Maintenance Manual

Spare Parts List

MASTERLOAD II TM

- For Vehicles

Used with:
Display Unit Program PO80 (Issue 6.2 or later)
Power Supply Program PO81 (Issue 1.7 or later)

LIQUID CONTROLS Publication TP00025B

February 2016
An IDEX Energy & Fuels Business
 SAFETY CRITICAL COMPONENT – RELATED DOCUMENT
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available on our web site, www.lcmeter.com. It is the responsibility of the local
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PUBLICATION: TP0025B, FEBRUARY 2016

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 AVERY-HARDOLL MAINTENANCE MANUAL
MASTERLOAD II™ (Vehicle)

REVISION PAGE
Keep this record in the front of the manual. When new issues are received, put the revised pages in the
manual. Write the issues number, date and initials on this page.

Issue PAGES APPROVED

No. AFFECTED DESCRIPTION OF CHANGE DATE BY

A ALL INITIAL RELEASE PER ECO 14290 06-AUG-2013 TIM LE

B ALL OWNERSHIP CHANGE, 08-FEB-2016 D.KARIMOV

REGULATORY UPDATES.

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TABLE OF CONTENTS
SUBJECT PAGE
CHAPTER 1 INTRODUCTION ........................................................................................................... 1-1
1.1 General ................................................................................................................................... 1-1
1.2 Revision Service...................................................................................................................... 1-1
1.3 Weights and Measurements .................................................................................................... 1-1
1.4 Associated Publications ........................................................................................................... 1-1
CHAPTER 2 TECHNICAL DESCRIPTION ......................................................................................... 2-1
2.1 General ................................................................................................................................... 2-1
2.2 MASTERLOAD II Systems ...................................................................................................... 2-1
2.3 Pulse Transmitter Unit ............................................................................................................. 2-3
2.4 Power Supply Unit ................................................................................................................... 2-3
2.5 Display Unit ............................................................................................................................. 2-5
2.6 Remote Display Units .............................................................................................................. 2-9
2.7 Flags and Error Messages..................................................................................................... 2-10
CHAPTER 3 SPECIFICATIONS ......................................................................................................... 3-1
3.1 General Specifications............................................................................................................. 3-1
3.2 Unit Dimensions / Detailed Specifications................................................................................ 3-3
3.3 Safety Markings………………………………………………………………...………………………3-8
CHAPTER 4 INSTALLATION............................................................................................................. 4-1
4.1 Receipt .................................................................................................................................... 4-1
4.2 Installation ............................................................................................................................... 4-1
4.3 Power Supply Unit ................................................................................................................... 4-1
4.4 Display Unit ............................................................................................................................. 4-3
4.5 Pulse Transmitter .................................................................................................................... 4-4
4.6 Temperature Probe - Installation ............................................................................................. 4-6
4.7 Electrical Installation ................................................................................................................ 4-8
4.8 An Overview of Typical System Wiring Diagrams (Wiring diagrams in back of this manual).. 4-10
4.9 Pulse Transmitter Wiring (Refer to Wiring Diagram) .............................................................. 4-15
4.10 Display Unit Wiring (Refer to Wiring Diagram) ....................................................................... 4-15
4.11 Override Switch ..................................................................................................................... 4-16
4.12 Power Supply Unit ................................................................................................................. 4-16
4.13 Power Supply Unit Wiring (Refer to Wiring Diagram) ............................................................. 4-19
4.14 External Valves and Deadman .............................................................................................. 4-21
4.15 Vehicle Cab Communication Wiring (Link to Cab Computer) (Refer to Wiring Diagram) ....... 4-21
4.16 Other Vehicle Systems (Refer to Wiring Diagram) ................................................................. 4-22
4.17 Transducer Wiring (Refer to Wiring Diagram) ........................................................................ 4-23

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TABLE OF CONTENTS - CONTINUED

SUBJECT PAGE
4.18 Densitometer Unit Wiring .......................................................................................................4-24
4.19 Differential Pressure Transducer Wiring .................................................................................4-25
4.20 Pressure Transducer Wiring...................................................................................................4-26
4.21 Remote Display Unit ..............................................................................................................4-26
4.22 Slip Printer .............................................................................................................................4-27
4.23 Deadman Timer System ........................................................................................................4-28
CHAPTER 5 COMMISSIONING..........................................................................................................5-1
5.1 Pre-Commissioning ..................................................................................................................5-1
5.2 Initial Power Up ........................................................................................................................5-2
5.3 Commissioning ........................................................................................................................5-2
5.4 Flag Setting Exercise ...............................................................................................................5-3
5.5 Flag Tables ..............................................................................................................................5-6
5.6 Initial Settings ..........................................................................................................................5-6
5.7 Low Security Flags .................................................................................................................5-16
5.8 High Security Flags ................................................................................................................5-21
5.9 Assessing Transaction Storage..............................................................................................5-28
5.10 Ticket Printer - Specification...................................................................................................5-29
5.11 Ticket Printer Operation - Non Preset System ........................................................................5-30
5.12 Ticket Printer Operation - Preset System ...............................................................................5-31
5.13 Setting Up the Preset Valve ...................................................................................................5-32
5.14 Calibration..............................................................................................................................5-35
5.15 Calibration Classes ................................................................................................................5-35
5.16 Masterload Calibration - With an Avery-Hardoll Bulkmeter .....................................................5-36
5.17 Calibrating Masterload ...........................................................................................................5-40
5.18 Display Unit Set-Up ................................................................................................................5-40
5.19 Temperature Device...............................................................................................................5-41
5.20 Densitometer Unit ..................................................................................................................5-41
5.21 Differential Pressure Transducer ............................................................................................5-41
5.22 Pressure Transducers ............................................................................................................5-42
5.23 Cab Computer System ...........................................................................................................5-42
5.24 Flag Settings - Recording .......................................................................................................5-45

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TABLE OF CONTENTS - CONTINUED

SUBJECT PAGE
CHAPTER 6 OPERATION ................................................................................................................. 6-1
6.1 Introduction ............................................................................................................................. 6-1
6.2 Non-Preset Delivery (see Figure 6.1) ...................................................................................... 6-1
6.3 Preset Delivery (see Figure 6.2) .............................................................................................. 6-2
6.4 Cab Computer Operation......................................................................................................... 6-4
CHAPTER 7 FAULT FINDING ........................................................................................................... 7-1
7.1 Introduction ............................................................................................................................. 7-1
7.2 Fault Finding Table .................................................................................................................. 7-1
CHAPTER 8 MAINTENANCE AND OVERHAUL ............................................................................... 8-1
8.1 Routine Maintenance and Overhaul ........................................................................................ 8-1
8.2 Display Unit - Removal (see Figure 8.1) .................................................................................. 8-2
8.3 Display PCB Replacement ...................................................................................................... 8-4
8.4 LCD Replacement (see Figure 8.2) ......................................................................................... 8-4
8.5 Push Button Replacement ....................................................................................................... 8-5
8.6 Processor PCB Replacement .................................................................................................. 8-5
8.7 Power Supply Unit Removal .................................................................................................... 8-5
8.8 Fuse Replacement .................................................................................................................. 8-7
8.9 Barrier Block Replacement ...................................................................................................... 8-7
8.10 Solid State Relay Replacement ............................................................................................... 8-8
8.11 PCB Replacement ................................................................................................................... 8-8
8.12 Pulse Transmitter Unit ............................................................................................................. 8-9
CHAPTER 9 SPARE PARTS ............................................................................................................. 9-1
9.1 General Information ................................................................................................................. 9-1
9.2 Ancillary Equipment ................................................................................................................. 9-1
9.3 Scope of Information ............................................................................................................... 9-1
APPENDIX A. CERTIFICATION CRITICAL INFORMATION ............................................................ A-1
IMPORTANT SAFETY INSTRUCTIONS…………………………………………………………………….A-2
GENERAL OPERATING LOCATION PRECAUTIONS…………………………………………………….A-3
MAINTENANCE HAZARDS…………………………………………………………………………………...A-4
PRODUCT SAFETY……………………………………………………………………………………………A-5
ENVIRONMENTAL GUIDELINES AND DETAILED SPECIFICATIONS ..……………………………….A-6

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LIST OF ILLUSTRATIONS
FIGURE PAGE
Figure 1.1 Typical Vehicle Installation .............................................................................................1-2
Figure 1.2 MASTERLOAD II System ...............................................................................................1-3
Figure 1.3 Non Preset System ........................................................................................................1-4
Figure 1.4 Non Preset System Including Cab Communication and Transducer Interface ................1-5

LIST OF ILLUSTRATIONS - CONTINUED

FIGURE PAGE
Figure 1.5 Preset Batch Delivery .....................................................................................................1-6
Figure 1.6 Preset System ................................................................................................................1-1
Figure 2.1 Non – Preset Display ......................................................................................................2-1
Figure 2.2 Preset Display ................................................................................................................2-2
Figure 2.3 Combined Display ..........................................................................................................2-2
Figure 2.4 Power Supply Unit Components .....................................................................................2-4
Figure 2.5 Main Display Unit Components (Preset Version Shown) ................................................2-6
Figure 2.6 Remote Display Unit Components (Non Button Version Shown) ..................................2-10
Figure 3.1 Display Unit and Power Supply Unit ...............................................................................3-3
Figure 4.1 Power Supply Unit Fitting Dimensions ............................................................................4-2
Figure 4.2 Display Unit Fitting Dimensions ......................................................................................4-4
Figure 4.3 Pulse Transmitter ...........................................................................................................4-5
Figure 4.4 Temperature Probe Dimensions .....................................................................................4-6
Figure 4.5 Compression Gland Assembly .....................................................................................4-10
Figure 4.6 Basic Non-Preset System .............................................................................................4-11
Figure 4.7 Non-Preset System Options Including Cab Communication and Transducer Interface .4-12
Figure 4.8 Basic Preset System ....................................................................................................4-13
Figure 4.9 Preset System Options Including Cab Communication Link and Transducer Input .......4-14
Figure 4.10 Override Switch Wiring .................................................................................................4-16
Figure 4.11 Power Supply - Internal Layout .....................................................................................4-18
Figure 4.12 Power Supply - Cable Separation .................................................................................4-19
Figure 4.13 Main Battery Supply .....................................................................................................4-20
Figure 4.14 Deadman Control Box ..................................................................................................4-21
Figure 4.15 Solid State Relay Loads ...............................................................................................4-23
Figure 4.16 Densitometer Wiring .....................................................................................................4-24
Figure 4.17 Differential Pressure Transducer Wiring .......................................................................4-25
Figure 4.18 Pressure Transducer Wiring .........................................................................................4-26
Figure 4.19 Connections to Display PCB.........................................................................................4-27

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LIST OF ILLUSTRATIONS - CONTINUED

Figure 4.20 Deadman Timer Wiring ................................................................................................ 4-29
Figure 5.1 SEt UP dAtA and FL00 Messages ................................................................................. 5-4
Figure 5.2 Typical Preset Batch Delivery ...................................................................................... 5-33
Figure 5.3 Typical Error Curves .................................................................................................... 5-36
Figure 5.4 Typical Calibration Rig ................................................................................................. 5-37
Figure 5.5 Meter Calibration Certificate......................................................................................... 5-44
Figure 5.6 Flag Record Table ....................................................................................................... 5-45
Figure 6.1 Non – Preset Display Format ......................................................................................... 6-2

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LIST OF ILLUSTRATIONS - CONTINUED

FIGURE PAGE
Figure 6.2 Preset Display Format ....................................................................................................6-3
Figure 8.1 Display Unit Components ...............................................................................................8-3
Figure 8.2 LCD Components ...........................................................................................................8-4
Figure 8.3 Power Supply Unit Components .....................................................................................8-6
Figure 8.4 Pulse Transmitter .........................................................................................................8-10
Figure 9.1 Power Supply Unit ..........................................................................................................9-2
Figure 9.2 Master / Remote Display Units .......................................................................................9-4
Figure 9.3 Pulse Transmitter ...........................................................................................................9-9

LIST OF TABLES
TABLE PAGE
Table 3.1 General Characteristics/Specifications ...........................................................................3-1
Table 3.2 Detailed Specifications ...................................................................................................3-4
Table 4.1 Kit - BEMY1115 - Contents.............................................................................................4-7
Table 5.2 Flag Table – Calibration Points.....................................................................................5-39
Table 7.1 Fault Finding ..................................................................................................................7-2
Table 8.1 Suggested Maintenance Program ..................................................................................8-2

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 AVERY-HARDOLL MAINTENANCE MANUAL
MASTERLOAD II™ (Vehicle)

IMPORTANT SAFETY INSTRUCTIONS

SAFETY REQUIREMENTS

This manual contains important instructions that must be followed during installation and maintenance
of the MASTERLOAD II equipment. The following are general safety precautions that are not related to
specific procedures and therefore do not appear elsewhere in this publication. Personnel must
understand and apply these procedures during maintenance.

Safety Alert Symbols

Safety alert symbols are used in this manual to identify potential or immediate personal injury hazards.
These symbols are explained below:

- indicates an imminently hazardous situation which, if not avoided,

will result in serious injury.

- indicates a potentially hazardous situation which, if not avoided,

could result in serious injury.

- indicates a potentially hazardous situation which, if not avoided,

may result in moderate injury.

- indicates a potentially hazardous situation which, if not avoided,

may result in property damage.

 Wear protective clothing (gloves, apron, etc.) approved for the materials and tools being used.
 Use only approved equipment and make sure firefighting equipment is readily available.
 When cleaners are used, read and follow the material safety data sheet (MSDS) instructions for
correct handling.

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MASTERLOAD II™ (Vehicle)

CHAPTER 1
INTRODUCTION
1.1 GENERAL

1.1.1 The MASTERLOAD II is a highly accurate and versatile microprocessor based measuring and
control system.
1.1.2 The system is suitable for all positive displacement bulkmeters and can be supplied complete
with a bulkmeter, or for retrofitting to other manufacturer’s equipment.
1.1.3 Existing installations with mechanical calibration may be easily converted to take full
advantage of the enhanced performance of the MASTERLOAD II system without the need to
remove the bulkmeter from the pipeline.
1.1.4 The installation (see Figure 1.1) provides the means of precisely controlling batch deliveries
for large or small automation systems.
1.1.5 Features of the MASTERLOAD II design.
 Dynamic multi-point calibration.
 Readout in a wide range of units.
 Precise preset batch delivery by weight or volume.
 A comprehensive data link to a data capture system or volume related pulsed output.
 Flexible mounting of display and power supply with additional (optional) display mounted
on platform of dispenser, aiding underwing refuelling.
 Receipt printout in the driver’s cab giving Invoice No. Vehicle No. Batch and Totaliser
Volumes. Optional printing of Temperature and Fluid Density when selected.
 Interlock with the vehicle Deadman system and optional Deadman Timer feature.
 Temperature correction to IP/ASTM tables.
 Interface to a Densitometer, pressure and differential pressure transducers.
 Constant monitoring of vehicle fuelling status, including alarms for differential pressure
and overspeeding.
 MASTERLOAD II is approved for use a Category 2 (Zone 1) Hazardous Area.

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Figure 1.1 Typical Vehicle Installation

1.1.6 This manual details the construction, installation and operation of MASTERLOAD II for
vehicles.
1.1.7 The equipment may also be used in static installations as described in a separate manual,
publication no TP0027.
1.1.8 The MASTERLOAD II system comprises: (see Figure 1.2)
 DISPLAY UNIT converts the pulses from the Pulse Transmitter Unit into readouts of
volume, flow rate, etc as described in TECHNICAL DESCRIPTION. If required, a
repeater display unit may be installed and linked to the main display unit to provide
information identical or additional to the main unit.
 POWER SUPPLY UNIT provides an Intrinsically Safe stabilised dc supply to the Display
Unit; It contains solid state relays (SSRs) for controlling a Preset Valve, Deadman Valve
and Indicator and a volume-related Pulsed Output. Variants are described in
TECHNICAL DESCRIPTION.

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 PULSE TRANSMITTER UNIT converts the rotation of the bulkmeter rotor to electrical
pulses which are analysed by the Display Unit.
 Temperature probe may be fitted into the product line for display of temperature or
compensated volume or for printing out temperature on a receipt. This option will only
function with a Display Unit that has the capability of temperature measurement.
 Densitometer, Pressure and Differential Pressure measurement, may be used if the
system is equipped with an internal interface module.

Figure 1.2 MASTERLOAD II System

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1.1.9 It is advisable that the Display Unit and Power Supply (see Figure 1.2) are mounted
separately, thus aiding access to the Bulkmeter capsule. Up to three remote Display Units may
be added to the system to provide remote readouts. These remote Displays may be
configured to act as repeaters or to indicate supplementary information e.g. Weight,
Temperature Compensated Volume.
1.1.10 The equipment may be configured as a Non-Preset System (see Figure 1.3) or as a Preset
System (see Figure 1.6). The Non-Preset System may be configured as a combination
display, i.e. to display Volume and Weight on the same display.

Figure 1.3 Non Preset System

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1.1.11 External control of the refuelling process can be achieved by linking Masterload to a cab
computer (see Figure 1.4). Masterload data is transferred automatically to the computer
equipment in the vehicle cab where a receipt can be printed and given to the pilot or flight
engineer. An override switch is fitted in this configuration and is for computer isolation.
1.1.12 The ability of Masterload to control a Preset Valve ensures that batch delivery is to a
programmable flow profile with a highly accurate cut-off, within +0.05/-0 litres of target
(see Figure 1.5).
1.1.13 Masterload can take additional information from 4 external transducers. In this way, differential
pressure, two pressure measurements and density may be monitored. All add vital control or
monitoring functions to the aircraft refuelling process.
1.1.14 Transducers used to pass this information to Masterload, will provide a 4-20 mA signal.

Figure 1.4 Non Preset System Including Cab Communication and Transducer Interface

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1.1.15 Preset batch control benefits are:

 External valve permissive.
 Programmable flow profile.
 Failsafe valve operation.
 Optional two stage opening.
 Controlled flow rates.
 Programmable deceleration rate.
 Extremely accurate cut-off.
 Safer loading.

Figure 1.5 Preset Batch Delivery

1.1.16 The MASTERLOAD II preset system with programmable flow profile provides improved safety
of valve opening and the elimination of pipeline shocks during valve closure.
1.1.17 Liquid Controls, LLC have developed a range of electronic Preset Valves compatible with
MASTERLOAD II and are available in 2½, 3 and 4 inch sizes. Instructions for setting up and
operating the Preset Valve are given in the Preset Valve manual TP0020.
1.1.18 An additional display unit may be fitted on the vehicle in a more convenient location, such as
the platform of a hydrant dispenser. Full reset and preset operations are also available on this
additional display unit.

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Figure 1.6 Preset System

1.2 REVISION SERVICE

1.2.1 This manual will be revised as necessary to show the current information.

1.3 WEIGHTS AND MEASUREMENTS

1.3.1 Weights and measurements in this manual are expressed in both English (U.S. customary)
and Metric (SI) units.

1.4 ASSOCIATED PUBLICATIONS

 TP0003 Bulkmeter Capsule (Calibrating Mechanism and Register)

 TP0020 Solenoid Operated Preset Valve
 TIS148 Technical Information Sheet for 8 in. Bermad Valve

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MASTERLOAD II™ (Vehicle)

CHAPTER 2
TECHNICAL DESCRIPTION
2.1 GENERAL

2.1.1 The use of a three channel pulse transmitter provides MASTERLOAD II with highly accurate
metering of product flow. Signals (pulse trains) from three channels are converted by a
microprocessor circuit and displayed in digital form on the front panel of the Display Unit.
2.1.2 Additional items may be added to enhance display and control facilities:
 Weight measurement.
 Temperature compensation.
 Cab computer link or printer for receipt printing.
 Additional display unit.
 Preset valve control.
 Density, Pressure measurement.
 Deadman Handle and Timer Lamp

2.2 MASTERLOAD II SYSTEMS

2.2.1 The basic or Non-preset system (see Figure 2.1) comprises the Pulse Transmitter, Power
Supply Unit and a Display Unit with 3 LCD displays indicating:
 Volume.
 Flow Rate/Temperature etc.
 Totaliser.

Figure 2.1 Non – Preset Display

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2.2.2 The Preset System (see Figure 2.2) provides the additional capability of operating a control
valve. The Display Unit has 4 LCD displays indicating:
 Volume.
 Preset Volume.
 Flow Rate/Temperature etc.
 Totaliser (Tote).

Figure 2.2 Preset Display

2.2.3 The combination display unit (see Figure 2.3) can show volume and weight on the same
display. Available in the following variations (non preset only):
 Litres and kilograms
 Decalitres/Dekaliters and kilograms
 Gallons and pounds
 US gallons and pounds
 Cu Metres & Tonnes

Figure 2.3 Combined Display

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2.3 PULSE TRANSMITTER UNIT

2.3.1 The electronic pulse transmitter is mounted directly onto the Avery Hardoll Controls bulkmeter
capsule within an O-ringed weatherproof enclosure.
2.3.2 In construction, the transmitter consists of a PCB and chopping disc that rotates with the meter
output shaft. As the disc rotates three light beams (channels) are interrupted to produce a
series of pulses (or trains). One revolution of the meter produces 227 pulses from each
channel which are fed to the Masterload Display Unit via a screened cable.
2.3.3 As the transmitter is factory--set, there is no requirement to adjust the pulses since each
channel produces a square wave of 50% +/-10% duty cycle (mark - to - space ratio).

