TP0027-9 Masterload Gantry PDF

Masterload MK II (gantry)
used with
Display unit program PO80 (Issue 5.6)
Power supply program PO81 (Issue 1.7)
Maintenance manual with spare parts catalogue

Publication ref TP0027
Issue 9 November 2006
The information contained herein is the property of Avery Hardoll

a division of Meggitt (UK) Ltd. No part may be reproduced or
used except as authorised by contract or other written
permission. The Company reserves the right to alter without
notice the specification, design or conditions of supply of any
product or service.
Avery-Hardoll
Whittaker Controls
Holland Way
Blandford Forum
Dorset DT11 7BJ
UK
12838 Saticoy St
North Hollywood
California 91605-3505
USA
Tel: +44 (0) 1258 486600

Fax: +44 (0) 1258 486601
Tel: +1 818 765 8160

Fax: +1 818 759 2194
www.meggittfuelling.com
www.wkr.com
www.meggitt.com
TP0027
AMENDMENT RECORD
AMENDMENT
NO.
CHAP/
PAGE
DESCRIPTION
DATE
Page (iii)/(iv)
TP0027
CONTENTS
Preliminary material
Title page
Amendment record
Contents and Associated publications (this page)
Health and safety at work act & product safety
Chapters
1
2
3
4
5
6
7
8
9
Introduction
Technical description
Specification
Installation
Commissioning
Operation
Fault finding
Maintenance and Overhaul
Spare parts
Wiring Diagram
ATEX Certificates
Supplement --- Previous Pulse Transmitter
ASSOCIATED PUBLICATIONS
TP0003
Bulkmeter Capsule (Calibrating Mechanism & Register)
TP0020
Solenoid Operated Preset Valve
TIS 148
Technical Information Sheet for 8in. Bermad valve
This manual may be used with earlier versions of program from that shown on the title page.
However, there may be additional features included in this manual that are unobtainable in earlier
program issues.
Page (v)/(vi)
TP0027
Avery--Hardoll
It is the aim of Avery--Hardoll to maintain a policy of continuous progress and for this reason reserve the
right to modify specifications without notice. This manual provides the information required to install,
service and overhaul the equipment. Although every effort has been made to ensure absolute accuracy,
Avery--Hardoll does not hold itself responsible for any inaccuracies that may be found.
HEALTH AND SAFETY AT WORK ACT 1974

REFERENCE: CHAPTER 37, PART 1, SECTION 6
Avery--Hardoll take every care to ensure that, in accordance with the above Act, our products, as far as is
reasonably practical in an industrial environment, are when operated and maintained in accordance with
the appropriate manual, safe without risk to health.
PRODUCT SAFETY
In the interest of safety it is strongly recommended by Avery--Hardoll that the following details receive
strict attention.
For the Purpose of Definition, the word PRODUCT applies to any product sold by Avery--Hardoll.
1
The Product is used only with fluids stated as acceptable by Avery--Hardoll.
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 Avery--Hardoll.
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 prior to use e.g. cracks, damaged seals,
seized or tight operating mechanisms.
The Product must be subjected to a regular maintenance programme, either in accordance with the
manual or as agreed with Avery--Hardoll.
Only technically competent personnel should repair or maintain the Product and only parts supplied
by Avery--Hardoll may be used.
Products covered by warranty may not be modified in any way without prior written permission of
Avery--Hardoll.
10 Products not in service, must be stored in a clean area, and should not be subjected to excessive
temperature, humidity, sunlight, or strong artificial light. Products should be protected to prevent
damage or the ingress of foreign matter.
11 Where applicable, attention should be drawn to dangers resulting from the generation of static
electricity in product flow lines. We strongly recommend account is taken of BS5958 parts 1 and 2.
Page (vii)/(viii)
TP 0027
Chapter 1
INTRODUCTION
1
GENERAL INFORMATION
1.1
The Masterload II is a highly accurate and versatile microprocessor based measuring and control
system.
1.2
The system is suitable for all positive displacement bulkmeters and can be supplied complete with a
bulkmeter, or for retrofitting to other manufacturers equipment.
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.
1.4
The installation provides the means of precisely controlling batch deliveries for large or small
automation systems.
PULSE
TRANSMITTER
POWER SUPPLY
UNIT
DISPLAY UNIT
(PRESET TYPE)
FIG. 1.1 MASTERLOAD II SYSTEM
INTRODUCTION
Chap 1
Page 1
TP 0027
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 data capture system (Office).
Flexible mounting of display(s) and power supply.
Gantry printer interface.
Additive injection.
Permissive feed input for safety interlocks.
Temperature correction to IP/ASTM tables.
Interface to a Densitometer, pressure and differential pressure transducers.
Masterload II is an Intrinsically Safe system for use in a Category 2 (Zone 1)

Hazardous Area.
1.6
This manual details the construction, installation and operation of Masterload II for loading gantries.
1.7
The equipment may also be used in vehicle mounted installations as described in a separate manual,
publication no TP0025.
1.8
The Masterload II system comprises:
1.9
Chap 1
Page 2
Display Unit, converts the pulses from the Pulse Transmitter Unit into readouts of
volume, flow rate, etc as described in Chapter 2. 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; a maximum of eleven solid state relays (SSRs) are also housed in the Power
Supply Unit for controlling Preset Valve, alarm or additive injectors. Variants are
described in Chapter 2.
Pulse Transmitter Unit, converts the rotation of the bulkmeter rotor to electrical pulses
which are relayed to the Display Unit.
Temperature probe, may be fitted into the product line to display temperature or for
temperature compensation. 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.
It is advisable that the Display Unit and Power Supply (shown in Fig 1.1) 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.
INTRODUCTION
TP 0027
1.10
The equipment may be configured as a Non-Preset System (Fig 1.2) or as a Preset System
(Fig 1.3). The Non-Preset System may be configured as a combination display, i.e. to display
Volume & Weight on the same display.
1.11
More control of the loading process can be achieved by linking Masterload to an office computer
system. Data collected from Masterload is transferred automatically to the office where a receipt can
be printed.
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 (Fig 1.4).
1.13
Masterload can take additional information from 4 external transducers. In this way, differential
pressure, two pressure measurements and density may be monitored.
1.14
Transducers used to pass this information to Masterload, will provide a 4-20 mA signal.
POWER SUPPLY UNIT
MAINS
SUPPLY
MAIN DISPLAY UNIT
ADDITIONAL DISPLAY UNIT
TO DEADMAN
CONTROL UNIT
BULKMETER
TEMPERATURE
PROBE
PULSE
TRANSMITTER
FIG 1.2 NON-PRESET SYSTEM
INTRODUCTION
Chap 1
Page 3
TP 0027
POWER SUPPLY UNIT
MAIN DISPLAY UNIT
MAINS
SUPPLY
BULKMETER
TEMPERATURE
PROBE
OUTPUT TO
PRESET
CONTROL
VALVE
PULSE
TRANSMITTER
FIG 1.3 PRESET SYSTEM

1.15
Preset batch control benefits are:

FLOW RATE
Litre/Min
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.
STAGE 2
2000
STAGE 3
DECELERATION
PRESET QUANTITY
500
BYPASS
VOLUME
STAGE 1
TIME
FIG 1.4 PRESET BATCH DELIVERY
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.
1.17
Avery--Hardoll have developed a range of electronic Preset Valves compatible with Masterload II and
available in 21/2, 3 and 4 inch sizes. Separate instructions for setting up and operating the Preset
Valve are given in the Preset Valve manual TP0020
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.
Chap 1
Page 4
INTRODUCTION
TP 0027
Chapter 2
TECHNICAL DESCRIPTION
CONTENTS
Para
1
2
3
4
5
6
7
General
Masterload II Systems
Pulse Transmitter Unit
Power Supply Unit
Display Unit
Remote Display Units
Flags and Error Messages
GENERAL
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.
1.2
Additional items may be added to enhance display and control facilities:
2
2.1
Weight measurement.
Temperature compensation.
Office data link.
Pulse output for Additive Injection.
Preset valve control.
Density, Pressure measurement.
MASTERLOAD II SYSTEMS
The basic or Non-preset system comprises the
Pulse Transmitter, Power Supply Unit and a Display
Unit with 3 LCD displays indicating:
Volume.
Flow Rate/Temperature/Pressure etc.
Totaliser.
FIG 2.1 NON-PRESET DISPLAY
Chap 2
Page 1
TP 0027
2.2
The Preset System provides the additional capability

of operating a control valve. The Display Unit has 4
LCD displays indicating:
Volume.
Preset Volume.
Flow Rate/Temperature/Pressure etc.
Totaliser (Tote).
FIG 2.2 PRESET DISPLAY
2.3
The combination display unit 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
FIG 2.3 COMBINED DISPLAY
PULSE TRANSMITTER UNIT
3.1
The electronic pulse transmitter is mounted directly onto the Avery--Hardoll bulkmeter capsule within
an O ringed weatherproof enclosure.
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.
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).
POWER SUPPLY UNIT
4.1
The Power Supply Unit is a flameproof enclosure which provides an Intrinsically Safe 10V dc supply
from either a 110V or 240V a.c. mains supply. The unit should be mounted in a convenient position
where access can be achieved, this will aid both installation and any future maintenance requirement.
4.2
The components of the Power Supply Unit are housed in a flame-proof (EEx d) cast aluminium box
sealed to IP65 specification. Cable entry is via safety authority approved brass glands screwed into
the base of the box. (Fig 2.4).
4.3
The Power Supply Unit main components are:
4.4
Chap 2
Page 2
Power supply PCB incorporating a maximum of 11 solid state relays (SSRs), together with a
microprocessor circuit.
One barrier block comprising seven independent barrier stages.
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.
TP 0027
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 110V or 240V. 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.
PCB
BARRIER BLOCK
ANALOGUE
INTERFACE
BOARD
SEPARATION SHEET
FIG 2.4 POWER SUPPLY UNIT COMPONENTS

4.6
The PCB has the ability to generate a power fail signal should 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.
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, this too becomes an intrinsically safe enclosure.
4.8
The Barrier is an Intrinsically Safe encapsulated module. It incorporates components manufactured

and approved to safety authority specification to limit excess current and voltage from reaching units
mounted in a CATEGORY 2 (ZONE 1) HAZARDOUS AREA.
4.9
The Solid State Relays (SSR) are controlled by an Intrinsically Safe data link between the Display
and Power Supply Units.
4.10
The power switched by the SSR is derived from an input permissive feed which is usually supplied
by an external interlock circuit and may be 110V or 240V a.c.. If the permissive feed is removed
during a delivery the transaction will be suspended.
4.11
The SSRs are numbered SSR1 to SSR11. SSR1 and SSR2 will operate a preset valve. SSR3 may
be used to operate a pump demand signal. SSR4-11 are used to control external devices (e.g.
additives).
4.12
On a Non-preset system, only one relay (SSR3) is fitted to the Power Supply Unit. This will generate
a pump demand signal, unless the Masterload system alarms, in which case this demand signal will
be removed.
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.
Chap 2
Page 3
TP 0027
4.14
If an external interlock is not required, the PSU may be configured to use the existing supply voltage
for uninterrupted valve control.
DISPLAY UNIT
5.1
The Display Unit provides a readout of 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.
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. (Fig 2.5).
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.
5.4
The Display Unit is Intrinsically Safe and may be mounted where convenient. For mounting and
wiring details refer to Chapter 4, Installation.
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.
5.6
The display PCB contains the driver circuitry for push buttons and LCDs. It is connected to the
processor board by a short ribbon cable.
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.
LCD
DISPLAY PCB
GLASS FACIA
SET-UP BUTTON
SECURITY SEALED
PLUG
PUSH BUTTON
FIG 2.5 MAIN DISPLAY UNIT COMPONENTS (PRESET VERSION SHOWN)

5.8
Non-preset displays will have three LCDs giving:

Batch Quantity
Chap 2
Page 4
TP 0027
Rate of Flow/Temperature
Non Resettable Tote
5.9
Preset displays will have four LCDs giving:

Batch Quantity
Preset Quantity
Rate of Flow/Temperature
Non Resettable Tote
5.10
5.11
The above displays may be in:
Litres
Cubic Metres
Decalitres/Dekaliters
kg
Imperial Gallons
lb
US Gallons
Tons
Combination displays will have four LCDs giving:

Batch Volume
Batch Weight
Rate of Flow and Temperature
Non Resettable Tote
5.12
Combination Display Units (non-preset only) are available in:
Imperial Gallons/Pounds
US Gallons/Pounds
Litres/Kilograms
Decalitres/Kilograms
Dekaliters/Kilograms
Cubic Metres/Tonnes
These Display Units are fitted with one push button for Reset.
5.13
Push buttons are mounted through the mask plate and apertures in the glass facia and sealed with
O ring seals.
5.14
Non-preset systems have only one push button for a simple Reset operation.
Chap 2
Page 5
TP 0027
5.15
Preset systems have three push buttons:

Reset - for Zeroing the batch display
Preset - for selecting a preset quantity
Stop/Run - for controlling product flow operations.
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.
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).
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 7 of this Chapter.
5.19
Should 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.
5.20
The Masterload II system uses a sophisticated communication protocol which enables an interface to
a computer or SCADA system. This will enable the facility of controlled loading operations and the
collection of all loading activity data.
5.21
Information available using the data link includes:
Chap 2
Page 6
Batch Quantity (uncompensated)
Tote
Batch Quantity (temperature compensated)
Weight
Pressure
Temperature
Differential pressure
Error codes
Preset valve
User identification
Rate of flow
TP 0027
REMOTE DISPLAY UNITS
6.1
Remote Display Units may be installed in addition to the main Display Unit. This gives the facility for
fixing a display in a more convenient location.
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.
6.3
Remote Display Units may be fitted with pushbuttons to match the functionality of the main display.
6.4
The maximum cable length between displays is 50 metres.

