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20121031 MLII_SMP_Installation Guide

1. A ae Toptech Ze Systems MultiLoad Il S Meter P Installation Guide Part 6067 October 31 2012 EC Declaration Of Conformity The signatory representing the manufacturer declares that the products listed below are in conformity with the essential requirements of the following EC Directive s when installed in accordance with the product installation instructions 2004 22 EC The Measuring Instruments Directive and its amending directives 2004 108 EC The Electromagnetic Compatibility Directive and its amending directives 94 9 EEC The Potentially Explosive Atmospheres Directive and its amending directives Product Process Controller with Operator Interface intended for use in potentially explosive atmospheres Model name number MultiLoad Il SMP Protective Systems Flameproof d Intrinsic Safety ib Notified Body ies Demko A S Testing and Certification NMi Certin B V Number 0122 Number 0539 Hugo de Grootplein 1 P O Box 514 Lyskaer 8 3314 EG Dordrecht DK 2730 Herlev Denmark The Netherlands Conformity has been demonstrated with reference to the following documentation EC type examination certificate 06 ATEX 0619833X EC type examination certificate TC7311 Compliance with the Essential Health and Safety Requirements has been assessed by reference to the following standards WELMEC guide 8 8 General and Administrative Aspects of the Voluntary System of Modular Evaluation of Measuring instruments under
2. 5 1 SWITCH ACCESS CONTROL The MultiLoad Il SMP contains switches which limit menu and configuration access These switches limit users from accessing Program Mode and as well as from changing Weights and Measures controlled parameters In Program Mode the operator has access to the following The Configuration Menu parameters The Diagnostics Menu and its functions Other administrative procedures such as clearing high level alarms To access Program Mode the MultiLoad Il terminal operator must 1 Move the Program Mode switch into the active position 2 At the idle card in screen enter the security code default security code is 000000 and press the lt Next gt key 5 1 1 EXTERNAL SWITCH ACCESS CONTROL One access control switch option is a pair of external access control switches These switches limit access to Program Mode and changes to Weights and Measures controlled parameters YOUR LOCAL WEIGHTS AND MEASURES OFFICE MAY NEED TO BE CONTACTED AFTER BREAKING THE SEAL AND CHANGING PARAMETERS THIS IS TYPICALLY DONE ONLY DURING METER PROVING OR TEMPERATURE CALIBRATION Depending on the date of manufacture the MultiLoad Il SMP may have one of three types of external switch design All can be sealed and locked to prevent access to Program Mode and to prevent changes of Weights and Measures controlled parameters MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 C
3. Part 6067 Chapter 4 I O Configuration 39 4 1 11 MULTILOAD II LECTRO COUNT REMOTE DISPLAY WIRING MODEL E1613 puugi sie 3 HI le t EA e SOON 1 12Vdc pate 4 Pee a D H sss Terminal Number Figure 4 11 MultiLoad Il Digital Analog UO Board Field Wiring Lectro Count Note Use only model E1613 The Lectro Count 12Vdc 12V common can be supplied by an external source Note Connect Port 10 to Lectro Count output pulse Connect Port 11 to Lectro Count reset pulse MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 4 2 IO BOARD SIMULATOR The I O Board simulator is a special version of an I O board intended for demo and lab systems The simulator merely has different firmware that allows configuration entirely from MultiLoad without requiring field signals 4 2 1 METER SIMULATION Product flow control loops can be run in a demonstration mode by imitating a virtual flow meter single or quadrature and its associated virtual Digital Control Valve Product flow simulation is automatically enabled when a meter is assigned to the simulator Ports 2 and 3 will be automatically assigned and actuated to simulate the upstream and downstream solenoids of an associated Digital Control valve Port 4 will be assigned as the primary meter pulser and the module will behave as if pulses were actually received on Po