2.4 POWER SUPPLY UNIT

2.4.1 The Power Supply Unit is a flameproof enclosure which provides an Intrinsically Safe 10V dc
supply from either a 12V or 24V vehicle battery supply. The unit shall be mounted in a
convenient position where access can be achieved, this will aid both installation and any future
maintenance requirement.
2.4.2 The components of the Power Supply Unit are housed in a flame-proof (Ex d) cast aluminium
box sealed to IP65 specification. Cable entry is via approved brass glands screwed into the
base of the box. (see Figure 2.4).
2.4.3 The Power Supply Unit main components are:
 Power supply PCB incorporating a maximum of 11 solid state relays (SSR’s), together
with a microprocessor circuit.
 One barrier block comprising seven independent barrier stages.
2.4.4 A cable separation sheet is fitted over the lower section of the power supply PCB to separate
Intrinsically Safe wiring from the Non-Intrinsically Safe input supply.
2.4.5 There are a number of versions of PCB fitted to the Power Supply Unit, these are determined
by the system requirements e.g. Preset/Non-Preset, Analog Interface, etc. and either 12V or
24V. When ordering a system, the intended input must be stated to ensure that the correct
board is factory-fitted to the Power Supply Unit. A 1A anti-surge fuse (FS1) is mounted on the
PCB to protect the power supply input, and an additional 13A fuse (FS2) is inserted into the
SSR supply line for the same purpose.

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PCB

BARRIER
BLOCK

ANALOGUE
INTERFACE
BOARD CABLE
(not shown – SEPARATION
inserted onto SHEET
PCB at this
location)

Figure 2.4 Power Supply Unit Components

2.4.6 The PCB has the ability to generate a power fail signal shall power loss to the system occur.
The signal is routed to the microprocessor housed in the Display Unit, requesting all system
data to be stored in a Non-Volatile Memory (NVR). The master or primary Display Unit will
continue to display data for 15 minutes whilst any repeater or additional display units will lose
their displayed information.
2.4.7 A barrier block is mounted on insulated pillars in front of the Power Supply PCB to provide
Intrinsically Safe connections between the Power Supply Unit and Display Unit. As the Pulse
Transmitter is supplied from the Display Unit, it too becomes an intrinsically safe apparatus.
2.4.8 The Barrier is an Intrinsically Safe encapsulated module. It incorporates components
manufactured and approved to limit excess current and voltage from reaching units mounted
in a CATEGORY 2 (ZONE 1) HAZARDOUS AREA.

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2.4.9 The Solid State Relays (SSR) are controlled by an Intrinsically Safe data link between the
Display and Power Supply Units.
2.4.10 The power switched by the SSR is derived from an input ‘Tank Bat +/-’ which is usually
supplied directly from the vehicle battery.
2.4.11 The SSRs are numbered SSR1 to SSR11. SSR1 and SSR2 will operate a preset valve. SSR3
may be used to interlock with the vehicle deadman system. SSR4 can be used to generate a
volume related pulsed output.
2.4.12 On a Non-preset system, only one relay (SSR3) is fitted to the Power Supply Unit. This will
generate a permanent signal to the deadman circuit, unless the Masterload system alarms, in
which case this signal will be removed. This will ensure that fuelling stops in the event of a
Masterload error.
2.4.13 When an interface to a densitometer or D.P. gauge is required, a small interface board is also
fitted. This analogue interface board simply plugs into the power supply board and may be
added at any time.

2.5 DISPLAY UNIT

2.5.1 The Display Unit provides readout information shown on liquid crystal displays (LCD) mounted
on a display PCB. Push buttons on the front panel of the unit allow the operator to set loading
parameters. Incoming and outgoing signals are routed through a microprocessor PCB.
2.5.2 The display PCB, microprocessor PCB and associated cables are housed in a cast aluminium
box formed in two halves and secured together by four cap head screws. The box is sealed to
IP65 specification. (see Figure 2.5).
2.5.3 A toughened glass facia fitted to the front half of the Display Unit is held in place by a rubber
surround, together with its associated Dial Mask.
2.5.4 The Display Unit is Intrinsically Safe and may be mounted where convenient. For mounting
and wiring details refer to INSTALLATION.
2.5.5 The display PCB is held in place on the front half of the Display Unit by a narrow groove in the
rubber surround.
2.5.6 The display PCB contains the driver circuitry for push buttons and LCD’s. It is connected to the
processor board by a short ribbon cable.
2.5.7 The display unit comes in various forms, preset, non-preset, temperature or non temperature
reading, and a variety of different units of measure.

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Figure 2.5 Main Display Unit Components (Preset Version Shown)

2.5.8 Non-preset displays will have three LCDs giving:

a. Batch Quantity
b. Rate of Flow/Temperature
c. Non Resettable Tote

2.5.9 Preset displays will have four LCDs giving:

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a. Batch Quantity
b. Preset Quantity
c. Rate of Flow/Temperature
d. Non Resettable Tote

2.5.10 The above displays may be in:

a. Litres
b. Decalitres/Dekaliters
c. Imperial Gallons
d. US Gallons
e. Cubic Metres
f. kg
g. lb
h. Tons
2.5.11 Combination displays will have four LCDs giving:
a. Batch Volume
b. Batch Weight
c. Rate of Flow and Temperature
d. Non Resettable Tote

2.5.12 Combination Display Units (non-preset only) are available in:

a. Imperial Gallons/Pounds

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b. US Gallons/Pounds
c. Litres/Kilograms
d. Decalitres/Kilograms
e. Dekaliters/Kilograms
f. Cubic Metres/Tonnes
Note: These Display Units are fitted with one push button for Reset.
2.5.13 Push buttons are mounted through the mask plate and apertures in the glass facia and sealed
with O-ring seals.
2.5.14 Non-preset systems have only one push button for a simple Reset operation.
2.5.15 Preset systems have three push buttons:
a. Reset - for Zeroing the meter
b. Preset - for programming a preset quantity
c. Stop/Run - for controlling product flow operations.
2.5.16 The microprocessor PCB is mounted at the rear of the Display Unit. The microprocessor logic
circuitry receives an Intrinsically Safe 10V DC input from the Power Supply Unit. Signals
received from the Pulse Transmitter are monitored by the microprocessor and organised to
give the required volume.
2.5.17 The microprocessor also transmits control signals to the solid state relays in the Power Supply
Unit and receives data via the push buttons (and temperature probe if fitted).
2.5.18 The MASTERLOAD II system uses a number of locations within its memory to control and
configure its operation. Each memory location is called a ‘Flag’. Flags are divided into ‘High’
and ‘Low’ security levels depending on their relevance. A set-up push button mounted on the
microprocessor PCB will access these flags after a sealed blanking plug on the underside of
the Display Unit has been removed. Operation of the set-up button enables all of the data
settings (Flags) in the microprocessor software program to be reviewed and altered. Low
security (Flags) can be altered by using either the set-up button or the reset button on the front
of the Display Unit using a special passcode entry mode. Flags are described in more detail in
paragraph 2.7.
2.5.19 Shall the system suffer power loss, all totaliser, calibration factors and set-up data are retained
for an indefinite period using a special memory device called a non-volatile random access
memory (NVR) on the processor board. The NVR requires no power for data retention.

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2.5.20 The MASTERLOAD II system has a very sophisticated communication protocol which enables
an interface to a cab computer. This will enable the facility of capturing data from all fuelling
activity, and printing a receipt for the pilot or flight engineer.
2.5.21 Information available using the data link includes:
a. Batch Quantity (uncompensated)
b. Batch Quantity (temperature compensated)
c. Pressure
d. Tote
e. Weight
f. Temperature

2.6 REMOTE DISPLAY UNITS

2.6.1 Remote Display Units (see Figure 2.6) may be installed in addition to the main Display Unit.
This gives the facility for fixing a display in a more convenient location, such as the platform of
a hydrant dispenser.
2.6.2 The software is configured by flag setting on the main Display Unit and by links on the Display
PCB, the next unit in the system can be made to either repeat the information displayed on the
previous unit or display supplementary information, such as temperature compensated volume
or weight.
2.6.3 Remote Display Units may be fitted with pushbuttons to match the functionality of the main
display.
2.6.4 The maximum cable length between displays is 50 metres.

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Figure 2.6 Remote Display Unit Components (Non Button Version Shown)

2.7 FLAGS AND ERROR MESSAGES

2.7.1 By programming various Flags within the microprocessor software Masterload may be
configured to meet current and future requirements.
2.7.2 The software contains various entry points called “Flags”.
2.7.3 Each Flag has a two digit identity number in the range 00 to 90.
2.7.4 Each flag is accompanied by a simple message, displayed in the Tote window, to indicate its
function.
2.7.5 The Flags are given two levels of security in the Masterload software:
a. Low Security Flags numbered 01 to 13
b. High Security Flags numbered 20 to 90
2.7.6 Flags may be accessed by 2 modes:
a. Low Security Entry
b. High Security Entry

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2.7.7 Low Security mode can be accessed by pressing the RESET push button on the Display Unit
front for ten seconds. This will enable the Low Security Flags to be changed and the High
Security Flags to be viewed. This Low Security Entry Mode will only be available once a four
digit passcode is entered. The passcode is programmed into Masterload during
commissioning.
2.7.8 The Low Security Flags contain information for:
a. System Configuration and Units of Display (Non Resettable) - for reference only
b. Temperature Display Format and Alarms
c. Density Correction Factor
d. Preset Flow (profile and form).
2.7.9 High Security mode may be accessed via a SET-UP push for on / push for off button. This
mode gives complete access to all Flags both high and low security.
2.7.10 The SET-UP button is only accessible from underneath the Display Unit and involves breaking
a lead security seal and removing a blanking plug.
2.7.11 The High Security Flags contain information for:
a. Mode of Operation (calibration, diagnostics)
b. Class of Calibration (1, 2, 3, 4 or 5)
c. Calibration Factors
d. Datum shift
e. Peripheral Interface Configuration
f. Data Communication Configuration
g. Temperature Correction
h. Low Security Passcode
i. Display Configuration
2.7.12 Flag 00 is unalterable and contains factory pre-set data defining the system (i.e. single, double
or triple capsule, readout in litres/gallons etc. and issue of program software in use.)
2.7.13 Flag 20 is used to enter the low security entry passcode. For example, if a flag value of 1234 is
set, then when this passcode is entered, access to low security mode is enabled. Flag 20 set
to 0000 allows access to low security flags without passcode entry. If a flag value of 9999 is
set, access for flag setting is denied; this can only be overruled by breaking the security seal
and removing the blanking plug underneath the Display Unit to gain access to the SET UP
button.

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2.7.14 The microprocessor has the ability to sense any faults that may occur during product delivery.
Error codes will be transmitted from the microprocessor to the Display Unit and displayed in
the Flow Rate window. Error messages will be displayed in the TOTE window. These
messages and the necessary corrective actions are explained in OPERATION. If an error is
detected, the deadman supply feed will be removed.
2.7.15 Flag details and set-up procedures are explained in COMMISSIONING and OPERATION.

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CHAPTER 3
SPECIFICATIONS
3.1 GENERAL

Table 3.1 General Characteristics/Specifications

Application ......................................................................................................... Electronic Fuel Measuring System

Electrical Power .................................................................................................................................. 12 or 24 VDC

Temperatures:
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating ................................................................................................................... –4 to 105°F (–20 to 40°C)

AVERY-HARDOLL
DESCRIPTION PART NUMBER

Power Supply Unit, supply voltage of 12 or 24 VDC, M20x1.5 cable BEMY105A-( )

gland entries

Master Display Unit, supply of intrinsically safe voltage of 10VDC. BEMY106A-( )

Repeater Display Unit, supply of intrinsically safe voltage of 10VDC BEMY126A-( )

Pulse Transmitter Assembly, supply voltage of 5 VDC (BM Series Meter) BMMZ33359A-1
Pulse Transmitter Assembly, supply voltage of 5 VDC (CM Series Meter) BMMZ33360A-1
Pulse Transmitter Assembly, supply voltage of 5 VDC (DM Series Meter) BMMZ33361A-1

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3.2 UNIT DIMENSIONS

3.2.1 The dimensions of units are shown in Figure 3.1.

Figure 3.1 Display Unit and Power Supply Unit

Note: To facilitate dismantling, always allow a space in front of the bulkmeter, equal in
depth to the bulkmeter in use.

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Table 3.2 Detailed Specifications

POWER SUPPLY UNIT

Enclosure Pressure Data

Reference Pressure ................................................................................................................................ 101 psi
1.5 x Over Pressure ............................................................................................................................ 151.5 psi

Electrical Data
Input Voltage ...................................................................................................................12 or 24 VDC Nominal
(From Vehicle battery master switch, NOT Ignition switch)
Solid State Relay Output Voltage ..................................................... 12 or 14 VDC (2amp max.) (SSR1, 2, &3)
12 or 14 VDC (1amp max.) (SSR4 to11)
* Each relay must supply a minimum current of 20 mA for correct operation.
External Fuse Rating ........................................................................... 10 ampere (Input supply must be fused)
Internal Fuse Rating:
FS1 .......................................................................................................................................................1 ampere
FS2 .....................................................................................................................................................13 ampere

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating .................................................................................................................. –4 to 105°F (–20 to 40°C)
Relative Humidity ..............................................................................................................................up to 100%

Weight (maximum) ......................................................................................................................... 14.3 lbs (6.5 kg)

Cable Entry Dimension

Thread Entry In Enclosure .................................................................................................... M20x1.5 (5 Places)
Cable Glands and Plug Thread Size .................................................................................................... M20x1.5
(Must Use Certified Flameproof Gland and Plugs)

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Table 3.2 Detailed Specifications - (cont.)

POWER SUPPLY UNIT (cont.)

Cable Rating
All cable specification are given in the wiring diagram at the back of the maintenance manual.

MASTER DISPLAY UNIT

Electrical Data
Input Voltage ...............................................................................................................10 VDC Intrinsically Safe
Output Voltage ..............................................................................................................5 VDC Intrinsically Safe

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating .................................................................................................................. –4 to 105°F (–20 to 40°C)
Relative Humidity ................................................................................................................................... up to 100%

Weight (maximum) ............................................................................................................................... 11 lbs (5 kg)

REPEATER DISPLAY UNIT

Electrical Data
Input Voltage ...............................................................................................................10 VDC Intrinsically Safe
Output Voltage ..............................................................................................................5 VDC Intrinsically Safe

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Table 3.2 Detailed Specifications - (cont.)

REPEATER DISPLAY UNIT (cont.)

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating .................................................................................................................. –4 to 105°F (–20 to 40°C)
Relative Humidity ................................................................................................................................... up to 100%

Weight (maximum) ...............................................................................................................................11 lbs (5 kg)

PULSE TRANSMITTER ASSEMBLY

Electrical Data
Input Voltage ............................................................................................................................................ 5 VDC

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 140°F (–20 to 60°C)
Operating .................................................................................................................. –4 to 140°F (–20 to 60°C)
Relative Humidity ................................................................................................................................... up to 100%

Weight (maximum) .............................................................................................................................4.5 lbs (2 kg)

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Table 3.2 Detailed Specifications - (cont.)

TEMPERATURE PROBE

Probe Type ............................................................................ Platinum Resistance Thermometer (PRT). 1/10 DIN

Temperature Probe Unit Operating Environment & Ratings

Temperatures
Ambient ..................................................................................................................... –4 to 140°F (–20 to 60°C)
Operating (Fluid) ................................................................................................... –58 to 392°F (–50 to 200°C)
Relative Humidity ................................................................................................................................... up to 100%
Accuracy .......................................................................................................................................................± 0.1°C
Discrimination ..................................................................................................................................................0.1°C

Weight (maximum) ............................................................................................................................. 4.5 lbs (2 kg)

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3.3 Safety Markings

The following safety markings are present on various components of the MASTERLOAD II system. Please
contact Liquid Controls, LLC for the current compliance status.
This equipment complies with all applicable European Directives. Refer to the
EU Declaration of Conformance available from Liquid Controls, LLC for listing of
2460 all applicable Directives and standards. The Quality Assurance Notification
pursuant to the European Directive for Equipment For Potentially Explosive
Atmospheres 94/9/EC (ATEX) has been performed by DNV GL, whose EU
ATEX Notified Body registration number is 2460.

EU Explosive Atmospheres symbol

Presafe 15 ATEX 7698X This equipment is certified by DNV GL under the ATEX Directive and under
Certification Scheme for Explosive Atmospheres of INTERNATIONAL
IECEx PRE 16.0003X ELECTROTECHNICAL COMMISSION (IECEx) under the indicated certificate
numbers, where X represents the following Special Condition for Safe Use: The
flamepaths on the power supply enclosure can only be repaired by the
manufacturer.

II Suitable for use in surface only installations.

2G High level of protection is provided against flammable gases, vapors, or liquids,

which may exist during normal operation.

Ex d Explosion protection is provided by a flameproof enclosure.

Ex ib Explosion protection is provided by intrinsically safe electrical circuits.

IIB Gas group, which includes ethylene, propane, and methane.

T6 Temperature class for surface temperature limitations is ≤ 85ºC.

T4 Temperature class for surface temperature limitations is ≤ 135ºC.

Gb Equipment group per IEC 60079-0 and EN 60079-0.

-20°C ≤ Tamb ≤ 40°C Safe limits of ambient temperature.

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CHAPTER 4
INSTALLATION
4.1 RECEIPT

4.1.1 The Masterload system will be delivered in suitably packed containers, any signs of damage to
containers must be reported immediately to the carrier.
4.1.2 To avoid damage, particularly to electronic components, all items are to be handled with care
at all times. Any deficiencies or damage shall be reported to the supplier.

4.2 INSTALLATION

4.2.1 For new installations, Masterload will be supplied in three separate units (Bulkmeter Capsule
assembly with Pulse Transmitter, Power Supply Unit and Display Unit). The bulkmeter
assembly is to be installed in the product line, and the Power Supply Unit and Display Unit
shall be mounted in a convenient position. Full instructions for installing the bulkmeter capsule
in the product line are given in publication TP0003.

WHEN CARRYING OUT THIS CONVERSION PAY ATTENTION TO

LOCAL REGULATIONS REGARDING THE USE OF EQUIPMENT IN
FLAMMABLE ATMOSPHERES.

THE DISPLAY UNIT CONTAINS CALIBRATION DATA RELATING TO A

SPECIFIC METER, BOTH DISPLAY AND METER MUST BE KEPT
TOGETHER. SERIAL NUMBERS ON THE METER AND DISPLAY MUST
MATCH.

4.3 POWER SUPPLY UNIT

4.3.1 The Power Supply is flameproof and may be mounted in a Category 2 (Zone 1)
Hazardous Area. Suitably locate the Power Supply Unit, up to 50 metres maximum cable
length from Display Unit. It is very important that this unit is located in such a position to
enable full access for maintenance.
4.3.2 Construct a suitable mounting bracket for Power Supply Unit (see Figure 4.1). Make sure the
bracket is adequate to support the weight of the unit (and Display Unit, if the two are required
to be fitted together, although this is not recommended).

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4.3.3 Offer up the Power Supply Unit into position, support the weight and secure to the mounting
bracket, using suitable nuts, bolts and washers.
4.3.4 To mount the Display Unit on the Power Supply Unit, cables shall be connected (Sections 9 to
14). Make sure the seal is serviceable and refit the front cover with the eight M6 socket cap
screws.

Figure 4.1 Power Supply Unit Fitting Dimensions

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4.4 DISPLAY UNIT

4.4.1 To mount the Display Unit remotely, proceed as follows.

4.4.2 The Display is Intrinsically Safe and may be mounted in a Category 2 (Zone 1)
Hazardous Area. Decide on a suitable location for the Display Unit taking into account the
following factors:
a. The maximum cable run length is 50 metres from the Bulkmeter Capsule.
b. The Display Unit readouts must be clearly visible from the normal operating position.
Angle the unit downwards if above eye level.
c. The operator must be able to reach the push-buttons.
d. The Display Unit requires external front illumination, avoid bright reflections from the
glass.
e. Allow access room around unit for maintenance.
f. Remove the security sealing wire from the set-up blanking plug. DO NOT REMOVE
BLANKING PLUG. Supporting the front face of the Display Unit, remove the four M5
socket cap screws and washers securing the front section of the unit to the rear section.
g. Gently ease forward the display front approx 40 - 60 mm. Reach inside the display unit
and carefully remove the ribbon connector plug from its socket on the PCB. Remove the
display front and place face downwards on a clean surface.
4.4.3 Construct a suitable mounting bracket for the Display Unit (see Figure 4.2) for dimensions).
Make sure the bracket is of adequate strength to support the weight of the unit.
4.4.4 Locate rear section of unit into position on mounting bracket and secure using four M6 socket
screws (min. length 55mm), plus four nuts and washers (see Figure 9.2).
4.4.5 Connect cables (Sections 8 and 10).
4.4.6 Connect the ribbon cable and refit the front section of the unit to the rear section and secure
with four M5 socket cap screws. Position one drilled sealing screw adjacent to blanking plug,
fit sealing wire and lead seal.
4.4.7 Remote Display Units (when supplied) shall always be mounted as separate items. Suitable
labels shall be fixed near all remotely mounted Display Units to identify product lines to which
they relate.

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Figure 4.2 Display Unit Fitting Dimensions

4.5 PULSE TRANSMITTER

Note: Fitting to an Avery-Hardoll Bulkmeter. Pulse Transmitters are Intrinsically Safe and may
be mounted in a Category 2 (Zone 1) Hazardous Area.
4.5.1 The pulse transmitter and adaptor plate are fitted in place of the mechanical calibrating
mechanism (see Figure 4.3).
4.5.2 The pulse transmitter is driven by a pin (1) that is located through the bulkmeter shaft and
engages with a slot on the transmitter shaft.
4.5.3 The transmitter assembly is secured to the adaptor plate with four cap head screws (2), spring
washers (3) and plain washers (4). Alignment is by two dowel pins (5).
4.5.4 An O ring (6) provides a seal between the transmitter (7) and the bulkmeter adaptor plate (8).
4.5.5 The adaptor plate is secured to the bulkmeter with two hex head screws (9), spring washers
(10) and plain washers (11) and two sealing screws (12), spring washers (13) and plain
washers (14). Alignment is by two dowel pins (15).
4.5.6 The Pulse transmitter is wired through a cable gland (16) at the bottom of the unit.