LCD
DISPLAY PCB
GLASS FACIA
FIG 2.6 REMOTE DISPLAY UNIT COMPONENTS (NON BUTTON VERSION SHOWN)
Chap 2
Page 7
TP 0027
FLAGS AND ERROR MESSAGES
7.1
By programming various Flags within the microprocessor software Masterload may be configured to
meet current and future requirements.
7.2
The software contains various entry points called Flags.
7.3
Each Flag has a two digit identity number in the range 00 to 90.
7.4
Each flag is accompanied by a simple message, displayed in the Tote window, to indicate its function.
7.5
The Flags are given two levels of security in the Masterload software:
7.6
Low Security Flags numbered 01 to 13
High Security Flags numbered 20 to 90
Flags may be accessed by 2 modes:
Low Security Entry
High Security Entry
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.
7.8
The Low Security Flags contain information for:
System Configuration and Units of Display (Non Resettable) - for reference only
Temperature Display Format and Alarms
Density Correction Factor
Preset Flow (profile and form).
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.
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.
7.11
The High Security Flags contain information for:
Mode of Operation (calibration, diagnostics)
Data Communication Configuration
Class of Calibration (1, 2, 3 or 4)
Temperature Correction
Calibration Factors
Low Security Passcode
Datum shift
Display Configuration
Peripheral Interface Configuration
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.)
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.
Chap 2
Page 8
TP 0027
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 Chapter 6. If an error is detected, the deadman supply feed will be
removed.
7.15
Flag details and set-up procedures are explained in Chapter 5 Commissioning and Chapter 6
Operation.
Chap 2
Page 9
TP 0027
Intentionally left blank
Chap 2
Page 10
TP 0027
Chapter 3
SPECIFICATION
1
STANDARDS
1.1
The Masterload II system is Intrinsically Safe and is ATEX approved.

Power Supply Unit (Flameproof)
II 2GE Exd IIB T6. Certificate No. ITS04ATEX 11903
Display Unit
II 2GE Ex ib IIB T6. Certificate No. BAS02ATEX 2199
II 2GE Ex ib IIB T6. Certificate No. DEMKO 01 ATEX 130641X
1.2
A copy of the ATEX certificates is included at the back of this manual.
1.3
Conformity with the Electromagnetic Compatibility Directive 89/336/EEC and in the UK, the
Electromagnetic Compatibility Regulations 1992 (SI 1992 No. 2372) as amended.
UNIT DIMENSIONS
2.1
The dimensions of units are shown below.

241
253
80
112
105.5
255
110.5
265
80
45
222
222
DISPLAY UNIT
TO FACILITATE DISMANTLING, ALWAYS ALLOW A SPACE IN FRONT OF THE

BULKMETER, EQUAL IN DEPTH TO THE BULKMETER IN USE.
3.1
POWER SUPPLY UNIT
UNIT WEIGHTS
NOTE
80
DISPLAY UNIT
5 Kg
POWER SUPPLY UNIT
6.5 Kg
ELECTRICAL
Main Supply voltage:
110V or 220-240V a.c. from mains supply.
3.2
Solid State Relay Output:

For a.c. output:
3.3
110V/240V a.c. SSR1-11 (1 amp max.)
Power to solid state relay outputs

For a.c. output:
110V/240V a.c.
Each relay must supply a minimum current of 20 mA for correct operation.
3.4
External fuse:
The input supply must be fused. The rating is, typically, 15 A.
SPECIFICATION
Chap 3
Page 1
TP 0027
3.5
Internal fuse ratings (Power Supply Unit):

FS1
3.6
1 amp
All cable specifications are given in the wiring diagram in the back of the manual.
OPERATING ENVIRONMENT
4.1
Units are designed to operate in an outdoor environment and are sealed to specification IP65.
4.2
The units are operational under the following conditions:

Ambient temperature, -20C to +40C
Relative humidity, up to 100%
Hazardous area rating, Category 2 (Zone 1).
TEMPERATURE PROBE
6.1
Chap 3
Page 2
Type:
Platinum Resistance Thermometer (PRT). 1/10 DIN
Accuracy:
+/- 0.1C
Discrimination:
0.1C
Range:
-30C to +120C.
SPECIFICATION
TP 0027
Chapter 4
INSTALLATION
CONTENTS
Para
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
Receipt
Installation
Power Supply Unit
Display Unit
Pulse Transmitter - Fitting to an Avery Hardoll Bulkmeter
Temperature Probe - Installation
Electrical Installation
An Overview of Typical System Wiring Diagrams
Pulse Transmitter Wiring
Display Unit Wiring
Power Supply Unit
Power Supply Unit Wiring
External Valves and Gantry Pump
Office Communication Wiring
Transducer Wiring
Densitometer Unit Wiring
Differential Pressure Transducer Wiring
Pressure Transducer Wiring
Remote Display Unit
Slip Printer
RECEIPT
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.
1.2
To avoid damage, particularly to electronic components, all items are to be handled with care at all
times. Any deficiencies or damage should be reported to the supplier.
2
2.1
INSTALLATION
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 should be mounted in a
convenient position. Full instructions for installing the bulkmeter capsule in the product line are given
in publication TP0003.
WARNING
WHEN CARRYING OUT THIS CONVERSION PAY ATTENTION TO LOCAL REGULATIONS
REGARDING THE USE OF EQUIPMENT IN FLAMMABLE ATMOSPHERES.
SINCE 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 BE MATCHED.
INSTALLATION
Chap 4
Page 1
TP 0027
3
POWER SUPPLY UNIT
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.
80mm
222mm
FOUR HOLES
7mm
FIG 4.1 POWER SUPPLY UNIT FITTING DIMENSIONS

3.2
Construct a suitable mounting bracket for the Power Supply Unit (see fig 4.1 for dimensions). The
Power Supply Unit and Display Unit may be fitted together, although this is not recommended).
Ensure the bracket is of adequate strength to support the weight of the unit (or units).
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.
3.4
To mount the Display Unit on the Power Supply Unit, cables should be reconnected (Sections 9 to
13). Make sure the seal is serviceable and refit the front cover with the eight M6 socket cap screws.
DISPLAY UNIT
4.1
To mount the Display Unit remotely, proceed as follows.
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:
Chap 4
Page 2
(1)
The maximum cable run length is 50 metres from the Bulkmeter Capsule.
(2)
The Display Unit readouts must be clearly visible from the normal operating position. Angle the
unit downwards if above eye level.
(3)
The operator must be able to reach the push-buttons.
(4)
The Display Unit requires external front illumination, avoid bright reflections from the glass.
(5)
Allow access room around unit for maintenance.
(6)
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.
(7)
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.
INSTALLATION
TP 0027
4.3
Construct a suitable mounting bracket for the Display Unit (see Fig 4.2 for dimensions). Ensure the
bracket is of adequate strength to support the weight of the unit.
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 (refer to Fig 9.2).
4.5
Connect cables (Sections 8 and 10).
80mm
222mm
FOUR HOLES
7mm
FIG 4.2 DISPLAY UNIT FITTING DIMENSIONS

4.6
Reconnect ribbon cable and refit front section of unit to rear section secure with four M5 socket cap
screws. Position one drilled sealing screw adjacent to blanking plug, fit sealing wire and lead seal.
4.7
Remote Display Units (when supplied) should always be mounted as separate items. Suitable labels
should be fixed near all remotely mounted Display Units to identify product lines to which they relate.
INSTALLATION
Chap 4
Page 3
TP 0027
5
PULSE TRANSMITTER - Fitting to an Avery Hardoll Bulkmeter. Pulse Transmitters are

Intrinsically Safe and may be mounted in a Category 2 (Zone 1) Hazardous Area.
5.1
The pulse transmitter and adaptor plate are fitted in place of the mechanical calibrating mechanism
(Refer to Fig 4.3).
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.
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).
5.3
An O ring (6) provides a seal between the transmitter (7) and the bulkmeter adaptor plate (8).
5.4
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).
5.5
The Pulse transmitter is wired through a cable gland (16) at the bottom of the unit.
8
6
11
9
10
5
4
3
2
15
14
13
12
16
FIG 4.3 PULSE TRANSMITTER
Chap 4
Page 4
INSTALLATION
TP 0027
6
TEMPERATURE PROBE - Installation

1/4 BSP THREAD
89/91mm
PROBE POCKET
87/85mm
15A/F
50mm MIN BEND
FIG 4.4 TEMPERATURE PROBE DIMENSIONS

6.1
The temperature probe 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).
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 the table below.
Note:
The processor PCB must be type ZPMZ1--285--1. This board includes the temperature
interface circuit.
Item Part No.
Description
Qty
ZEMZ0309-02
TEMPERATURE PROBE
ZESZ0309-03
FABRICATED POCKET ASSY
BECZ1062
ADAPTOR
ZMMZ0135-6
BONDED SEAL
ZMPZ0158-4
WASHER
ZACZ0305-06
TUBING SLEEVE
ZACZ0305-07
TUBING NUT
BEPD1098
TEMPERATURE PROBE INSTALLATION DRAWING
6.2.1
Isolate the system from all electrical and product supplies. Drain product from bulkmeter.
6.2.2
Remove screwed plug from manifold and remove sealing washer from plug. Check that the
sealing washer is in good condition and fit to the probe pocket (Fig 4.4).
INSTALLATION
Chap 4
Page 5
TP 0027
6.2.3
Screw the pocket into the manifold well.
6.2.4
Screw the temperature probe into the pocket, take care not to bend or twist the cable tail.
ELECTRICAL INSTALLATION
WARNING
PRIOR TO CARRYING OUT ANY WORK ENSURE THAT ALL AIRPORT/COMPANY
PROCEDURES ARE FOLLOWED.
All electrical installation work is to be carried out by suitably qualified personnel.
All cable installations and junction boxes are used in accordance with EN60079-14.
Ensure:
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.
ELECTRO-STATIC SENSITIVE DEVICES.
This equipment contains Electro-static sensitive devices. The precautions specified in BS EN

1000015-1 must be obeyed.
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.
7.1
Refer to the general wiring diagram at back of this manual for details of all cables required when
installing Masterload.
7.2
FITTING THE CABLE GLANDS
Limitations:
Install the gland in accordance with relevant code e.g. BS5345.
A seal shall be formed between the equipment and the gland to maintain the appropriate degree
of protection against ingress of dust, solids and water.
The gland should 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, e.g. EN50018.
7.2.1
Chap 4
Page 6
Place the cable alongside the equipment, allow sufficient length for connecting the cores to
the appropriate terminals plus at least 20mm extra length, then cut off any surplus.
INSTALLATION
TP 0027
7.2.2
Approximately 22mm back from the equipment face (See Fig. 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.
7.2.3
Remove the surplus outer sheath, taking care not to cut the braid or inner sheath.
7.2.4
Remove the surplus braid by bending it and breaking it at the cut part.
7.2.5
Remove a further 20mm of outer sheath (See Fig. 4.5 dimension C), taking care not to cut
the braid or inner sheath.
A
B
OUTER SHEATH
INNER SHEATH
OUTER FACE
OF EQUIPMENT
ARMOUR (If applicable)
FIG 4.5 COMPRESSION GLAND ASSEMBLY

7.2.6
Engage and tighten 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
7.2.7
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.
7.2.8
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.
7.2.9
Pass the clamping spigot (3), tapered end first, over the inner sheath.
7.2.10
Splay out the braid evenly and locate the tapered end of the clamping spigot (3) under it.
7.2.11
Feed the inner sheath of the cable through the entry component (1) until the clamping
spigot (3) fits in the counterbore.
7.2.12
Push the cable towards the equipment then locate and tighten the compression nut (5) onto
the entry component (1) to clamp the braid. Untighten the compression nut and remove it
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.
Feed the inner sheath back through the entry component and the rubber inner seal and
relocate and tighten the compression nut onto the entry component until a seal is formed
between the inner seal and the inner sheath
The inner sheath shall protrude/through the entry component to ensure that there is
sufficient surface for sealing.
7.2.13
Tighten the tailnut (6) onto the compression nut (5) until a seal is formed between the outer
seal (7) and the outer sheath.
If difficulty is found in forming a seal, untighten the tailnut (6) half a turn, then re--tighten.
INSTALLATION
Chap 4
Page 7
TP 0027
8
AN OVERVIEW OF TYPICAL SYSTEM WIRING DIAGRAMS
8.1
NON-PRESET SYSTEM
8.2
Fig 4.6 shows the simplest configuration of Masterload on a Gantry.
8.3
A control signal is given to the gantry pump offering additional security to the fuelling process.
POWER SUPPLY UNIT
MAIN DISPLAY UNIT
BULKMETER
TEMP.
PROBE
SSR3 TO
DEADMAN
CONTROL UNIT
MAINS
SUPPLY
PULSE
TRANSMITTER
FIG 4.6 BASIC NON-PRESET SYSTEM

8.4
PRESET SYSTEM
8.5
Fig 4.7 shows a basic Masterload preset system complete with an additional display unit that can be
fixed in a more suitable location. This additional display can be supplied with or without control
buttons which, when fitted, provide the ability to control fuelling from an alternative location.
8.6
A simple gantry pump signal offers additional security to the fuelling process.
8.7
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)
Line pressure/s
Densitometer Input
8.8
If there are not enough power supply entries, the use of a junction box is recommended, as shown in
Fig 4.7.
8.9
Fig 4.8 shows a communications link to the office providing data to a computer.
8.10
Additive injectors can also be driven from additional relays in the power supply unit.
Chap 4
Page 8
INSTALLATION
TP 0027
POWER SUPPLY UNIT
DISPLAY UNIT
SSR3
TO DEADMAN
CONTROL UNIT
SSR1 & SSR2
PRESET VALVE
BULKMETER
TEMPERATURE
PROBE
MAINS
SUPPLY
TRANSDUCER
JUNCTION BOX
(IF REQUIRED)
VEHICLE PRESSURE
DIFFERENTIAL PRESSURE TRANSDUCER
DENSITOMETER INPUT
PULSE
TRANSMITTER
FIG 4.7 BASIC PRESET SYSTEM
INSTALLATION
Chap 4
Page 9
TP 0027
POWER SUPPLY UNIT
DISPLAY UNIT
COMMUNICATIONS
TO OFFICE
OVERRIDE
SWITCH
BULKMETER
EXTERNAL DEVICE
e.g. PULSE OUTPUT
TRANSDUCERS
(eg DENSITOMETER)
TEMPERATURE
PROBE
PULSE
TRANSMITTER
MAINS
SUPPLY
JUNCTION
BOX
JB1
SSR1
SSR2
TO PRESET
VALVE SOLENOIDS
SSR3 TO DEADMAN CONTROL UNIT
FIG 4.8 PRESET SYSTEM OPTIONS - INCLUDING OFFICE

COMMUNICATIONS LINK AND TRANSDUCER INPUT
Chap 4
Page 10
INSTALLATION
TP 0027
9
PULSE TRANSMITTER WIRING (Refer to Wiring Diagram at back of document)

NOTE:
Refer to Section 7.2 before fitting cable glands.
9.1
A 12 core screened cable is used to connect the Pulse Transmitter from the Display Unit.
9.2
Loosen the cable gland.
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.
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.
9.4
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.
9.5
Connect wiring to the terminal block. Tighten cable gland on transmitter housing.
9.6
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.
9.7
Insert and connect the wiring to the transmitter housing and tighten compression fitting.
9.8
Refit the transmitter, checking that the O ring does not distort in the housing. Tighten the four cap
head screws.
10
DISPLAY UNIT WIRING (Refer to Wiring Diagram at back of document)
10.1
Remove the display front ensuring that adequate room is left below the Display Unit for cable entries.
10.2
Route the cables from the Power Supply and the Transmitter through the cable glands into display
enclosure. Ensure that the screen is clamped within the cable glands and tighten glands.
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.
10.4
Connect wires to TB1, TB2 and TB3.
10.5
Cut back the Pink, Turquoise and Green wires which are not required.
10.6
Fit cable ties and replace the display front.