4. 4723 D gt DISPLAY ASSEMBLY o KEYPAD BARRIER ASSEMBLY KEYPAD ASSEMBLY D v D A D Figure 7 5 Exploded view front panel assembly MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 7 Drawings and Part Numbers 60 I O BOARD MICROPROCESSOR inn POWER SUPPLY COMMUNICATIONS ma S e Figure 7 6 Power Supply Comm Board amp I O Board Chassis The Toptech replacement part numbers are shown in the table below Part Part Number Part Part Number SMP Display Assembly 1 4721 DC Power Supply Board 6 SMP Barrier Assembly 2 1501 Revision 1 0 obsolete CPU Display Ribbon Cable 3 1583 Revision 1 1 4729 SMP Keypad 4 1438 O Board 7 Digital Analog I O revision 1 1 4718 CPU Board 8 Revision 1 0 obsolete Revision 2 0 4723 AC Power Supply Board 5 Revision 1 0 obsolete Revision 1 1 4728 MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 8 Hardware Revision History CHAPTER 8 HARDWARE REVISION HISTORY Date Description 12 14 2006 Initial product release with C US UL Listing 05 24 2007 ATEX Certificate issued 07 09 2007 Replaced Samsung SRAM with Cypress 08 20 2007 New firmware released for I O board because of PIC18F die revision 02 01 2008 Rele
5. A MAXIMUM SPECIFIED GAP OF FLANGE JOINT IS 0 08mm A AMBIENT TEMPERATURE RANGE IS BETWEEN 40 C AND 60 C A CAUTION COVER BOLTS MUST HAVE A YIELD STRESS OF AT LEAST 450 N mm A WARNING TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES disconnect from the supply circuit before opening enclosure Keep tightly closed when circuits are live A WARNING Substitution of components may impair intrinsic safety gt WARNING Do not open when an explosive gas atmosphere is present A WARNING All unused conduit entries must be sealed with a conduit plug which satisfies the flameproof d method of protection Blanking elements must be removable with the aid of a tool ATEX certified suitable for Gas Group IIB and suitable for an ambient temperature range of 40 C to 60 C A CAUTION Battery may explode if mistreated DO NOT RECHARGE DISASSEMBLE OR DISPOSE OF IN FIRE A CAUTION Field wiring must have a temperature rating of 75 C or greater It must also have a temperature rating for the lowest expected minimum ambient temperature A Consult installation manual for required cable entry size and thread A A battery is soldered to the processor board for retention of data time and date This battery should last more than ten years Please return the board to Toptech Systems for battery replacement This battery must be replaced with Matsushita Electric model BR2477A only Use of another battery may present a risk of fire
6. Host TMS MultiLoad Il 1 RS485 COM 1 TDA RDA TDB RDB RDA TDA RDB TDB Figure 3 3 RS485 4 Wire Host to Multiple MultiLoad Ils MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 22 MultiLoad Il n Chapter 3 Data Communications Interface 23 3 1 5 HOST TMS COMMUNICATIONS COM 1 RS 485 2 WIRE The Host TMS Computer System can be connected to the MultiLoad Il via RS485 2 wire on COM 1 The TD and RD pairs tied together at the Host TMS and all MultiLoad IIs Host TMS MultiLoad Il RS485 COM 1 TDA RDA TDB RDB RDA TDA RDB TDB Figure 3 4 RS485 2 Wire Host to a Single MultiLoad Il Host TMS MultiLoad Il 1 MultiLoad Il n RS485 COM 1 COM 1 TDA RDA RDA TDB RDB RDB RDA TDA TDA RDB TDB TDB Figure 3 5 RS485 4 Wire Host to Multiple MultiLoad Ils MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface 24 3 1 6 Host TMS COMMUNICATIONS COM 1 RS 232 The Host TMS Computer System can be connected to the MultiLoad Il via RS232 on COM 1 The TX and RX are swapped at the Host TMS MultiLoad Il has the ability to multi drop onto a RS232 line Host TMS MultiLoad Il RS232 COM 1 TX RX RX TX GND GND Figure 3 6 RS232 Host to a Single MultiLoad Il Host TMS MultiLoad Il 1 MultiLoad Il n RS232 COM 1 COM 1 TX RX RX RX TX TX GND GND GND Figure 3 7 RS232 Host to Multiple MultiLoad Ils MultiLoad Il Single Meter P