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Figure 4.3 Pulse Transmitter

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4.6 TEMPERATURE PROBE - INSTALLATION

4.6.1 The temperature probe (see Figure 4.4) normally locates in a well in the bulkmeter manifold.
The well can be inserted in the pipeline adjacent to the manifold (max. cable length from Pulse
Transmitter is 1 metre).

Figure 4.4 Temperature Probe Dimensions

4.6.2 If a temperature probe has not been fitted from the factory, and a temperature reading or
temperature compensation is required, fit the probe to the bulkmeter manifold using the
Temperature Probe Fitting Kit as listed in Table 4.1.
Note: The processor PCB must be type ZPMZ1-285-1. This board includes the temperature
interface circuit.
a. Isolate the system from all electrical and product supplies. Drain product from bulkmeter.
b. Remove screwed plug from manifold and remove sealing washer from plug. Check that
the sealing washer is in good condition and fit to probe well (see Figure 4.7).
c. Screw the well into the manifold.

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d. Screw the temperature probe into the well, take care not to bend or twist the cable tail.

Table 4.1 Kit - BEMY1115 - Contents

Item Part No. Description Qty

1 ZEMZ0309-02 TEMPERATURE PROBE

2 ZESZ0309-03 FABRICATED POCKET ASSY 1

3 BECZ1062 ADAPTOR 1

4 ZMMZ0135-6 BONDED SEAL 1

5 ZMPZ0158-4 WASHER 1

6 ZACZ0305-06 TUBING SLEEVE 1

7 ZACZ0305-07 TUBING NUT 1

8 BEPD1098 TEMPERATURE PROBE INSTALLATION DRAWING 1

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WORK MUST BE CARRIED OUT ONLY BY SUITABLY QUALIFIED

PERSONNEL. BEFORE RETURNING TO WORK, FOLLOW ALL
AIRPORT/COMPANY SAFETY PROCEDURES.

MAKE SURE ALL CABLE INSTALLATIONS AND JUNCTION BOXES ARE

USED IN ACCORDANCE WITH IEC/EN 60079-14.

4.7 ELECTRICAL INSTALLATION

MAKE SURE:
 There are no free wire strands or solder particles left inside enclosure.
 No damage has been caused during wiring installation.
 Cable glands are securely tightened.
 All terminal screws are securely tightened.

THIS EQUIPMENT CONTAINS ELECTRO-STATIC SENSITIVE DEVICES.

FOLLOW THE PRECAUTIONS AS SPECIFIED IN APPROPRIATE STANDARD
CONCERNING PROTECTION OF ELECTRONIC DEVICES FROM
ELECTROSTATIC PHENOMENA.

ELECTRO-STATIC SENSITIVE DEVICES:

 No Arc welding is to be carried out after this equipment has been fitted. Welding can
generate sufficient voltage within the equipment to severely damage the components.
 An equipment manual must be available before installation commences.
 Wiring to be independently checked before power is applied to the equipment.
 Voltages higher than the equipment specification must not be applied to the equipment.
4.7.1 Variations in vehicle layout, make precise installation details for individual vehicles beyond the
scope of this manual. The installation information given outlines the general installation for
Masterload. Refer to the general wiring diagram at the back of document for details of all
cables required when installing Masterload.

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4.7.2 Fitting the Cable Glands

Limitations:
 Install the gland in accordance with relevant code
 The gland shall not be modified in any way.
 The standard operating temperature of the gland is -20 deg C to +80 deg C.
 When fitted with braided or non-armoured cables, the gland is only suitable for fixed
apparatus.
 Aluminium or aluminium alloy glands must not be used for cables with bare copper braid.
 The minimum number of full threads engaged and depth of thread engagement between a
flameproof gland and the flameproof equipment shall be in accordance with the
requirements of the appropriate standard.
 A seal shall be formed between the equipment and the gland to maintain the correct
degree of protection against ingress of dust, solids and water.
a. Place the cable alongside the equipment, allow sufficient length for connecting the cores
to the applicable terminals plus at least 20mm extra length, then cut off any surplus.
b. Approximately 22mm back from the equipment face (see Figure 4.5 dimension ’B’) and
square to the longitudinal axis, cut through the outer sheath of the cable and partly
through the braid, taking care not to cut the inner sheath.
c. Remove the surplus outer sheath, taking care not to cut the braid or inner sheath.
d. Remove the surplus braid by bending it and breaking it at the cut part.
e. Remove a further 20mm of outer sheath (see Figure 4.5 dimension ’C’), taking care not to
cut the braid or inner sheath.

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Figure 4.5 Compression Gland Assembly

f. Engage and torque the entry component (1) into the equipment, (refer to limitations -
sealing). Secure with a locknut if required. Remove rubber inner seal (2) from entry
component.
g. Pass the shroud over the outer sheath, if required. Then pass tailnut (6) that includes
outer seal (7) and skid washer (8), loosely assembled with compression nut (5), over the
outer sheath.
h. Pass the clamping ring (4) over the braid, making sure the orientation of the ring is
appropriate to the type and size of the braid.
i. Pass the clamping spigot (3), tapered end first, over the inner sheath.
j. Splay out the braid evenly and locate the tapered end of the clamping spigot (3) under it.
k. Feed the inner sheath of the cable through the entry component (1) until the clamping
spigot (3) fits in the counterbore.
l. Push the cable towards the equipment then locate and torque the compression nut (5)
onto the entry component (1) to clamp the braid. Remove the compression nut and the
cable from the entry component. Check the tightness of the entry component in the
equipment and put the rubber inner seal (2) back into the counterbore.
m. Feed the inner sheath back through the entry component and the rubber inner seal and
relocate and torque the compression nut onto the entry component until a seal is formed
between the inner seal and the inner sheath.
n. The inner sheath shall protrude/through the entry component for correct surface for
sealing.
o. Torque the tailnut (6) onto the compression nut (5) until a seal is formed between the
outer seal (7) and the outer sheath.
Note: If difficulty is found in forming a seal, unscrew the tailnut (6) half a turn, then
torque.

4.8 AN OVERVIEW OF TYPICAL SYSTEM WIRING DIAGRAMS

4.8.1 Non – Preset System:

a. Figure 4.6 shows the simplest configuration of Masterload on a vehicle.
b. A simple interface/permissive is given to the vehicle Deadman circuitry offering additional
security to the fuelling process.

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Figure 4.6 Basic Non-Preset System

c. The basic system can be enhanced as shown in Figure 4.7. This shows the addition of a
repeat display unit which can be mounted in a more suitable location on the vehicle such
as the fuelling platform. This additional display can be supplied with or without the Reset
button.
d. A communications link to the vehicle cab provides data to a vehicle cab computer system.
This link has a manual override switch, which can be operated if the computer is not
required.
e. Up to four transducer inputs can be fed into the power supply unit, and these can
incorporate any or all the following:
 Differential Pressure (DP gauge)
 Vehicle pressure/s
 Densitometer Input
f. If there are not enough power supply entries, the use of a junction box is recommended
as shown in Figure 4.7.

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Figure 4.7 Non-Preset System Options Including Cab Communication and Transducer Interface

4.8.2 Preset System:

a. Figure 4.8 shows a basic Masterload preset system complete with additional display unit.
This can be fixed in a more suitable location on the vehicle, such as the fuelling platform.
This additional display can be supplied with or without control buttons which, when fitted,
provide the ability to control fuelling from an alternative position on the vehicle.
b. A simple interface/permissive is given to the vehicle Deadman circuitry offering additional
security to the fuelling process.
c. Up to four transducer inputs can be fed into the power supply unit and these can
incorporate any or all the following;
 Differential Pressure (DP gauge)
 Vehicle pressure/s
 Densitometer Input

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d. If there are not enough power supply entries, the use of a junction box is recommended,
as shown in Figure 4.8.

Figure 4.8 Basic Preset System

e. Figure 4.9 shows a communications link to the vehicle cab providing data to a vehicle
computer system. This link has a manual override switch, which can be operated if the
computer is not required.
f. Additive injectors can also be driven from additional relays in the power supply unit.

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Figure 4.9 Preset System Options Including Cab Communication Link and Transducer Input

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4.9 PULSE TRANSMITTER WIRING (Refer to Wiring Diagram)

Note: Before fitting the cable glands, refer to paragraph 4.7.2.

4.9.1 A 12 core screened cable is used to connect the Pulse Transmitter from the Display Unit.
4.9.2 Loosen the cable gland.
4.9.3 Strip back the outer insulation of cable a distance of 250 mm. Pass the exposed inner sheath
through both parts of the cable gland. Feed the cable behind the transmitter support plate.
4.9.4 Clamp the screen (wire braid) with the outer part of the cable gland and the inner sheath with
the inner part of the cable gland.
4.9.5 Cut back the Pink and Turquoise wires which are not required and strip remaining wire ends a
distance of 8 mm, twist and lightly tin if possible.
4.9.6 Connect wiring to the terminal block. Torque cable gland on transmitter housing.
4.9.7 To wire a Temperature Probe, remove the compression fitting (nut, seal and olive) from the
transmitter housing and assemble onto the 5 mm tube at the cable sheath end of Temperature
Probe.
4.9.8 Insert and connect the wiring to the transmitter housing and torque compression fitting.
4.9.9 Refit the transmitter, checking that the O-ring does not distort in the housing. Torque the four
cap head screws.

4.10 DISPLAY UNIT WIRING (Refer to Wiring Diagrams in the back of this document)

4.10.1 Remove the display front ensuring that adequate room is left below the Display Unit for cable
entries.
4.10.2 Route the cables from the Power Supply and the Transmitter through the cable glands into
display enclosure. Make sure the screen is clamped within the cable glands and torque
glands.
4.10.3 Route wiring to terminal block TB1, TB2 and TB3 on the processor board. Allow 20mm slack
and trim wiring to length. Strip wire ends 8mm, twist and tin.
4.10.4 Connect wires to TB1, TB2 and TB3.
4.10.5 Cut back the Pink, Turquoise and Green wires which are not required.
4.10.6 Fit cable ties and replace the display front.

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TO PREVENT THE PCB FOULING WHEN FITTING THE DISPLAY

UNIT FRONT, MAKE SURE IT IS COMPLETELY LOCATED IN THE
GROOVE OF THE RUBBER SURROUND.

4.11 OVERRIDE SWITCH

4.11.1 If Masterload is connected to a vehicle cab computer system, an override switch must be
fitted. This switch is used to isolate the equipment from Masterload shall the need arise.
4.11.2 Determine cable run and allow 600 mm at each end for termination.
4.11.3 Route cable and trim wires to length, allow 20 mm for slack. Strip wire ends 8 mm, twist and
lightly tin.
4.11.4 Connect the wiring between the Switch and TB4 as shown in Figure 4.10.
4.11.5 Torque cable gland and refit display unit front to rear enclosure and secure with four cap
headed screws and washers.

Figure 4.10 Override Switch Wiring

4.12 POWER SUPPLY UNIT

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4.12.1 Masterload may be powered from either a 12 or 24V vehicle battery supply, which must only
be routed to Masterload via the Master Switch on the vehicle (see Figure 4.13).
4.12.2 Remove front cover of Power Supply Unit as described in paragraph 4.3.
4.12.3 Check the power setting of the PCB by fitting link 1 in accordance with the following table.

POWER LK1 (LINK 1)

12V OPERATION HORIZONTAL
24 V OPERATION VERTICAL

The position of Link 1 is near the right hand corner of the Power Supply PCB.

ALL CABLE GLANDS AND BLANKING PLUGS USED ON THE UNIT

MUST BE FLAMEPROOF APPROVED.

4.12.4 The Power Supply Unit (see Figure 4.11) is flameproof for a Category 2 (Zone 1) Hazardous
Area.

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BARRIER
BLOCK

SOLID STATE
RELAYS

EARTHING CABLE
WIRE SEPARATION
MOUNTING SHEET
HOLE
EARTHING
WIRE

Figure 4.11 Power Supply - Internal Layout

4.12.5 Route all Non-Intrinsically safe wiring behind the cable separation sheet (see Figure 4.12).
4.12.6 Route all Intrinsically Safe wiring (from barrier block) in-front of the cable separation sheet.
4.12.7 Route earthing wire through the hole of the cable separation sheet (See Figure 4.11) and
mount terminal ring onto earthing wire mounting hole on rear enclosure.

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Figure 4.12 Power Supply - Cable Separation

WHEN CARRYING OUT THE INSTALLATION OF CABLES, FOLLOW

ALL LOCAL REGULATIONS REGARDING THE USE OF EQUIPMENT IN
HAZARDOUS AREAS.

4.13 POWER SUPPLY UNIT WIRING (Refer to Wiring Diagram)

4.13.1 The main vehicle supply wiring is identical for Preset and Non-preset Systems.
DO NOT CONNECT ANY OTHER DEVICE BETWEEN THE 10A
FUSE AND THE MASTERLOAD SYSTEM.

4.13.2 A fuse rated at 10A must be fitted at the supply end of the power cable, and this supply must
originate from the vehicle Master Switch (see Figure 4.13).

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Figure 4.13 Main Battery Supply

4.13.3 If there are insufficient cable entries within the Power Supply Unit the fitting of a junction box is
recommended.
4.13.4 Remove power supply cover and cable separation sheet, feed 240 mm of cable through
flameproof approved cable gland and into enclosure.
4.13.5 Strip back insulation to about 20 mm from cable entry and offer up wiring to TB1 and TB2.
4.13.6 Trim wires to length, allow 20mm for slack. Strip wire ends 8 mm, twist and lightly tin.
4.13.7 Connect wires to terminal block TB1 and TB2 and torque cable gland.

THE CABLE FROM POWER SUPPLY TO THE DISPLAY UNIT IS

INTRINSICALLY SAFE AND MUST BE ROUTED ABOVE THE CABLE
SEPARATION SHEET.
MAKE SURE THERE IS CONNECTION BETWEEN THE UNDERSIDE OF
THE BARRIER (EARTH PLANE) AND A HIGH INTEGRITY EARTH
WHERE THE IMPEDANCE FROM THE POINT OF CONNECTION TO THE
MAIN POWER SYSTEM EARTH POINT IS LESS THAN 1Ω. A LINK
BETWEEN THE BARRIER AND ENCLOSURE EARTH STUD MAY BE
ACCEPTABLE.

4.13.8 If the Display Unit is remotely mounted, the maximum allowable cable length is 50 metres.
4.13.9 When feeding the cable through the gland, make sure the screen is terminated within the
gland.
4.13.10 Route wiring to Barrier Block (see Figure 4.12) and torque cable gland.
4.13.11 Refit power supply lid. Make sure the seal is serviceable and secure lid using eight M6 socket
cap screws.

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4.14 EXTERNAL VALVES AND DEADMAN

4.14.1 Preset Masterload Systems have three solid state relays (SSR‟s) fitted. Two fitted for a
Preset Valve and one for a Deadman control unit:
1. SSR 1 is connected to the UPSTREAM solenoid (N/O) of a Preset Valve.
2. SSR 2 is connected to the DOWNSTREAM solenoid (N/C) of a Preset Valve.
3. SSR 3 is connected to supply side of the deadman control unit (see Figure 4.14).
4.14.2 Refer to Wiring Diagram at back of document for connection information.
4.14.3 Non-Preset Masterload System has only one solid state relay (SSR3). This is used to link to
the deadman control unit.

Figure 4.14 Deadman Control Box

4.14.4 Permissive Signal

1. The current supplied to the SSR, s for powering external valves may be taken from the
DC supply on the Power Supply board or from an external permissive supply. If an
external 12/24 VDC signal is used then link 2 (LK2) on the PSU board must be removed
and the permissive is connected into TB1 pin 3.

4.15 VEHICLE CAB COMMUNICATION WIRING (LINK TO CAB COMPUTER)

(Refer to Wiring Diagram)

4.15.1 Twisted pair data cable is used for this connection. Connection to the PSU is via TB5.

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4.15.2 Extreme care shall be taken when making the terminal block connections between equipment.
Labeling or identifying conductors shall be adopted to avoid confusion. Connections are as
follows:

MASTERLOAD CAB COMPUTER

Tx Rx

Rx Tx

4.15.3 Determine cable run and allow 600 mm each end for termination.
4.15.4 Route cable and feed 600 mm of cable through cable gland on PSU.
4.15.5 Torque cable gland.
4.15.6 Strip back insulation a distance of 100 mm.
4.15.7 Trim wires to length, allowing 20 mm for slack. Strip wire ends 8 mm, twist and lightly tin.
4.15.8 Connect wires to TB5 and cab computer.

4.16 OTHER VEHICLE SYSTEMS (REFER TO WIRING DIAGRAM)

4.16.1 Connection to alternative vehicle cab computer systems can be by two distinct methods; Full
Duplex link, or a simple pulsed output by volume (e.g. 1 pulse/litre).
4.16.2 Connecting Masterload to other vehicle cab computers via a full duplex link, is achieved in
exactly the same way as in paragraph 4.18. Detail on data protocol may be obtained on
request, if required.
4.16.3 Vehicle cab equipment requiring a simple volume related pulse can make use of an extra solid
state relay (SSR4) within the power supply unit (see Figure 4.15). It is important to recognize
that the voltage of this volume related pulse will be equal to the vehicle battery voltage. If an
alternative power supply is required, guidance may be sought from our Customer Support
department.
4.16.4 The connection V4 will offer this pulsed DC output for volume related pulses. A choice of
pulses per unit of volume is available using Flag 70.3.

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VEHICLE VOLTAGE R1

12V dc 330Ω (0.5W)

24V 1KΩ - (1.0W)

Figure 4.15 Solid State Relay Loads

4.17 TRANSDUCER WIRING (Refer to Wiring Diagram)

4.17.1 External transducers will be flameproof and will provide a 4-20 mA output. These can be used
to control and monitor the metering process.
4.17.2 A maximum of 4 transducers can be linked to Masterload, these include; a densitometer input,
a differential pressure gauge, and two vehicle pressure indicators.
4.17.3 When installing a transducer make sure it is connected to the applicable terminals of TB4.

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4.18 DENSITOMETER UNIT WIRING

4.18.1 The Densitometer connections differs from other transducers in that it requires a three core
cable. See Figure 4.16.
4.18.2 Connect the wiring between the Densitometer and TB4 as shown in Figure 4.16 and wiring
diagram at back of document.
4.18.3 Check installed wiring for correct polarity of connection.

Figure 4.16 Densitometer Wiring

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4.19 DIFFERENTIAL PRESSURE TRANSDUCER WIRING

4.19.1 A two core cable is required to connect the Differential Pressure Transducer to the power
supply unit (see Figure 4.17).
4.19.2 Connect the wiring between the Differential Pressure Transducer and TB4 as shown in Figure
4.17 and wiring diagram at back of document.
4.19.3 Check installed wiring and make sure the polarity of connection is correct.

Figure 4.17 Differential Pressure Transducer Wiring

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4.20 PRESSURE TRANSDUCER WIRING

4.20.1 A two core cable is required to connect the Pressure Transducer to the power supply unit, if
two pressure units are required, use the second transducer input (see Figure 4.18).
4.20.2 Check installed wiring and make sure the polarity of connection is correct.

Figure 4.18 Pressure Transducer Wiring

4.21 REMOTE DISPLAY UNIT

4.21.1 A Remote Display Unit may be mounted anywhere convenient within a maximum cable length
of 50 metres from the main Display Unit or the previous remote display.
4.21.2 The procedure for mounting is identical to that of the Main Display Unit (Refer to wiring
diagram).
4.21.3 Detach the display front.
4.21.4 Route cable from main Display Unit and feed through cable gland (see Figure 4.19).
4.21.5 Allow about 250 mm of slack to enable easy access and removal of display unit front when
wiring is connected.

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4.21.6 Form wiring into a loom and fit cable ties. Route loom to terminal blocks TB1 and TB3 located
on the component side of the display PCB.
4.21.7 Cut back wire ends 8 mm, twist and lightly tin.
4.21.8 Connect wiring and make sure the screen is clamped within the gland (Refer to wiring
diagram).
4.21.9 Torque cable gland and refit the display front to rear enclosure and secure with four cap
headed screws.
4.21.10 Further remote displays are identically wired, from TB2 on the previous display to TB1 and
TB3 on the display being added (as stated above).

Figure 4.19 Connections to Display PCB

4.22 SLIP PRINTER

4.22.1 The communications link from Masterload to a local printer will be fed via an RS422/232
converter (Amplicon 909-245-20). The connecting cable will be a two pair twisted link with
overall screen. Refer to wiring diagram for details.

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4.23 DEADMAN TIMER SYSTEM

4.23.1 The operator clasps a deadman handle throughout the fuelling process to ensure that the
deadman valve (on the vehicle) remains open. If the handle is released for more than
2 seconds, the deadman valve closes and stops fuel flowing.
4.23.2 To ensure that the operator is still grasping the handle correctly (i.e. not taped the handle
closed) he is required to pulse the handle momentarily after a period of 2- 1/2 minutes. After
this time, the deadman warning lamp flashes every second to prompt the operator. This
warning is given for 20 sees., after which the deadman and lamp will switch off and fuelling will
cease. During normal operation, when the deadman handle is held, the warning lamp remains
illuminated continuously.
4.23.3 To use Masterload for this operation, the following connections must be made: Connect the
deadman handle into TB4 of the Processor PCB (see Figure 4.20). Connect the deadman
warning lamp into TB3 of the Power Supply PCB (see Figure 4.20). Make sure there is a relay
in position K8 of the Power Supply PCB.
4.23.4 Flag 70 (position 1) must be set to ”2” for deadman timer control. The system is now ready for
use.
Note: If extra warning lamps are required, an additional relay may be fitted into position K9
within the Power Supply Unit in order to provide a further 21W of power
.