CAUTION
TO PREVENT THE PCB FOULING WHEN FITTING THE DISPLAY UNIT FRONT, ENSURE THAT
IT IS COMPLETELY LOCATED IN THE GROOVE OF THE RUBBER SURROUND.
INSTALLATION
Chap 4
Page 11
TP 0027
11
POWER SUPPLY UNIT
11.1
Masterload may be powered from either a 110V or 240V a.c. mains supply.
11.2
Remove front cover of Power Supply Unit by removing the eight cover screws.
11.3
Check the power setting of the PCB by fitting links in accordance with the following table.
POWER
LK3 (LINK 3)
LK4 (LINK 4)
LK5 (LINK 5)
110V a.c. OPERATION
OUT
IN
IN
240V a.c. OPERATION
IN
OUT
OUT
LINKS
BARRIER BLOCK
COVER SCREWS
RELAY(S)
CABLE
SEPARATION
SHEET
FIG 4.9 POWER SUPPLY - INTERNAL LAYOUT
Chap 4
Page 12
INSTALLATION
TP 0027
BARRIER BLOCK
INTRINSICALLY
SAFE WIRING
CABLE
SEPARATION
SHEET
NON-INTRINSICALLY
SAFE WIRING
FLAMEPROOF APPROVED CABLE

GLANDS AND ADAPTORS
FIG 4.10 POWER SUPPLY - CABLE SEPARATION

11.4
The Power Supply Unit is flameproof for a Category 2 (Zone 1) Hazardous Area, all cable glands
and blanking plugs used on the unit must be flameproof approved.
11.5
Route all Non-Intrinsically safe wiring behind the cable separation sheet (Fig 4.10).
11.6
Route all Intrinsically Safe wiring (from barrier block) in-front of the cable separation sheet.
12
POWER SUPPLY UNIT WIRING (Refer to Wiring Diagram at back of document)

WARNING
WHEN CARRYING OUT THE INSTALLATION OF CABLES ENSURE THAT ALL LOCAL
REGULATIONS REGARDING THE USE OF EQUIPMENT IN HAZARDOUS AREAS ARE
12.1
If there are insufficient cable entries within the Power Supply Unit the fitting of a junction box is
recommended.
12.2
Remove power supply cover and cable separation sheet, feed 240 mm of cable through flameproof
approved cable gland and into enclosure.
12.3
Strip back insulation to approx 20 mm from cable entry and offer up wiring to TB1.
12.4
Trim wires to length, allow 20mm for slack. Strip wire ends 8 mm, twist and lightly tin.
12.5
Connect wires to terminal block TB1 and tighten cable gland.

WARNING
THE CABLE FROM POWER SUPPLY TO THE DISPLAY UNIT IS INTRINSICALLY SAFE AND
MUST BE ROUTED ABOVE THE CABLE SEPARATION SHEET.
ENSURE THAT 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 1. A LINK
BETWEEN THE BARRIER AND ENCLOSURE EARTH STUD MAY BE ACCEPTABLE.
INSTALLATION
Chap 4
Page 13
TP 0027
12.6
If the Display Unit is remotely mounted, the maximum allowable cable length is 50 metres.
12.7
When feeding the cable through the gland, ensure that the screen is terminated within the gland.
12.8
Route wiring to Barrier Block (Fig 4.10) and tighten cable gland.
12.9
Refit power supply lid. Ensure that the seal is serviceable and secure lid using eight M6 socket cap
screws.
13
EXTERNAL VALVES AND GANTRY PUMP
13.1
Preset Masterload Systems have three solid state relays (SSRs) fitted. Two fitted for a Preset
Valve and one for a gantry pump demand signal:
SSR 1 is connected to the UPSTREAM solenoid (N/O) of a Preset Valve.

SSR 2 is connected to the DOWNSTREAM solenoid (N/C) of a Preset Valve.
SSR 3 supplies the gantry pump demand.
13.2
Refer to Wiring diagram at back of document for connection information.
13.3
Non-Preset Masterload System has only one solid state relay (SSR3). This provides the pump
demand signal.
13.4
Permissive Signal
A permissive signal (110V / 250V) may be supplied (e.g. from a scully device to energise the
Masterload valve control relays. If this facility is required, Link 1 (LK1) on the PSU board must be
removed and the permissive signal connected to pin 4 of TB1.
14
OFFICE COMMUNICATION WIRING (Refer to Wiring Diagram at back of document)
14.1
Twisted pair data cable is used for this connection. Connection to the PSU is via TB4.
14.2
Extreme care should be taken when making the terminal block connections between equipment.
Labelling or identifying conductors should be adopted to avoid confusion. Connections are as follows:
MASTERLOAD
Tx
Tx
Rx
Rx
OFFICE
Rx
Rx
Tx
Tx
14.3
Determine cable run and allow 600 mm each end for termination.
14.4
Route cable from office and feed 600 mm of cable through cable gland on PSU.
14.5
Tighten cable gland.
14.6
Strip back insulation a distance of 100 mm.
14.7
Trim wires to length, allowing 20 mm for slack. Strip wire ends 8 mm, twist and lightly tin.
14.8
Connect wires to TB4.
15
TRANSDUCER WIRING (Refer to Wiring Diagram at back of document)
15.1
Chap 4
Page 14
External transducers will be flameproof and will provide a 4-20 mA output. These can be used to
control and monitor the metering process.
INSTALLATION
TP 0027
15.2
A maximum of 4 transducers can be linked to Masterload, these include; a densitometer input, a

differential pressure gauge, and two pressure indicators.
15.3
When installing a transducer ensure that it is connected to the appropriate terminals

of TB3.
16
DENSITOMETER UNIT WIRING
16.1
The Densitometer connections differs from other transducers in that it requires a three core cable.
Refer to Fig 4.11.
16.2
Connect the wiring between the Densitometer and TB4 as shown in Fig 4.11 below and wiring
diagram at back of document.
16.3
Recheck the installed wiring and ensure that the polarity of connection is correct and appropriate.
Den +
0V
LINK
Den -
TB1
DENSITOMETER UNIT
SOLATRON 7828
Default Range: 750 - 850 kg / cu metre
0V
TB3 1
0V
Den +
Den +
Den -
Den -
TB2
TB1
TB2
MASTERLOAD POWER SUPPLY

FIG 4.11 DENSITOMETER WIRING
INSTALLATION
Chap 4
Page 15
TP 0027
17
DIFFERENTIAL PRESSURE TRANSDUCER WIRING
17.1
A two core cable is required to connect the Differential Pressure Transducer to the power supply unit
(Fig 4.12).
17.2
Connect the wiring between the Differential Pressure Transducer and TB3 as shown in Fig 4.12 and
wiring diagram at back of document.
17.3
Recheck installed wiring and ensure that the polarity of connection is correct and appropriate.
TB3
1
CABLE FROM DP TRANSDUCER dp +
dp +
dp -
dp -
TB2
TB1
TB2
PSU
FIG 4.12 DIFFERENTIAL PRESSURE TRANSDUCER WIRING
Chap 4
Page 16
INSTALLATION
TP 0027
18
PRESSURE TRANSDUCER WIRING
18.1
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 (Fig 4.13).
18.2
Recheck installed wiring and ensure that the polarity of connection is correct and appropriate.
FROM PRESSURE
TRANSDUCER (1)
TB3
1
P1 +
P1 +
P2 +
P2 +
P1 -
P1 -
P2 -
P2 -
TB2
FROM PRESSURE
TRANSDUCER (2)
TB1
TB2
TB4
PSU
FIG 4.13 PRESSURE TRANSDUCER WIRING
INSTALLATION
Chap 4
Page 17
TP 0027
19
REMOTE DISPLAY UNIT
19.1
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.
19.2
The procedure for mounting is identical to that of the Main Display Unit (refer to wiring diagram at
back of document).
MAIN DISPLAY
OR OTHER REMOTE
DISPLAY PCB
REMOTE DISPLAY
PCB
1
1
TB3
TB2
TB1
CABLE FROM MAIN

DISPLAY OR OTHER
REMOTE DISPLAY UNIT
12 CORE CABLE
TO ADDITIONAL
DISPLAY UNIT
FIG 4.14 CONNECTIONS TO DISPLAY PCB

19.3
Detach the display front.
19.4
Route cable from main Display Unit and feed through cable gland (Fig 4.14).
19.5
Allow approximately 250 mm of slack to enable easy access and removal of display unit front when
wiring is connected.
19.6
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.
19.7
Cut back wire ends 8 mm, twist and lightly tin.
19.8
Connect wiring and ensure that the screen is clamped within the gland (refer to wiring diagram at
back of document).
19.9
Tighten cable gland and refit the display front to rear enclosure and secure with four cap headed
screws.
19.10
Further remote displays are identically wired, from TB2 on the previous display to TB1 and TB3 on
the display being added (as stated above).
Chap 4
Page 18
INSTALLATION
TP 0027
20
20.1
SLIP PRINTER
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 the wiring diagram at the back of document for details.
INSTALLATION
Chap 4
Page 19
TP 0027
Chap 4
Page 20
INSTALLATION
TP 0027
Chapter 5
COMMISSIONING
CONTENTS
Para
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Pre-Commissioning
Initial Power Up
Commissioning
Flag Setting Exercise
Flag Tables
Initial Flag Settings
Low Security Flags
High Security Flags
Setting up the Preset Valve
Remote Pump Start
Calibration
Calibration Classes
Masterload Calibration - with an Avery---Hardoll brand Bulkmeter
Re-calibrating Masterload
Display Unit Set-up
Temperature Device
Densitometer Unit
Differential Pressure Transducer
Pressure Transducers
Flag Settings --- Recording
PRE-COMMISSIONING
ALL SITE RULES SHOULD BE ADHERED TO WHEN COMMISSIONING MASTERLOAD
1.1
The completed Masterload system, pipework and ancillaries must be reviewed prior to commissioning
to verify the installation is correct and conforms to all necessary safety standards.
1.2
Check all meters, valves etc to ensure correct orientation in system.
1.3
Confirm that the pipework, has been purged of all entrained foreign matter and air, flush tested and
leak checked.
1.4
Ensure that all valves in system are CLOSED.
1.5
Ensure that the Vehicle Master Switch is switched OFF.

THE POWER SUPPLY IS A FLAMEPROOF UNIT FOR USE IN A CATEGORY 2 (ZONE 1)
HAZARDOUS AREA. ENSURE THAT THE COVER IS TIGHTLY SECURED AT ALL TIMES.
NEVER REMOVE COVER WHEN SUPPLY VOLTAGE IS PRESENT.
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.
1.7
Check wiring terminals and cable glands for tightness.
1.8
Re-check installed wiring connections in power supply.
1.9
Replace power supply cover and tighten all cap head screws.
1.10
Remove front section of the Masterload Display Unit and re-check installed wiring connections.
1.11
Replace display front with securing screws.
COMMISSIONING
Chap 5
Page 1
TP 0027
1.12
Remove pulse transmitter cover and re-check all wiring connections.
1.13
Replace transmitter cover, ensuring that no wires are trapped between metal faces.
1.14
On initial power up of system ALL VALVES MUST BE CLOSED.
1.15
When product flow is required during calibration, open valves with caution.
INITIAL POWER UP
IN THE FOLLOWING CASES, ESPECIALLY 2.4.2 WHERE NON-INTRINSICALLY SAFE VOLTAGE
IS PRESENT, WORK SHOULD BE CARRIED OUT ONLY BY A QUALIFIED ELECTRICIAN.
2.1
Make sure all valves are CLOSED.
2.2
Switch ON master switch.
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.
2.4
If the Display Unit fails to work then either:

2.4.1
There is a fault between the Power Supply Unit and the Display Unit.
2.4.2
2.5
There is a fault between the Power Supply Unit and the master switch.
In the case of 2.4.1, remove the display front to check that the ribbon cable between the processor
board and the display front is connected. If a wiring fault is suspected then this work should only be
carried out by a qualified electrician.
COMMISSIONING
COMMISSIONING MUST ONLY BE CARRIED OUT BY A QUALIFIED SERVICE ENGINEER.
3.1
Prior to starting the commissioning procedure it is advisable to become fully conversant with the
operation of the Display Unit buttons.
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 Fig 5.1).
3.3
Flags are divided into two levels of security within the software:
3.4
Low Security Flags (01 to 19).
High Security Flags (20 to 90).
Low Security Flags.

