external and internal.

18

1. If the meter has been in operation it must be

emptied 2. Rinse the meter with clean, hot water, then

empty it and dry it. The meter must not be left with damp surfaces on the inside.

3. Spray on an anti-corrosion oil. It is also possible to use acid-free oil, such as hydraulic oil. As an alternative, you can use silicon oil or a fire-resistant type of polyglycol-based hydraulic oil. Fill the meter with sufficient oil for the oil to start running out of the meter.

4. Pump the oil inside to the meter until oil comes ot of te dischatge port, so that all internal surfaces are lubricated.

5. This process must be repeated every six months.

Frost protection: Meters that are out of operation during periods of frost must be emptied of liquid to avoid frost damage. You can use anti-frost liquids, but you must make sure that the elastomers used in the meter will not be damaged by the liquid used, RV type antifreeze liquids are suggested. Electronic Counter Register

1. Detach the cables outgoing from the counter register and incoming to the power source, and fold them by the electric band in order not to oxidize. It is not necessary for the cables incoming to the counter register, because the glends can not put the moisture access inside of the casing.

2. Put out the counter register from the meter and oil the gears and gear plate. After oiling put the counter register on the meter.

3. To bandage the counter register with a clean clothe to not to expose it to the excessive cold or hot temperatures.

4. There are seals on the counter register. Prevent seals from getting damage.

5. The counter register composes of electronic parts. Take the precautions not to expose to a shock.

6. MAINTENANCE

The pumping liquid is hazardous for the skin. Use full face mask (if not use glasses) and wear your plastic gloves. To protect your skin against smudging the liquid.

The pumping liquid is hazardous for breathing. In case of breathing, head ache, vertigo or more serious health problems may occur. Stop your work and go out for a fresh air immediately!

The possibility of a spark result to rubbing of two metals, assembling or disassembling is very dangereous when there is liquid in the pump. A fire or an explosion danger exists according to the specification of the liquid.

The pump consists of rotating parts. To insert an organ like finger to these parts without taking safety precautions may cause of woundings or rupturing an organ.

6.1.Safety Seals

The meter is protected by the seals against dismantling the equipments or the covers where the adjustment screw can be reached by which the measurement will be effected. The lead seals are used for the sealing. There are 4 points in the meter where the seals are used.

On the connection between the meter casing and the counter register,

On the adjustment screw cover,

On the inlet of the air seperator discharge tube,

On the outlet of the air seperator discharge tube,

19

In every condition it is easy to reach the seals. The figure shows the places of the seals.

Figure 13. Places of the Seals

Figure 14. Place of the seal

THE METER WILL BE OUT OF GUARANTEE IF THE SEAL(S)

IS (ARE) BROKEN!

6.2.Calibration

The calibration of the meter is done by the IPT. In necessary conditions, users can also do this operation (For the details about the calibration, colsult to IPT). On the other hand, the repeatability of the meter should be done by the operator. Thereby the operator can understand whether the meter needs repair work or not. The ER 91 M/E A1013 meter can not be sensitive more than % ± %0.25 defined in the factory. It is important to test the repeatability and sensitivity of the meter. To test the repeability;

a. Do a fast test with the etalon scale and counter register (high flow rate in minute) and record how much or little the counter register counts. Do not change the calibration of the counter register.

b. Do a slow test with the etalon scale and counter register (low flow rate in minute) and record how much or little the counter register counts.

If the records of the fast and slow tests are similar or close, the meter can successfully be calibrated. If the records are very out of the nominal tolerance of the meter, a repair work must be done before the calibration. Accuracy Adjustment There is an accuracy adjustment system in the meter where you can change the rate in the data read from the counter register and volume passes through the meter. This adjustment system protected afer control of the meter. Consult to IPT for the operation principle of the accuracy adjustment system.

Graphic 1. Pressure Loss Curve

Graphic 2. Typical Sensitivity Curve

20

ER 91 M/E A1013 meter has the capacity of measuring 10 liters in slow and 100 liters in fast operations correctly.

6.3.Filter

The filter should be controlled periodically and make sure of its cleanliness. That the filter is the most important equipment in effective working of the pump has never been forgotten.

Figure 15. Disassembly of the Filter After untighten 4 pieces of M12 screws, the cover is detached. Now it is possible to reach the filter. The filter keeps the possible unknown particles in the liquid flowing to the pump, that means the inside of the pump will be dirty and the outside of its will be clean. After detaching the filter, clean it by exposing the outside of it to the pressurized air.

