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Service Guide339296 339296-1339316 Series339317 339318338315

Fluid Control System (FCS)

WARNINGDo not allow the pump within this sys-

tem to operate at a discharge pressure greaterthan 1000 psi (69 Bars).

Component damage and personal injury canoccur.

ScopeThe Fluid-Guard fluid control system (FCS) is

designed to be incorporated into a dispensing system for managing a single fluid.

The system monitors the fluid in the unit of measure of the chosen pulse meter. See Table 1 on page 3 for details.

Fluid Dispensing System

The integration of the FCS requires certain standards within the dispensing system.

Pumping Station

For example, the pump assembly should be air-operated. An air solenoid valve allows regulated air to be shut-off from the fluid pump when the FCS is not in operation.

Clean Regulated Air Pressure

The air line components for the pumping station must consist of an air regulator, a moisture separator, and lubricator.*

The air pressure must be regulated to ensure the pump’s operating pressure is maintained.

Clean Fluid

The FCS also contains a fluid solenoid valve, a pulse meter, and a pressure-relief valve (optional).

* Necessary for pump motors that require lubrication.

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ite Corporationohnson City, Tennessee 37601

All these components require a 40-micron fluid filter. See Figure 1 for details.

Overview of the FCSThe fluid control system is an electro-mechanical

monitoring and security system for a single fluid. The system consists of a selection of the components listed in Table 1.

Fluid Console

The fluid console is the heart of the system. It can control as many as 12 dispensing stations one at a time.

The fluid console consists of a(n):• On/Off switch (keyed for security)• Start switch (energizes air and fluid valves)• Dispensing indicator(illuminates when station is enabled)• Station Select switch (selects 1 of 12 stations)• Preset Quantity counter (for quantity entry)• Total Dispensed counter (displays cumulative total)

The console contains a transformer that converts main electrical power into 24 V dc.

Air Solenoid Valve

When energized, the air solenoid valve opens to deliver air pressure for pump operation.

Fluid Solenoid Valve

When energized, the fluid solenoid valve opens to allow the fluid to be dispensed from the control valve.

Pulse Meters

There are four different pulse meters that can be incorporated into the system. Each model meters in a different unit of measure. See Page 7 for details.

Ready Light Kit

This light illuminates to inform the floor technician that the fluid is now enabled to be dispensed.

AssemblyA typical fluid control system is illustrated on pages 2 and 3.

SER 339296

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04 by Alemite Corporation

ormation that is the property of Alemite Corporationosed to others without express written permission. Revision (3-04)rtdeal.com - [email protected]

SER 339296 Fluid Control System

Revision (3-04) 2 Alemite Corporation1-800-548-1191 - http://www.partdeal.com - [email protected]

Fluid Control System SER 339296

Alemite Corporation 3 Revision (3-04)

FCS Component Part Number FCS Component Part Number

Fluid Console (115 V ac) 339296 Pulse Meter (Gallons) 339316-1

Fluid Console (230 V ac) 339296-1 Pulse Meter (Liters) 339316-2

Air Solenoid Valve 339317 Pulse Meter (Quarts) 339316-3

Fluid Solenoid Valve 338315 Pulse Meter (Pints) 339316-4

Ready Light Kit 339318

Table 1 FCS Available Components

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Revision (3-04) 4 Alemite Corporation

Figure 1 Typical Pumping Station

Legend: Items in Bold are part of the Fluid Control System



Figure 2 Fluid Console Models 339296 and 339296-1

Console Model Power Requirement Circuit Board Power Cord Plug Fuse

339296 115 V ac 339297 Included 0.14 Ampere

339296-1 230 V ac 339297-1 Not Included 0.2 Ampere

atm

co

i

Fluid ConsoleThere are two models of fluid

consoles available. See Figure 2 for details.

DescriptionEach fluid console consists of a(n):• On/Off switch (Keyed)• Start switch• Dispensing indicator• Station Select switch• Preset Quantity counter• Total Dispensed counter

On/Off Switch

This key-operated switch ensures the security of the fluid.

The switch must be in the ON position to enable the system to operate.