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Figure 4.20 Deadman Timer Wiring

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CHAPTER 5
COMMISSIONING
FOLLOW ALL SITE RULES WHEN COMMISSIONING MASTERLOAD

5.1 PRE-COMMISSIONING

5.1.1 The completed Masterload system, pipework and ancillaries must be reviewed before to
commissioning to make sure the installation is correct and conforms to all necessary safety
standards.
5.1.2 Check all meters, valves etc to for correct orientation in system.
5.1.3 Make sure the pipework has been purged of all entrained foreign matter and air, flush tested
and leak checked.
5.1.4 Make sure all valves in system are CLOSED.
5.1.5 Make sure the Vehicle Master Switch is switched OFF.

THE POWER SUPPLY IS A FLAMEPROOF UNIT FOR USE IN A

CATEGORY 2 (ZONE 1) HAZARDOUS AREA. NEVER REMOVE COVER
WHEN SUPPLY VOLTAGE IS PRESENT AND MAKE SURE THE COVER
IS TIGHTLY SECURED.

5.1.6 Remove cover of power supply unit and check that the wiring from the master switch is
correctly routed underneath the cable separation sheet.
5.1.7 Check wiring terminals and cable glands for tightness.
5.1.8 Check installed wiring connections in power supply.
5.1.9 Replace power supply cover and torque all cap head screws.
5.1.10 Remove front section of the Masterload Display Unit and check installed wiring connections.
5.1.11 Replace display front with securing screws.
5.1.12 Remove pulse transmitter cover and check all wiring connections.
5.1.13 Replace transmitter cover and make sure no wires are trapped between metal faces.
5.1.14 All valves must be closed on initial power up of system.
5.1.15 When product flow is required during calibration, open valves with caution.

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WORK SHALL BE CARRIED OUT BY A QUALIFIED ELECTRICIAN ONLY.

IN THE FOLLOWING CASES, REFER TO PARAGRAPH 5.2.4 (b). WHERE
NON-INTRINSICALLY SAFE VOLTAGE IS PRESENT.

5.2 INITIAL POWER UP

5.2.1 Make sure all valves are CLOSED.

5.2.2 Switch ON vehicle master switch.
5.2.3 The Display Unit will show an ‘8’ in every segment of all the liquid crystal displays for 3
seconds before returning to a normal display.
5.2.4 If the Display Unit fails to work then either:
a. There is a fault between the Power Supply Unit and the Display Unit.
b. There is a fault between the Power Supply Unit and the vehicle master switch.
5.2.5 In the case of paragraph 5.2.4 (a), remove the display front to check that the ribbon cable
between the processor board and the display front is connected.
Note: If a wiring fault is suspected then this work shall only be carried out by a qualified
electrician.

COMMISSIONING MUST BE CARRIED OUT BY A QUALIFIED SERVICE

ENGINEER ONLY.

5.3 COMMISSIONING

5.3.1 Before starting the commissioning procedure it is advisable to become fully conversant with
the operation of the Display Unit buttons.
5.3.2 Masterload uses the RESET button located on the front of the Display Unit and the SET-UP
button located internally underneath to configure the system via “Flags” (see Figure 5.1).
5.3.3 Flags are divided into two levels of security within the software:
a. Low Security Flags (01 to 19).
b. High Security Flags (20 to 90).
5.3.4 Low Security Flags contain:
 Low security pass-code
 Calibration data

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 Datum shift
 Temperature compensation
 Density, differential pressure and pressure measurement selection
 Display configuration
 Preset valve selection
 Communication settings
5.3.5 High Security Flags.
High Security Flags contain the parameters that AFFECT MEASUREMENT and are only
accessible via the SET-UP button protected by a security sealed blanking plug.
These Flags contain:
 Low security pass-code.
 Calibration data.
 Datum shift.
 Temperature compensation.
 Density, differential pressure and pressure measurement selection.
 Display configuration.
 Preset valve selection.
 Communication settings.
5.4 FLAG SETTING EXERCISE

5.4.1 Remove the blanking plug located underneath the Display Unit to gain access to the SET-UP
button (see Figure 5.1).
5.4.2 The SET-UP button is of the latching type, push for on/push again for off.
5.4.3 Switch on the electrical power to the Masterload system.
5.4.4 Press the SET-UP button, the message “SEt UP dAtA” will scroll across the BATCH
WINDOW of the Display Unit to be replaced by a series of numbers. Each Flag will be
accompanied by a descriptive message appearing on the Totaliser display.

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Figure 5.1 SEt UP dAtA and FL00 Messages

5.4.5 “FL 00” will appear in the FLOW RATE WINDOW and rEF dAtA (Reference data) in the
TOTE WINDOW.
5.4.6 The information displayed in the batch window is the contents of Flag 00.
5.4.7 All changes to Flag values are accomplished by using the RESET button in a manner similar
to setting a digital watch. A cursor will briefly flash on the digit being altered.
5.4.8 In the following example Flag 00 will be changed to Flag 75.

FL 00

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5.4.9 Press and hold the RESET button, the first numeral after the letters FL displayed in the FLOW
RATE window will increment from 0 to 9.
5.4.10 Flag information displayed in the BATCH and TOTE window will also change reflecting the
movement through the Flag table.
5.4.11 Release the RESET button when “7” appears.
5.4.12 The FLOW RATE window shall now display FL 70 and the TOTE window the message
OFFICE.

FL 70
5.4.13 Press and hold the RESET button again. The second numeral now increments from 0 to 9.
Note: The TOTE window will go blank when the numeral reaches 6 as Flags 76 - 79 are
unused.
5.4.14 Release the RESET button when “5” appears. Flag 00 has now been changed to Flag 75.

FL 75
5.4.15 Each press and release of the RESET button advances the review facility to the next
numeral with the exception of Flag 00.
5.4.16 The review facility advances through the Flag number displayed in the FLOW RATE window
and then on to the Flag information displayed in the BATCH window. This allows the alteration
of Flag values as required. Flag 00 is unalterable and for reference only.
5.4.17 If unsure of the review facility, press the RESET button repeatedly and the cursor will flash as
the review advances from one numeral to the next.
5.4.18 Pressing and holding the RESET button allows the required numeral to increment to the
required value.
5.4.19 When changing Flags and Values care must be taken to make sure: No Flag values, other
than those required, are accidentally changed.
5.4.20 The system will return to normal operating mode when the SET-UP button is pressed, at which
time all alterations to Flag values are saved and stored in memory (NVR) and take immediate
effect.

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5.5 FLAG TABLES

5.5.1 The Flag table is split into four sections, the first gives the Flag number, the second is split into
six columns corresponding to the data (displayed in the batch window) and the third gives the
function.
5.5.2 A fourth column contains a message that appears in the totaliser window to assist the
operator. An * symbol indicates a number (0-9) to be entered by the operator.
5.5.3 Occasionally, the operator must alter an associated (i.e. linked Flag) before progressing. A
message displayed in the totaliser window acts as a prompt to the operator by providing a
general description of the Flag function (e.g. “SET UP”).
5.5.4 Table 5.1 gives a complete set of available Flags followed by a more detailed description of
each Flag.

5.6 INITIAL SETTINGS

5.6.1 To allow product flow and to try the system after installation it is necessary to enter a number
of basic settings into the Flag table. These are highlighted in Table 5.1 as Figures within
mauve boxes i.e. 0

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Table 5.1 Initial Settings

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
00
0 DM (Steel) Meter REF dAtA
1 SINGLE Capsule
2 DOUBLE Capsule
3 TRIPLE Capsule
4 QUAD Capsule
5 S259 Meter

r REPEATER SYSTEM

Volume Weight Density

0 Litres Kg Kg/Cu.M
1 Imp. Gallons Lb Lb/Imp.Gall
2 Decalitres Kg Kg/Cu.M
3 US. Gallons Lb Lb/US Gall
4 Cubic Metres Tonnes Kg/Cu.M
5 Litres x 10 Kg Kg/Cu.M
6 Cubic Metres Tonnes Kg/Cu.M
7 As 0 (with tote in Decalitres)
As 1 (with batch & tote in Tons, RoF in
8
Tons/Hr)
9 As 6 (with volumes to two decimal places)

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
Pulse Adjustment Factor REF dAtA
00 0 Litres
1 10 Lts/rev. (Repeater & single end drum)
2 50 Lts/rev.
3 100Lts/rev. (Repeater & double end drum)
4 Imp. Gallons
5 US. Gallons
6 Repeater & printer (single end drum)
7 Repeater & printer (double end drum)
8
9 Programmable Pulse Weighting
6. 2 Program Issue

01 0 Normal run Set UP

1 Display fine increments

0 No reverse flow count

1 Tote “frozen” in reverse
2 Count reverse flow

0 Batch restored on power- up

1 Batch cleared on power - up

02 0 Flow Rate Display InPutS

1 Temperature Display
0 No display

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6

02 1 InPutS
1 Continuous display
2 Instantaneous value/Resulting average
3 Average run display (may be toggled)

0 °C
1 °F
2 Density Display
0 No display
1 Continuous display
2 Instantaneous value/Resulting average
3 Average run display (may be toggled)
3 Pressure 1 Display
0 No display
1 Continuous display
2 Instantaneous value/Resulting max.
* * * Max. pressure for alarm
4 Pressure 2 Display
0 No display
1 Continuous display
2 Instantaneous value/Resulting max.
* * * Max. pressure for alarm
5 Differential Pressure Display
0 No display
1 Continuous display
2 Instantaneous value/Resulting max.
* * Max. filter dp at 100% (for alarm)

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
03 +/- * * ° C Low Temperature Alarm LO t °C
04 * * * ° C High Temperature Alarm HI t °C
05 * * * * * Density (when designated by Flag 54) dEnSity

06 4 4 Figure Preset PrESEt

5 5 Figure Preset
6 6 Figure Preset

* Preset Limit
07 0 No Auto Calibration AUtO CAL
1 Auto Calibration

0 No Mark/Space Test
1 Channel Mark/Space Test

0 Local Mode (when set by Flag 70)

1 System Mode (when set by Flag 70)
10 * * * 0 1st Stage Flow Rate (Lpm/Gpm) PrESEt
11 * * * 0 1st Stage Volume (Litres/Gallons)
12 * * * 0 Max.Flow Rate (Lpm/Gpm)

13 * * 0 Flow Rate Deceleration (Lpm/s Gpm/s)

* * By-pass Volume (Litres/Gallons)

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
20 R * * * * Pass Code (R used for ERS only) PASSCOdE
21 1 Class 1 Calibration ClASS
2 Class 2 Calibration
3 Class 3 Calibration
4 Class 4 Calibration
5 Class 5 Calibration
* * * * 100% FLOW
22 0 Normal Mode tESt
1 Channel Mark/Space Test (50-50-50)
2 Calibration Mode (Factors ignored)
3 Verification Mode (Factors used)
4 Self Test
5 Soak Cycle
23 Temperature Compensation Test Display
CLASS 1 2 3 4 5
30 0. * * 5% Cal. X CAL 5
31 0. * * 10% Cal. X X CAL 10
32 0. * * 15% Cal. X CAL 15
33 0. * * 20% Cal. X X X X CAL 20
34 0. * * 30% Cal. X CAL 30
35 0. * * 50% Cal. X X CAL 50
36 0. * * 75% Cal. X X X CAL 75
37 0. * * 100% Cal. X X X X ? CAL 100
40 * * * * System Flow Rate Limit toP roF

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
50 0. * * Datum shift SHIFt
51 0 Uncompensated t COEF
1 * * * * Temperature Compensation to 15 °C
2 * * * * Temperature Compensation to 20 °C
3 * * * * Temperature Compensation to 31.5 °C
52 IP/ASTM Table Selection IP tAbLE
0 Generalised Crude Oils (“A” Tables)
1 Generalised Products (“B” Tables)
0 Table 54: No HYC/FL.05 = Density @ ref
1 : No HYC/Fl.05 = Density @ t °C
2 Table 53: HYC on/Fl 05 = Density @ t °C
53 * * ° C Temperature Probe Offset Prt
54 0 No Density 4-20 IP
1 Density Entry (Accessed via Flag 05)
2 Densitometer

0 No Pressure
1 One Pressure measurement
2 Two Pressure measurements

0 No Differential Pressure
1 Differential Pressure measurement
60 0 No Preset Control VALVE
1 Avery-Hardoll Preset Valve
2 Low flow volume (simple preset/S259)
3 Large Valve

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
60 4 Deadman valve control

* Min. preset value (not available with large valve set)

0 No Interlocks
1 Interlocks (Earth, Overspill & Arm Position)
* * Pump Trip Out Time (Secs)
70 0 Vehicle Deadman Control OFFICE
1 Gantry Pump Control
2 Vehicle System with Deadman Timer

0 Local Mode
1 System Mode (1200 baud rate)
2 Low security “switch” for System / Local (1200)
3 System Mode (9600 baud rate)
4 Low security “switch” for System / Local (9600)
5 Ticket Printer without Preset
6 Ticket Printer with Preset

0 Normal Mode
1 1 Pulse per unit displayed(from SSR4)
2 1 Pulse per 1/10 unit displayed (from SSR4)
3 1 Pulse per 10 units(from SSR4)

0 Disable “too slow” message

1 Enable “too slow” message

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
70 0 Data request mode OFFICE
1 Data transmit mode

0 No cab computer
1 Cab computer linked up
71 G G B B M M Meter data (no cab computer) dAtA
* * * * * * Vehicle No (cab computer)
73 * * * Device address AddrESS
74 * No of digits for Cab id Id
* Driver ID
* Load No
Pot No
* (Cab, driver & load set to '0' to disable ID mode)

75 * * Time Out (Secs) dELAy

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Table 5.1 Initial Settings - (cont.)

DATA
Flag FUNCTION MESSAGE
D1 D2 D3 D4 D5 D6
90 Main Display Additional Display diSPLAy
0 BATCH Prime Secondary
PRESET Preset Preset
TOTE Prime Secondary

1 BATCH Prime REPEAT

PRESET Secondary
TOTE Secondary

2 BATCH Prime
PRESET Secondary REPEAT
TOTE Prime

3 BATCH Volume(Ltrs)
REPEAT
PRESET Weight (Kgs)
(LBS/GALLS)
TOTE Tote (Lt)

4 BATCH Nett/Gross
PRESET Preset REPEAT
TOTE Prime
0 Prime = Uncompensated Volume
1 = Compensated Volume
2 = Weight
0 Secondary = Uncompensated Volume
1 = Compensated Volume
2 = Weight

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5.6.2 The data given in each Flag is allocated a column number (D1– D6) relating to the 6 data
columns. Example:

Flag No. D1 D2 D3 D4 D5 D6

70 1 1 1 1 1 1

5.6.3 As previously explained, some Flags are linked to others. When a function is not required then
any related features are inaccessible and remain blanked out. This association is indicated by
the word “LINKED” and the affected Flags are indicated.
Example: Flag 02 cannot be set for pressure measurement until Flag 54 is set.

5.7 LOW SECURITY FLAGS

5.7.1 Flag 00
Flag 00 is the only Flag that is unalterable by the operator. It is used to inform the user of the
type and size of meter and the units of measure.
D1 0 Avery-Hardoll DM (Steel meter) software.
1 Avery-Hardoll Single capsule meter software.
2 Avery-Hardoll Double capsule meter software.
3 Avery-Hardoll Triple capsule meter software.
4 Avery-Hardoll Four capsule meter software.
5 Avery-Hardoll S259 meter software
r Software used with the Electronic Repeater System.
D2 0 Volume display in Litres. Weight display in Kilograms.
1 Volume display in Imperial Gallons. Weight display in pounds.
2 Volume display in Decalitres. Weight display in Kilograms.
3 Volume display in US. Gallons. Weight display in Pounds.
4 Volume display in Cubic Metres. Weight display in Tonnes.
5 Volume display in Litres x 10. Weight display in Kilograms.
6 Volume display in Cubic Metres. Flow rate in Cubic Metres per Hour. Weight
display in Tonnes.
7 Batch volume display in Litres. Tote volume display in Decalitres.

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8 Weight display in Tons with flow rate in Tons/Hr.

9 As 6 with volumes to two decimal places.
D3 0-5 A range of different pulse weightings to suit the meter. Each number giving a
different number of pulses from the transmitter per revolution of the shaft.
6 Electronic Repeater software used with a Ticket Printer and single Figure Veeder
Root end drum.
7 Electronic Repeater software used with a Ticket Printer and double Figure Veeder
Root end drum.
9 A variable pulse weighting for non-Avery-Hardoll meters.
D5-D6 These locations give the software issue being used in the system.

5.7.2 Flag 01
D1 0 Normal setting displaying whole units in the batch window.
1 The batch window displays 1/100’s of units.
D2 0 Only forward flow will be displayed. Any reverse flow will be indicated by a
negative sign in the flow rate window.
1 The batch display only will decrement during reverse flow.
2 Both batch and totaliser displays will decrement during reverse flow.
D3 0 The batch display is restored to its previous count on power up.
1 The batch display will reset to zero on power up.

5.7.3 Flag 02
Flag 02 is used to organise the flow rate window to display flow rate, density, pressure or
differential pressure Each setting of D1 is used in conjunction with D2-D6.
D1 0 Flow rate only is indicated.
D1 1 Temperature may be displayed. (LINKED Flags 03,04)
D2 0 No temperature displayed.
D2 1 A continuous display of temperature.
D2 Temperature is displayed while the reset button is pressed during flow. An
2
average temperature reading is displayed once the flow has stopped.
D2 3 An average temperature is displayed once flow has stopped.
D3 0 Temperature given in °C

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D3 1 Temperature given in °F

D1 2 Density may be (LINKED Flag 54)

displayed.
D2 0 No density displayed.
D2 1 A continuous display of density.
D2 2 Density is displayed while the reset button is pressed during flow.
An average density reading is displayed once the flow has
stopped.
D2 3 An average density is displayed once flow has stopped.

D1 3 One Pressure (LINKED Flag 54)

measurement may
be displayed.
D2 0 No pressure displayed.
D2 1 A continuous display of pressure.
D2 2 Pressure is displayed while the reset button is pressed during
flow. A maximum pressure reading is displayed once the flow has
stopped.
D4-D6 A pressure (psi.) entered here will provide an upper limit of
measurement. Once this Figure is exceeded, a pressure error will
be displayed and any Masterload controlled valves will be shut. If
no limit is required this Figure shall be set to 200psi.

D1 4 Two Pressure (LINKED Flag 54)

measurements may
be displayed.
D2 0 No pressure displayed.
D2 1 A continuous display of a second pressure measurement.
D2 2 A second pressure is displayed while the reset button is pressed
during flow. A maximum pressure reading is displayed once the
flow has stopped.

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D4-D6 A pressure (psi.) entered here will provide an upper limit of

measurement from the second pressure transducer. Once this
Figure is exceeded, a pressure error will be displayed and any
Masterload controlled valves will be shut. If no limit is required
this Figure shall be set to 200psi.

D1 5 Differential pressure (LINKED Flag 54)

may be displayed
D2 0 No differential pressure displayed.
D2 1 A continuous display of a differential pressure
D2 2 A differential pressure is displayed while the reset button is
pressed during flow. A maximum differential pressure reading is
displayed once the flow has stopped.
D5-D6 A differential pressure (psi.) entered here will provide an upper
limit of measurement from the differential pressure transducer.
This is designed to monitor the condition of an in-line filter. Once
the flow rate has exceeded 50% of the maximum calibration flow
rate (see Flag 21) a comparison is made of the differential
pressure against the limit. If 80% of this Figure is exceeded
(when extrapolated to 100% flow), a “filter” warning message will
be displayed. Once this Figure exceeds 100%, a differential
pressure error will be displayed and any Masterload controlled
valves will be shut. If no limit is required this Figure shall be set to
30psi.

5.7.4 Flag 03 (LINKED Flags 02, 51)

Flag 03 is the low temperature limit in °C. (Min. setting -30°C). Once the measured
temperature falls below this Figure a temperature error (“too cold”) will be displayed. When not
required this must be set to -20°C.
5.7.5 Flag 04 (LINKED Flags 02, 51)
Flag 04 is the high temperature limit in °C. (Max. setting 120°C). Once the measured
temperature rises above this Figure a temperature error (“too hot”) will be displayed. When not
required this must be set to 120°C.
5.7.6 Flag 05 (LINKED Flag 54)
This Flag is used to enter the density when a densitometer is not connected to the system.
5.7.7 Flag 06 (LINKED Flag 60)
This Flag provides the format for the preset display.

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D1 4 The preset display will be 4 Figures (0-9999).