21

6.4. Disassembly

Figure 16. Meter and Air separator Disassembly

22

Poze No

Code Description Qty Poze No

Code Description Qty

1 11050012 Body Assembly 1 1.19.10 97010004 Bushing Ø18xØ14x9,5 2

1.1 11050011 Bottom body assembly 1 1.19.11 11050029 Cover 1

1.1.1 11050019 Bottom body 1 1.19.12 99500013 Seal Ø8*Ø18*8 mm 1

1.1.2 99230007 Gasket, Slider 1 1.19.13 98900129 Compensator Screw Spring 1

1.1.3 11040039 Seat 1 1.19.14 98810003 Nut M8 2

1.1.4 94000029 Metal Sheet (Inox), Cover Plunger 3 1.19.15 98740019 Index Plate 1

1.1.5 99841049 1/2"-3/4" Sleeve 1 1.19.16 98740018 Upper part, Adjusting Disc 1

1.1.6 99930008 M6*25 Inbus Screw 6 1.19.17 98400008 Pın, Adjusting Disc 1

1.2 99300059 O-ring 200x4 1 1.19.18 90600002 Clow 1

1.3 97610013 Pin 5x19,8 2 1.20 99930022 Inbus screw M10x35 9

1.4 11040089 Slider 1 1.21 11040099 Counter Support flange 1

1.5 99930007 M6*20 Inbus Screw 6 1.22 99930006 Inbus screw M6x16 4

1.6 98780015 Bracket assembly 1 1.23 99930002 Inbus screw m5x10 6

1.6.1 99840098 Bracket 1 2 99300006 O-ring 2

1.6.2 97610010 Pin 4x25,5 1 3 99400017 Flange Inlet 1 ½" 1

1.6.3 98410006 Pin 2x6 1 4 99920017 Screw M10x25 4

1.6.4 99710017 Washer Ø10 1 5 96400051 Label 1

1.6.5 98780018 Bracket 1 6 97110040 M10*50 Stud Bolt 4

1.7 11040041 Main Pivot Bracket Assembly 1 7 94100021 Assembly clape 1

1.7.1 97610012 Pin 5x10 3 7.1 96910001 Pin 1,5x20 1

1.7.2 11040049 Bracket 1 7.2 99730002 PUL RAYNEL Ø6 2

1.7.3 99850149 Screw, Main Pivot 1 7.3 94100020 Clape sheet 1

1.7.4 98740029 Main Pivot Gear 1 7.4 94100020 Clape sheet 1

1.7.5 99620005 Retaining Ring 471/19 1 7.5 98910020 Clape sheet spring 1

1.7.6 99620001 Retaining Ring 471/10 1 7.6 99710012 PUL Ø6 1

1.7.7 99020027 Adjustment Gear 1 7.7 98400011 Clape shaft 1

1.7.8 98780038 Wear Plate 1 8 98830006 M10 Nut 4

1.7.9 99850098 Pin 4 9 11030091 Assembly air separator 1

1.8 97630005 M16 Ball, Wear 1 9.1 11030099 Body, Air Separator 1

1.9 98780037 Metal Sheet Inox-Wear Plate 1 9.2 99720001 Washer, polyamide 1

1.10 11040051 Slack Roller Assembly 1 9.3 99400017 Flange, inlet 1 ½” 1

1.10.1 11040059 Slack Roller 1 9.4 97110040 Stud bolt M10x50 8

1.10.2 99820018 Shaft, Wobble Plate 1 9.5 95700002 Filter 1

1.11 98820001 Nut, flanged M6 3 9.6 99300006 O-Ring 2

1.12 97630006 M13 Ball 3 9.7 11030089 Strainer cover 1

1.13 98720022 Slack Spring Assembly 1 9.8 96800003 Flat washer M10 4

1.13.1 98720028 Slack Spring 2 9.9 98830006 Nut M10 8

1.13.2 98760015 Washer, Slack Spring 1 9.10 99840021 Float 1

1.13.3 96910001 Pin, Cotter 1,5x20 2 9.11 96900002 Pin 1,5x25 1

1.14 99840107 Conical drum 1 9.12 94510021 Assembly Bias 1

1.15 97000160 Bushing 1 9.12.1 98720039 Spring, Bias 3

1.16 94000011 Piston assembly 3 9.12.2 99710004 Washer ø4 3

1.16.1 94000019 Piston Connector, Plunger 1 9.12.3 95600001 Sheet screw d3.5x9.5 3