Station Select Switch

The console operator sets this switch to the number of the dispensing station that requires fluid.

Preset Quantity Counter

This 6-digit liquid-crystal display shows the amount of fluid to be dispensed to a tenth of a unit. The unit of measure is established by the model of the pulse meter. Refer to the section entitled Pulse Meter for details.

For quantity entry, see steps 3-6 in the section entitled Operation.

Start Switch

Press this push-button switch to energize the air and fluid solenoid valves.

Dispensing Indicator

This indicator illuminates once the Start switch is pressed. It informs the console operator that the fluid is now enabled to be dispensed.

The indicator deactivates once the quantity is dispensed in full.

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Total Dispensed Counter

This 8-digit liquid-crystal display accumulates and shows the combined total mount of fluid dispensed from all stations. The register displays the amount to a enth of a unit. The unit of measure is established by the model of the pulse

eter. Refer to the section entitled Pulse Meter for details.

NOTE: The display cannot be reset to zero.

Printed Circuit Board

The printed circuit board within each model contains a transformer that onverts electrical current (either 115 or 230 V ac) into 24 V dc. The maximum utput is 1.2 amperes.

Labels (Fluid Type and Units of Measure)

A set of 14 vinyl labels depicting various fluids and units of measure are ncluded. Affix the proper set of labels to the console as illustrated in Figure 2.

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Figure 3 Back Panel of Fluid ConsoleModels 339296 and 339296-1

Operation

1. Make sure the key is set to the On position. See Figure 3.

2. Position the Station Select switch to the number of the station that requires fluid.

NOTE : Procedures 3-6 are per-formed on the Preset Quantitycounter.

3. Press the E (Edit) and 1 keys simultaneously.

NOTE: The display shows the valueof the last quantity dispensed andPRG in the lower right hand corner.PRG indicates the program mode isenabled.

Should the operator fail to press adigit key within 15 seconds, the dis-play shows zero and the programmode in disabled. To enable the pro-gram mode once again, repeat step 3.

4. Press the appropriate digit key(s) the required number of times to enter the amount to be dispensed.

IMPORTANT: The factory has setthe number 1 key to represent tenthsof a unit. The number 2 key is a sin-gle whole unit, the number 3 repre-sents tens, etc.

EXAMPLE: To enter a quantity of4.2 units, press the 1 key twice andpress the 2 key four times.

5. Press the E (Edit) key.

The display shows the value of zero.

6. Press the 6 and 4 keys (Reset) simultaneously.

The display shows the current quantity to be dispensed once again.

NOTE: Should the value require tobe changed, repeat steps 3 - 6.

Revision (3-04)1-800-548-1191 - http

7. Press the Start switch.

This energizes the:• air and fluid solenoid valves• Dispensing indicator• Ready Light

The floor operator can now begin dispensing.

All components deenergize once the quantity on the Preset Quantity counter counts down to zero.

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Figure 4 Pulse Meter Model 339316 Series

Pulse Meter Model Unit of Measure

339316-1 Gallons

339316-2 Liters

339316-3 Quarts

339316-4 Pints

Pulse Meter

Description

There are four models of pulse meters available with the FCS. Each model meters in a different unit of measure. See Figure 4.

Each meter measures the amount of fluid being dispensed and sends the signal to the Fluid Console to record the count.

Operation

Fluid enters the inlet port and passes through the metering chamber. The mechanical measurement is converted to an electrical signal with the use of a 10-lobe cam and a limit switch.

Overhaul

NOTE : Refer to Figure 5 forcomponent identification on alloverhaul procedures.

Disassembly

1. Remove Shroud Screws (12) that secure Shroud (1) to Housing (11).• Remove the Shroud from the Housing.

2. Remove Switch Screws (2) that secure Limit Switch (3) to Mounting Plate (4).• Remove the Limit Switch from the

Mounting Plate.

3. Remove Mounting Plate Screws (5) that secure the Mounting Plate to the Housing as required.• Remove the Mounting Plate from the

Housing.