7. Additive Meter Pulser Switch 3 Additive Meter Pulser Switch 2 Additive Meter Pulser Switch 1 Additive Meter Pulser Switch Port 6 Input ANN Port 7 Input Port 4 Input Port 0 Output 1 Additive Valve Solenoid Port 1 Output 2 Additive Valve Solenoid IEEE Port 2 Output 43 Additive esa Valve E Solenoid RODA SE 44 additive Valve Solenoid Neutral AAA AIA ZS SK Terminal_ Terminal A Terminal_ Number Number Number Figure 4 3 MultiLoad Il Digital Analog I O Board Field Wiring Additive Meters and Injection Valves n Note Most additive injection meters only provide an Open Collector pull down type output Typically a 1 000 Ohm 1 4 watt pull up resistor needs to be added in the pulser junction box to pull this output to 12V when the output is off MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 30 Chapter 4 I O Configuration 31 4 1 3 MULTILOAD II RTD TEMPERATURE PROBE WIRING 4 Wire 100 Ohm Platium RTD Alpha 0 0385 White Red 2 Wire RTD Connection v White v v v Terminal Red Number Red 3 Wire RTD Connection Figure 4 3 MultiLoad Il Digital Analog UO Board Field Wiring RTD i Note All 4 wires MUST be run to the sensor Do not simply jumper REF to COM or REF to V at the FCM Il For 3 wire and 2 wire prob
8. MID OIML R117 1 2007 E Dynamic measuring systems for liquids other than water EN 61000 6 4 2007 Generic emissions for industrial operating environments EN 61000 6 2 2005 Generic immunity for industrial operating environments EN 60079 0 2009 Electrical apparatus for explosive gas atmospheres General requirements EN 60079 1 2007 Electrical apparatus for explosive gas atmospheres Flameproof enclosures d EN 60079 11 2007 Electrical apparatus for potentially explosive atmospheres Intrinsic safety i Year of CE Marking 2006 Name William J Porthouse Position Director of Engineering amp Production Date 31 Oct 2012 C 1124 Florida Centrai Pkwy Systems Inc USA LOUD CONTROLS GROUP MODEL MULTILOAD Il SMP INPUT POWER PART NO 4809 Die CLASS 2 GELV LIMITED CE 0575 Il 2G 88 260vac 47 63Hz 300mA 160mA Ex d ib IIB T4 40 C lt Ta s 60 C Gb IP85 DEMKO 06 ATEX 0819833X ne La d MAX METER INPUT FREQUENCY 5kHz 1 B Da 0 30Vde naig ne PRESSURE INPUT RANGE 0 4000 KPa hi RTD INPUT 1002 0 00385 TYPE 4 IP65 40 C Tamb lt 60 C ANALOG INPUT 4mA 20mA CLASSI DIV 1 GROUPS C amp D T4 APPROVALS NTEP C ofC07 010 wenn ur ave TC7311 SERIAL NO A WARNING TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES CONDUIT RUNG MUST HAVE GEALING FITTING CONNECTED WITHIN 18 INCHES OF THE ENCLOGURE WARMING TO REDUCE THE RIGK OF KANITION OF HAZARDOUS ATHOSPHERES DISCONNECT FROM
9. THE SUPPLY CIRCUIT BEFORE OPENING ENCLOSURE KEEP TIGHTLY CLOSED WHEN CIRCUITS ARE LIVE WAN SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINGK SAFETY WARNING DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE IG PREGENT CONSULT INSTALLATION MANUAL FOR REQUIRED CABLE ENTRY SIZE amp THREAD AVERTISSEMENT RISOLIE DE DN LEA SCELLEMENTE DES CONDUITS DOT ETRE INSTALL WENS DE 18 POUCES DU B IER AVERTISSEMENT RISQUE DEG DECH COUPER LE COURANT AVANT D ENLEVER LE COUVERCLE O AVERTISSEMENT LA SUBSTITUTION DE COMPOSANTS PEUT COMPROMETTRE LA S CURIT NTFINS QUE RN GE PAS DAAN SINE pn ATMOSPHERE EXPLOSIVE PEUT TRE PR