5 The preset display will be 5 Figures (0-99999).
6 The preset display will be 6 Figures (0-999999).
D2 A single Figure entry that provides the maximum allowable preset volume for the
most significant digit.
Example: If a four Figure preset is requested (i.e. D1=4) and D2=3 then the
maximum preset setting will be 3000.
5.7.8 Flag 07
D1 0 Normal operation (i.e. not set for automatic calibration).
1 The meter is set to be calibrated automatically by the Masterload Autocal system
(ref. Manual TP0038).
D2 0 Normal operation (i.e. not set for transmitter mark/space test).
1 The totaliser display is used as a transmitter pulse monitor. Three ratios are
shown giving the high (i.e. mark) portion of the pulse from each transmitter
channel. If any channel is permanently low, the display will indicate “Lo” similarly,
a permanent high will be shown as “Hi”. Three examples are shown below.
a) No flow Hi – Lo – Lo
b) Correct setting during flow D2 50 – 48 – 49
c) A channel 1 fault. Hi – 50 – 48
This test is designed as a quick test for the service engineer to monitor the
transmitter output pulses by using the passcode entry (i.e. without breaking the
setup button security seal). If no buttons are pressed and no pulses are seen by
the meter (i.e. the flow has stopped) then the meter will revert to normal mode
after a period of 30 seconds. Refer to Flag 22 for a permanent test facility.
D3 0 Local mode (LINKED Flag 70)
The system is set to function in a stand-alone situation without control from cab
computer or other management system.
1 The system is set to function in conjunction with a cab computer or other
management package.
5.7.9 Flag 10 (LINKED Flag 60)
D1-D4 The first stage flow rate for the operation of a preset valve. This is useful for
minimising the risk of static discharge when filling an empty tank. Typically, a
Figure of 10% of the maximum flow rate is used. This setting is only available in
tens of units (i.e. the least significant digit is fixed at “0”)
Example: 0250

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5.7.10 Flag 11 (LINKED Flag 60)

D1-D4 The first stage volume for the operation of a preset valve. This is used with Flag
10 and shall match the volume required to cover the filling nozzle. As above, this
setting is only available in tens of units. Example:0180

5.7.11 Flag 11 (LINKED Flag 60)

D1-D4 The maximum flow rate for the preset valve, with the least significant digit fixed at
“0”. Example:3450

5.7.12 Flag 13 (LINKED Flag 60)

D1-D3 The flow deceleration rate (i.e. the reduction of flowrate/sec.) when controlled by
a preset valve. Typically set to 150.
D5-D6 The volume allowed to pass through the control loop pipework (at 2-4 lpm.) during
the final stage of a preset delivery (range 0-9.9). Refer to the Preset Valve
Manual (TP0020) for more details. This is typically set to 1.0 litres.

5.8 HIGH SECURITY FLAGS

5.8.1 Flag 20
D1 This digit is inaccessible except when used with an Electronic Repeater System
(ref. TP0002).
D3-D6 A four digit passcode (0-9999) used to gain entry to the Flag settings (refer to
Ch2). When set to 9999 the passcode entry is disabled.

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5.8.2 Flag 21
This Flag is used to set the calibration class (i.e. the number of calibration points to be used)
and the maximum (100%) flow rate to be used for the calibration process. The more calibration
points selected the more accurate is subsequent measurement. However, the greater the
number of points, the longer the calibration process takes.
D1 1 Calibration class 1 (8 calibration points at 5%, 10%, 15%, 20%, 50%, 75%, 100%
of the max. flow rate (D3 – D6))
2 Calibration class 2 (4 calibration points at 10%, 20%, 75%, 100% of the max. flow
rate (D3 – D6))
3 Calibration class 3 (2 calibration points at 20% and 100% of the max. flow rate
(D3 – D6))
4 Calibration class 4 (1 calibration point at 100% of the max. flow rate (D3 – D6))

5 Calibration class 5 (4 calibration points at 20%, 50%, 75%, 100% of the max. flow
rate (D3 – D6)). This class of calibration is designed to assist operators where the
maximum flow rate is unobtainable when meter calibration is performed. The
maximum calibration flow rate is entered using (D3-D6) as normal. Only 3
calibration values are entered at 20%, 50% and 75%. Masterload will then
calculate the calibration correction required for the unobtainable 100% point by
extrapolation. If required, this extrapolated value may be observed using flag 37
but it is unalterable.
D3-D6 A four digit (0-9999) maximum flow rate setting for calibration. The above
calibration points are calculated using this as the 100% Figure. When calibrating
the meter, it is important to establish that this flow rate is obtainable.

5.8.3 Flag 22
This Flag provides test facilities and calibration settings.
D1 0 Normal setting.
1 This setting mimics the actions of the mark/space test of Flag 07, However, unlike
Flag 07, the test does not time-out.
2 This setting is used during calibration (ref. Ch.5) to allow the meter to display
volume that is uncalibrated (i.e. “raw” data). Any calibration Figures previously
entered are unused and stored away. During this mode, any preset valve control
is disabled.
3 Verification mode. Calibration factors are used by the meter and the display
shows units in 1/100‟s. During this mode, any preset valve control is disabled.

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4 Self test. This provides an aid to fault finding. Masterload will automatically cycle
through the following tests: Displays, Relays, Office and Program. To stop the test
and manually step through, hold the Reset button until the display stops cycling.
By toggling the Reset button the test is now under manual control.
To test the office link, short Tx to Rx and to
5 Soak cycle. This provides a continuous cycle for preset systems. Any preset valve
connected to the meter will continuously cycle through a delivery sequence.
5.8.4 Flag 23
This Flag is used as a test display where the batch display shows the current temperature.
5.8.5 Flag 30-37 (LINKED Flag 21)
The meter calibration factors are entered here. Only those factors relating to the class selected
under Flag 21 are available. These are indicated by an “X” in Table 5.1.
5.8.6 Flag 40
Flag 40 is used to set the maximum flow rate for the system. In practice, this is linked to the
meter size. The operator will be unable to enter a Figure that is greater than the maximum
specified flow rate for the meter (e.g. 1500Lpm. for a AH single capsule meter). Once this flow
rate is exceeded the meter will automatically shut down any valves and the error message “too
fast” will be displayed. When setting Flag 21, it is essential that the maximum calibration flow
rate is not set to a Figure higher than Flag 40. A setting of “0000” will disable this feature.
5.8.7 Flag 50
If the meter is to be used on products other than distillate an offset (providing a datum shift in
calibration) may be entered as a viscosity correction. For most applications this figure is
usually kept at 0.00%. In some cases, where meters are mounted vertically, it may be
necessary to enter a datum shift to assist calibration.
5.8.8 Flag 51 (LINKED Flag 52)
Flag 51 is used for temperature compensation and works in conjunction with Flag 52. When
the tables of Flag 52 are followed, the required reference temperature must be entered.
D1 0 Uncompensated volume.
1 Temperature compensation to 15°C reference.
2 Temperature compensation to 20°C reference.
3 Temperature compensation to 31.5°C reference.
D3-D6 A four Figure setting for temperature coefficient may be entered here which does
not follow the IP/ASTM temperature correction tables. These four digits are
preceded by 0.00.

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Example: If a coefficient of 0.001286 is required, 1286 must be entered. If Flag 52

tables are used, the temperature coefficient entered here must be 0000.
5.8.9 Flag 52 (LINKED Flags 05, 51)
Flag 52 gives the IP/ASTM table selection for temperature compensation. Where possible, this
Flag shall be used in preference to the fixed setting of Flag 51. However, some products such
as lubricating oil, are not covered by the IP/ASTM tables 53A/B and 54A/B.
D1 0 “A” Tables for Generalised Crude Oils.
D2 1 “B” Tables for Generalised Products (e.g. Gasolines, Jet fuels and fuel oils).
0 Table 54. To be selected in conjunction with Flags 05 and 51 to enable
temperature compensation relative to the density (Flag 05) value (at base
temperature) to a reference temperature of 15°C, 20°C or 31.5°C as determined
by Flag 51. The system must be equipped with a temperature probe for this
measurement.
1 Table 54. To be selected in conjunction with Flags 05 and 51 to enable
temperature compensation relative to the density (Flag 05) value (at any
temperature recorded by the temperature probe). This mode will accept an input
from a densitometer connected to the system.
2 Table 53. To be selected in conjunction with Flags 05 and 51 to enable
temperature compensation relative to the density (Flag 05) value (at any
temperature recorded by the temperature probe).
The density factor is subject to hydrometer correction as per tables 53A and 53B.
If the product to be metered is not covered by these tables, a coefficient of
expansion Figure may be entered in Flag 51 (i.e. a reproduction of table 54C).

5.8.10 Flag 53
This Flag provides a temperature probe offset. This shall only be used if it is considered
necessary to adjust the displayed temperature reading to match the recording from a
reference thermometer. Usually this is set to 0.0°C.

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5.8.11 Flag 54 (LINKED Flags 02, 05)

Flag 54 provides the choice of transducers (4-20mA) to be monitored by the system. It is
essential that this Flag is set before the transducer display (Flag 02) is organised. Before any
4-20mA transducer is used, the analogue interface (ZPMZ1-288) module must be fitted to the
Masterload PSU.
D1 0 No density measurement required.
1 Density to be entered manually via Flag 05.
2 An in-line densitometer will be used to measure density.
D2 0 No pressure measurement required.
1 One pressure measurement will be taken by the system.
2 Two pressure measurements will be taken.
D3 0 No differential pressure measurement required.
1 A differential pressure measurement will be taken by the system.

5.8.12 Flag 60 (LINKED Flags 06, 10, 11, 12, 13)

This Flag is used when deliveries are to be controlled by a preset valve.
D1 0 No preset control.
1 Control by a Avery-Hardoll solenoid preset valve.
2 A two stage valve control. The first stage will shut down the flow at a volume
given by Flag 13 (by-pass volume). This setting will allow a bypass volume of 0-
990 litres. The figures given in Flag 13 will represent decalitres (the decimal point
will not be displayed).
3 Preset valve control for systems fitted with slow acting valves. This is an ideal
setting for 8” valves. (Refer to the technical information sheet TIS 148).
4 This is a crude method of preset where the deadman valve is closed when the
preset quantity has passed through the system. To operate this setting, Flag 70
must be set for vehicle deadman control (D1=0).
D2 This is usually set to “0”. If a minimum preset quantity is required to prevent small
deliveries taking place, this bit may be set to a Figure (0-9) representing the
number of 100 litres. Example: Setting 2 would prevent deliveries of less than 200
litres. When used in conjunction with the large valve setting (D1=3), this provides
a second stage shutdown flowrate. (Refer to the technical information sheet
TIS 148).
D3 0 No interlock sensing.

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1 There are three interlock senses available (Earth connection, Overspill and
loading Arm position). Since these senses are related to gantry use, they are
explained in more detail in TP0027A.
D5-D6 This shall be set to 0 as it is a crude pump controlled preset for gantries.

5.8.13 Flag 70 (LINKED Flags 07)

D1 0 This is the setting for vehicles and uses delivery control by deadman. The
deadman valve (controlled via SSR3) is permanently enabled except when a
Masterload error is detected.
1 Setting for a gantry system.
2 Vehicle System with Deadman Timer (see INSTALLATION Para 23).
D2 0 This is used when Masterload is stand-alone (local mode) and not connected to
any external devices (e.g. cab computer).
1 This is the setting for system mode if Masterload is intended to be connected to
peripheral equipment (e.g. cab computer). Baud rate is 1200
2 If Masterload is intended to be switched between local and system modes (e.g.
during a communications fault) it is desirable that this rearrangement can be
made via low security (i.e. without the need to break the security seal). Using this
setting enables Flag 07 (D3) to be set up. Baud rate is 1200.
3 As selection 1 with baud rate as 9600.
4 As selection 2 with baud rate as 9600.
5 Communication link to a local ticket printer (refer to end of section).
D3 (LINKED Flag 80)
SSR4 may be used to issue calibrated volume pulses to an external system.
Usually this output will provide pulses at the voltage level used by the system.
Thus a 240 volt system will provide 240 volt pulses.
It is possible to feed different voltage levels via SSR4 by using the interlock input.
It is not possible to use this facility with additive injection in use (Flag 80).
0 No pulse output.
1 A pulse output from SSR4 representing 1 pulse per unit of volume displayed.
(Pulse width 6mS).
2 A pulse output from SSR4 representing 10 pulses per unit of volume displayed.
(Pulse width 600μS).
3 A pulse output from SSR4 representing 1 pulse per 10 units displayed.

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D4 Masterload has an in-built safety feature to warn the operator of leaks and to act
as an anti-theft device. If a flow rate of less than 1% of the maximum flow rate
(Flag 40) is detected for more than 30 seconds, the message “too slo” will be
displayed and any valves will be shut. Once this is detected the system remains
inoperative (i.e. no button response) for at least 1 minute.
0 Disable the low flow message.
1 Enable the low flow message.
D5 This is used to establish the communication link from Masterload to an office or
external device. For vehicle use this redundant.
D6 0 System not linked to a cab computer.
2 Masterload connected to a cab computer. In this mode the Reset button is
disabled.
5.8.14 Flag 71
This Flag is used to enter a five Figure vehicle number (0-99999) when used with a cab
computer.
5.8.15 Flag 73-74
Not used for vehicle systems.
5.8.16 Flag 75
This is the delivery time out in seconds (typically 30 secs) and regulates the time period after
flow has ceased before the preset valve is automatically shut off.
Note: When the flag is set to “0”, there is no time out.
5.8.17 Flag 90
Flag 90 is used to format the display. Display information has been split into two groups:
Prime Defines the standard display data.
Secondary Defines extra data that is the available.
Both Prime and Secondary data may be set to give:
Uncompensated Volume
Compensated Volume
Weight
Note: If Flag 51 is set to 0, then the compensated volume will be the same as the
uncompensated value.
If set to display weight, the correct density must be entered via Flag 05 or by
densitometer.

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Masterload will always use the value of Flag 05 even if Flag 54, D1=0.
D1 3 This format is useful for displaying volume and weight on the same display unit.
The flow rate is given in US Gallons/min.
4 This mode is intended to display compensated and uncompensated volume (i.e.
Net and Gross) on the same batch display. The Reset button is used to toggle
between these two states and a curser on the LCD display points to the
appropriate Net or Gross legend on the dial mask.

5.8.18 Flag 99
Flag 99 is used to view details from previous transactions. This facility is generally known as
Transaction Storage.
Masterload is capable of storing details from 40 transactions. This can be useful if running in
system mode and the controlling computer suffers some form of crash. Transactions can still
proceed in stand-alone (local) mode and details of past deliveries may be recalled using this
facility.

5.9 ASSESSING TRANSACTION STORAGE

5.9.1 Press and hold the Reset button to gain entry to the passcode (refer to TECHNICAL
DESCRIPTION).
5.9.2 Enter the passcode to gain access to the Set Up data.
5.9.3 Select Flag 99.
5.9.4 The display will show d-1 (the last recorded delivery) together with the delivery details:
1. Batch window Nett Batch
2. Preset window ID number (Cab No.)
3. Tote window Final Tote
5.9.5 Press the Reset button to decrement the delivery (displaying d-2, d-3 etc.) If the Reset button
is left untouched for 40 seconds, the display will leave this facility and revert to normal display.
Every new transaction will become d-1 and the delivery at the bottom of the pile (i.e. d-40) will
be lost.

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5.10 TICKET PRINTER - SPECIFICATION

5.10.1 The local printer used with masterload is an EPSON TM--U295 (or equivalent).
Specification: Supply voltage: +24V +/-10%
Current: Mean approx. 600mA
Peak approx. 5.5A
Printing speed: 35 (5x7 font)
Paper feed: 12.5 lines
No. of characters: 95
Life: 3,000,000 lines
MTBF: 180,000 hours
Temperature: 5 °C to 40°C (Operating)
-10 °C to 50 °C (Storage)

This printer will receive serial data via an RS422/RS232 twisted pair communications link.
Connection to the device is shown in the wiring diagram at the back of document.
An override switch may be incorporated to allow deliveries to be carried out without the
operation of the printer. The preset display window is used for operator messages
The basic printed ticket will provide the following information. No provision is made for the
printing of date and time.
:
Invoice No. 6 figures
Cab ID No. Max. 6 figures

Start Tote 8 figures

End Tote 8 figures

Batch Volume 6 figures

A pre-printed ticket with customer’s company header is used a “blank”. A “boxed” region on
the ticket will provide a suitable printing area. The letters giving data type (e.g. Batch Volume)

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will also be transmitted from the Masterload system, this will help combat any problems with
alignment.

If the system is configured for temperature or density measurement the printed ticket will
provide this additional information as follows.
Invoice No. 6 figures
Cab ID No. Max. 6 figures

Start Tote 8 figures

End Tote 8 figures

Batch Volume 6 figures

Temperature 8 Max. 3 figures plus 1 decimal place (ºC)

Density Max. 4 figures plus 1 decimal place (Kg/cu M)

A bank of 10 DIL switches in the base of the printer will be set as tabulated.

Switch Function ON OFF

1 Data reception error (prints) X
2 Receive buffer capacity (512 bytes) X
3 Handshaking (XON/XOFF) X
4 Word length (8 bits) X
5 Parity check (Yes) X
6 Parity selection (Odd) X
7 X
8 Transmission speed (9600 baud) X
9 Pin 6 reset signal X
10 Pin 25 reset signal X

5.11 TICKET PRINTER OPERATION - NON PRESET SYSTEM

5.11.1 The Non Preset System uses two buttons to operate the ticket printer (see below). The centre
button is unused.

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5.11.2 The sequence of events will be:

a. Place the ticket paper under the print head of the cab printer.
b. Press Reset to reset the batch. This action will instigate the printing of Invoice No., Cab
No. and Start Tote.
c. If the printer is not functioning correctly or is not connected, the message ”Print Off” will
appear on the display. If this problem persists, the process may be switched to manual
using an override switch. Once in override, the ticket may be written out manually.
d. If no paper is not detected, the message ”Paper Out” will appear on the display.
e. Make the delivery.
f. When the delivery ceases, the Print button is pressed to activate the final printing of the
ticket giving End Tote and Batch volumes.
g. Once again, c) and d) apply. If the printer fails between printing the start and finish totes,
the ticket may be completed manually.
h. Once the Print button is pressed the message ”Print” will appear in the display for a few
seconds.
i. To re-print the ticket (e.g. if a duplicate is required) press the Print button again. Note, the
duplicate ticket will have the same printed invoice number as the previous ticket but will be
followed by a “D” to indicate duplicate. A maximum of 255 duplicates are available.
j. Once the delivery has started and product is flowing, the Reset and Print buttons have no
effect.

5.12 TICKET PRINTER OPERATION - PRESET SYSTEM

5.12.1 The Preset System uses all three buttons to operate the delivery and print the ticket. The
sequence of events will be:

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a. Place the ticket paper under the print head of the cab printer.
b. Having selected the preset quantity using the Preset button, press Reset to reset the
batch. This action will instigate the printing of Invoice No., Cab No. and Start Tote.
c. If the printer is not functioning correctly or is not connected, the message ”Print Off” will
appear on the display. If this problem persists, the process may be switched to manual
using an override switch. Once in override, the ticket may be written out manually.
d. Make the delivery.
e. When the delivery ceases and the preset display has counted down to zero, the message
“Print” will appear on the display for a few seconds. At this point, final printing of the
ticket-s carried out automatically giving End Tote and Batch volume.
f. If the printer fails between printing the start and end totes, the ticket may be printed
manually following the operation of the override switch.
g. To re-print the ticket (e.g. if a duplicate is required) press the Stop/Run button.
Note: The duplicate ticket will have the same printed invoice number as the previous
ticket but will be followed by a “D” to indicate duplicate. A maximum of 255
duplicates are available.

5.13 SETTING UP THE PRESET VALVE

5.13.1 By controlling an electrical preset valve the Masterload gives precise batch delivery sequences
unaffected by any changes in line pressure.
5.13.2 By using Flag Settings (refer to Para 7), a flow profile similar to that in Figure 5.2 can be
achieved repeatedly.

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Figure 5.2 Typical Preset Batch Delivery

5.13.3 Stage 1, can be programmed to deliver a small amount of fuel at a low flow rate, in order to
reduce any risk of static build up when fuelling empty vessels.
5.13.4 During Stage 2, flow will be maintained at the maximum flow rate determined by the pumping
capacity of the system.
5.13.5 Masterload is capable of controlling most valves by pulsing two electrical solenoids. The
Avery-Hardoll brand Preset Valve (see TP0020) comes in a range of sizes and materials and
are ideally suited to the Masterload Metering System. For applications using other
manufacturers equipment please contact the Product Support Department.
5.13.6 To set-up Masterload preset control, Flag 60 must be set up for the valve type (refer to
Para 8).
5.13.7 Flag 10 controls the first stage flow rate.
5.13.8 Flag 11 controls the volume passed at first stage flow.
5.13.9 Flag 12 controls the maximum working flow rate.
5.13.10 Flag 13 controls the deceleration rate (in Lpm/sec). Masterload will calculate at which point in
the delivery that the preset valve shall begin to close. This is monitored and the valve is
controlled as the preset quantity diminishes to provide a smooth closure with accurate product
delivery. Flag 13 also controls the volume at which the valve closes before the end of the
preset quantity and enters a by-pass volume phase. This final low flow phase allows the final
shut off to occur accurately.

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5.13.11 This manual provides information for setting up Masterload with the Avery-Hardoll brand
Preset Valve. When used in conjunction with other manufacturers equipment, refer to the
manual supplied with the preset valve for set-up information.
Note: For setting up the large valve refer to Technical Information Sheet TIS 148.
5.13.12 When setting up the valve close both needle valves. Open the upstream needle valve 3/4 turn
and the downstream needle valve 1/4 turn, to provide a controlled flow rate for commissioning.
Note: Opening the upstream needle valve increases closing speed.
Opening the downstream needle valve increases opening speed.
The upstream needle valve must always be open further than the downstream needle
valve.
5.13.13 To investigate the valve operation set the following:
a. Flag 60 - 1
b. Flag 22 - 2
c. Flag 10 - 400
d. Flag 11 - 100
e. Flag 12 - 900
f. Flag 13 - 100 - 1.0
5.13.14 Preset a quantity on the Display Unit and press the STOP/RUN button to instigate a delivery.
5.13.15 For further information refer to the Solenoid Operated Preset Valve manual, Publication No.
TP0020.

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5.13.16 The deceleration rate (Flag 13) is in units of lpm / sec (or gpm / sec for gallon systems). With a
maximum flow rate of 500 lpm and deceleration of 100 lpm / sec, the valve would close in 5
seconds. The volume at which the valve closes before the end of preset is calculated from:

(FLOW RATE)2
= 20.8 litres
120 X DECELERATION
5.13.17 After the final needle valve settings have been achieved, the by-pass volume (Flag 13) shall
be set to give a rapid and accurate shut-off to the preset batch. If the preset batch has over-
run, increase by-pass volume to cause the valve to close earlier. If the valve closes too early,
causing a prolonged time at low by-pass flow rate, then reduce the by-pass volume.
Note: Altering needle valve settings at this point changes the rate of valve closure. This
may necessitate alteration of the by-pass volume.