4. Loosen Setscrew (7) that secures Cam (6) to Spindle (13 or 16).• Remove the Cam from the Spindle.

Alemite Corporation

Specifications

Inlet and OutletConnections

Min. Operating Pressure

Max. Operating Pressure

psi Bars psi Bars

1/2 " NPTF (f) 35 2.4 1000 69

Table 2 Pulse Me

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5. Unscrew Housing Cap (20) from the Housing.

6. Remove O-Ring (19) and Screen (18) from the Housing.

Model Dependent Step 7. Remove Chamber and Piston Assembly (15) and Gear Train

Assembly (14) from the Housing(Models 339316-2, 339316-3, and 339316-4).

Remove Chamber and Piston Assembly (17) from the Housing (Model 339316-1).

7 Revision (3-04)

Flow RateMin. Operating

TemperatureMax. Operating

TemperatureAccuracyGallons Liters

Min. Max. Min. Max. ° F ° C ° F ° C

0.4 4.0 1.5 15.1 -10 -23 150 65 ± 0.65 %

ter Model 339316 Series - Specifications

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Figure 5 Pulse Meter Model 339316 Series - Exploded View




ItemNo. Part No. Description Qty Notes Numeric Order

Part # (Item #)

1 393307-150 Shroud 1 (2)

2 Screw, Switch, 4 - 24 x 5/8 " 2 (5)

3 Switch, Limit 1 (11)

4 393307-192 Plate, Mounting 1 393307-58 (14)

5 Screw, Mounting Plate, 4 - 40 x 3/8 " 2 393307-60 (19)

6 Cam, 10-Lobe 1 393307-68 (13)

7 Setscrew, Cam 1 393307-69 (16)

8 393307-133 Nut, Packing Gland 1 393307-72 (14)

9 393307-130 O-Ring 1 393307-74 (15)

10 393307-128 Washer 1 393307-76 (18)

11 Housing 1 393307-77 (20)

12 393307-129 Screw, Shroud 2 393307-78 (14)

13 393307-68 Spindle 1 Model 339316-2, 3, 4 393307-128 (10)

14

393307-78 Gear Train Assembly (Liter) 1 Model 339316-2 393307-129 (12)

393307-58 Gear Train Assembly (Quart) 1 Model 339316-3 393307-130 (9)

393307-72 Gear Train Assembly (Pint) 1 Model 339316-4 393307-133 (8)

15393307-155 Chamber and Piston Assembly (Liter) 1 Model 339316-2 393307-150 (1)

393307-74 Chamber and Piston Assembly (Quart) 1 Model 339316-3, 4 393307-154 (17)

16 393307-69 Spindle Model 339316-1 393307-155 (15)

17 393307-154 Chamber and Piston Assembly (Gallon) Model 339316-1 393307-191 (3)

18 393307-76 Screen 1 393307-192 (4)

19 393307-60 O-Ring 1 393307-193 (7)

20 393307-77 Cap, Housing 1 393307-194 (6)

Legend:Part numbers left blank (or in italics) are not serviced separately

designates a repair kit item

Repair Kit

Part No. Kit Symbol Description

393307-195 Kit, Repair



8. Unscrew Packing Gland Nut (8) from the Housing.

9. Remove O-Ring (9) and Washer (10) from the Housing.

Clean and Inspect

NOTE: Use the repair kit for replacementparts. Make sure all the components areincluded in the kit before discarding usedparts.

1. Clean all metal parts in cleaning solvent. The solvent should be environmentally safe.

2. Inspect all parts for wear and/or damage.• Replace as necessary.

Assembly

NOTE: Prior to assembly, lubricate O-Ring(9) and Washer (10) with clean oil.

1. Install Washer (10) into Housing (11).

2. Install Spindle (13 or 16) [stem first] into the bottom of the Housing.

3. Hold the Spindle in the Housing and install and seat O-Ring (9) onto the Spindle’s stem.

4. Screw Packing Gland Nut (8) into the Housing.• Tighten the Packing Gland Nut to a maximum of 80

inch-pounds (9 Nm).