SENTE CONSULTE LE MANUEL D INSTALLATION POUR LE FILETARE ET LA TAILLE DES PRERAE ETOUPEA MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 SAFETY WARNINGS AVERTISSEMENTS DE S CURIT NORTH AMERICAN INSTALLATIONS A A gt gt This equipment is suitable for use in Class Division 1 Groups C and D locations or non hazardous locations only WARNING TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES conduit runs must have a sealing fitting connected within 18 inches of the enclosure WARNING TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES disconnect from the supply circuit before opening enclosure Keep tightly closed when circuits are live WARNING Substitution of components may impair intrinsic safety WARNING Do not open when an explosive gas a
10. a wire and lead seal to detect unauthorized access A single fold down cover can be locked to prevent bolt removal The cover is marked W amp M or Program adjacent to each bolt to indicate the bolt function i Figure 5 3 Type 3 Program W amp M Switches Li Do not use a wrench to tighten the bolts Insert the bolts hand tight only Over tightening will damage the bolt assembly HAND TIGHTEN ONLY MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 43 Chapter 5 Configuration 5 1 5 INTERNAL SWITCH ACCESS CONTROL Two DIP switches on the CPU board also provide the closure of the Program Mode W amp M switch contacts When the MultiLoad Il does not have the external Program Mode W amp M switch installed it is necessary to use these DIP switches on the CPU board to enable program mode and W amp M access The switches are numbered 1 through 4 with 1 being closest to the front of the enclosure top of the picture and 4 being toward the back of the enclosure bottom of the picture When switch is in the ON position the switch is in the active state allowing access A switch is ON when it moved right and OFF when moved to the left Switch 3 is the program mode switch Switch 4 is the W amp M access switch In the example in Figure 5 4 below the Program Mode switch is currently Active while the W amp M Switch is not active Figure 5 5 shows the location of the DIP sw
11. and suitable for an ambient temperature range of 40 C to 60 C Do not route AC and DC wiring in the same conduit All wiring must enter the MultiLoad Il enclosure through conduit via entries in the bottom of the enclosure All conduits must be terminated at the enclosure by use of appropriately rated conduit hubs or glands Wires must be stripped 4 and fully inserted into terminal block with no bare conductor exposed The terminal blocks are designed to accept wires sizes 12 AWG 3 31 mm through 24 AWG 0 205 mm The recommended tightening torque is 0 5 Nm 4 4 inch pound force to 0 6 Nm 5 3 inch pound force Both ac and dc input models require a safety ground connection as described in section 2 3 3 below A service loop is recommended for all wires and cables entering the enclosure bottom of the enclosure Keep AC wiring separated from all other wiring in the enclosure by use of D Do not allow service loop cables to overlap the circuit boards Col any cable length in the the supplied partitions see wire partition instructions below Wiring must comply with all local electrical codes MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing The MultiLoad Il SMP 16 2 5 2 AC POWERED MODELS Provide over current protection using a 15 Amp circuit breaker or equivalent The breaker also serves as a means of disconnection from the operating supply