BEFORE COMMENCING CALIBRATION, FOLLOW ALL LOCAL

SAFETY AND EMERGENCY PROCEDURES.

5.14 CALIBRATION

5.14.1 In order to calibrate the Masterload system it is necessary to connect an accurately calibrated
Test Meter to the product line.
5.14.2 Throughout calibration, make sure the manual valve is opened and closed smoothly so as not
to cause unnecessary disturbances within the system. Do not attempt to stop product flow at
an exact number on the totaliser by closing the operating valve abruptly.

5.15 CALIBRATION CLASSES

5.15.1 Masterload is capable of being calibrated to four standards (i.e. Classes).

5.15.2 The four calibration classes are:
 CLASS 1 (8 point) - Provides maximum accuracy across the entire flow range with
calibration at flow rates (5%, 10%, 15%, 20%, 30%, 50%, 75% and 100%).
 CLASS 2 (4 point) - Provides accuracy with calibration at flow rates (10%, 20%, 75% and
100%) whilst maintaining an efficient recalibration programme.
 CLASS 3 (2 point) - Provides accuracy with calibration at flow rates (20% and 100%) whilst
maintaining an efficient recalibration programme.

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 CLASS 4 (1 point) - Provides a minimum calibration with a single flow rate calibration point
(usually at 100%) similar to a mechanical calibrator. This class may be used before the
preferred class of calibration is established.
5.15.3 Figure 5.3 depicts typical class error curves for performance with an Avery-Hardoll Bulkmeter
Capsule.

Figure 5.3 Typical Error Curves

COMPANIES AND ORGANISATIONS MAY HAVE THEIR OWN RULES

AND REGULATIONS REGARDING CALIBRATION, THESE MUST BE
FOLLOWED AND WHEREVER POSSIBLE USED IN CONJUNCTION
WITH THE FOLLOWING INSTRUCTIONS.

5.16 MASTERLOAD CALIBRATION - With an Avery-Hardoll Bulkmeter

5.16.1 The following procedure is written for a typical calibration rig (see Figure 5.4) containing a test
meter, the meter under test and a control valve. This ideal calibration layout may not always
be practical. Variations of this procedure will be covered later in this Chapter.
5.16.2 Once the class of calibration has been decided the information must be entered into Flag 21.
The default setting is class 2.
5.16.3 The 100% flow rate of either the meter or the system, (whichever is the lower) must also be
entered into Flag 21 which is a High Security Flag and requires access to the SET-UP button
to gain entry.

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Figure 5.4 Typical Calibration Rig

5.16.4 The default settings are as follows:

 SINGLE CAPSULE 1140 lpm
 DOUBLE CAPSULE 2280 lpm
 TRIPLE CAPSULE 3404 lpm
5.16.5 If the 100% flow rate is set to 0000, the default value will be re-entered on leaving set-up
mode. For optimum accuracy, it is recommended that the default value is replaced by the
value required by the site operator.
5.16.6 Select Flag 22 and enter “2” for CALIBRATION MODE. This causes Masterload to ignore all
calibration data that may be present and to treat the capsule as a raw meter.
Note: The display readings given during calibration mode are the basic meter units. For
example, if the meter has a weight display in tons, the display will revert to imperial
gallons. Similarly a kilogram meter will display litres.
5.16.7 Press the SET-UP button to return to normal display mode. The volume display indicates
1/100 litres for absolute accuracy.
5.16.8 Before starting the calibration process, refer to Meter Calibration Certificate (see Figure 5.5).
This may be photocopied if necessary.
Note: Columns 1-10 refer to the Test Meter and columns 11-14 refer to the Meter under
Test

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5.16.9 Calculate the % flow rates for all calibration points for the selected calibration class (Flag 21).
Example: If the 100% flow rate is 1800Lpm for class 2 calibration, the following calibration
points must be used.
100% 75% 20% 10%
1800 Lpm. 350 Lpm. 360 Lpm. 180 Lpm.
5.16.10 On preset systems disable the preset control by setting Flag 60 to 0.
5.16.11 Enter all client data and serial numbers etc. on the calibration certificate together with the
totaliser values of both the Test Meter and Meter under Test on the certificate.
5.16.12 On preset systems, press the Stop/Run button.
5.16.13 Open the manual valve slowly and run product through the test rig at 100% flow rate for a
period of 1 minute. This is the “wetting” run and serves to purge the system of air and to obtain
a stable temperature.
5.16.14 Enter the run number and flow rate in columns 1 and 2 of the certificate.
5.16.15 Make three proving runs at each calibration flow rate, beginning with the lowest flow. All
proving runs must be equal to or greater than the volume delivered at 100% flow rate in 1
minute. Care must be exercised at the lower rates as too small a volume may not give the
required repeatability. It is therefore recommended that a duration of two minutes be used to
provide accurate results.
5.16.16 Enter the Test Meter readings in column 3 together with the run numbers and flow rates. If
required, enter the temperature and pressure in columns 9 and 10.
5.16.17 Enter the Test Meter factor in column 4 and, if required, calculate from the Figure of columns 9
and 10, the temperature and pressure correction factors for columns 5 and 6.
5.16.18 Add columns 4,5 and 6 to give a total correction factor for column 7.
5.16.19 Multiply column 7 by the Test Meter reading (column 3) to enter a corrected volume Figure in
column 8.
5.16.20 Enter the start and finish totaliser readings of the Meter under Test in column 11 and subtract
the start tote from the finish tote (column 11) to gain the meter reading for column 12.
5.16.21 Subtract the MUT meter reading (column 12) from the Test Meter corrected volume (column 8)
to give the difference in column 13.
Note: If there is a delay of more than ten minutes between runs, then a further stabilising
(i.e. wetting) run shall be completed. Make sure the rig remains pressurised
throughout the calibration process.

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5.16.22 Evaluate the % error or factor ( column 13) by subtracting the meter reading (column 12) from
the corrected volume (column 8). Multiply the result by 100% and divide the answer by the
corrected volume (column 8).

CORRECTED VOLUME (TM) – MEASURED VOLUME (MUT)

% ERROR = X 100%
CORRECTED VOLUME (TM)

5.16.23 Add the three proving run % errors together and divide the result by three to give the
average % error for the flow-rate.
Note: The calibration factor entered into the Flag table (refer to Table 5.1) is the % error
(14) with the polarity changed. For example:- 10% flow rate average % error = + 0.12.
The calibration factor would be -0.12. For Flag entry points on class 1, 2 and 3
calibrations refer to Table 5.2.

Table 5.2 Flag Table – Calibration Points

CLASS
Flag No. % Flow Rate
1 2 3 4
30 5% X
31 10% X X
32 15% X
33 20% X X X
34 30% X
35 50% X
36 75% X X
37 100% X X X X

5.16.24 In order to achieve the final proving runs, Flag 22 must now be set to position “3” (verification
mode). It is now necessary to achieve three acceptance runs at the maximum / general
operating flow rate.
5.16.25 A Static Slip Test is not necessary with Masterload as extremely low flow rates can be
detected and displayed as error conditions if required.

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5.16.26 After calibration has been completed, change Flag 22 to “0” (normal mode) and record the
finish totalisers of both meters and complete the calibration certificate.

5.17 CALIBRATING MASTERLOAD

5.17.1 Companies and Organisations may have their own rules and regulations regarding re-
calibration. These must be followed and wherever possible used in conjunction with the
following method recommended by Liquid Controls, LLC.
5.17.2 Set Flag 22 to “3” (Verification Mode) and record the totaliser values of both the Reference
Meter and the Meter Under Test. (See note in 12 F).
5.17.3 Run product at 100% flow rate for a period of one minute to stabilise the system.
5.17.4 Conduct a single run (minimum duration 2 minutes) at the lowest flow rate used to calibrate
the meter.
5.17.5 Check that the overall error is not greater than that specified by the company. If within
allowable tolerance, conduct a run of not less than 1 minute duration at the next flow rate used
for calibration.
5.17.6 If the error is now greater than that allowed, then the relevant calibration factor within
Masterload must be adjusted and a second run conducted. When the error is within the
allowable tolerance, proceed to the next flow rate and repeat the exercise. All runs must not be
less than 1 minute duration.
5.17.7 Re-calibrating the 100% flow rate requires three runs of not less than 1 minute duration to be
completed. If any adjustments are required to this calibration factor then three verification runs
must be completed after final adjustment.
5.17.8 When re-calibration is complete, record the finish tote Figures of both meters and change Flag
22 value to “0” (normal mode).

5.18 DISPLAY UNIT SET-UP

5.18.1 The Main Display Unit has a switch (SW2) mounted on the component side of the processor
board to control direction of flow.
5.18.2 If reverse flow is indicated (i.e. a negative sign preceding the flow rate), carefully remove the
display front and change the position of SW2.
5.18.3 The Additional Display Unit may be configured to either repeat the information shown on the
main Display Unit, or to show additional information.
5.18.4 This is configured via Flag 90 (refer to Table 5.1 details) and by adding a push-in link to the
underside of the main display board in one of two positions marked “LK 1” and “LK 2”.

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5.18.5 Fit “LK 1” if repeated information is required.

5.18.6 Fit “LK 2” if additional information is required.

5.19 TEMPERATURE DEVICE

5.19.1 Make sure the temperature probe is wired correctly (refer to INSTALLATION).
5.19.2 It is not necessary for further calibration of this device as it has been factory set.
5.19.3 To check the integrity of the Temperature probe and circuitry set the Flag 02 to display
continuous temperature (i.e. Flag 02 = 110)
5.19.4 Exit the Set-Up mode, and the temperature reading will be displayed continuously in the Rate
of Flow window.

5.20 DENSITOMETER UNIT

5.20.1 Make sure the Densitometer is wired correctly (refer to INSTALLATION). Although the
Densitometer range is factory set at 750 - 850 kg / cu metre, other densities may be
accommodated. Contact Liquid Controls, LLC for advice.
5.20.2 To check the Densitometer reading, enter Set-Up mode, and set Flag 54 to 200.
5.20.3 Exit the Set-Up mode, and simply press the RESET button. The Density value shall be
displayed in the Batch window for two seconds before the EIGHTS check appears and the
batch quantity zeroes.
5.20.4 The reset button can be pressed at any time to check the Density reading.
5.20.5 If the pipework is not completely full, the Density reading will not be correct.
5.20.6 If a continuous reading of Density is required on the Masterload display, set Flag 02 to 21.
5.20.7 Exit the Set-Up mode, and the Density value will be displayed continuously in the Rate of Flow
window.
5.20.8 If the density is out of range, the error “Density” will appear in the tote window

5.21 DIFFERENTIAL PRESSURE TRANSDUCER

5.21.1 A value for maximum differential pressure at 100% flow is required to be entered in Flag 02, in
order for the transducer to be effective.
5.21.2 It is not necessary for further calibration of this device as it has been factory set.
5.21.3 To check the Differential Pressure reading, enter Set-Up mode, and set Flag 54 to 001. For a
max. pressure of 15 psi @ 100% flow set Flag 02 to:

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5 1 1 1 5

5.21.4 Exit the Set-Up mode, and the Differential Pressure value will be displayed continuously in the
Rate of Flow window.
5.21.5 If a differential pressure error exists, the word “dP” will appear in the tote window.

5.22 PRESSURE TRANSDUCERS

5.22.1 If vehicle pressures are required to be monitored, a maximum of two additional pressure
transducers can be interfaced to Masterload.
5.22.2 A pressure transducer fitted will usually be within the range of 0 - 200psi (although other
ranges are available). An error message „Pressure will be displayed in the rate of flow window
if the maximum rating is exceeded.
5.22.3 It is not necessary for further calibration of this device as it has been factory set.
5.22.4 To check the first/only Pressure transducer reading, enter Set-Up mode, and set Flag 54 to
010 with Flag 02 set to:

3 1 2 0 0

5.22.5 Exit the Set-Up mode, and the Pressure reading will be displayed continuously in the Rate of
Flow window.
5.22.6 To check a second Pressure transducer reading (if fitted), enter Set-Up mode, and set the
following Flag 54 to 020 with Flag 02 set to:

4 1 2 0 0

5.22.7 Exit the Set-Up mode, and the Pressure reading from the second pressure transducer will be
displayed continuously in the Rate of Flow window.

5.23 CAB COMPUTER SYSTEM

5.23.1 In order to activate the link between Masterload and a cab computer make sure Flag 70 is set
to:

0 1 0 0 0 1

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5.23.2 To isolate the Masterload from a cab computer enabling further Masterload commissioning,
set the override switch to the „Override‟ position.
5.23.3 Masterload connected to equipment requiring a simple volume related pulse, shall be wired in
accordance with the wiring diagram at the back of this manual.
5.23.4 To enable Masterload to generate a volume related pulse from SSR4 within the power supply
unit, make sure Flag 70 is set for 1 or 10 pulses/litre (refer to Table 5.1).
5.23.5 It is important to recognise that the voltage of this volume related pulse will be equal to the
Vehicle battery voltage. If an alternative power supply is required, assistance may be sought
from the Customer Support department.
5.23.6 The 1 pulse per litre output is available for flow rates over the range of 0 - 4500 Lpm.
However, for 10 pulses per litre the maximum allowable flow rate is 2000 Lpm. Flow rates
above this value will result in an incorrect pulse count.

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Figure 5.5 Meter Calibration Certificate

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5.24 FLAG SETTINGS - RECORDING

5.24.1 It is recommended that all flag settings are recorded for future reference. This can be entered
on a Flag record table, an example is shown in Figure 5.6.

Figure 5.6 Flag Record Table

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CHAPTER 6
OPERATION
FOLLOW ALL LOCAL REGULATIONS REGARDING THE USE OF
EQUIPMENT IN HAZARDOUS AREAS.

6.1 INTRODUCTION

6.1.1 With Masterload commissioned as described in COMMISSIONING, and Flag 22 is set to “0”
(normal mode) the system is now ready for operation.
6.1.2 It is important that operators are familiar with all controls and displays before attempting a
delivery.
6.1.3 The operation of Masterload is very much dictated by the configuration and Flag settings. For
further details on Flags refer to COMMISSIONING.

6.2 NON-PRESET DELIVERY (see Figure 6.1)

6.2.1 Switch on the Vehicle Master Switch.

6.2.2 The display unit shall show an ‘8’ in all segments of the display windows for approximately 3
seconds as a display test. If any display segment is missing, refer to FAULT FINDING. This
check may be repeated by pressing the RESET button.
6.2.3 The display unit now shows ‘0’ in the ‘batch’ and ‘rate of flow’ windows with the ‘tote’ window
showing the current total.
6.2.4 Open the control valve to instigate a delivery.
6.2.5 The batch window displays the delivery in progress together with the rate of flow. If density,
temperature or differential pressure are required during a delivery, these can be obtained by
pressing the reset button (refer to Flag 02 for these settings).
6.2.6 Close the control valve when the desired batch volume (or weight) is reached. Enter details of
delivery in accordance with company procedures.
6.2.7 To start a new delivery press the RESET button to zero the batch display. To make a
continuation delivery, open the control valve and the batch volume will continue as an
accumulative total.

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Figure 6.1 Non – Preset Display Format

6.2.8 If Masterload has been configured to display batch temperature or density these will appear
after flow has stopped for 3 seconds, indicating the average temperature and density of the
last batch delivered.

6.3 PRESET DELIVERY (see Figure 6.2)

6.3.1 Switch on the Vehicle Master Switch.

6.3.2 The display unit shall show an ‘8’ in all segments of the display windows for approximately
3 seconds as a display test. If any display segment is missing, refer to FAULT FINDING. This
check may be repeated by pressing the RESET button.
6.3.3 Press and hold the PRESET button, the first digit in the preset window will start to count up,
release the button on the required value. When the button is released the next digit is ready for
setting. Repeat for all digits to set the required preset value. To move on a digit, press
momentarily and release. By repeatedly pressing the Preset button, any digit may be set or
altered.
6.3.4 If Masterload has been configured to have a maximum preset value (refer to Flag 06), the left
hand (most significant) digit will count up to this figure then return to zero. When the digit
reaches the maximum preset any remaining digits will also return to zero, this can be used as
quick method of setting or clearing a value.

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Figure 6.2 Preset Display Format

6.3.5 Press the STOP/RUN button to start a delivery. The rate of flow window will display ‘run’ when
the valve opens, this is replaced by rate of flow.
6.3.6 With delivery in progress the Batch and Totaliser windows count up and the Preset window
counts down. If density, temperature or differential pressure are required during a delivery,
these can be obtained by pressing the reset button (refer to Flag 02 for these settings).
6.3.7 Masterload will stop delivery when the preset value has counted down to zero. The rate of flow
window will display ‘StOP’.
6.3.8 If Masterload has been configured to display batch temperature or density these will appear
after flow has stopped for 3 seconds, indicating the average temperature and density of the
last batch delivered.
6.3.9 Enter details of delivery in accordance with company procedures.
6.3.10 Press the RESET button to reset the batch display to zero ready for the next delivery. The
previous preset figure is displayed, this may be changed or used for the next delivery.
6.3.11 If an accumulative delivery is required, i.e. filling various compartments with the same amount
of product, then a different method may be used. Instead of pressing the RESET button after
the first delivery, press the PRESET button and the previous preset figure will re-appear. If this
value requires changing then follow the procedure in Para 3C. The second compartment may
now be filled, the batch figure shown will be an accumulation of both deliveries. This method
may be used for as many compartments as is required.

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6.3.12 For an emergency stop press the STOP/RUN button. The rate of flow window will show
‘StOP’. To restart, press the button again, providing the system has not timed-out. If this has
occurred reset the system and repeat from Para 3C but only enter the remaining undelivered
volume into the preset.
6.3.13 The maximum preset quantity can be controlled by entering the required value into Flag 06.
Note: The system cannot be reset during delivery.

6.4 CAB COMPUTER OPERATION

6.4.1 The connection of Masterload to a cab computer can be considered as a partnership;

Masterload is responsible for the metering side of fuelling, while the cab comuter is
responsible for collating fuelling data with other transaction information, for administrative
purposes.
6.4.2 Make sure the Masterload has been set up for cab computer communication, as follows:

FLAG
70 0 1 0 0 0 1

6.4.3 Masterload will now communicate with the computer console in the vehicle cab.
Note: The Masterload Reset button is inoperative when in cab computer mode.
6.4.4 When linked to the cab computer, Masterload will show the message ‘Stop’ in the Rate of Flow
window until the computer enables the meter for a fuelling transaction.
6.4.5 Although Masterload is responsible for supplying a permissive to the Deadman circuitry, the
cab computer shall control the Deadman when in communication mode. A signal from the cab
computer will inhibit the deadman permissive from Masterload until a transaction is authorised.
Computer authorisation shall reset the Masterload Batch quantity to zero and enable the
deadman permissive.
6.4.6 If the Deadman permissive is required to be returned to its normal state, the Override Switch
must be set to its Override position.
6.4.7 Connection to a vehicle cab computer system can be achieved by Full Data link, or by a
simple pulsed output by volume (i.e. 1 pulse per unit of volume displayed). Detail on data
protocol may be obtained on request.

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MASTERLOAD II™ (Vehicle)

6.4.8 Vehicle cab equipment requiring a simple volume related pulse can make use of an extra solid
state relay within our power supply unit (refer to INSTALLATION for details). It is important to
recognise that the voltage of this pulse will be equal to the Vehicle battery voltage. If an
alternative power supply is required, assistance may be sought from the Customer Support
department.
6.4.9 The number of pulses per unit displayed can be configured in Flag 70. Note that the 10 pulse
per unit displayed setting may only be used for flow rates less than 2000 Lpm. Higher flows
must be accomodated using the 1 pulse per unit setting.

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 AVERY-HARDOLL MAINTENANCE MANUAL
MASTERLOAD II™ (Vehicle)

CHAPTER 7
FAULT FINDING
FAULT FINDING AND REPAIR MUST ONLY BE CARRIED OUT BY
SUITABLE QUALIFIED PERSONNEL. THE POWER SUPPLY UNIT
CONTAINS NON-INTRINSICALLY SAFE WIRING. FOLLOW ALL
REGULATIONS REGARDING THE USE OF EQUIPMENT IN A CATEGORY 2
(ZONE 1) HAZARDOUS AREA.

7.1 INTRODUCTION

7.1.1 The following paragraphs provide a guide to faults that may occur, their possible causes and
remedy. They may not cover all possible faults. If a fault cannot be traced or rectified, please
contact the Service Department for advice.
7.1.2 During operation faults may occur with Masterload or the system to which it is installed. Some
faults will be sensed by Masterload, which are displayed as ERROR messages in the Rate of
Flow window. Masterload will protect the system by automatically shutting it down if an error is
recognised.

7.2 FAULT FINDING TABLE

7.2.1 Once Masterload detects a recognised fault, the rate of flow window displays the word
“ERROR” alternating with the normal flow rate indication. Simultaneously the Totaliser window
alternates between the totaliser value and error message. These messages are tabulated in
Table 7.1 and result in the shutdown of the Deadman and preset valve (if fitted). Table 7.1 also
gives the order of priority and if more than one error is active, only the higher priority error will
be displayed.

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Table 7.1 Fault Finding

DISPLAYED ERROR
POSSIBLE CAUSE ACTION
MESSAGE

No Pulse Transmitter not connected. Fit Transmitter.

(No signal from
Transmitter cable damaged Renew Transmitter cable.
Transmitter)
Faulty Transmitter connections Check/remake connections within Transmitter.

Pulses Transmitter faulty. Renew Transmitter.

(Transmitter giving false
Processor PCB faulty. Renew Processor PCB.
signals)

NVR Fail Insufficient power from supply. Check battery voltage (on load). Recharge.
(Memory corruption)
Renew Barrier block.
Faulty Barrier block.
Renew Power Supply PCB.
Power Supply Unit faulty.
Renew Processor PCB.
Processor PCB faulty.