These Flags contain:
Chap 5
Page 2
System configuration and units of display.
Temperature and pressure display format and alarms.
Density correction factor.
Preset flow (profile and form).
COMMISSIONING
TP 0027
3.5
High Security Flags.
3.6
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.
FLAG SETTING EXERCISE
4.1
Remove the blanking plug located underneath the Display Unit to gain access to the SET-UP button
(Fig 5.1).
4.2
The SET-UP button is of the latching type, push for on/push again for off.
4.3
Switch on the electrical power to the Masterload system.
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.
SEt UP dAtA
FL 00
rEF dAtA
SEALED CAP
COVERING SET-UP
BUTTON
Fig 5.1 SEt UP dAtA AND FL00 MESSAGES

4.5
FL 00 will appear in the FLOW RATE WINDOW and rEF dAtA (Reference data) in the TOTE
WINDOW.
COMMISSIONING
Chap 5
Page 3
TP 0027
4.6
The information displayed in the batch window is the contents of Flag 00.
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.
4.8
In the following example Flag 00 will be changed to Flag 89.
FL
4.9
00
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.
FL
00
4.10
Flag information displayed in the BATCH and TOTE window will also change reflecting the movement
through the Flag table.
4.11
Release the RESET button when 8 appears.
4.12
The FLOW RATE window should now display FL 80 and the TOTE window the message AdditiVE.
FL
4.13
80
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 86 - 89 are unused.
FL
4.14
80
Release the RESET button when 9 appears. Flag 00 has now been changed to Flag 89.
FL
89
4.15
Each press and release of the RESET button advances the review facility to the next numeral
With the exception of Flag 00.
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.
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.
4.18
Pressing and holding the RESET button allows the required numeral to increment to the required
value.
4.19
When changing Flags and Values care must be taken to ensure that:
No Flag values, other than those required, are accidentally changed.
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.
Chap 5
Page 4
COMMISSIONING
TP 0027
FLAG TABLES
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.
5.2
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.
5.3
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).
5.4
The Table below gives a complete set of available Flags followed by a more detailed description of
each Flag.
INITIAL FLAG SETTINGS
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 1 as Figures within grey boxes e.g. 1
Flag
00
Data
D1
D2
D3
D4
D5
Function
D6
0
1
2
3
4
5
DM (Steel) Meter
SINGLE Capsule
DOUBLE Capsule
TRIPLE Capsule
QUAD Capsule
S259 Meter
Repeater System
REF dAtA
Weight
Density
Volume
Litres
Kg
Kg/Cu.M
Imp. Gallons Lb
Lb/Imp.Gall
Decalitres
Kg
Kg/Cu.M
US. Gallons
Lb
Lb/US Gall
Cubic Metres Tonnes
Kg/Cu.M
Litres x 10
Kg
Kg/Cu.M
Cubic Metres Tonnes
Kg/Cu.M
As 0 (with tote in Decalitres)
As 1 (with batch & tote in Tons, RoF in Tons/Hr
As 6 (with volumes to two decimal places)
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
COMMISSIONING
Message
Pulse Adjustment Factor

Litres
10 Lts/rev. (Repeater & single end drum)
50 Lts/rev.
100Lts/rev. (Repeater & double end drum)
Imp. Gallons
US. Gallons
Repeater & printer (single end drum)
Repeater & printer (double end drum)
5.
Programmable Pulse Weighting

Program Issue
Chap 5
Page 5
TP 0027
Flag
01
Data
D1
D2
D3
D4
D5
D6
0
1
Normal run
Display fine increments
0
1
2
Flow Rate Display

0
1
2
3
0
1
0
1
2
3
Density Display
No display
Continuous display
Instantaneous value/Resulting average
Average run display (may be toggled)
0
1
2
Pressure 1 Display
No display
Continuous display
Instantaneous value/Resulting max.
*
Max. pressure for alarm

Pressure 2 Display
No display
Continuous display
0
1
2
*
InPutS
Temperature Display
No display
Continuous display
Instantaneous value/Resulting average
Average run display (may be toggled)
EC
EF
*
4
Set UP
Batch restored on power-up

Batch cleared on power-up
0
1
Message
No reverse flow count

Tote frozen in reverse
Count reverse flow
0
1
02
Function
Max. pressure for alarm

Differential Pressure Display
No display
Continuous display
0
1
2
*
Max. filter dp at 100% (for alarm)
03
04
+/*
*
*
*
*
E
E
C
C
Low Temperature Alarm

High Temperature Alarm
LO t EC
HI t EC
05
*.
Density (when designated by Flag 54)
dEnSity
Chap 5
Page 6
COMMISSIONING
TP 0027
Flag
06
Data
D1
D2
D3
D4
D5
4
5
6
0
1
No Auto Calibration
Auto Calibration
*
*
*
10
11
12
20
21
1
2
3
4
Local Mode (when set by Flag 70)

System Mode (when set by Flag 70)
*
*
*
*
*
*
0
0
0
*
22
By-pass Volume
Pass Code (R used for ERS only)
PASSCOdE
Class 1 Calibration
Class 2 Calibration
Class 3 Calibration
Class 4 Calibration
ClASS
(Litres/Gallons)
100% flow
Normal Mode
Channel Mark/Space Test (50-50-50)
Calibration Mode (Factors ignored)
Verification Mode (Factors used)
Self Test
Soak Cycle
tESt
Temperature Compensation Test Display
30
31
32
33
34
35
36
37
COMMISSIONING
PrESEt
*.
23
50
1st Stage Flow Rate (Lpm/Gpm)

1st Stage Volume
(Litres/Gallons)
Max.Flow Rate
(Lpm/Gpm)
Flow Rate Deceleration (Lpm/s Gpm/s)
0
1
2
3
4
5
40
AUtO CAL
No Mark/Space Test
Channel Mark/Space Test
0
1
PrESEt
Preset limit
0
1
13
Message
4 Figure Preset
5 Figure Preset
6 Figure Preset
*
07
Function
D6
Class
1
x
x
x
x
x
x
x
x
0.
0.
0.
0.
0.
0.
0.
0.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
5% Cal.
10% Cal.
15% Cal.
20% Cal.
30% Cal.
50% Cal.
75% Cal.
100% Cal.
System Flow Rate Limit
toP roF
0.
Datum shift
SHIFt
x
x
x
x
CAL 5
CAL 10
CAL 15
CAL 20
CAL 30
CAL 50
CAL 75
CAL 100
Chap 5
Page 7
TP 0027
Flag
51
52
Data
D1
D2
0
1
2
3
0
1
*
*
*
D4
*
*
*
D5
*
*
*
D6
*
*
*
0
1
2
*
53
54
D3
0
1
2
0
1
2
Uncompensated
Temperature Compensation to 15EC
Temperature Compensation to 20EC
Temperature Compensation to 31.5EC
t COEF
IP/ASTM Table Selection

Generalised Crude Oils (A Tables)
Generalised Products (B Tables)
Table 54: No HYC/FL.05 = Density @ ref
: No HYC/Fl.05 = Density @ tEC
Table 53: HYC on/Fl 05 = Density @ tEC
IP tAbLE
Temperature Probe Offset
Prt
No Density
Density Entry (Accessed via Flag 05)
Densitometer
4-20 IP
No Differential Pressure
Differential Pressure measurement
0
1
2
3
4
No Preset Control
Avery-Hardoll Preset Valve
Low flow volume (simple preset/S259)
Large Valve
Deadman valve control
*
VALVE
Min. preset value (not available with large

valve set)
0
1
No Interlocks
Interlocks (Earth,Overspill & Arm Position)
*
Chap 5
Page 8
Message
No Pressure
One Pressure measurement
Two Pressure measurements
0
1
60
Function
Pump trip-out time (secs.)
COMMISSIONING
TP 0027
Flag
70
Data
D1
D2
D3
D4
D5
Function
D6
0
1
Vehicle Deadman Control

Gantry Pump Control
Message
OFFICE
Local Mode
System Mode (1200 baud rate)
Low security switch for System / Local (1200)
System Mode (9600 baud rate)
Low security switch for System / Local (9600)
Ticket Printer without Preset
Ticket Printer with Preset
0
1
2
3
4
5
6
0
1
2
3
Normal Mode
1 Pulse per unit displayed (from SSR4)
1 Pulse per 1/10 unit displayed (from SSR4)
1 Pulse per 10 units (from SSR4)
0
1
Disable too slow message

Enable too slow message
0
1
No Flowmaster
Flowmaster linked up
M
*
Meter data (non Flowmaster)

Vehicle No (Flowmaster)
dAtA
AddrESS
G
*
G
*
B
*
73
Device 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
COMMISSIONING
M
*
0
1
71
B
*
Data request mode

Data transmit mode
Time out (secs)
dELAy
Chap 5
Page 9
TP 0027
Flag
Data
D1
D2
D3
D4
D5
Function
D6
90
Main Display
0
1
2
3
4
0
1
2
0
1
2
6.2
Message
Additional
Display
Secondary
Preset
Secondary
BATCH
PRESET
TOTE
BATCH
PRESET
TOTE
BATCH
PRESET
TOTE
BATCH
PRESET
TOTE
BATCH
PRESET
TOTE
Prime
Preset
Prime
Prime
Secondary
Secondary
Prime
Secondary
Prime
Volume(Ltrs)
Weight (Kgs)
Tote (Lt)
Nett/Gross
Preset
Prime
Prime
= Uncompensated Volume
= Compensated Volume
= Weight
Secondary
= Uncompensated Volume
= Compensated Volume
= Weight
diSPLAy
REPEAT
REPEAT
REPEAT
(lbs/Galls)
REPEAT
The data given in each Flag is allocated a column number (D1 D6) relating to the 6 data columns.
Example:
6.3
D1
D2
D3
D4
D5
D6
70
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:
Chap 5
Page 10
Flag No.
Flag 02 can not be set for pressure measurement until Flag 54 is set.
COMMISSIONING
TP 0027
LOW SECURITY FLAGS
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
1
2
3
4
5
t
r
Avery-Hardoll DM (Steel meter) software.

Avery-Hardoll Single capsule meter software.
Avery-Hardoll Double capsule meter software.
Avery-Hardoll Triple capsule meter software.
Avery-Hardoll Four capsule meter software.
Avery-Hardoll S259 meter software
Software used in conjunction with a turbine meter.
Software used with the Electronic Repeater System.
D2
0
1
2
3
4
5
6
Volume display in Litres. Weight display in Kilograms.

Volume display in Imperial Gallons. Weight display in pounds.
Volume display in Decalitres. Weight display in Kilograms.
Volume display in US. Gallons. Weight display in Pounds.
Volume display in Cubic Metres. Weight display in Tonnes.
Volume display in Litres x 10. Weight display in Kilograms.
Volume display in Cubic Metres. Flow rate in Cubic Metres per Hour.
Weight display in Tonnes.
Batch volume display in Litres. Tote volume display in Decalitres.
Weight display in Tons with flow rate in Tons/Hr.
As 6 with volumes to two decimal places.
7
8
9
D3
0-5
6
7
9
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.
Electronic Repeater software used with a Ticket Printer and single Figure Veeder Root
end drum.
Electronic Repeater software used with a Ticket Printer and double Figure Veeder Root
end drum.
A variable pulse weighting for non-Avery--Hardoll meters.
These locations give the software issue being used in the system.
D5-D6
Flag 01
D1
0
1
Normal setting displaying whole units in the batch window.

The batch window displays 1/100s of units.
D2
0
1
2
Only forward flow will be displayed. Any reverse flow will be indicated by a negative sign in
the flow rate window.
The batch display only will decrement during reverse flow.
Both batch and totaliser displays will decrement during reverse flow.
0
1
The batch display is restored to its previous count on power up.

The batch display will reset to zero on power up.
D3
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.
COMMISSIONING
Chap 5
Page 11
TP 0027
D1
Flow rate only is indicated.
D1
Temperature may be displayed.

(LINKED Flags 03,04)
D2
0
No temperature displayed.
D2
1
A continuous display of temperature.
D2
2
Temperature is displayed while the reset button is pressed during flow. An
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
D3
1
Temperature given in F
D1
(LINKED Flag 54)

Density may be 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
(LINKED Flag 54)

One Pressure 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
should be set to 200psi.
D1
(LINKED Flag 54)

Two Pressure 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.
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 should be set to 200psi.
D1
Differential pressure may be displayed.

(LINKED Flag 54)
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 should be
set to 30psi.
Chap 5
Page 12
COMMISSIONING
TP 0027
Flag 03
Flag 03 is the low temperature limit in C. (Min. setting -30C). Once the measured temperature falls
below this Figure a temperature error (too cold) will be displayed. When not required this must be
set to -20C.
Flag 04
Flag 04 is the high temperature limit in C. (Max. setting 120C). Once the measured temperature
rises above this Figure a temperature error (too hot) will be displayed. When not required this must
be set to 120C.
(LINKED Flag 54)
Flag 05
This Flag is used to enter the density when a densitometer is not connected to the system.
(LINKED Flag 60)
Flag 06
This Flag provides the format for the preset display.

D1
4
5
6
The preset display will be 4 Figures (0-9999).

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.
D2
Flag 07
D1
0
1
Normal operation (i.e. not set for automatic calibration).

The meter is set to be calibrated automatically by the Masterload Autocal system
(ref. Manual TP0038).
D2
0
1
Normal operation (i.e. not set for transmitter mark/space test).