1.16.2 98770039 Plunger Disc 1 9.12.4 99860029 Pin Ø6xØ5x Ø4x4mm 3

1.16.3 93900019 Plunger Cup Kit 1 9.12.5 98720021 Spring, Rocker 1

1.16.4 98770049 Plunger Cup Support 1 9.12.5.1 98720029 Air separator bias sheet 1

1.16.5 99930002 Bolt allen M5x10 2 9.12.5.2 98780059 Sheet, bias connection 1

1.17 98760027 Washer 3 9.12.6 94510029 Block, Seal 1

1.18 99850129 Bearing Seat, Plunger 3 9.13 99960008 Screw M5x16 3

1.19 11040021 Cover Assembly 1 9.14 99710008 Washer Ø5 3

1.19.1 99840067 Bushing, Gear 1 9.15 99230004 Seal 1

1.19.2 99020020 Counter Drive Gear Complete 1 9.16 99300009 O-Ring 123,42x3,53 1

1.19.3 99840039 Adjustment Shaft Ø8x125 1 9.17 11010029 Cover,air separator 1

1.19.4 99610001 Retaining Ring 471/8 1 9.18 99841049 Rackor ½ “ – ¾ “ 1

1.19.5 99500003 Seal 8x18x8 1 9.19 96800002 Washer M8 6

1.19.6 99020021 Drive Shaft Gear 1 9.20 99920012 M8*30 Hex Screw 6

1.19.7 98410007 Pin 3x20 2 10 97210001 Ring, polyamide 2

23

1.19.8 99840038 Center Gear Shaft 1 11 99841059 3/4" Nut 2

1.19.9 99850089 Drive Shaft 1 12 98600026 air tube 1

Table 4. Meter and Air Separator Spare Parts

Figure 17. Mechanical Counter Register Disassembly

24

Poz No Code Description Qty.

Poz No Code Description Qty.

01 94540050 Case 1 36 98720038 Drum inner spring 5

02 96610001 Rivet Ø2.4*8 4 37 94540040 Nail 5

03 96210002 Dust cover 1 38 99020028 First drum rear gear 1

04 99910001 M3.9*13 screw 3 39 99020029 First drum front gear 1

05 99841025 Resetting knob 1 40 99620001 Ø10 retaining ring 5

06 93400029 Policarbonate glass 1 41 97020003 Total drive bushing 1

07 99960002 M4*8 screw 2 42 93310019 Right side support 1

08 93300019 Total support 1 43 99930029 M6*10 inbus screw 4

09 93200010 Totalizator drum 8 44 99840088 Fixing bushing 1

10 99000009 totalizator transfer gear 7 45 99850085 Ø8*210 shaft 1

11 99850015 shaft Ø2*55 1 46 99840109 Adjustment bushing 1

12 99850039 Total shaft Ø2.4*55 1 47 99600003 Ø6 retaining ring 1

13 93100019 Totalizator frame 1 48 99020024 transfer gear 4

14 99020023 totalizator gear z:10 1 49 99850063 Ø5*175 shaft 1

15 99600001 Ø2,3 retaining ring 1 50 99600004 Ø4 retaining ring 1

16 97000020 Bushing 1 51 99730001 Ø5*Ø10*0.2 washer 2

17 99850049 Shaft Ø3*72 1 52 94540030 Resetting holder 1

18 99940001 M3*6 setskur screw 1 53 98770119 Resetting sheet 1

19 97000019 Drive gear core 1 54 98900109 Resetting spring 1

20 99020022 Totalizator gear z:25 1 55 98700040 Base support 1

21 99620003 Ø6 retaining ring 1 56 98410005 Pin Ø2*16 2

22 99841023 Conical gear core 1 57 94540020 Transmission clow 1

23 99020018 Conical gear z:24 1 58 97000170 Support bushing 1

24 98640059 Ø6*175 shaft 1 59 99921002 M6*25 screw 4

25 99020026 Transfer gear 1 60 96100159 Drive shaft 1

26 99940003 M5*6 setskur screw 5 61 99730004 Ø8*Ø14*0.2 washer 15

27 99841024 Transfer gear core 1 62 99020025 88 – z:12 gear 1

28 99930001 M5*8 inbus screw 3 63 99000004 88 – z:16-z:36 gear 1

29 97020004 Ø6*2 bushing 2 64 96100169 Ø6- 16/36 gear shaft 1

30 93320019 Left side support 1 65 99000005 Conical gear z:27 1

31 98910040 Drum spring 5 66 96810002 Ø5 washer 3

32 99020030 Middle drum rear gear 4 67 96400027/ 96400028 Litre – Liters label 1

33 99020031 Middle drum front gear 4 68 96400029/ 96400030

Çalışırken sıfırlamayın – do not reset while operating label 1

34 93200029 Middle drum 4 69 96400018 MCR label 1

35 93200039 First drum 1 70 99841027 Bushing 1

71 93410010 Glass support 1

Table 5. Mechanical Counter Register Spare Parts

25

Figure 18. Electronic Counter Register Disassembly

Poz No Code Description Qty.