Preset Incorrect flag settings. Check Flag 60 and Flags10-13.

(Preset overrun)
Preset valve badly set up. Adjust preset needle valves.
Preset valve incorrectly wired. Check preset valve wiring and connections.
Use self test (Flag 22) to check SSRs. Renew?
Faulty SSRs.
Check valve seat. If necessary renew seal.

Preset valve leaking.

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Table 7.1 Fault Finding – (cont.)

DISPLAYED ERROR
POSSIBLE CAUSE ACTION
MESSAGE

Too Hot Faulty temperature probe. Read temperature (Flag 02).

(Temperature error) Renew probe?
Temperature circuit module not fitted. Fit temperature module.
Faulty temperature probe wiring. Check wiring and connections.
Temperature alarm set too low. Set Flag 03 correctly.
Incorrect flag setting. Disable temperature if not required (Flag
02).
Faulty processor PCB. Renew Processor PCB.

Too Cold Faulty temperature probe. Read temperature (Flag 02). Renew
(Temperature error) probe?
Temperature alarm set too high. Set Flag 03 correctly.
Faulty processor PCB. Renew Processor PCB.

Too Fast System flow rate (flag 40) set too Set Flag 40 correctly.
(Flow rate too high) low.
Reduce flow rate by external valves.
Flow rate too high.
Check that the program is correct (Flag 00).

EPROM program (meter size

mismatch)

Too Slow Flow rate below 1% of max. for Check valve - preset valve for leaks
(Flow rate too low for too 30secs.
Max flow rate set too low
long)
Incorrect flag setting (Flag 21). (Flag 21).

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Table 7.1 Fault Finding – (cont.)

DISPLAYED ERROR
POSSIBLE CAUSE ACTION
MESSAGE

Density Incorrect flag setting (Flag 54) Density accidentally requested (Flag 54).
(Density error)
Renew densitometer.
Densitometer error
Product density out of range (500-1200
Density reading out of range Kg/CuM).
Check wiring connections against diagram.
Incorrect densitometer wiring

Press 1 Incorrect flag setting (Flag 54) Pressure 1 accidentally requested (Flag 54).
(Pressure 1 reading
Renew Pressure Transducer.
out of range)
Pressure 1 transducer error
Reduce rig pressure below 200psi.
Max pressure exceeded
Check wiring connections against diagram.

Incorrect transducer wiring

Press 2 Incorrect flag setting (Flag 54) Pressure 2 accidentally requested (Flag 54).
(Pressure 2 reading
Renew Pressure Transducer.
out of range)
Pressure 2 transducer error
Reduce rig pressure below 200psi.
Max pressure exceeded
Check wiring connections against diagram.

Incorrect transducer wiring

DP Incorrect flag setting (Flag 54) Differential Pressure accidentally requested

(Differential Pressure (Flag 54).
reading out of range)
Incorrect transducer wiring Check wiring connections against diagram.

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Table 7.1 Fault Finding – (cont.)

DISPLAYED ERROR
POSSIBLE CAUSE ACTION
MESSAGE

Earth Incorrect flag setting (Flag 60). Interlocks accidentally requested (Flag 60).
(Earth interlock missing)
Connect Earth clip.
Earth interlock not made.
Renew Processor PCB.
Faulty processor PCB.

Spill Incorrect flag setting (Flag 60). Interlocks accidentally requested (Flag 60).
(Overspill interlock
Check overfill condition & overspill switch.
missing)
Overspill interlock not made.
Renew Processor PCB.

Faulty Processor PCB.

Guidance on other hardware faults is given in the following table.

Table 7.1 Fault Finding – (cont.)

FAULT POSSIBLE CAUSE ACTION

Blank display Vehicle master switch off Switch master switch on.
No power to system Check power cable and connections.
Renew or fit fuse.
Fuse FS1 blown or not fitted in PSU
Renew Display PCB.
Display PCB faulty
Renew Processor PCB.
Processor PCB faulty
Plug in ribbon.
Display PCB ribbon not plugged in
Renew Barrier block.
Barrier block blown
Check wiring against wiring diagram.
Incorrect wiring
Inspect all connections.

Bad connections

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Table 7.1 Fault Finding – (cont.)

FAULT POSSIBLE CAUSE ACTION

Scrambled display Display PCB faulty Renew Display PCB.

(ie random segments)
Processor PCB faulty Renew Processor PCB.
Incorrect wiring Check wiring against wiring
diagram.
Bad connections
Inspect all connections.
Barrier block blown (No Power Fail)
Renew Barrier block.

Scrambled display only after Low battery power Check vehicle battery voltage
power off while on load.
No Power Fail signal Check Barrier (renew if
necessary).

Flow Rate displayed but no Meter set for reverse flow Open the Display Unit and
batch count change the position of switch
SW2 on the Processor PCB.

Missing display segments or Faulty LCD Use Flag 22 to test display.

malformed characters Renew LCD.
Faulty Display PCB Renew Display PCB.
Damaged display ribbon cable/plug Repair cable/plug or fit new
Display PCB.

No push-button response No power (no buttons operate) Check power to PSU and barrier
output.
Faulty push-button Check operation of pushbutton
with a meter.
Faulty wiring Make sure the ribbon cable is
correctly fitted.
Faulty Processor PCB Renew Processor PCB.
Incorrect Flag setting No Reset button response if Flag
70 is incorrect.

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Table 7.1 Fault Finding – (cont.)

FAULT POSSIBLE CAUSE ACTION

Erroneous batch displayed Incorrect flag settings Check flag settings against requirements.
Faulty Transmitter Renew Processor PCB.
Faulty Processor PCB

Masterload power on but no Power Fail signal missing Check Barrier and renew if necessary.
display response
Faulty Power Supply PCB Renew Power Supply PCB.

Flag data changed and Masterload switched off when power Check vehicle wiring and battery voltage
totaliser display not is below voltage specification for correct operational voltage.
updated during power off

Incorrect or missing Link 1 or 2 fitted incorrectly Check link position.

additional display data
Incorrect setting of Flag 90 Set Flag 90 as required.
Incorrect wiring Check wiring against Wiring Diagram.
Renew Main Display PCB.
Faulty Main Display PCB
Renew Additional Display PCB.
Faulty Additional Display PCB

No operation of Preset valve Incorrect valve wiring Check wiring against wiring diagram.
Check SSR’s by Flag 22. Renew if
Faulty SSR1 or SSR2 necessary.

Meter counts continuously Valve seat leaking Check valve seat for debris. Ref. TP0020.
Use Flag 22 to check operation. Ref.
Downstream solenoid valve faulty TP0020.

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Table 7.1 Fault Finding – (cont.)

FAULT POSSIBLE CAUSE ACTION

Meter will not calibrate Incorrect flag settings Set Fl 21 and 22 using the calibration
procedure.
Faulty Transmitter Check factors in Flags 30-37.
Incorrect calibration factors entered Investigate meter internals.
Meter capsule worn or faulty

No permissive feed Incorrect interlocks Check system interlocks.

Emergency stop faulty or set Renew pushbutton or release emergency
stop.

Deadman not operating Incorrect wiring Check wiring against wiring diagram.
(when controlled by
Faulty relay Check SSR3 using Flag22. Renew if
Masterload)
faulty.

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CHAPTER 8
MAINTENANCE AND OVERHAUL
WORK MUST ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL.
FOLLOW ALL REGULATIONS IN REGARDS TO THE USE OF EQUIPMENT
IN A CATEGORY 2 (ZONE 1) HAZARDOUS AREA. ELECTRO-STATIC
SENSITIVE DEVICES.

THIS EQUIPMENT CONTAINS ELECTRO-STATIC SENSITIVE DEVICES.

FOLLOW THE PRECAUTIONS AS SPECIFIED IN APPROPRIATE STANDARD
CONCERNING PROTECTION OF ELECTRONIC DEVICES FROM
ELECTROSTATIC PHENOMENA

8.1 ROUTINE MAINTENANCE AND OVERHAUL

 No Arc welding is to be carried out after this equipment has been fitted. Welding can generate
sufficient voltage within the equipment to severely damage the components.
 An equipment manual must be available before installation commences.
 Before power is applied to the equipment, make sure the wiring is independently checked.
 Voltages higher than the equipment specification must not be applied to the equipment.
8.1.1 Routine maintenance tasks required by Masterload are minimal and listed in Figure 8.1.
8.1.2 The maintenance intervals recommended are suitable for most normal applications, although
maintenance frequencies shall be increased if the system is subject to high levels of dust, dirt
or vibration.
8.1.3 Before beginning maintenance, make sure all necessary materials and spare parts are
available.
8.1.4 If a Gantry printer is connected to the Masterload, switch off the Gantry printer before
changing flag data.

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Table 8.1 Suggested Maintenance Program

FREQUENCY TASK

MONTHLY Clean display front.

Check cable runs for security and any signs of damage or
deterioration.

SIX MONTHLY Check calibration as detailed in Chapter 5.

Up-date Masterload record card.
Check tightness of cable glands.

TWO YEARLY Check tightness of all terminal screws and fastenings.

Check mating surfaces of casings, renew all O-rings and
gaskets.

8.1.5 During overhaul the following components can be changed:

 Processor PCB
 Display PCB
 Display LCD’s
 Display Push-buttons
 Power Supply PCB
 Barrier Block
 Solid State Relays (SSR)
 Fuses

8.2 DISPLAY UNIT - REMOVAL (see Figure 8.1)

8.2.1 Support the front face of the Display Unit and remove and retain the four M5 socket head cap
screws securing the display front to the rear section of the unit.
Note: This will necessitate removal of the security sealing wire from the set-up blanking
plug.

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Figure 8.1 Display Unit Components

8.2.2 Take care not to damage the ribbon cable connecting the display PCB to the processor PCB
located in the rear section.
8.2.3 Lower the display front carefully and disconnect the ribbon cable from the processor PCB.
8.2.4 Remove the display front and place face downwards onto a clean surface.
8.2.5 Note the positions of wiring entering the Display Unit and how they are terminated. Label as
necessary and disconnect wiring at the screw terminals.
8.2.6 Loosen cable glands and remove wiring from Display Unit.
8.2.7 Support the rear section and remove and retain the four M6 socket head cap screws.
8.2.8 Remove the rear section and place on a clean surface.

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8.2.9 Assemble the Display Unit if no further immediate work is to be carried out.

8.3 DISPLAY PCB REPLACEMENT

8.3.1 Remove the display front (paragraph 8.2).

8.3.2 Note the positions then disconnect the wiring from the push-button(s) at terminal block TB3 on
the display PCB.
8.3.3 Pull back the rubber surround and remove PCB.
8.3.4 Replacement is reversal of the above procedure.
8.3.5 Make sure the PCB is completely seated in the groove of the rubber seal to prevent fouling
when refitting the display front.

8.4 LCD REPLACEMENT (see Figure 8.2)

8.4.1 With the display PCB removed, unscrew and retain the four fixing screws and washers
(located on the component side of PCB) which secure the LCD bezel to the PCB.

Figure 8.2 LCD Components

8.4.2 Remove and retain bezel.

8.4.3 Remove the LCD. Retain the foam pad and the two elastomeric strips.

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8.4.4 Fit the foam pad and elastomeric strips to the underside of the replacement LCD.
8.4.5 Fit LCD to display PCB. Locate bezel onto LCD and secure to PCB using the four fixing
screws and washers.

8.5 PUSH BUTTON REPLACEMENT

8.5.1 With the display PCB removed as described in paragraph 8.3, note the positions of the wiring
to the push button. Label as necessary and, using a soldering iron, remove wiring at rear of
push-button (see Figure 8.1).
8.5.2 Loosen the two locking screws from retaining nut at rear of push-button.
8.5.3 Remove retaining nut.
8.5.4 Remove push-button from glass facia.
8.5.5 Remove the O-ring seal.
8.5.6 Remove switch cap and bezel and fit to new push-button.
8.5.7 Replace the O-ring seal. Renew if necessary.
8.5.8 Replacement is the reverse of the above procedure.

8.6 PROCESSOR PCB REPLACEMENT

8.6.1 With the display front removed as described in paragraph 8.3, note the positions of and
disconnect the wiring from terminal blocks TB1, TB2, TB3 and TB4 on the processor PCB (see
Figure 8.1).
8.6.2 Remove and retain the four mounting screws and washers securing the PCB to the rear
enclosure of the Display Unit.
8.6.3 Remove the processor PCB.
8.6.4 Replacement is reversal of the above operation.
BEFORE COMMENCING ANY WORK ON THE UNIT. MAKE SURE
THE INPUT SUPPLY HAS BEEN ISOLATED AT THE DISTRIBUTION
BOARD FOR AT LEAST 6 MINUTES.

8.7 POWER SUPPLY UNIT REMOVAL

8.7.1 The main Display Unit may have been mounted to the Power Supply Unit (see Figure 8.3).
This will have to be removed to allow access to the Power Supply Unit (paragraph 8.3).

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8.7.2 Support the weight of the power supply front cover and remove the eight M6 socket head cap
screws securing the two halves of the unit.
8.7.3 Remove the front cover and the O-ring seal fitted between the two halves.
8.7.4 Unscrew and retain the two securing screws and washers from the cable separation sheet.
Remove the cable separation sheet.
8.7.5 Note positions of wiring and how they are terminated. Label as necessary and disconnect.
REAR
ENCLOSURE PCB ‘O’ RING
SEAL
BARRIER
BLOCK

SOLID STATE
FUSE RELAYS
FS2
FUSE CABLE
(DC)
FS1 SEPARATION
SHEET FRONT MOUNTING
COVER POINTS FOR
DISPLAY
UNIT

Figure 8.3 Power Supply Unit Components

8.7.6 Loosen cable glands and remove wiring from Power Supply Unit.
8.7.7 Fit cable separation sheet.
8.7.8 Fit front cover using the O-ring seal and eight M6 socket head cap screws to protect internal
components.
8.7.9 Support the weight of the Power Supply Unit and remove the four mounting bolts and washers.
8.7.10 Place the Power Supply Unit face-up on a clean surface.

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8.8 FUSE REPLACEMENT

8.8.1 Support the weight of the Power Supply front cover and remove the eight M6 socket head cap
screws securing the two halves of the unit (see Figure 8.3).
8.8.2 Remove the front cover and the O-ring seal fitted between the two halves.
IMPORTANT: Note the positions of the intrinsically safe wires which pass over the top of
the cable separation sheet. Label as necessary.
8.8.3 Unscrew and retain the two securing screws from the cable separation sheet. Remove the
cable separation sheet to gain access to the fuses mounted on the power supply PCB.
8.8.4 Renew fuse.

ALL INTRINSICALLY SAFE WIRING MUST PASS OVER CABLE

SEPARATION SHEET.

8.8.5 Fit cable separation sheet.

8.8.6 Fit front cover to rear enclosure using the O-ring seal and eight M6 socket head cap screws.

8.9 BARRIER BLOCK REPLACEMENT

8.9.1 With the front cover removed (paragraph 8.2), note positions of intrinsically safe wiring from
output (TB2) side of barrier block (terminals 1 to 9) and how they are terminated. Label as
necessary and disconnect.
8.9.2 Unscrew and retain the two securing screws from the cable separation sheet. Remove the
cable separation sheet (see Figure 8.3).
8.9.3 Note positions of non-intrinsically safe wiring to input (TB1) side of barrier block (terminals
1 to 11) and how they are terminated. Label as necessary and disconnect.
8.9.4 Remove and retain the two screws securing the barrier block to two mounting pillars.
8.9.5 Remove barrier block.

ALL INTRINSICALLY SAFE WIRING MUST PASS OVER CABLE

SEPARATION SHEET.

8.9.6 Replacement is reversal of the above procedure.

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8.10 SOLID STATE RELAY REPLACEMENT

8.10.1 With the front cover removed (paragraph 8.8), note positions of intrinsically safe wiring from
output side of barrier block (terminals 1 to 9) and how they are terminated. Label as
necessary and disconnect.
8.10.2 Unscrew and retain the two securing screws and washers from the cable separation sheet.
Remove the cable separation sheet (see Figure 8.3).
8.10.3 Remove and retain the two screws and washers securing the barrier block to two mounting
pillars.
8.10.4 Raise barrier block sufficient to gain access to solid state relays.
8.10.5 Remove the defective solid state relay from it’s socket, and replace with an applicable spare. It
is possible that the legs on the new relay are too long, cut the legs of the new relay to the
same length as the legs on the defective relay.

ALL INTRINSICALLY SAFE WIRING MUST PASS OVER CABLE

SEPARATION SHEET.

8.10.6 Replacement is reversal of the above procedure.

8.11 PCB REPLACEMENT

8.11.1 Remove the front cover (paragraph 8.2).

8.11.2 Remove the barrier block (paragraph 8.9).
8.11.3 Note positions of wiring and how they are terminated. Label as necessary and disconnect.
8.11.4 Remove and retain the two nuts and four barrier block mounting posts and the two screws
securing the PCB to the rear enclosure (see Figure 8.3).
8.11.5 Remove power supply PCB.
8.11.6 Replacement is reversal of the above procedure.

BEFORE DISMANTLING, MAKE SURE THE TRANSMITTER IS

ISOLATED FROM ITS ELECTRICAL SUPPLY.

DISMANTLING THE TRANSMITTER ASSEMBLY IS NOT

RECOMMENDED BY LIQUID CONTROLLS, LLC AND CANNOT TAKE
ANY RESPONSIBILITY FOR THE MALFUNCTION OF THE EQUIPMENT
THROUGH DAMAGE CAUSED BY INCOMPETENT PERSONNEL.

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PLEASE CONTACT OUR SERVICE DEPARTMENT IN THE FIRST

INSTANCE SHALL A PROBLEM OCCUR. ANY ALTERATION OR
DAMAGE COULD AFFECT THE PERFORMANCE OF THE
TRANSMITTER AND MAY RENDER ANY WARRANTY VOID. CARE
SHALL BE TAKEN NOT TO BEND THE BULKMETER SHAFT WHEN
SEPARATING THE TRANSMITTER FROM THE ADAPTOR PLATE.

8.12 PULSE TRANSMEITTER UNIT

8.12.1 Disassembly - Transmitter (see Figure 8.4).

a. Remove four cap head screws (1), spring washers (2) and plain washers (3) from
transmitter cover (4). Remove transmitter assembly from bulkmeter adaptor plate (5) and
place onto a clean dry working surface.
b. Remove the O-ring (7).
c. Loosen the cable gland (17). Disconnect the external cable from the terminal block (11)
and withdraw the cable.
d. Remove four cap head screws (8) securing the support plate (9) to the transmitter
cover (4).
e. Remove two cap head screws (10) securing the terminal block (11) to the support
plate (9).
f. Remove four cap head screws (12) securing the transmitter (13) to the support plate (9).
Carefully remove the transmitter, terminal block and internal cable as an assembly.
g. Remove two countersunk screws (14) from cable guard (15). Remove the cable guard
from the support plate (9).
h. Collect two dowel pins (16).
i. Remove cable gland (17) and fibre washer (18).
j. Remove plug (19) and dowty washer (20).
k. Carefully remove the tension pin (6) from the bulkmeter shaft. Do not apply excessive
pressure as the bulkmeter shaft may bend.

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Figure 8.4 Pulse Transmitter

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8.12.2 Cleaning and Inspection

a. Thoroughly clean all components using approved cleaning methods and materials.
Inspect for damage or excessive wear. Renew components as necessary, renew O-rings
and seals.
8.12.3 Assembly - Transmitter
a. Assemble the transmitter in the reverse order of disassembly procedure above. Care shall
be taken to align the cable on the cable guard (15). Use the special centralizing tool (21)
to align the transmitter shaft with the support plate (9).

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CHAPTER 9
SPARE PARTS
9.1 GENERAL INFORMATION

9.1.1 When ordering spare parts please quote the Part number and Description
9.1.2 ‘+’ in the Fig/Item No. column indicates Item is not illustrated.
9.1.3 ‘*’ in the Part No. column indicates Item is recommended to be held as a spare part.