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
b)
Correct setting during flow
Hi Lo Lo
50 48 49
Hi 50 48
c)
A channel 1 fault.
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 secs.
Refer to Flag 22 for a permanent test facility.
D3
0
1
COMMISSIONING
Local mode
(LINKED Flag 70)
The system is set to function in a stand-alone situation without control from Flowmaster.
DO NOT USE FOR GANTRY APPLICATIONS.
Chap 5
Page 13
TP 0027
(LINKED Flag 60)
Flag 10
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
D1-D4
(LINKED Flag 60)
Flag 11
The first stage volume for the operation of a preset valve. This is used with Flag 10 and
should match the volume required to cover the filling nozzle. As above, this setting is only
available in tens of units.
Example:
0180
D1-D4
(LINKED Flag 60)
Flag 12
The maximum flow rate for the preset valve, with the least significant digit fixed at 0.
Example:
3450
D1-D4
(LINKED Flag 60)
Flag 13
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.
HIGH SECURITY FLAGS
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.
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
2
3
4
D3-D6
Chap 5
Page 14
Calibration class 1 (8 calibration points at 5%, 10%, 15%, 20%, 50%, 75%, 100% of the
max. flow rate (D3-D6)).
Calibration class 2 (4 calibration points at 10%, 20%, 75%, 100% of the max. flow
rate (D3-D6)).
Calibration class 3 (2 calibration points at 20% and 100% of the max. flow rate (D3-D6)).
Calibration class 4 (1 calibration point at 100% of the max. flow rate (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.
COMMISSIONING
TP 0027
Flag 22
This Flag provides test facilities and calibration settings.
D1
0
1
2
3
4
Normal setting.
This setting mimics the actions of the mark/space test of Flag 07, However, unlike Flag 07,
the test does not time-out.
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.
Verification mode. Calibration factors are used by the meter and the display shows units in
1/100s. During this mode, any preset valve control is disabled.
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 Tx to Rx.
Soak cycle. This provides a continuous cycle for preset systems. Any preset valve
connected to the meter will continuously cycle through a delivery sequence.
Flag 23
This Flag is used as a test display where the batch display shows the current temperature.
(LINKED Flag 21)
Flag 30-37
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 the Flag table (above).
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.
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.
(LINKED Flag 52)
Flag 51
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
1
2
3
COMMISSIONING
Uncompensated volume.
Temperature compensation to 15C reference.
Temperature compensation to 20C reference.
Temperature compensation to 31.5C reference.
Chap 5
Page 15
TP 0027
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.
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.
D3-D6
Flag 52
Flag 52 gives the IP/ASTM table selection for temperature compensation. Where possible, this Flag
should 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
1
A Tables for Generalised Crude Oils.

B Tables for Generalised Products (e.g. Gasolines, Jet fuels and fuel oils).
D2
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 15C, 20C or 31.5C as determined by Flag 51. The system must be
equipped with a temperature probe for this measurement.
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.
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).
Flag 53
This Flag provides a temperature probe offset. This should 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 0.0C
Flag 54
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
1
2
No density measurement required.

Density to be entered manually via Flag 05.
An in-line densitometer will be used to measure density.
D2
0
1
2
No pressure measurement required.

One pressure measurement will be taken by the system.
Two pressure measurements will be taken.
D3
0
1
No differential pressure measurement required.

A differential pressure measurement will be taken by the system.
Flag 60
(LINKED Flags 06,10,11,12,13)

This Flag is used when deliveries are to be controlled by a preset valve.
Chap 5
Page 16
COMMISSIONING
TP 0027
D1
0
1
2
3
4
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).
D2
D3
No preset control.
Control by an Avery-Hardoll solenoid preset valve.
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).
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).
This is a crude method of preset deliveries for vehicle systems.
0
1
No interlock sensing.
There are three interlock senses available (Earth connection, Overspill and loading Arm
position).
This is used as a crude pump controlled preset. A two digit timer (in seconds) can be
programmed to turn off the gantry pump from a no flow situation after a set delay. This will
only operate on preset systems where the Run button is pressed to initiate the start of
delivery.
D5-6
(LINKED Flag 07)
Flag 70
D1
0
1
This is the setting for vehicle use.

Setting for a gantry system. The gantry pump is controlled (via SSR3) by the run button.
D2
This is used when Masterload is stand-alone (local mode) and not connected to any
external devices (e.g. Office).
This is the setting for system mode if Masterload is intended to be connected to peripheral
equipment (e.g. Office). Baud rate is 1200.
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.
As selection 1 with baud rate as 9600.
As selection 2 with baud rate as 9600.
Communication link to a local ticket printer (refer to end of section).
1
2
3
4
5
(LINKED Flag 80)
D3
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.
0
1
2
3
D4
COMMISSIONING
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).
No pulse output.
A pulse output from SSR4 representing 1 pulse per unit of volume displayed.
(Pulse width 6mS).
A pulse output from SSR4 representing 10 pulses per unit of volume displayed.
(Pulse width 600S).
A pulse output from SSR4 representing 1 pulse per 10 units displayed.
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
Chap 5
Page 17
TP 0027
0
1
will be shut. Once this is detected the system remains inoperative (i.e. no button response)
for at least 1 minute.
Disable the low flow message.
Enable the low flow message.
0
1
This is used to establish the communication link from Masterload to an office or external
device.
Data is sent from Masterload on request from the office.
Data is sent from Masterload on a periodic basis (once every second).
0
1
This is the setting for gantry use.

For vehicle use only.
D5
D6
Flag 71
This Flag is used to enter meter data for office use.
D1-2
Product grade (00-99). Refer to Table below.
D3-4
Bay No. (00-99)
D5-6
Meter No. (00-99)
DEFINITION OF GRADE IDENTS

GRADE IDENT
FLAG 71
GRADE IDENT
FLAG 71
UNLEADED
KEROSINE
GAS OIL
DERV
PREMIUM
BURN OIL
PREM ULD
SUP. ULD
HSD
AVGAS
REGULAR
P.B. OIL
JET A1
00
01
02
03
04
05
06
07
08
09
10
11
12
BLACK OIL
MGO
LFO
KERO
HFO
4 STAR
MOGAS
PARAFFIN
ETHANOL
INT. FACE
DIESEL
SPARE
SPARE
13
14
15
16
17
18
19
20
21
22
23
24
25
Flag 73
D1-3
A three digit meter address is set for interrogation by the office.
Flag 74
D1
Number of digits for cab I.D.
D2
Number of digits for driver I.D.
D3
Number of digits for load number.
D4
Number of digits for compartment (pot) number.

NOTE:
If all D1---D4 are set to 0 the I.D. mode is disabled.
Chap 5
Page 18
COMMISSIONING
TP 0027
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.
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
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.
Masterload will always use the value of Flag 05 even if Flag 54, D1=0.
D1
3
4
This format is useful for displaying volume and weight on the same display unit.
The flow rate is given in US Gallons/min.
This mode is intended to display compensated and uncompensated volume (i.e. Nett 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 Nett or Gross legend on
the dial mask.
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.
Assessing Transaction Storage

a)
b)
c)
d)
e)
Press and hold the Reset button to gain entry to the passcode (refer to Chapter 2).
Enter the passcode to gain access to the Set Up data..
Select Flag 99.
The display will show d-1 (the last recorded delivery) together with the delivery details:.
Batch window Nett Batch
Preset window ID number
Tote window
Final Tote
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.
COMMISSIONING
Chap 5
Page 19
TP 0027
Ticket Printer -- Specification

The local printer used with masterload is an EPSON TM--U295 (or equivalent).
Specification:
Supply voltage:
Current:
Printing speed:
Paper feed:
No. of characters:
+24V +/--10%
Mean approx. 600mA
Peak approx. 5.5A
35 (5x7 font)
12.5 lines
95
Life:
MTBF:
3,000,000 lines
180,000 hours
Temperature:
5E C to 40E C (Operating)
--10E C to 50E 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 printed ticket will provide the following information:
Invoice No.
Cab ID No.
6 figures
Max. 6 figures
Start Tote
End Tote
8 figures
8 figures
Batch Volume
6 figures
No provision will be made for the printing of date and time.

A pre--printed ticket with customers 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) will also be transmitted from the Masterload
system, this will help combat any problems with alignment. A suggested ticket format is shown below.
Chap 5
Page 20
COMMISSIONING
TP 0027
A bank of 10 DIL switches in the base of the printer will be set as tabulated.
Switch
Function
ON
OFF
Data reception error
(prints)
Receive buffer capacity
(512 bytes)
Handshaking
(XON/XOFF)
Word length
(8 bits)
Parity check
(Yes)
Parity selection
(Odd)
X
X
X
X
X
Transmission speed
(9600 baud)
Pin 6 reset signal
10
Pin 25 reset signal
The preset display window is used for operator messages .
Ticket Printer Operation -- Non Preset System

The Non Preset System uses two buttons to operate the ticket printer (see below). The centre button is unused.
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 the presence of a ticket 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.
COMMISSIONING
Chap 5
Page 21
TP 0027
j)
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.
k)
Once the delivery has started and product is flowing, the Reset and Print buttons have no effect.
Ticket Printer Operation -- Preset System

The Preset System uses all three buttons to operate the delivery and print the ticket. The sequence of events
will be:
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.
SETTING UP THE PRESET VALVE
9.1
By controlling an electrical preset valve the Masterload gives precise batch delivery sequences
unaffected by any changes in line pressure.
9.2
By using Flag Settings (refer to Para 7), a flow profile similar to that in Fig 5.2 can be achieved
repeatedly.
FLOW RATE
STAGE 2
Flag 13
Flag 12
PRESET QUANTITY
STAGE 1
Flag 10
TIME
Flag 11
Fig 5.2 TYPICAL PRESET BATCH DELIVERY

9.3
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.
9.4
During Stage 2, flow will be maintained at the maximum flow rate determined by the pumping capacity
of the system.
Chap 5
Page 22
COMMISSIONING
TP 0027
9.5
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.
9.6
To set-up Masterload preset control, Flag 60 must be set up for the valve type (refer to Para 8).
9.7
Flag 10 controls the first stage flow rate.
9.8
Flag 11 controls the volume passed at first stage flow.
9.9
Flag 12 controls the maximum working flow rate.
9.10
Flag 13 controls the deceleration rate (in Lpm/sec). Masterload will calculate at which point in the
delivery that the preset valve should 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.
9.11
When
This manual provides information for setting up Masterload with the Avery--Hardoll Preset Valve.
used in conjunction with other manufacturers equipment, refer to the manual supplied with the preset
valve for set-up information.
For setting up the large valve refer to Technical Information Sheet TIS 148.
9.12
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.
9.13
To investigate the valve operation set the following:

Flag 60
Flag 22
Flag 10
Flag 11
Flag 12
Flag 13
1
2
400
100
900
100 - 1.0
9.14
Preset a quantity on the Display Unit and press the STOP/RUN button to instigate a delivery.
9.15
For further information refer to the Solenoid Operated Preset Valve manual, Publication No. TP0020.
9.16
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
120 x DECELERATION
9.17
= 20.8 litres
After the final needle valve settings have been achieved, the by-pass volume (Flag 13) should 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
COMMISSIONING
Chap 5
Page 23
TP 0027
Altering needle valve settings at this point changes the rate of valve closure. This may
necessitate alteration of the by-pass volume.
10
REMOTE PUMP START
10.1
Masterload will control pump operation from SSR3 output within the power supply unit. A single
conductor will contain a pump demand signal at permissive supply potential when the RUN button is
pressed. This demand signal will be removed:
10.1.1
On pressing the STOP button.
10.1.2
When the preset quantity reaches Zero.
10.1.3
If the Masterload II system errors.
10.1.4
If product flow is Zero for the duration of a timer in Flag 75.
10.1.5
The permissive supply is removed.
10.2
Verify that the permissive supply is present at the Masterload, ie all the safety interlocks have been
met. The preset valve will not give an audible click if the permissive supply is not present.
10.3
To test the pump control, ensure that an upstream valve is closed, or the signal to start the pump will
also open the preset valve.
10.4
Transfer local pump control to remote (if required).
10.5
Enter a preset value of over 10 litres into Masterload and press RUN.
10.6
Listen for the audible click and refer to fault finding (Chapter 7) if not present.
10.7
Press STOP button to stop the pump.
11
CALIBRATION
WARNING
PRIOR TO COMMENCING CALIBRATION, ENSURE THAT ALL LOCAL SAFETY AND EMERGENCY
PROCEDURES ARE ADHERED TO.
11.1
In order to calibrate the Masterload system it is necessary to connect an accurately calibrated Test
Meter to the product line.
11.2
Throughout calibration, ensure that 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.
Chap 5
Page 24
COMMISSIONING
TP 0027
12
CALIBRATION CLASSES
12.1
Masterload is capable of being calibrated to four standards (i.e. Classes).
12.2
The four calibration classes are:
12.3
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.
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.
Fig 5.3 depicts typical class error curves for performance with an Avery--Hardoll brand
Bulkmeter Capsule.
% ERROR
0.1
% ERROR
0.1
CLASS 1
0
FLOW
RATE
UNCALIBRATED
FLOW
CLASS 2
-0.1
CLASS 3
FLOW
RATE
10%
5%
20%
30%
50%
75%
15%
100%
UNCALIBRATED
FLOW
CLASS 4
-0.1
10%
5%
20%
30%
50%
75%
100%
15%
CLASS 1 AND CLASS 2
CLASS 3 AND CLASS 4
Fig 5.3 TYPICAL ERROR CURVES
COMMISSIONING
Chap 5
Page 25
TP 0027
13
MASTERLOAD CALIBRATION - with an Avery--Hardoll bulkmeter
13.1
The following procedure is written for a typical calibration rig (Fig 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.
PLEASE NOTE
COMPANIES AND ORGANISATIONS MAY HAVE THEIR OWN RULES AND REGULATIONS
REGARDING CALIBRATION, THESE MUST BE OBEYED AND WHEREVER POSSIBLE USED IN
CONJUNCTION WITH THE FOLLOWING INSTRUCTIONS.
DIRECTION
OF FLOW
CONTROL VALVE
BULKMETER
UNDER TEST
TEST
BULKMETER
Fig 5.4 TYPICAL CALIBRATION RIG