Model Dependent Step 5. Install and seat Chamber and Piston Assembly (15)

[circular hole end first] onto the bottom of Gear Train Assembly (14) (Models 339316-2, 339316-3, and 339316-4).• Make sure the Chamber and Piston Assembly engages

properly with the slot in the Gear Train Assembly.

Model Dependent Step 6. Install and seat the Gear Train and Chamber and Piston

Assembly [gear train first] into the housing and onto the spindle (Models 339316-2, 339316-3, and 339316-4).• Operate the assembly by hand to ensure all the

components are properly engaged.

Install and seat Chamber and Piston Assembly (17) [gear end first] into the Housing and onto the spindle (Model 339316-1).• Make sure the Chamber and Piston Assembly engages

properly with the Spindle.• Operate the assembly by hand to ensure all the

components are properly engaged.

Revision (3-04) 101-800-548-1191 - http://www

7. Install and seat Screen (18) [concave side first] and O-Ring (19) into the Housing.

8. Screw Housing Cap (20) into the Housing.• Tighten the Housing Cap to a maximum of 50 foot-

pounds (54 Nm).

9. Align the flats and install and seat Cam (6) onto the Spindle.

10. Tighten Setscrew (7) that secures the Cam to the Spindle.

11. Install Mounting Plate (4) onto the Housing.• Make sure the holes are aligned properly.

12. Install Mounting Plate Screws (5) that secure the Mounting Plate to the Housing.• Tighten the Screws securely.

13. Install Limit Switch (3) onto the Mounting Plate.• Make sure the rocker points toward the center of the

meter.

14. Install Switch Screws (2) that secure the Limit Switch to the Mounting Plate.

IMPORTANT: Operate the Cam by hand toensure the Limit Switch operates correctly.

15. Tighten the Switch Screws securely.

16. Install Shroud (1) onto the Housing.

17. Install Shroud Screws (12) that secure the Shroud to the Housing.• Tighten the Screws securely.

Wiring

Refer to the section entitled Electrical Installation for details.

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Figure 6 Air Solenoid Valve Model 339317

Air Solenoid Valve

Manufacturer

The air solenoid valve is manufactured by:

Skinner Valve

New Britain, ConnecticutJurong Town, Singapore

Replacement parts should be procured from either address.

Installation

CAUTIONA filter/separator must be used with thisvalve.

Cleanliness is essential during installa-tion. Make sure all of the air lines arefree of foreign material prior to valveoperation. Valve may become cloggedand not function properly.

Description

The Air Solenoid Valve is 2-way normally closed and pilot-operated. The valve is equipped with an LED indicator light. When energized, the valve allows regulated air pressure to operate the pump.

Wiring


Specifications

Alemite Corporation


Min. Operating Pressure

Max. OPres

psi Bars psi

3/8 “ NPTF (f) 5 0.4 150

Table 3 Air Solen

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11 Revision (3-04)
perating sure

Power Requirement Current Draw Termination Seal Type

Bars

10.3 24 V dc 0.4 Amps DIN 43650 Buna N

oid Valve Model 339317 - Specifications

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Figure 7 Fluid Solenoid Valve Model 338315


Manufacturer

The fluid solenoid valve is manufactured by:

HydraForce, Inc.

Lincolnshire, IllinoisTokyo, Japan

Replacement parts should be procured from either address.

Installation

CAUTIONA 40-micron filter must be used with thisvalve. The filter is normally installed nearthe outlet of the pump.

Cleanliness is essential during installa-tion. Make sure all of the fluid tubing isfree of foreign material prior to valveoperation. Valve may become cloggedand not function properly.

Description

The Fluid Solenoid Valve is normally closed and pilot-operated. The valve is equipped with an LED indicator light and a manual override. When energized, the valve opens and allows fluid to be dispensed from the control valve.

Operation

The valve assembly consists of two separate internal valves; the primary needle valve and the secondary valve. The primary valve actuates first, which in turn, causes the secondary valve to operate.