9.2 ANCILLARY EQUIPMENT

9.2.1 LIQUID DENSITY TRANSDUCER (4-20mA) 41440

9.2.2 DIFFERENTIAL PRESSURE GAUGE (4-20mA) Range 0-30 psi ZMMZ0322-08
9.2.3 PRESSURE TRANSDUCER (4-20mA) Range: 0-16 BAR ZMMZ0322-09
9.2.4 OVERRIDE SWITCH ASSEMBLY (Includes Gland) ABMZ1516

9.3 SCOPE OF INFORMATION

9.3.1 The parts list is arranged in the general order of disassembly. The listing is indentured to show
the relationship between each part and its next higher assembly. Item numbers used in the
parts list are keyed to the corresponding numbers of the accompanying illustration.
9.3.2 Abbreviations
ASSY Assembly
FIG. Figure
IPL Illustrated Parts List
MOD Modification
‘+’ in the Fig/Item column indicates item is not illustrated
REF Item is for reference purposes only and is not available as a spare
‘*’ in the Fig/Item column indicates item is a suggested spare part

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1
19 4
8 2
3

20
8
7 5
8
9 17
16 10
6

14

Figure 9.1 Power Supply Unit

When ordering the Power Supply PCB (item 1 in the diagram) use the Part No. given in the table below

1 SSR 3 SSRs 5 SSRs

12 Volt PowerSupply PCB NON PRESET PRESET PRESET

Without 4-20mA ZPMZ1A-286-1 ZPMZ1A-286-3 ZPMZ1A-286-5

Interface
With 4-20mA ZPMZ1A-286-2 ZPMZ1A-286-4 ZPMZ1A-286-6
Interface

1 SSR 3 SSRs 5 SSRs

24 Volt PowerSupply PCB NON PRESET PRESET PRESET

Without 4-20mA ZPMZ1A-286-13 ZPMZ1A-286-15 ZPMZ1A-286-17

Interface
With 4-20mA ZPMZ1A-286-14 ZPMZ1A-286-16 ZPMZ1A-286-18
Interface

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ITEM No
In Fig 9.1. PART NUMBER DESCRIPTION QTY

2 BEMZ144A BARRIER ASSEMBLY 1

3 ZO22M242030A SEAL 1
4 ZS3225M06025A SCREW, SOCKET CAP HD, HTS, ZNPL, M6 X 25 MM 8
5 ZS2203M04008A SCREW, M4X8 LG 5
6 BEPZ1382A CABLE SEPARATION SHEET 1
7 ZS5003M04012A SCREW, CH HD, SLOTTED, NYLON, M4 X 12 LG 2
8 ZMPZ0286-1 PILLAR, INSULATING 3
9 ZEMZ0152-55 FUSE, 1A, ANTI-SURGE, (20 MM) 1
10 ZEMZ0152-53 FUSE, 13A, (1 inch) 1
Not Illustrated BESZ1035A ANGLE, SS 1
Not Illustrated ANMY6068A SCREW, M5X10 LG, HEX HD, SS 1
Not Illustrated ANMY6067A WASHER, SHAKEPROOF, EXT, SS, M5 1
14 ZMMZ0247-43 CABLE GLAND-CENELEC/ATEX APPROVED A/R
Not Illustrated PPMZ9242 BLANKING PLUG, M20 A/R
16 ZN2201M04A NUT, HEX, M3, ZNPL, M4 2
17 ZEMZ0143-62 SOLID STATE RELAY A/R
Not Illustrated ZPMZ1-288 ANALOGUE INTERFACE BOARD A/R
19 ANMY6062A PILLAR, CONDUCTIVE 1
20 ANMY6066A WIRE ASSEMBLY (EARTH) 1
Not Illustrated ZS2244M04012B STUD for mounting WIRE ASSEMBLY (EARTH) 1
Not Illustrated ZN1001M04A NUT for mounting WIRE ASSEMBLY (EARTH) 1
Not Illustrated ZW8205M04A WASHER SHAKEPROOF for mounting WIRE ASSEMBLY 1
(EARTH)
Not Illustrated ZW2201M04A WASHER PLAIN for mounting WIRE ASSEMBLY (EARTH) 1

Suggested spare parts are shown in bold type

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Figure 9.2 Master / Remote Display Units

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ITEM No
In Fig 9.2. PART NUMBER DESCRIPTION QTY
1 ZPMZ1-285 PROCESSOR PCB WITHOUT TEMPERATURE A/R
1 ZPMZ1-285-1 PROCESSOR PCB WITH TEMPERATURE A/R
2 ZW2201M04A WASHER, PLAIN, STL, ZNPL, M4 4
3 ZS2203M04008A SCREW, CH HD, SLOTTED, STL, ZNPL, M4 X 8 MM 4
4 ZPMZ1A-283-1 MASTER DISPLAY PCB - PRESET A/R
4 ZPMZ1A-283-2 MASTER DISPLAY PCB - NON-PRESET A/R
4a ZPMZ1A-283-3 REMOTE DISPLAY PCB - PRESET A/R
4a ZPMZ1A-283-4 REMOTE DISPLAY PCB - NON-PRESET A/R
5 ZEMZ0179-11 LCD - BATCH VOLUME 1
5 ZEMZ0179-14 LCD - PRESET 1
5 ZEMZ0179-13 LCD - RATE OF FLOW 1
5 ZEMZ0179-13 LCD – TOTE 1
6 ZEPZ0296-3 BEZEL- BATCH VOLUME 1
6 ZEPZ0296-2 BEZEL- PRESET 1
6 ZEPZ0296-1 BEZEL- RATE OF FLOW 1
6 ZEPZ0296-1 BEZEL- TOTE 1
7 BERZ1033 SEAL 1
8 DISPLAY MASK SEE TABLE OVERLEAF 1
9 BEGZ1032-1 NON-PRESET GLASS FACIA 1
9 BEGZ1032-3 PRESET GLASS FACIA A/R
10 ZW8206M05A WASHER, SHAKEPROOF, INT, SP ST, ZNPL, M5 4

Suggested spare parts are shown in bold type

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ITEM No
In Fig 9.2. PART NUMBER DESCRIPTION QTY

11 ZS3225M05030A SOCKET HEAD CAP SCREW - M5 2

12 ZMSZ0110-5 SECURITY SCREW - M5 2
13 BEMS1108 PUSH - BUTTON SWITCH KIT consisting: 1
13 ZEMZ0150-45 SWITCH 1
13 ZEAZ0150-46 SWITCH RING 1
13 ZEAZ0150-47 CAP – SWITCH 1
13 ZO32M022116A O-RING SEAL 1
14 ZMMZ0247-45 CABLE GLAND - CENELEC / ATEX APPROVED A/R
15 PPMZ9242 BLANKING PLUG, M20 A/R
16 ZACZ0017-12 BLANKING PLUG, 1/2 IN BSP 1
17 ZAFZ0010-20 WASHER, FIBRE, 1/2 IN BSP 1

Suggested spare parts are shown in bold type

Figure 9.2 Item 8 MASTER DISPLAY MASK

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When ordering a Display mask use the table below in conjunction with the illustration.

Key:
L = Litres K = Kilograms D = Decalitres
G = UK Gallons US = US Gallons C = Cubic Meters
Dk = Dekaliters T = Tonnes P = Pounds
GN = Gross/Nett Litres CH = CuM/Hr

Use the part No. BESZ1380A- followed by one of the numbers in the table

Example: BESZ1380A-31 (A NON PRESET DISPLAY in Litres without temperature)

Batch L L L L D D D G G G US US US Dk Dk Dk C K C GN C C L
Preset L K K D K G P US P Dk K K T L C
ROF L L L L L L L G G G US US US L L L L L L L CH CH L
Tote L L K L D D D G G G US US US Dk Dk Dk C K C L C C D

No Temp. 25 38 37 31 26 42 32 27 40 33 28 41 34 29 44 35 39 30 43

Temp. 1 13 2 14 3 15 4 16 5 17 6 51 36 45 46

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REMOTE DISPLAY DISK

The Remote Display mask part No. is BESZ1381A- followed by one of the numbers in the tables
Example: BESZ1381A-32 (A non-Preset display in Litres without temperature or buttons)

Batch L L L L D D D G G G
Preset L K K D K G P
ROF L L L L L L L G G G
Tote L L K L D D D G G G

No Buttons 25 38 37 32 26 42 31 27 40 33
1 Button 138 137 132 142 131 140 133

3 Buttons 125 126 127

Batch US US US Dk Dk Dk K K C C P L
Preset US P Dk K K T
ROF US US US L L L L K L L P L
Tote US US US Dk Dk Dk K K C C P D
No Buttons 28 41 45 29 44 34 30 36 39 43 35 46
1 Button 141 145 144 134 136 139 143 135
3 Buttons 128 129 130

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Figure 9.3 Pulse Transmitter

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ITEM No
In Fig 9.3. PART NUMBER DESCRIPTION QTY
1 ZS3225M06025A SKT CAP HEAD M6 X 25 4
2 ZW8207M06A WASHER SPRING M6 4
3 ZW2202M06A WASHER DIA 6 4
4 BEMZ33413 MASTERLOAD PULSER 1
Not Illustrated BEMZ33414 NON MASTERLOAD PULSER 1
5 BMAZ33368 CABLE GUARD 1
6 ZS2201M04008A CSK SLOT HEAD SCREW M4 X 8 2
7 NOT SPARED TERMINAL BLOCK (ATTACHED TO CABLE) REF
8 ZS2201M03016A SXT CAP HEAD M3 X 16 2
9 ZS3228E0812A SCREW HEX HEAD 1/4 UNF X 3/4 IN 2
10 ZW2203G08A WASHER 1/4 IN LARGE STEEL 4
11 ZW8207G08A WASHER 1/4 IN SPRING COIL 4
12 BMAZ33348 TRANSMITTER ADAPTER, BM AND CM 1
Not Illustrated BMAZ33351 TRANSMITTER ADAPTER, DM 1
13 ZT8001E0310A PIN TENSION 3/32 IN DIA 1
14 ZASZ0104-2 DOWEL PIN 1/4 IN DIA X 3/4 IN 2
15 BESZ2362 SCREW SEALING 2
16 ZO32M144530A O RING 1
17 ZASZ0104-9 DOWEL PIN 1/4 IN DIA X 1 IN 2
18 BECZ1095 PLUG M10 X 1 1
19 ZMPZ0158-4 DOWTY WASHER 1
20 ZMMZ0247-43 CABLE GLAND M20 1
21 56396 CABLE GLAND FIBRE WASHER M20 1
22 T8353 CENTRALISING TOOL REF
Not Illustrated BMSZ33338 SPACER (CM METER) REF
Not Illustrated BEAZ1455A-2 LABEL ATEX 1

Suggested spare parts are shown in bold type

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APPENDIX A.
CERTIFICATION CRITICAL INFORMATION
NOTE: Any change made to this section of the manual shall conform to the requirements of
SCPD3100, SCPD3102 certification drawings.

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IMPORTANT SAFETY INSTRUCTIONS

EQUIPMENT SAFETY INFORMATION

The following safety information discusses hazards peculiar to the equipment, which are likely to be
encountered during maintenance activity.

EQUIPMENT INSTALLATION PRECAUTIONS

 The design of the piping system must provide adequate pressure and temperature protection to
prevent exceeding the limits of the meter.
 Before assembling the meter to the piping system, make sure all foreign debris are eliminated in the
meter and pipeline to make sure the meter will not be damaged by foreign debris.
 Flanged Piping Connections.
 Make sure the meter orientation is correct and install the meter in-line with the flanges. Make sure
the piping flanges are correctly positioned and spaced. Do not force the piping in order to fit the
meter. Do not use the flange bolting to pull the piping into the correct position.
 Install the gaskets and the bolts as directed in the INSTALLATION section.
 Torque the flange closure bolts after the first exposure to elevated temperature.
 Slowly pressurize the system to make sure there are no leaks in the meter connection, make sure
all air/vapor is eliminated from the piping system to prevent trapping air/vapor in the meter.
 The meter is designed to support its own weight only. Adjoining piping shall be independently
supported.

EQUIPMENT OPERATION PRECAUTIONS

 Do not exceed the pressure/temperature limits of the meter.

 Do not lubricate the meter. Use of lubrication or sealants may void the warranty or cause pre-
mature failure of the meter.

EQUIPMENT MAINTENANCE PRECAUTIONS

 Do not loosen any fasteners or attempt to remove the meter from the line until all pressure is
isolated and reduced to zero from the system.

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GENERAL OPERATING LOCATION PRECAUTIONS

 Routinely check for any leaks in the piping connections.

 Use only authorized replacement parts or hardware.
 Follow Lock-Out/Tag-Out procedures when working on the meter and make sure personnel
protection equipment such as electrical grounds are installed.
 Make sure all electrical wiring is correctly terminated and all wire terminals are securely connected.
Avoid hazardous voltage situations that can result from unsafe conditions such as, but not limited to
the following:
 Incorrect grounding
 Handling electrical leads or devices with wet hands or on wet ground
 Damaged electrical wire insulation
 Incorrect connection of the power terminals.
 Short circuits to ground.

EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE SEALING

PROPERTIES OF MATERIALS USED IN THE METER.

THIS EQUIPMENT IS SUITABLE FOR USE IN GROUP II, CATEGORY 2,

ZONE 1 OR HAZARDOUS LOCATIONS.

EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY

IMPAIR SUITABILITY FOR GROUP II, CATEGORY 2, ZONE 1.

AVERTISSEMENT-RISQUE D'EXPLOSION - LA SUBSTITUTION DE

COMPOSANTS PEUT RENDRE CE MATÉRIEL INACCEPTABLE POUR
LES EMPLACEMENTS DE GROUP II, CATEGORY 2, ZONE 1.

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MAINTENANCE HAZARDS

 FLUOROCARBON. DO NOT HANDLE O-RINGS/SEALS IF THEIR MATERIAL APPEARS

CHARRED, GUMMY OR STICKY. USE TWEEZERS AND WEAR NEOPRENE OR PVC GLOVES.
DO NOT TOUCH ADJACENT PARTS WITH UNPROTECTED HANDS. NEUTRALIZE ADJACENT
PARTS WITH A SOLUTION OF CALCIUM HYDROXIDE. IF THE DEGRADED MATERIAL OR
ADJACENT PARTS TOUCH THE SKIN, DO NOT WASH OFF WITH WATER; SEEK IMMEDIATE
MEDICAL AID FOR POSSIBLE CONTAMINATION WITH HYDROFLUORIC ACID.
HYDROFLUORIC ACID IN CONTACT WITH SKIN HAS DELAYED SYMPTOMS OF
CONTAMINATION AND IS EXTREMELY TOXIC.
 WORK MUST BE CARRIED OUT ONLY BY SUITABLY QUALIFIED PERSONNEL.
 BEFORE RETURNING TO WORK, FOLLOW ALL AIRPORT/COMPANY SAFETY
PROCEDURES.

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PRODUCT SAFETY
In the Interest of safety it is strongly recommended by Liquid Controls, LLC the following details receive
strict attention.

For the purpose of definition, the word PRODUCT applies to any product sold by Liquid Controls, LLC
 The Product is used only with fluids stated as acceptable by Liquid Controls, LLC
 The Product, whilst in service, must not be subjected to pressures greater than the Maximum
Working Pressure or tested to pressures greater than the Test Pressure as specified in the
manual.
 The Product must only be coupled/connected to equipment considered acceptable by Liquid
Controls, LLC
 The Product must be handled using the lifting handles where fitted, or in accordance with the
manual.
 The Product must not be misused or handled in any way liable to cause damage.
 The Product must be inspected for any signs of damage before use e.g. cracks, damaged seals,
seized or tight operating mechanisms.
 The Product must be subjected to a regular maintenance program, either in accordance with the
manual or as agreed with Liquid Controls, LLC
 Only technically competent personnel shall repair or maintain the Product and only parts supplied
by Liquid Controls, LLC may be used.
 Products covered by warranty may not be modified in any way without before written permission of
Liquid Controls, LLC
 Products not in service, must be stored in a clean area, and shall not be subjected to excessive
temperature, humidity, sunlight, or strong artificial light. Products shall be protected to prevent
damage or the ingress of foreign matter.
 Where applicable, attention shall be drawn to dangers resulting from the generation of static
electricity in product flow lines.
 This equipment is not suitable for use with Liquid Petroleum Gas (L.P.G).
 An air separator must be installed if air/vapor is present in flow during normal operation of meter.

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ENVIRONMENTAL GUIDELINES

RELIEVE INTERNAL PRESSURE

BEFORE REMOVAL OF THE METER OR ANY ACCESSORIES, IN THE INTEREST OF SAFETY, IT

IS STRONGLY RECOMMENDED BY LIQUID CONTROLLS, LLC THAT ALL INTERNAL PRESSURES
OF THE ENTIRE SYSTEM MUST BE RELIEVED TO ZERO AND THE FOLLOWING DETAILS
RECEIVE STRICT ATTENTION.

 Drain all fluid within the meter and accessories and dispose of the fluid per the methods as
applicable by local state laws and regulations. Do not pollute the environment by disposing the
fluid incorrectly.
 Dispose the meter and accessories correctly per applicable local laws and regulations. Do not
pollute the environment by disposing the meter and accessories incorrectly.
 When maintaining meter, dispose of seals and gaskets appropriately per applicable local laws and
regulations.

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Table 3.2 Detailed Specifications

POWER SUPPLY UNIT

Enclosure Pressure Data

Reference Pressure ................................................................................................................................ 101 psi
1.5 x Over Pressure ............................................................................................................................ 151.5 psi

Electrical Data
Input Voltage ................................................................................................................... 12 or 24 VDC Nominal
(From Vehicle battery master switch, NOT Ignition switch)
Solid State Relay Output Voltage ..................................................... 12 or 14 VDC (2amp max.) (SSR1, 2, &3)
12 or 14 VDC (1amp max.) (SSR4 to11)
* Each relay must supply a minimum current of 20 mA for correct operation.
External Fuse Rating ........................................................................... 10 ampere (Input supply must be fused)
Internal Fuse Rating:
FS1 .......................................................................................................................................................1 ampere
FS2 .....................................................................................................................................................13 ampere

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating ...................................................................................................................–4 to 105°F (–20 to 40°C)
Relative Humidity ..............................................................................................................................up to 100%

Weight (maximum) ......................................................................................................................... 14.3 lbs (6.5 kg)

Cable Entry Dimension

Thread Entry In Enclosure.................................................................................................... M20x1.5 (5 Places)
Cable Glands and Plug Thread Size .................................................................................................... M20x1.5
(Must Use Certified Flameproof Gland and Plugs)

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Table 3.2 Detailed Specifications - (cont.)

POWER SUPPLY UNIT (cont.)

Cable Rating
All cable specification are given in the wiring diagram at the back of the maintenance manual.

MASTER DISPLAY UNIT

Electrical Data
Input Voltage .............................................................................................................. 10 VDC Intrinsically Safe
Output Voltage ..............................................................................................................5 VDC Intrinsically Safe

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating .................................................................................................................. –4 to 105°F (–20 to 40°C)
Relative Humidity ................................................................................................................................... up to 100%

Weight (maximum) ...............................................................................................................................11 lbs (5 kg)

REPEATER DISPLAY UNIT

Electrical Data
Input Voltage .............................................................................................................. 10 VDC Intrinsically Safe
Output Voltage ..............................................................................................................5 VDC Intrinsically Safe

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Table 3.2 Detailed Specifications - (cont.)

REPEATER DISPLAY UNIT (cont.)

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 105°F (–20 to 40°C)
Operating .................................................................................................................. –4 to 105°F (–20 to 40°C)
Relative Humidity ................................................................................................................................... up to 100%

Weight (maximum) ............................................................................................................................... 11 lbs (5 kg)

PULSE TRANSMITTER ASSEMBLY

Electrical Data
Input Voltage ............................................................................................................................................ 5 VDC

Operating Environment
Temperatures
Ambient ..................................................................................................................... –4 to 140°F (–20 to 60°C)
Operating .................................................................................................................. –4 to 140°F (–20 to 60°C)
Relative Humidity ................................................................................................................................... up to 100%

Weight (maximum) ............................................................................................................................. 4.5 lbs (2 kg)

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 AVERY-HARDOLL MAINTENANCE MANUAL
MASTERLOAD II™ (Vehicle)

Table 3.2 Detailed Specifications - (cont.)

TEMPERATURE PROBE

Probe Type ............................................................................ Platinum Resistance Thermometer (PRT). 1/10 DIN

Temperature Probe Unit Operating Environment & Ratings

Temperatures
Ambient ..................................................................................................................... –4 to 140°F (–20 to 60°C)
Operating (Fluid) ................................................................................................... –58 to 392°F (–50 to 200°C)
Relative Humidity ................................................................................................................................... up to 100%
Accuracy ...................................................................................................................................................... ± 0.1°C
Discrimination ................................................................................................................................................. 0.1°C

Weight (maximum) .............................................................................................................................4.5 lbs (2 kg)

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 AVERY-HARDOLL MAINTENANCE MANUAL
MASTERLOAD II™ (Vehicle)

3.3 Safety Markings

The following safety markings are present on various components of the MASTERLOAD II system. Please
contact Liquid Controls, LLC for the current compliance status.
This equipment complies with all applicable European Directives. Refer to the
EU Declaration of Conformance available from Liquid Controls, LLC for listing of
2460 all applicable Directives and standards. The Quality Assurance Notification
pursuant to the European Directive for Equipment For Potentially Explosive
Atmospheres 94/9/EC (ATEX) has been performed by DNV GL, whose EU
ATEX Notified Body registration number is 2460.

EU Explosive Atmospheres symbol

Presafe 15 ATEX 7698X This equipment is certified by DNV GL under the ATEX Directive and under
Certification Scheme for Explosive Atmospheres of INTERNATIONAL
IECEx PRE 16.0003X ELECTROTECHNICAL COMMISSION (IECEx) under the indicated certificate
numbers, where X represents the following Special Condition for Safe Use: The
flamepaths on the power supply enclosure can only be repaired by the
manufacturer.

II Suitable for use in surface only installations.

2G High level of protection is provided against flammable gases, vapors, or liquids,

which may exist during normal operation.

Ex d Explosion protection is provided by a flameproof enclosure.

Ex ib Explosion protection is provided by intrinsically safe electrical circuits.

IIB Gas group, which includes ethylene, propane, and methane.

T6 Temperature class for surface temperature limitations is ≤ 85ºC.

T4 Temperature class for surface temperature limitations is ≤ 135ºC.

Gb Equipment group per IEC 60079-0 and EN 60079-0.

-20°C ≤ Tamb ≤ 40°C Safe limits of ambient temperature.

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February 2016 TP0025B – Rev B

Liquid Controls, LLC, 105 Albrecht Drive, Lake Bluff, IL 60044, USA www.AHmeters.com
 USE OR DISCLOSURE OF DATA ON THIS PAGE IS SUBJECT TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT

February 2016 TP0025B – Rev B

Liquid Controls, LLC, 105 Albrecht Drive, Lake Bluff, IL 60044, USA www.AHmeters.com
 USE OR DISCLOSURE OF DATA ON THIS PAGE IS SUBJECT TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT

February 2016 TP0025B – Rev B

Liquid Controls, LLC, 105 Albrecht Drive, Lake Bluff, IL 60044, USA www.AHmeters.com
 LIQUID CONTROLS
An IDEX Energy & Fuels Business

105 Albrecht Drive

Lake Bluff, IL 60044-2242
1.800.458.5262
1.847.295.1050 © 2016 Liquid Controls LLC
Fax: 1.847.295.1057
www.LCmeter.com
www.AHmeters.com