13.2
Once the class of calibration has been decided the information must be entered into Flag 21. The
default setting is class 2.
13.3
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.
13.4
The default settings are as follows:
SINGLE CAPSULE
1140 lpm
DOUBLE CAPSULE
2280 lpm
TRIPLE CAPSULE
3404 lpm
13.5
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.
13.6
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.
13.7
Press the SET-UP button to return to normal display mode. The volume display indicates 1/100 litres
for absolute accuracy.
13.8
Before starting the calibration process, refer to Meter Calibration Certificate (Fig 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.
Chap 5
Page 26
COMMISSIONING
TP 0027
13.9
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%
1800Lpm.
350Lpm.
360Lpm.
180Lpm.
13.10
On preset systems disable the preset control by setting Flag 60 to 0.
13.11
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.
13.12
On preset systems, press the Stop/Run button.
13.13
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.
13.14
Enter the run number and flow rate in columns 1 & 2 of the certificate.
13.15
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.
13.16
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.
13.17
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.
13.18
Add columns 4,5 and 6 to give a total correction factor for column 7.
13.19
Multiply column 7 by the Test Meter reading (column 3) to enter a corrected volume Figure in
column 8.
13.20
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.
13.21
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 should be completed. Also ensure that the rig remains pressurised throughout the calibration
process.
13.22
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).
% ERROR =
COMMISSIONING
CORRECTED VOLUME (TM) - MEASURED VOLUME (MUT)

CORRECTED VOLUME (TM)
X 100%
Chap 5
Page 27
TP 0027
13.23
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 is the % error (14) with the polarity changed .
For example:- 10% flow rate average % error = + 0.12. The calibration factor would be -0.12.
Refer to Table 5.4 for Flag entry points for class 1, 2 and class 3 calibration.
TABLE 5.4 Flag TABLE - CALIBRATION POINTS

CLASS
Flag No.
No
% FLOW RATE
30
5%
31
10%
32
15%
33
20%
34
30%
35
50%
36
75%
37
100%
13.24
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.
13.25
A Static Slip Test is not necessary with Masterload as extremely low flow rates can be detected and
displayed as error conditions if required.
13.26
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.
14
RE-CALIBRATING MASTERLOAD
14.1
Companies and Organisations may have their own rules and regulations regarding re-calibration.
These must be obeyed and wherever possible used in conjunction with the following method
recommended by Meggitt Fuelling Products, Avery--Hardoll.
14.2
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 13.6).
14.3
Run product at 100% flow rate for a period of one minute to stabilise the system.
14.4
Conduct a single run (minimum duration 2 minutes) at the lowest flow rate used to calibrate the meter.
14.5
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.
Chap 5
Page 28
COMMISSIONING
TP 0027
14.6
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 the allowable tolerance,
proceed to the next flow rate and repeat the exercise. All runs must not be less than 1 minute
duration.
14.7
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.
14.8
When re-calibration is complete, record the finish tote Figures of both meters and change Flag 22
value to 0 (normal mode).
15
DISPLAY UNIT SET-UP
15.1
The Main Display Unit has a switch (SW2) mounted on the component side of the processor board to
control direction of flow.
15.2
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.
15.3
The Additional Display Unit may be configured to either repeat the information shown on the main
Display Unit, or to show additional information.
15.4
This is configured via Flag 90 (refer to Flag table 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.
15.5
Fit LK 1 if repeated information is required.
15.6
Fit LK 2 if additional information is required.
16
TEMPERATURE DEVICE
16.1
Ensure that the Temperature probe has been wired correctly (refer to Chapter 4 Installation).
16.2
It is not necessary for further calibration of this device as it has been factory set.
16.3
To check the integrity of the Temperature probe and circuitry set the Flag 02 to display continuous
temperature (i.e. Flag 02 = 110)
16.4
Exit the Set-Up mode, and the temperature reading will be displayed continuously in the Rate of Flow
window.
17
DENSITOMETER UNIT
17.1
Ensure that the Densitometer has been wired correctly (refer to Chapter 4 Installation). Although the
Densitometer range is factory set at 750 - 850 kg / cu metre, other densities may be accommodated.
Contact Meggitt Fuelling Products, Avery--Hardoll for advice.
17.2
To check the Densitometer reading, enter Set-Up mode, and set Flag 54 to 200.
17.3
Exit the Set-Up mode, and simply press the Reset button. The Density value should be displayed in
the Batch window for two seconds before the eights check appears and the batch quantity zeroes.
17.4
The reset button can be pressed at any time to check the Density reading.
17.5
If the pipework is not completely full, the Density reading will not be correct.
17.6
If a continuous reading of Density is required on the Masterload display, set Flag 02 to 21.
17.7
Exit the Set-Up mode, and the Density value will be displayed continuously in the Rate of Flow
window.
17.8
If the density is out of range, the error Density will appear in the tote window
COMMISSIONING
Chap 5
Page 29
TP 0027
18
DIFFERENTIAL PRESSURE TRANSDUCER
18.1
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.
18.2
18.3
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:
5
18.4
Exit the Set-Up mode, and the Differential Pressure value will be displayed continuously in the Rate of
Flow window.
18.5
If a differential pressure error exists, the word dP will appear in the tote window.
19
PRESSURE TRANSDUCERS
19.1
If vehicle pressures are required to be monitored, a maximum of two additional pressure transducers
can be interfaced to Masterload.
19.2
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.
19.3
19.4
To check the first/only Pressure transducer reading, enter Set-Up mode, and set Flag 54 to 010 with
Flag 02 set to:
3
19.5
Exit the Set-Up mode, and the Pressure reading will be displayed continuously in the Rate of Flow
window.
19.6
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
19.7
Chap 5
Page 30
Exit the Set-Up mode, and the Pressure reading from the second pressure transducer will be
displayed continuously in the Rate of Flow window.
COMMISSIONING
TP 0027
Fig 5.5 METER CALIBRATION CERTIFICATE

COMMISSIONING
Chap 5
Page 31
TP 0027
20
FLAG SETTINGS - RECORDING
20.1
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 below.
Fig 5.6 FLAG RECORD TABLE
Chap 5
Page 32
COMMISSIONING
TP 0027
Chapter 6
OPERATION
CONTENTS
Para
1
2
3
4
5
Introduction
Non-Preset Delivery
Preset Delivery
Operation with a DCU Link
Operation of ID/Load entry mode - Preset systems
INTRODUCTION
1.1
With Masterload commissioned as described in Chapter 5 and ensuring that Flag 22 has been reset
to 0 (normal mode) the system is now ready for operation.
1.2
It is important that operators are familiar with all controls and displays before attempting a delivery.
1.3
Ensure that all local regulations regarding the use of equipment in a hazardous area are complied
with.
1.4
The operation of Masterload is very much dictated by the configuration and Flag settings. For further
details on Flags refer to Chapter 5.
NON-PRESET DELIVERY
FIG 6.1 NON-PRESET DISPLAY FORMAT

2.1
Switch on the Vehicle Master Switch.
2.2
The display unit should 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 Chapter 7. This check may be
repeated by pressing the RESET button.
2.3
The display unit now shows 0 in the batch and rate of flow windows with the tote window showing
the current total.
2.4
Open the control valve to instigate a delivery.
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).
OPERATION
Chap 6
Page 1
TP 0027
2.6
Close the control valve when the desired batch volume (or weight) is reached. Enter details of
delivery in accordance with company procedures.
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.
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.
PRESET DELIVERY
FIG 6.1 PRESET DISPLAY FORMAT

3.1
Switch on the Vehicle Master Switch.
3.2
The display unit should 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 Chapter 7. This check may be
repeated by pressing the RESET button.
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.
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.
3.4
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.
3.5
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).
3.6
Masterload will stop delivery when the preset value has counted down to zero. The rate of flow
window will display StOP.
3.7
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.
3.8
Enter details of delivery in accordance with company procedures.
Chap 6
Page 2
OPERATION
TP 0027
3.9
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.
3.10
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 3.3. 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.
3.11
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 3.3 but only enter the remaining undelivered volume into the preset.
3.12
The maximum preset quantity can be controlled by entering the required value into Flag 06.
Note:
The system cannot be reset during delivery.
OPERATION WITH A DCU LINK
4.1
Masterload II can be connected to an office system via our DCU 16 (See TP0018 for more details).
For connection to a DCU certain flags and conditions will need to be met. Modes of metering
operation fall into two main categories. Basic Data Capture mode and ID Entry Mode.
4.2
The Basic Data Capture mode will send all information regarding a load to the DCU.
The data can be displayed on a printer or fed to a computer for further analysis. It will not prompt
the operator for authorisation, it will simply let him set a preset quantity and load. Ensure that Flag
70 is configured or set as follows.
FLAG 70
4.3
The ID Entry mode will prompt the operator for entry of a identifier, in this case a 4 digit identifier
(Flag 74). Once accepted, the operator is then further prompted to enter a compartment number.
The display will then show the familiar preset entry screen, on completion of which the RUN button
can be pressed to instigate flow. At the end of each batch, the display will prompt for details of the
next batch delivery.
This information can be displayed on a printer or fed to a computer for further control and analysis
functions. Ensure that Flags 70 and 74 are configured or set as follows.
OPERATION
FLAG 70
FLAG 74
Chap 6
Page 3
TP 0027
4.4
For either of the above options to be achieved, Flags 70-75 must be configured as detailed below.
Flag 70 is set to instigate the communication mode.
FLAG 70
4.5
Flag 71 is set to give product and location parameters. (See Tables 6.3 and 6.4 for details).
4.5.1
The first two digits of this Flag contain information regarding the grade of product.
FLAG 71
4.5.2
The second pair of digits contain information regarding the meter bay position
(i.e. 01 = Bay 1).
4.5.3
The third pair of digits should contain information as to the meter number/ident (i.e. 12 =
meter 12).
4.6
Flags 73 to 75 as follows (See Table 6.3 for flag details).
FLAG 73
A unique number must be present in the location in order for successful data
communication. Usually the meter number is used to avoid confusion
(i.e. Meter 12 = 012)
NOTE:
If two numbers are the same, data confliction will cause disruption to the
loading process.
FLAG 74
For basic data capture mode (Para 7.2), this flag should simply contain a zero.
For full office control, it will be necessary to use an identification entry routine.
This identification can be either 2, 3, 4, 5 or 6 digits in length which is fixed by
changing the first digit. Extra IDs can be enabled if required by using the second
and third digits in a similar manner. (See Chap 5 Section 8).
FLAG 75
This flag can be set between 0-99 secs. Its function is to remove the run
demands from the preset valve and pump after the valve time has elapsed. This
provides a safety interlock should the permissive be removed for any reason.
NOTE:
When set to 0, there is no timeout.
Chap 6
Page 4
OPERATION
TP 0027
OPERATION OF ID/LOAD ENTRY MODE - Preset systems
5.1
This mode is necessary when Masterload is in communication with an office system via a data
collection unit (DCU). This operation will enable the office to identify the operator and meter in use
for printing of loading tickets and log records.
Refer to the Terminal Management System manual TP0045.
5.2
When in ID/Load Entry mode (Flag 74), Masterload will display the following information on the main
Display Unit between deliveries:
0000
EntEr
CAb
5.3
The Preset push-button is used to enter a 4 digit vehicle code in a similar manner to the Reset
push-button with flag data.
5.4
When the code has been entered e.g. 1234, the display unit will show:
1234
ACCEPt
CAb
5.5
Pressing the Preset push-button again will cause Masterload to request acceptance of this code
from the automation system.
5.6
If the system does not recognise the code, Masterload returns to the Enter CAb display and a
message not accepted please re-enter is shown in the totaliser display.
5.7
The entry may be reset by pressing the Reset push -button which will return the cursor to the
first digit entry point of the code.
5.8
If the Reset push-button is pressed again, the code is reset to zero.
5.9
If the Reset push-button is pressed once more whilst the code is at zero, a normal 8s check and
reset cycle is executed.
5.10
When the ID is accepted the display unit shows:
0
EntEr
ID
5.11
The Preset Push-button is now used to enter an ID number.
5.12
The above sequence is followed for verification of the ID and for entry of Load and Pot
(compartment) numbers.
5.13
Flag 74 may be set up with more than one load number for multible deliveries for the same vehicle.
OPERATION
Chap 6
Page
5/65
Page
TP 0027
Chap 6
Page 6
OPERATION
TP 0027
Chapter 7
FAULT FINDING
CONTENTS
Para
1
2
Introduction
Fault Finding Table
INTRODUCTION
WARNING
FAULT FINDING AND REPAIR MUST ONLY BE CARRIED OUT BY SUITABLE QUALIFIED PERSONNEL.
THE POWER SUPPLY UNIT CONTAINS NON-INTRINSICALLY SAFE WIRING. ENSURE THAT ALL
REGULATIONS REGARDING THE USE OF EQUIPMENT IN A CATEGORY 2 (ZONE 1) HAZARDOUS
AREA ARE COMPLIED WITH.
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.
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.
FAULT FINDING
Chap 7
Page 1
TP 0027
FAULT FINDING TABLE
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 below and result in the shutdown of the Gantry Pump and preset
valve (if fitted). The table also gives the order of priority and if more than one error is active, only the higher
priority error will be displayed.
Displayed Error
Message
Possible Cause
Action
No Pulse
Transmitter not connected.

Transmitter cable damaged
Faulty Transmitter connections
Fit Transmitter.
Renew Transmitter cable.
Check/remake connections within Transmitter.
(Transmitter giving
false signals)
Transmitter faulty.
Processor PCB faulty.
Renew Transmitter.
Renew Processor PCB.
NVR Fail
Insufficient power from supply.

Faulty Barrier block.
Power Supply Unit faulty.
Check battery voltage (on load). Recharge.

Renew Barrier block.
Renew Power Supply PCB.
Incorrect flag settings.

Preset valve badly set up.
Preset valve incorrectly wired.
Faulty SSRs.
Preset valve leaking.
Check Flag 60 and Flags10-13.

Adjust preset needle valves.
Check preset valve wiring and connections.
Use self test (Flag 22) to check SSRs. Renew?
Check valve seat. If necessary renew seal.
Incorrect communications wiring.

Faulty processor PCB.
Check wiring against wiring diagram.

Check Flags 70-75.
Faulty temperature probe.

Temperature circuit module not
fitted.
Faulty temperature probe wiring.
Temperature alarm set too low.
Incorrect flag setting.
Read temperature (Flag 02). Renew probe?