When the coil is energized, the primary

Revision (3-04)

Specifications


Operating PressureFlow Rate

psi Bars

1/2 “ NPTF (f) 30 - 3000 2.1 - 207 See Figure 8

Table 4 Fluid Sole

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needle valve lifts and allows fluid into the delivery port. Fluid pressure equalizes and assists the movement of the secondary valve.

Manual Override

To place the valve in the manual override mode-of-operation:• Push down on the knob and turn counterclockwise 180 °.

Wiring


12 Alemite Corporation

Power Requirement

Current Draw Termination

OperatingTemperature Required

Filtration° F ° C

24 V dc 0.60 Amps DIN 43650 -40 to 248 -40 to 120 40-Micron

noid Valve Model 338315 - Specifications

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Figure 8 Fluid Solenoid Valve Pressure Drop versus Flow Rate



Getting StartedPrior to installing the fluid piping and wiring the

system, it is mandatory to create a layout that includes all the components in the FCS (including wiring junction boxes, if desired).

A proper understanding of the system’s design is crucial to ease the installation and wiring process.

Work Sheet

As an aid, use the work sheet at the end of this Service Guide.

NOTE: Figure 10 illustrates a complete wiring diagram of the FCS system.

Revision (3-04) 1

Table 5 15-Wire Cable Color Code

Wire ColorFCS Component

Neutral Power (+)

Black All Solenoid Valves

White Pulse Meter

Red Air Solenoid Valve and Pulse Meter

Green No. 1 Fluid Solenoid Valve

Orange No. 2 Fluid Solenoid Valve

Blue No. 3 Fluid Solenoid Valve

White/Black No. 4 Fluid Solenoid Valve

Red/Black No. 5 Fluid Solenoid Valve

Green/Black No. 6 Fluid Solenoid Valve

Orange/Black No. 7 Fluid Solenoid Valve

Blue/Black No. 8 Fluid Solenoid Valve

Black/White No. 9 Fluid Solenoid Valve

Red/White No. 10 Fluid Solenoid Valve

Green/White No. 11 Fluid Solenoid Valve

Blue/White No. 12 Fluid Solenoid Valve

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Electrical Installation

CAUTIONAll wiring must be in accordance with appropriate regulations. All electrical connections should be made by qualified personnel only.

Prior to applying power to a new installation, alwayscheck the wiring for correct polarity and ensure allterminal connections are secure.

Hazardous voltages exist within the fluid console.Always disconnect the power before removing thecover.

Fluid Console

Specifications

Contact Relay• current rating - 10 Amperes• voltage rating - 30 V dc• coil to contact isolation - 4k V ac.• open contacts - 1k V rms.• adjacent contacts - 2.5k V rms.

Station Select Switch

As stated previously, the station select switch can control as many as 12 separate dispensing stations (fluid solenoid valves).

15-Wire Cable

The wires for each station are within the 15-wire cable from the fluid console. This cable consists of the neutral wire and the power wire required for each component within the system. See Table 5 for details.

Wire Connections

The recommended wire to attach to the 15-wire cable is length dependent. See Table 6 for details.

4 Alemite Corporation

Wire GaugeLength of Wire

Feet Meters

20 up to 100 up to 30.5

18 100 - 200 30.5 - 61

16 200 - 300 61 - 91.4

14 300 - 400 91.4 - 122

12 400 - 500 122 - 152.4

Table 6 Comparison of Wire Gauge with Length of Run

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Figure 9 Air and Fluid Solenoid ValveElectrical Connections

Air Solenoid Valve

Valve Connector

IMPORTANT: The air solenoid valvecontains a diode in its connector. Thediode prevents electrical surges fromdamaging the contacts on the relaywithin the fluid console.

CAUTIONMake sure to connect the Red power wire(+) to the number 1 terminal on this con-nector. See Figure 9. Damage to compo-nents can occur.

Connect the Red power wire within the 15-wire cable to terminal number 1 in the air solenoid valve’s connector.

Connect the Black neutral wire to terminal number 2. See Figure 9.


Valve Connector

IMPORTANT: The fluid solenoidvalve contains a diode in its connec-tor. The diode prevents electricalsurges from damaging the contactson the relay within the fluid console.