Poz No Code Description Qty.

01 99960004 M4*20 screw 8 18 99930029 M6*10 inbus screw 1

02 91740001 Power card 1 19 98700029 Disc guard 1

03 97010003 Bushing 16 20 99960001 M4*6 screw 2

04 99210001 Gasket 1 21 93400017 Glass 1

05 98410005 Ø2*16 mm pin 1 22 93410049 Frame 1

06 94510010 Clow 1 23 99961001 M4*8 screw 14

07 97810001 M20 Blind cap 2 24 91710003 Main/display card 1

08 14020019 Back case 1 25 99960014 M4*30 screw 4

09 96610001 Ø2.4*8 rivet 4 26 99200004 Gasket 1

10 96400019 Label 1 27 14021037 Front case 1

11 99210002 Gasket 1 28 99930015 M8*35 inbus screw 11

12 14020029 Back cover 1 29 91300004 Keyboard 1

13 99930013 M8*25 inbus screw 15 30 94540160 Button 1

14 97000180 Ø8* Ø12*22 bushing 1 31 99841089 Nippel 1

15 99840089 Shaft, pulser disc 1 32 99300028 Ø13,5*2,5 O-ring 1

16 91730003 Pulser card 1 33 99890029 Nut 1

17 99730008 Ø6* Ø12*1 washer 1 34 93100003 Pulsar disc 1

Table 6. Electronic Counter Register Spare Parts

26

6.5.Junk Meter

Take the cautions to prevent the environment from the risks of the meter can damage.

Empty the meter completely.

The meter is made of recyclable materials as iron, steel etc. Make effort for the recycling.

6.6. Periodic Maintenance

No

PARTS

Daily

Weekly

Monthly

3 Months

Year

REASON

A. MECHANICAL REGISTER

1 Register totalizator control

X The totalizator doesn’t count while the momentary digits count- the total gear may come away from its place.

2 Transmission clow control

X If there is fuel out from meter but the register doesn’t count, the transmission clow may be broken or the pin came away from its place.

3 Seal control X Up to metrological specifications

B.ELECTRONICAL REGISTER

1 Keyboard (membrane) control

X Must be replaced with a new one if it is not working.

2 Display control X If the display doesn’t work, the display card may be faulty or there is a problem in the electric connections.

3 Seal control X Up to metrological specifications

C. BODY

1 Body leakage control X Body must be tested under pressure to control for leakage problems.

2 Calibration control with prover

X Control for accuracy of meter.

3 Seal control X Up to metrological specifications

D. AIR ELIMINATOR – FILTER

1 Strainer cleaning and control

X If the strainer is torn, the foreign substances may come into meter and may damage. They also prevent working the air releasing system and let fuel goes out of meter without counting.

2 Joints, gasket, flange etc. Control

X Any faults on the meter parts may result counting of air or fuel leakage from meter.

3 Air eliminator tube control

X The nuts on the air eliminator tube must be tighten strongly. If not, fuel leakage can be seen.

4 Float control X Float is the main part for air releasing system. It can be burst because of high pressure.

5 Air eliminator cap, gasket, o-ring, screw control

X For leakage problems.

6 Seal control X Up to metrological specifications

Table 7. Periodic Maintenance Plan

27

7.TROUBLESHOOTING

Problem Possible Reason Possible Solution

The meter allows product passes through but the counter register does not work

The reset button may jammed. This button may jammed and blocks the record in old type counter registers. Control the reset button. The totalizator will continue recording.

The screws or retaining rings that hold the gears on the gear plate may be untighten.

In case of untighten of these screws, both the momentary and totalizator will not record. Tighten the screws.

Abrasions, breakings, outbreaks of pins on the gear plate gears.

The gear system must be repaired. Consult to IPT.

The meter does not let the liquid pass through or the counter register does not count.

Coming out of plunger bearing seat or the ball on the plunger bearing seat.