Fit temperature module.
Check wiring & connections with wiring diagram.
Set Flag 03 correctly.
Disable temperature if not required (Flag 02).
Faulty temperature probe.

Temperature alarm set too high.
Read temperature (Flag 02). Renew probe?

System flow rate (flag 40) set too

low.
Flow rate too high.
EPROM program (meter size mismatch)

Reduce flow rate by external valves.
Check that the program is correct (Flag 00).
Flow rate below 1% of max. for

30secs.
Incorrect flag setting (Flag 21).
Check valve - preset valve for leaks

Max flow rate set too low (Flag 21).
(No signal from

Transmitter)
Pulses
(Memory corruption)
Preset
(Preset overrun)
Office
(Communications
failure)
Too Hot
(Temperature error)
Too Cold
(Temperature error)
Too Fast
(Flow rate too high)
Too Slo
(Flow rate too low
for too long)
Chap 7
Page 2
FAULT FINDING
TP 0027

Densitometer error.
Density reading out of range.
Incorrect densitometer wiring.
Density accidentally requested (Flag 54).

Renew densitometer.
Product density out of range (500-1200 Kg/CuM).
Check wiring connections against diagram.

Pressure 1 transducer error.
Max. pressure exceeded.
Incorrect transducer wiring.
Pressure 1 accidentally requested (Flag 54).

Renew Pressure Transducer.
Reduce rig pressure below 200psi.
(Pressure 2 reading
out of range)

Pressure 2 transducer error.
Max. pressure exceeded.
Pressure 2 accidentally requested (Flag 54).

Renew Pressure Transducer.
Reduce rig pressure below 200psi.
DP
Diff. pressure accidentally requested (Flag 54).
(Differential
Pressure reading
out of range)
Earth

Earth interlock not made.
Faulty Pprocessor PCB.
Interlocks accidentally requested (Flag 60).

Connect Earth clip.

Overspill interlock not made.
Faulty Processor PCB.
Interlocks accidentally requested (Flag 60).

Check overfill condition & overspill switch.
Density
(Density error)
Press 1
(Pressure 1 reading
out of range)
Press 2
(Earth interlock
missing)
Spill
(Overspill interlock
missing)
FAULT FINDING
Chap 7
Page 3
TP 0027
Guidance on other hardware faults is given in the following table.
Fault
Possible Cause
Action
Blank display
No power to system.
Fuse FS1 blown or not fitted in PSU.
Display PCB faulty.
Display PCB ribbon not plugged in.
Barrier block blown.
Incorrect wiring.
Bad connections.
Check power cable & connections.

Renew or fit fuse.
Renew Display PCB.
Plug in ribbon.
Inspect all connections.
Scrambled display
(i.e. random
segments)
Display PCB faulty.

Incorrect wiring.
Bad connections.
Barrier block blown (No Power Fail)
Renew Display PCB.

Inspect all connections.
Scrambled display
only after power off
Low supply voltage.

No Power Fail signal.
Check mains voltage.

Check Barrier (renew if necessary).
Flow Rate displayed

but no batch count.
Meter set for reverse flow.
Open the Display Unit and change the position of

switch SW2 on the Processor PCB.
Missing display
segments or
malformed
characters.
Faulty LCD
Faulty Display PCB
Damaged display ribbon cable/plug
Use Flag 22 to test display. Renew LCD.

Renew Display PCB.
Repair cable/plug or fit new Display PCB.
No push-button
response.
No power (no buttons operate)

Faulty push-button.
Faulty wiring.
Incorrect Flag setting.
Check power to PSU and barrier output.

Check operation of pushbutton with a meter.
Ensure ribbon cable is correctly fitted.
No Reset button response if Flag 70 is incorrect.
Erroneous batch
displayed.

Faulty Transmitter
Check flag settings against requirements.

Use Flag 22 to set up transmitter.
Masterload power
on but no display
response.
Power Fail signal missing.

Faulty Power Supply PCB.
Check Barrier and renew if necessary.

Renew Power Supply PCB.
Flag data changed

and totaliser display
not updated during
power off.
Masterload switched off when power Check mains voltage to ensure correct
is below voltage specification.
operational voltage is maintained.
Incorrect or missing
additional display
data.
Link 1 or 2 fitted incorrectly.

Incorrect setting of Flag 90.
Incorrect wiring.
Faulty Main Display PCB.
Faulty Additional Display PCB.
Check link position.

Set Flag 90 as required.
Check wiring against Wiring Diagram.
Renew Main Display PCB.
Renew Additional Display PCB.
No operation of
Preset valve.
Incorrect valve wiring.

Faulty SSR1 or 2.

Check SSRs by Flag 22. Renew if necessary.
Chap 7
Page 4
FAULT FINDING
TP 0027
Meter counts
continuously.
Valve seat leaking.

Downstream solenoid valve faulty.
Check valve seat for debris. Ref. TP0020.

Use Flag 22 to check operation. Ref. TP0020.
Meter will not

calibrate.

Faulty Transmitter
Incorrect calibration factors entered.
Meter capsule worn or faulty.
Set Fl 21 & 22 using the calibration procedure.
No permissive feed
Incorrect interlocks
Emergency stop faulty or set.
Check system interlocks.

Renew pushbutton or release emergency stop.
Pump demand not

operating
(when controlled by
Masterload)
Incorrect wiring.
Faulty relay.

Check SSR3 using Flag22. Renew if faulty.
FAULT FINDING
Check factors in Flags 30-37.

Investigate meter internals.
Chap 7
Page 5
TP 0027
Chap 7
Page 6
FAULT FINDING
TP 0027
Chapter 8
MAINTENANCE AND OVERHAUL

CONTENTS
Para
1
2
3
4
5
6
7
8
9
10
11
12
Routine Maintenance and Overhaul

Display Unit Removal
Display PCB Replacement
LCD Replacement
Push-button Replacement
Processor PCB Replacement
Power Supply Unit Removal
Fuse Replacement
Barrier Block Replacement
Solid State Relay Replacement
PCB Replacement
ROUTINE MAINTENANCE AND OVERHAUL

WARNING
WORK MUST ONLY BE CARRIED OUT BY QUALIFIED PERSONNEL.
ENSURE THAT ALL REGULATIONS REGARDING THE USE OF EQUIPMENT IN A CATEGORY 2
(ZONE 1) HAZARDOUS AREA ARE COMPLIED WITH.
ELECTRO-STATIC SENSITIVE DEVICES.
This equipment contains Electro-static sensitive devices. The precautions specified in BS EN

1000015-1 must be obeyed.
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.
1.1
Routine maintenance tasks required by Masterload are minimal and listed below in Table 8.1.
1.2
The maintenance intervals recommended are suitable for most normal applications, although
maintenance frequencies should be increased if the system is subject to high levels of dust, dirt or
vibration.
1.3
Before commencing any maintenance, ensure that all necessary materials and spare parts are
available.
1.4
If a Gantry printer is connected to the Masterload, switch off the Gantry printer before changing flag
data.
MAINTENANCE & OVERHAUL
Chap 8
Page 1
TP 0027
TABLE 8.1 SUGGESTED MAINTENANCE PROGRAM

FREQUENCY
TASK
Clean display front.
MONTHLY
SIX MONTHLY
Check cable runs for security and any signs of

damage or deterioration.
Check calibration as detailed in Chapter 5.

Up-date Masterload record card.
Check tightness of cable glands.
Check tightness of all terminal screws and fastenings.

TWO YEARLY
1.5
Check mating surfaces of casings, renew all O rings and gaskets.
During overhaul the following components can be changed:
Processor PCB
Display PCB
Display LCDs
Display Push-buttons
Power Supply PCB
Barrier Block
Solid State Relays (SSR)
Fuses
DISPLAY UNIT - Removal
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.
Chap 8
Page 2
TP 0027
PROCESSOR
PCB
REAR
ENCLOSURE
DISPLAY
PCB
RUBBER
SURROUND
GLASS FASCIA
AND MASK
DISPLAY
SURROUND
CABLE
GLAND
BLANKING
PLUG
RETAINING
NUT
O RING
SEAL
PUSH
BUTTON
SWITCH
BEZEL
FIG 8.1 DISPLAY UNIT COMPONENTS

2.2
Take care not to damage the ribbon cable connecting the display PCB to the processor PCB located
in the rear section.
2.3
Lower the display front carefully and disconnect the ribbon cable from the processor PCB.
2.4
Remove the display front and place face downwards onto a clean surface.
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.
2.6
Loosen cable glands and remove wiring from Display Unit.
2.7
Support the rear section and remove and retain the four M6 socket head cap screws.
2.8
Remove the rear section and place on a clean surface.
2.9
Re-assemble the Display Unit if no further immediate work is to be carried out.
Dispay PCB Replacement
3.1
Remove the display front (see previous paragraph).
3.2
Note the positions then disconnect the wiring from the push-button(s) at terminal block TB3 on the
display PCB.
3.3
Pull back the rubber surround and remove PCB.
Chap 8
Page 3
TP 0027
3.4
Replacement is reversal of the above procedure.
3.5
Ensure that the PCB is completely seated in the groove of the rubber seal to prevent fouling when
refitting the display front.
LCD Replacement
LCD BEZEL
LCD
FOAM PAD
ELASTOMERIC
STRIPS
FIG 8.2 LCD COMPONENTS

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.
4.2
Remove and retain bezel.
4.3
Remove the LCD. Retain the foam pad and the two elastomeric strips.
4.4
Fit the foam pad and elastomeric strips to the underside of the replacement LCD.
4.5
Fit LCD to display PCB. Locate bezel onto LCD and secure to PCB using the four fixing screws and
washers.
Push-button Replacement
5.1
With the display PCB removed as described in Section 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
(Fig 8.1).
5.2
Loosen the two locking screws from retaining nut at rear of push-button.
5.3
Remove retaining nut.
5.4
Remove push-button from glass facia.
5.5
Remove the O ring seal.
5.5
Remove switch cap and bezel and fit to new push-button.
5.6
Replace the O ring seal. Renew if necessary.
5.6
Replacement is the reverse of the above procedure.
Processor PCB Replacement
6.1
Chap 8
Page 4
With the display front removed as described in Section 3, note the positions of and disconnect the
wiring from terminal blocks TB1, TB2, TB3 and TB4 on the processor PCB (Fig 8.1).
TP 0027
6.2
Remove and retain the four mounting screws and washers securing the PCB to the rear enclosure of
the Display Unit.
6.3
Remove the processor PCB.
6.4
Replacement is reversal of the above operation.
POWER SUPPLY UNIT REMOVAL

ENSURE THAT THE INPUT SUPPLY HAS BEEN ISOLATED AT THE DISTRIBUTION BOARD
FOR AT LEAST 6 MINUTES BEFORE COMMENCING ANY WORK ON THE UNIT.
7.1
The main Display Unit may have been mounted to the Power Supply Unit. This will have to be
removed to allow access to the Power Supply Unit (Section 3).
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.
7.3
Remove the front cover and the O ring seal fitted between the two halves.
7.4
Unscrew and retain the two securing screws and washers from the cable separation sheet. Remove
the cable separation sheet.
7.5
Note positions of wiring and how they are terminated. Label as necessary and disconnect.
REAR
ENCLOSURE
PCB
BARRIER BLOCK
O RING SEAL
FUSE FS1
SOLID STATE
RELAYS
CABLE
SEPARATION
SHEET
MOUNTING
POINTS FOR
DISPLAY UNIT
FRONT
COVER
FIG 8.3 POWER SUPPLY UNIT COMPONENTS

7.6
Loosen cable glands and remove wiring from Power Supply Unit.
Chap 8
Page 5
TP 0027
7.7
Refit cable separation sheet.
7.8
Refit front cover using the O ring seal and eight M6 socket head cap screws to protect internal
components.
7.9
Support the weight of the Power Supply Unit and remove the four mounting bolts and washers.
7.10
Place the Power Supply Unit face-up on a clean surface.
Fuse Replacement
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 (Fig 8.3).
8.2
Remove the front cover and the O ring seal fitted between the two halves.
8.3
IMPORTANT: Note the positions of the intrinsically safe wires which pass over the top of the cable
separation sheet. Label as necessary.
8.4
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.
8.5
Renew fuse.
ALL INTRINSICALLY SAFE WIRING MUST PASS OVER CABLE SEPARATION SHEET.
8.6
Refit cable separation sheet.
8.7
Refit front cover to rear enclosure using the O ring seal and eight M6 socket head cap screws.
Barrier Block Replacement
9.1
With the front cover removed (Section 8), 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.
9.2
Unscrew and retain the two securing screws from the cable separation sheet. Remove the cable
separation sheet (Fig 8.3).
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.
9.4
Remove and retain the two screws securing the barrier block to two mounting pillars.
9.5
Remove barrier block.