CAUTIONMake sure to connect the designated powerwire (+) to the number 1 terminal on thisconnector. See Table 5 and Figure 9. Dam-age to components can occur.

Connect the required power wire within the 15-wire cable to terminal number 1 in the fluid solenoid valve’s connector. See Table 5.

EXAMPLE: For the number 1 fluidsolenoid valve connect the Greenpower wire within the 15-wire cableto terminal number 1 in the valve’sconnector.

Connect the Black neutral wire to terminal number 2. See Figure 9.

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Pulse Meter

Meter Switch Connection

Connect the Red power wire within the 15-wire cable to either the Normally Open (N.O.) or Normally Closed (N.C.) terminal on the switch. See Figure 5.

Connect the White neutral wire to the Common terminal.

Ready Light Kit

Connect the ready light in parallel with each fluid solenoid valve.

EXAMPLE: For the number 1 fluid solenoidvalve connect either of the wires within theready light to the Green power wire within the15-wire cable. Connect the remaining wirewithin the ready light to the Black neutral wirewithin the 15-wire cable. See Figure 10.

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Figure 10 FCS Field Wiring Diagram




Troubleshooting Chart

System Indications Possible Causes Solutions

Fluid console fuse fails at initial installation

1. System wired incorrectly2. Electrical short circuit

1. Inspect wiring *2. Locate and eliminate short

Fluid console fuse fails after initial installation

Electrical short circuit Locate and eliminate short

Meter display goes blank once the start switch is pressed

Air and/or fluid solenoid valve wired incorrectly

Inspect wiring *

Reduced or zero flow 1. Clogged fluid solenoid valve

2. Clogged air solenoid valve

3. Pulse meter Chamber and Piston Assembly jammed

4. Damaged coil in air and/or fluid solenoid valve

5. Operating pressure below minimum specified for air and/or fluid solenoid valves

6. Damaged fluid console relay due to diode failure in air and/or fluid solenoid valve

1. Clean fluid system filter and air solenoid valve

2. Clean air system filter and fluid solenoid valve

3. Clean pulse meter

4. Replace coil

5. Increase air and/or fluid pressure

6. Replace fluid console circuit board and Connector

Pulse meter is not accurate 1. Flow rate above maximum2. Flow rate below minimum

1. Decrease flow rate2. Increase flow rate

Fluid console does not record delivery

1. Pulse meter electrical connection failure

2. Pulse meter gear train jammed3. Pulse meter Limit Switch failure

1. Check wiring

2. Rebuild pulse meter3. Replace Limit Switch

* If either the air or the fluid solenoid valve were wired incorrectly, the diode on the Connector must be checked.

Changes Since Last Printing

Changed Air and Fluid Solenoid Valve Configuration and Operation


Fluid Control System Equipment

Fluid Console (115 V ac)

Fluid Console (230 V ac)

Pulse Meter (Gallons)

Pulse Meter (Liters)

Pulse Meter (Quarts)

Pulse Meter (Pints)

Air Solenoid Valve [24 V dc, 3/8 " NPTF (f)] (one per fluid)

Fluid Solenoid Valve [24 V dc, 1/2 " NPTF (f)] (one per station)

Ready Light Kit (one per station)

Mechanical Components and Accessories

Air Line Filter and Regulator, 1/4 " NPTF (f)



Air Line Lubricator, 1/4 " NPTF (f)



Air-Operated Pump Assembly (one per fluid)

Relief Valve [900 psi (62 Bars)] (one per fluid)

Relief Valve Installation Kit (one per fluid)

Reel Assemblies

Wall Mount Kit

Control Valves

Hydraulic Tubing

Tube Fittings

Cable Ties

* Only on pump motors that require lubrication.

Quantity Part No.

339296

339296-1

339316-1

339316-2

339316-3

339316-4

339317

338315

339318

Installation Work Sheet

Choose one per fluid

[1/2 " NPTF (f)] (Choose one per fluid)

Choose one per fluid338860

338861

338862

5904-2

5906-2

5908-2

339277-1

339276

Ft.

Choose one per fluid *


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