12. as required by UL IEC 61010 1 and CAN CSA C22 2 NO 61010 1 The disconnect device may not be blocked or be made difficult to operate by the MultiLoad Il or any other device Note that installation of disconnects are typically prohibited in Class Division 2 locations Power required 85 250 Vac 47 63 Hz 300 mA 85Vac 150 mA 250Vac The power connector is located in the right hand corner of the Power Supply Communication board as shown in figure 2 1 Select supply wire rated 300V or better with a flammability rating of at least VW 1 O IH D E TEE Figure 2 4 MultiLoad Il AC Power Supply Comm Board MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing The MultiLoad Il SMP 17 A plastic flap has been installed over TB1 and along the right edge of the enclosure All services loops or excess AC wiring should be placed under the partition This includes AC wiring attached to TB1 of the optional I O board The figures below illustrate how to gain access to the terminal blocks and replace the partitions so that wires containing Hazardous voltages are separated from all low voltage circuits including field wired circuits f f Figure 2 5 AC Supply Terminal Block Access Figure 2 6 Removal of AC Wiring Side Partition Figure 2 7 Replacement of AC Wiring Side Partition MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing
13. block plugs used to section 2 3 as required by UL 1 3 10 02 2009 Expanded I O section to show pictorially all wiring configurations standard in MultiLoad Il installation manuals 1 4 2 18 2011 Added wiring diagrams for 2 Meter I O board added wiring diagrams for Lectro Count added Intertek requirements including Canadian required French bilingual warnings added Canadian IS ground wiring instructions 1 4 3 11 2011 Editorial pp 3 51 54 noted SD Card menu in Chapter 5 1 4 10 24 2011 Editorial pp 56 Corrected TT to 1518 1583 is no longer in use 10 29 2012 Corrected additive input mistake 10 29 2012 Removed revision number control by date 10 29 2012 Added Hardware revision table 10 29 2012 Clarified 4 20mA input wiring Corrected COM2 label errors in diagram 10 29 2012 Updated label updated warnings updated European DOC 10 29 2012 Updated AC PS board COMO 5 pin prerelease COM2 2wire 485 addition MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 62
14. communications limited to 50 feet requiring a minimum of 3 wires transmit receive and ground Additional wires are required for hardware handshaking when using printers and data loggers Wire used must meet the following 24 AWG 3 conductor with overall shield data only or 8 conductor with overall shield full handshaking 30 DE maximum between conductors MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface 21 3 1 3 FCMI FCM II PCM COMMUNICATIONS COM 0 RS 485 FCM I FCM Il and PCM modules are all connected on a RS 485 bus connected to COM 0 on the MultiLoad Il The TD and RD pairs are swapped at the MultiLoad Il If an internal I O board is installed this board is already connected to COM 0 and is addressed as FCM 0 All FCMs must be uniquely addressed MultiLoad Il FCM PCM FCM PCM COM 0 0 n TDA RDA RDA TDB RDB RDB RDA TDA TDA RDB TDB TDB Figure 3 1 FCM PCM Connections MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface 3 1 4 HOST TMS COMMUNICATIONS COM 1 RS 485 4 WIRE The Host TMS Computer System can be connected to the MultiLoad Il via RS485 4 wire on COM 1 The TD and RD pairs are swapped at the Host TMS Host TMS MultiLoad Il RS485 COM 1 TDA RDA TDB RDB RDA TDA RDB TDB Figure 3 2 RS485 4 Wire Host to a Single MultiLoad Il recommended