9.6
10
Solid State Relay Replacement
10.1
With the front cover removed (Section 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.
10.2
Unscrew and retain the two securing screws and washers from the cable separation sheet. Remove
the cable separation sheet (Fig 8.3).
Chap 8
Page 6
TP 0027
10.3
Remove and retain the two screws and washers securing the barrier block to two mounting pillars.
10.4
Raise barrier block sufficient to gain access to solid state relays.
10.5
Remove the defective solid state relay from its 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.
10.6
11
PCB Replacement
11.1
Remove the front cover (Section 8).
11.2
Remove the barrier block (Section 10)
11.3
Note positions of wiring and how they are terminated. Label as necessary and disconnect.
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 (Fig 8.3).
11.5
Remove power supply PCB.
11.6
12
12.1
DISASSEMBLY -- TRANSMITTER (Refer to Fig. 8.4).
12.2
Dismantling the transmitter assembly IS NOT RECOMMENDED by Meggitt Fuelling Products,

Avery--Hardoll and cannot take any responsibility for the malfunction of the equipment
through damage caused by incompetent personnel.
Please contact our Service Department in the first instance should a problem occur. Any
alteration or damage could affect the performance of the transmitter and may render any
warranty void.
Care should be taken not to bend the bulkmeter shaft when separating the transmitter from
the adaptor plate.
Before dismantling, ensure the transmitter is isolated from its electrical supply.
12.3
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.
12.4
Remove the O ring (7).
12.5
Loosen the cable gland (17). Disconnect the external cable from the terminal block (11) and withdraw
the cable.
12.6
Remove four cap head screws (8) securing the support plate (9) to the transmitter cover (4).
12.7
Remove two cap head screws (10) securing the terminal block (11) to the support plate (9).
12.8
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.
12.9
Remove two countersunk screws (14) from cable guard (15). Remove the cable guard from the
support plate (9).
Chap 8
Page 7
TP 0027
11
10
15
12
13
4
14
9
21
16
20
19
18
17
FIG 8.4 PULSE TRANSMITTER

12.10
Collect two dowel pins (16).
12.11
Remove cable gland (17) and fibre washer (18).
12.12
Remove plug (19) and dowty washer (20).
12.13
Carefully remove the tension pin (6) from the bulkmeter shaft. Do not apply excessive pressure as
the bulkmeter shaft may bend.
12.14
CLEANING AND INSPECTION.
12.15
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.
12.16
ASSEMBLY -- TRANSMITTER.
12.22
Assemble the transmitter in the reverse order of disassembly procedure above. Care should be
taken to align the cable on the cable guard (15). Use the special centralising tool (21) to align the
transmitter shaft with the support plate (9).
Chap 8
Page 8
TP 0027
Chapter 9
SPARE PARTS
CONTENTS
Para
1
2
1
1.1
General information
Ancillary equipment
GENERAL INFORMATION
When ordering spare parts please quote the following information:
Part number and Description.
Publication TP reference number and issue.
Figure number (e.g. 9.1-1 )
1.2
+ in the Fig/Item No. column indicates Item is not illustrated.
1.3
* in the Part No. column indicates Item is recommended to be held as a spare part.
2
2.1
ANCILLARY EQUIPMENT
LIQUID DENSITY TRANSDUCER (4-20mA)
ZEMY0325-1
PRESSURE TRANSDUCER (4-20mA) Range: 0-16 BAR
ZMMZ0322-09
SPARE PARTS
Chap 9
Page 1
TP 0027
1
2
17
4
16
15
9
8
7
14
FIG 9.1 POWER SUPPLY UNIT

Fig/
Item No.
Part No.
Description
Qty
POWER SUPPLY UNIT

9.1
POWER SUPPLY PCB
SEE TABLES BELOW
When ordering the Power Supply PCB, use the Part No. ZPMZ1-284- followed by one of the numbers in the
table.
Example : ZPMZ1-284-37
(A 240V a.c. non-preset PCB).
240 Volt Power Supply PCB.

1
(Non-preset)
3
(Preset)
5
(1 Additive)
PRESET
7
(2 Additives)
PRESET
9
(3 Additives)
PRESET
11
(4 Additives)
PRESET
37
39
41
43
45
47
38
40
42
44
46
48
1
(Non-preset)
3
(Preset)
5
(1 Additive)
PRESET
7
(2 Additives)
PRESET
9
(3 Additives)
PRESET
11
(4 Additives)
PRESET
Without
4-20mA Interface
25
27
29
31
33
35
With
4-20mA Interface
26
28
30
32
34
36
No. of SSRs
Without 4-20mA
Interface
With 4-20mA
Interface
110 Volt Power Supply PCB.

No. of SSRs
Chap 9
Page 2
SPARE PARTS
TP 0027
Fig/
Item No.
*
*
2
3
4
5
6
7
8
9
10 +
11 +
12 +
13 +
14
15
16
17
Part No.
BEMZ144
Z022M244530A
ZS3225M06025A
ZS2203M04008A
BEPZ1382
ZS5003M04012A
ZMPZ0286-1
ZEMZ0152-55
BESZ1035
ZS3228M05010A
ZW8205M050A
ZMMZ0247-43
PPMZ9242
ZN2201M04A
ZEMZ0143-61
ZPMZ1-288
* = Suggested spare part
SPARE PARTS
Description
Qty
BARRIER ASSEMBLY
SEAL
SCREW, SOCKET CAP HD, HTS, ZNPL, M6 X 25 MM
SCREW
CABLE SEPARATION SHEET
SCREW, CH HD, SLOTTED, NYLON, M4 X 12 LG
PILLAR, INSULATING
FUSE, 1A, ANTI-SURGE , (20 MM)
ANGLE
SCREW, HEX HD, M5 X 10 MM
WASHER, SHAKEPROOF, EXT, ZNPL, M5
CABLE GLAND-CENELEC/BASEEFA APPROVED
BLANKING PLUG, M20
NUT, HEX, M3, ZNPL, M4
SOLID STATE RELAY
ANALOGUE INTERFACE BOARD
1
1
8
4
1
2
4
1
1
1
1
A/R
A/R
2
A/R
A/R
+ = Item not illustrated
Chap 9
Page 3
TP 0027
1
4,4A
8
9
10
11 & 12
17
14
16
13
FIG 9.2 MASTER / REMOTE DISPLAY UNITS

Fig/
Item No.
9.2
Part No.
Description
Qty
MASTER / REMOTE DISPLAY UNIT

1
PROCESSOR PCB (Not required in Remote Display)

ZPMZ1-285
PROCESSOR PCB WITHOUT TEMPERATURE
ZPMZ1-285-1
PROCESSOR PCB WITH TEMPERATURE
2
3
ZW2201M04A
ZS2203M04008A
DISPLAY PCB (Master Display Unit)

ZPMZ1-283-1
DISPLAY PCB - PRESET
ZPMZ1-283-2
DISPLAY PCB - NON-PRESET
4a
DISPLAY PCB (Remote Display Unit)

ZPMZ1-283-3
DISPLAY PCB - PRESET
ZPMZ1-283-4
DISPLAY PCB - NON-PRESET
LIQUID CRYSTAL DISPLAY (LCD)

ZEMZ0179-11
LCD - BATCH VOLUME
ZEMZ0179-14
LCD - PRESET
ZEMZ0179-13
LCD - RATE OF FLOW
ZEMZ0179-13
LCD - TOTE
Chap 9
Page 4
WASHER, PLAIN, STL, ZNPL, M4

SCREW, CH HD, SLOTTED, STL, ZNPL, M4 X 8 MM
4
4
1
1
1
1
SPARE PARTS
TP 0027
Fig/
Item No.
Part No.
Description
Qty
9.2- 6
BEZEL
ZEPZ0296-3
ZEPZ0296-2
ZEPZ0296-1
ZEPZ0296-1
BEZEL
BEZEL
BEZEL
BEZEL
BERZ1033
SEAL
DISPLAY MASK
SEE TABLE OVERLEAF
GLASS FASCIA
BEGZ1032-1
BEGZ1032-3
NON-PRESET
PRESET
10
11
12
13
ZW8206M05A
ZS3225M05030A
ZMSZ0110-5
BEMS1108
ZEMZ0150-45
ZEAZ0150-46
ZEAZ0150-47
ZO32M022116A
ZMMZ0247-45
PPMZ9242
ZACZ0017-12
ZAFZ0010-20
WASHER, SHAKEPROOF, INT, SP ST, ZNPL, M5

SOCKET HEAD CAP SCREW - M5
SECURITY SCREW - M5
PUSH - BUTTON SWITCH KIT consisting:
SWITCH
SWITCH RING
CAP - SWITCH
O RING SEAL
CABLE GLAND - CENELEC / BASEEFA APPROVED
BLANKING PLUG, M20
BLANKING PLUG, 1/2 IN BSP
WASHER, FIBRE, 1/2 IN BSP
14
15
16
17
SPARE PARTS
- BATCH VOLUME
- PRESET
- RATE OF FLOW
- TOTE
1
1
1
1
4
2
2
1
1
1
1
1
A/R
1
1
Chap 9
Page 5
TP 0027
Fig 9.2 item 8 MASTER DISPLAY MASK
When ordering a Display mask use the table below in conjunction with the illustration.
Batch
Preset
Key: L = Litres
G = UK Gallons
Dk = Dekaliters
GN = Gross/Nett
ROF
Tote
K = Kilograms
US = US Gallons
T = Tonnes
Litres
D = Decalitres
C = Cubic Meters
P = Pounds
CH = CuM/Hr
Buttons
Use the part No. BESZ1380- followed by one of the numbers in the table
Example : BESZ1380-31 (A non-Preset display in Litres without temperature)
Batch
Preset
ROF
Tote
No Temp.
L
L
L
D
G
G
US
US
US
US
US
US
Dk
Dk
Dk
US
Dk
L
C
L
GN
CH
CH
51
36
45
46
Dk
Dk
25 38 37 31 26 42 32 27 40 33
28
41
34
29
44
35
39 30 43
16
17
15
Dk
US
14
US
US
13
Temp.
REMOTE DISPLAY MASK

The Remote Display mask part No. is BESZ1381- followed by one of the numbers in the tables
Example : BESZ1381-32 (A non-Preset display in Litres without temperature or buttons)
Batch
Preset
ROF
Tote
No Buttons
1 Button
25
38
138
37
137
3 Buttons
125
Batch
US
US
Preset
US
ROF
US
US
Tote
US
No Buttons
1 Button
28
3 Buttons
128
Chap 9
Page 6
32
132
26
42
142
31
131
27
40
140
33
133
126
US
Dk
39
139
43
143
35
135
46
Dk
Dk
US
US
US
Dk
Dk
Dk
41
141
45
145
29
44
144
34
134
30
36
136
129
127
Dk
130
SPARE PARTS
TP 0027
12
11
10
9
5
4
3
11
15
16
14
13
10
22
17
19
18
21
20
FIG 9.3 ELTOMATIC PULSE TRANSMITTER

Fig/
Item No.
9.3
Part No.
Description
Qty
ELTOMATIC PULSE TRANSMITTER

1
2
3
4
+
5
6
7
8
9
10
11
12
ZS3225M06025A
ZW8207M06A
ZW2202M06A
BEMZ33358
BEMZ33350
BMAZ33368
ZS2201M04008A
NOT SPARED
ZS2201M03016A
ZS3228E0812A
ZW2203G08A
ZW8207G08A
BMAZ33348
SPARE PARTS
SKT CAP HEAD M6 X 25

WASHER SPRING M6
WASHER DIA 6
ELTOMATIC PULSER (MASTERLOAD)
ELTOMATIC PULSER (NON--MASTERLOAD)
CABLE GUARD
CSK SLOT HEAD SCREW M4 X 8
TERMINAL BLOCK (ATTACHED TO CABLE)
SXT CAP HEAD M3 X 16
SCREW HEX HEAD 1/4 UNF X 3/4 IN
WASHER 1/4 IN LARGE STEEL
WASHER 1/4 IN SPRING COIL
TRANSMITTER ADAPTER, BM AND CM
4
4
4
1
1
1
2
REF
2
2
4
4
1
Chap 9
Page 7
TP 0027
+
*
*
*
*
+
+
13
14
15
16
17
18
19
20
21
22
23
24
BMAZ33351
ZT8001E0310A
ZASZ0104--2
BESZ2362
ZO32M144530A
ZASZ0104--9
BECZ1095
ZMPZ0158--4
ZMMZ0247--43
56396
T8353
BMSZ33338
BEAZ1455
* = Suggested spare parts
Chap 9
Page 8
TRANSMITTER ADAPTER, DM
PIN TENSION 3/32 IN DIA
DOWEL PIN 1/4 IN DIA X 3/4 IN
SCREW SEALING
O RING
DOWEL PIN 1/4 IN DIA X 1 IN
PLUG M10 X 1
DOWTY WASHER
CABLE GLAND M20
CABLE GLAND FIBRE WASHER M20
CENTRALISING TOOL
SPACER (CM METER)
LABEL (ATEX) UNIVERSAL
1
1
2
2
1
2
1
1
1
1
REF
REF
1
SPARE PARTS

TP0027-9 Masterload Gantry PDF

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

TP0027-9 Masterload Gantry PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Masterload MK II (gantry)

Maintenance manual with spare parts catalogue

The information contained herein is the property of Avery Hardoll

Tel: +44 (0) 1258 486600

Tel: +1 818 765 8160

Bulkmeter Capsule (Calibrating Mechanism & Register)

Solenoid Operated Preset Valve

Technical Information Sheet for 8in. Bermad valve

HEALTH AND SAFETY AT WORK ACT 1974

The Product is used only with fluids stated as acceptable by Avery--Hardoll.

The Product must only be coupled/connected to equipment considered acceptable by Avery--Hardoll.

FIG. 1.1 MASTERLOAD II SYSTEM

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 data capture system (Office).

Flexible mounting of display(s) and power supply.

Gantry printer interface.

Permissive feed input for safety interlocks.

Temperature correction to IP/ASTM tables.

Interface to a Densitometer, pressure and differential pressure transducers.

Masterload II is an Intrinsically Safe system for use in a Category 2 (Zone 1)

The Masterload II system comprises:

Densitometer, Pressure and Differential Pressure measurement, may be used if the

POWER SUPPLY UNIT

MAIN DISPLAY UNIT

ADDITIONAL DISPLAY UNIT

FIG 1.2 NON-PRESET SYSTEM

MAIN DISPLAY UNIT

ADDITIONAL DISPLAY UNIT

FIG 1.3 PRESET SYSTEM

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.

FIG 1.4 PRESET BATCH DELIVERY

Additional items may be added to enhance display and control facilities:

Office data link.

Pulse output for Additive Injection.

Preset valve control.

Density, Pressure measurement.

Flow Rate/Temperature/Pressure etc.

The Preset System provides the additional capability

Flow Rate/Temperature/Pressure etc.

The combination display unit can show volume and

Litres and kilograms

Decalitres/Dekaliters and kilograms

Gallons and pounds

US gallons and pounds

Cu Metres & Tonnes

FIG 2.3 COMBINED DISPLAY

PULSE TRANSMITTER UNIT

POWER SUPPLY UNIT

The Power Supply Unit main components are:

One barrier block comprising seven independent barrier stages.

FIG 2.4 POWER SUPPLY UNIT COMPONENTS

The Barrier is an Intrinsically Safe encapsulated module. It incorporates components manufactured