This situation occurs when the meter used over capacity. Fix the part in its place.

The filter in the air separator did not cleaned or the meter used without filter. The plungers do not do their duties.

Changing of the plungers are necessary.

Breaking down or coming out of the centering gear or transferring gear.

Changing of the gears or fixing to their place are necessary. Check whether the part come out of its place damaged to other parts.

The result of using other than standard petroleum products or unappropriate liquid, worn in the plunger cup kit.

Changing of the kit is necessary.

The mechanism which provides the movement of the float in the air separator broke down, the springs provides the conduction lost its stress.

Change the mechanism and the springs.

Air separator or the filter clape choked. Clean the air separator and the filter. Determine the pressure before and after the meter while the pump is operating. The equal values shows the problem is not in the meter.

Clape between the air separator and the meter choked. Clean the clape.

Detaching of main pivot pin. Wobble plate assembly may lock the plunger due to wrong operation. Fix the pins in their places.

The meter transfers more liquid than the counter register counts.

Meter calibration broke down. The meter should be tested for the repeatability. (Section 6.2). If the meter is in good condition, calibrate the meter.

Counter register broke down. Consult to IPT.

The meter transfers less liquid than the counter register counts.

A leakage in the inlet of the pump. Control all the connections included the pump gaskets. The air sucked to the system and pumped to the meter effects the counter.

Meter calibration broke down. The meter should be tested for the repeatability. (Section 6.2). If the meter is in good condition, calibrate the meter.

Counter register broke down. Consult to IPT.

The meter sounds excessive impact noise.

The meter valve or another internal part needs repair work or change.

Consult to IPT.

Table 8. Solution Table

28

8.GUARANTEE

ER 91 M/E A1013 meters are guaranteed for 2(two) years.

THE METER IS ONLY GUARANTEED IF IT IS OPERATED APPROPRIATE TO THE CLAUSES WRITTEN INSIDE THIS

MANUAL. THE METER IS NEVER OPERATED OTHER THAN THE OPERATING LIMITS (DEFINED IN THE TECHNICAL

SPECIFICATION TITLE)!

Guarantee Conditions

Guarantee duration starts at the shipping of the item to the customer and enclose for a time of 2 years.

The meter with all the parts included is under guarantee of our firm.

In case of malfunctions in the period of guarantee, the time passed for the repair work will be added to the guarantee time. The repair time is at most 30 business days. This period starts with getting the information by the factory, service station or to the importer (if there isn’t any service station)

The importer must destine a similar product to the customer until the the repair work is completed.

The seller has the responsibility to repair or made it repaired without demanding any charges in the name of changing parts, labor cost or anything else if the product breaks down due to assembly, material or workmanship in the period of guarantee.

From the date of shipping to the customer, on condition of being in guarantee period; if the product breaks down twice for the same reason or breaks down 4 times because of different reasons in a year or breaks down 6 times, and moreover the break downs prevent benefiting to the product,

Excessing the maximum duration for the repair work,

In the case of determining with a report by the service station (if there isn’t a service station by the seller, the dealer, the agent or the manufacturer orderly ) that the repair of the product can not be possible, the customer claims changing the product to a new one free of charge, refund of money or cost discount at the same amount of fault amount.

The malfunctions result to operating the meter contrary to the clauses written in the manual is out of guarantee.

The customer could consult to the Ministry of Industrial and Commerce and Protected of Consumer and Competition General Management about the occuring problems .

COMPANY AND TECHNICAL SERVICE

ADDRESS 100. Yil Blv. No:25 06370 Ostim/Ankara/TURKEY

TELEPHONE +90 312 385 12 85 (pbx)

FAX +90 312 385 92 82

WEB SITE www.ismet.com.tr

E-MAIL ismet@İsmet.com.tr

METER SERIAL NO :

DATE :

STAMP/SIGNATURE :

29

9. PRODUCT TEST/CALIBRATION FORM

PRODUCT INFORMATION :

PRODUCT TYPE :

PRODUCT SERIAL NO :

PRODUCTION PLACE :

PRODUCTION DATE :

TEST / CALIBRATION AREA :

AREA TEMPERATURE :

TEST/CALIBRATION LIQUID TEMPERATURE :

TEST/CALIBRATION LIQUID TYPE :

TEST / CALIBRATION RESULT :

Test

No

Flow

(Liters)

Flow Read

(Liters)

Difference

(Liters)

Error Rate

( % )

1 1000

2 500

3 50

4 20

5 10

TESTED BY CONTROLLED BY