15. iii 24 3 1 7 Host Ticket Printer Data Logger COM 2 RS 232 rennes 25 9 18 TT 26 CHAPTER 4 UO COMMUTATION EE 27 4 1 Connecting Field Devices to the I O Board mens 27 4 1 1 MultiLoad Il Flow Meter and Control Valve Wiring iiiii 29 4 1 2 MultiLoad Il Additive Wiring ie 30 4 1 3 MultiLoad Il RTD Temperature Probe Wiring is 31 4 1 4 MultiLoad Il 4 20mA Input Wiring Loop Current Provided by External Power Supply 32 4 1 5 MultiLoad Il 4 20mA Input Wiring Loop Current Provided by Transmitter 33 4 1 6 MultiLoad Il 4 20mAOutput Wiring ii 34 4 1 7 MultiLoad II AC Output Woo 35 4 1 8 MultiLoad II DC Permissive Status Wiring rs 36 4 1 95 MultiLoad 1l DC Output WINING is saaan deed Ee REENEN EE 37 4 1 10 MultiLoad II 2 Output Air Eliminator Wiring sr 38 4 1 11 MultiLoad Il Lectro Count Remote Display Wiring 39 4 2 VO BOARD SIMULA TOR GA io POLlice alia 40 MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 42r Metr EI EE 40 Ee e Re E EE 40 4 2 3 Analog SIMUIATION DEE 40 4 2 4 Generic VO E ET 40 CHAPTER 5 ue UC E 41 5 1 Switch Access Control natiiana lan iii 41 511 External Switch Access Control arie iii 41 5 1 2 External Type 1 Program W amp M switcheS ur 42 5 1 3 External Type 2 Program W amp M switche
16. longer has to be made either will work Twisted Pairs N a A D N Q Figure 3 10 Ethernet Connections MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 26 Chapter 4 I O Configuration 27 CHAPTER 4 I O CONFIGURATION 4 1 CONNECTING FIELD DEVICES TO THE I O BOARD The I O board is mounted above the Power Supply Comm board The I O board is connected to the Power Supply Comm board at J4 amp J5 Corresponding connections are on bottom side of the I O board Disconnect from the supply circuit before opening enclosure Keep tightly closed when circuits are live The quantity and electrical ratings of the I O are described in the table below TYPE I O DIGITAL ANALOG I O ELECTRICAL RATING QUANTITY LOCATION AC Outputs 5 TB1 12 250 Vac rms 500 mA per point TB1 DC Outputs 3 TB3 0 30 Vdc 600 mA per point TB3 DC Inputs 5 TB2 Right 5 30Vdc TB2B 2 High Speed Dual Channel flow meter inputs 1 5000Hz Miscellaneous signal inputs 12Vdc Source 167mA Max Load Isolated Power Supply TB2 Left Power for flow meter pulsers or preamps RTD Input 1 TB4 100 ohm platinum four wire Coefficient 0 00385 Ohm Ohm C Analog Input 1 TB5 4 20mA 1 5V maximum burden Analog Output 1 TB6 4 20mA Requires 12Vdc 30Vdc Supply MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Co
17. surface The following wire sizes may be used 10 AWG 5 26 mm or 11 AWG 4 17 mm AN Do not connect the power supply dc common to earth ground MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface CHAPTER 3 DATA COMMUNICATIONS INTERFACE The MultiLoad Il has four communications ports see Figure 2 4 each with a specific purpose The following section provides the information required to select and make the wiring connections to the ports Communication Port Interface Type Typical Function Terminal Figure 2 4 Comm Port 0 RS 485 Internal I O board TB2 FCM I FCM Il PCM Communication Comm Port 1 RS 232 or RS 485 Host Communication TB3 RS 232 TMS TB4 RS 485 Comm Port 2 RS 232 or Ticket Printer Data TB5 RS 485 2 wire Logger Ethernet 10 100MBPS Host Communication J3 TMS Cat 5 Cable HI If a service loop is used the maximum wire length in the service loop should not exceed 3 inches 75mm Li Separate AC and DC wiring by at least 3 inches 75mm Do not allow excess wire in the service loop to overhang printed circuit board MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface 20 3 1 COMMUNICATIONS PROTOCOL SELECTION AND CONNECTION 3 1 1 RS 422 485 RS 422 485 communications protocol is designed for multi point i e computer to mult
18. 21031 Part 6067 Chapter 6 Service and Repair 55 6 1 4 KEYPAD REMOVAL AND REPLACEMENT Removal 1 Using a security screwdriver bit available from Toptech remove all security screws holding on the Keypad bezel 2 Remove the bezel 3 Using a flat screwdriver carefully pry out the keypad 4 Disconnect the keypad cable from the back of the keypad Installation 1 Connect the keypad cable to the back of the keypad 2 Carefully install the keypad into the cover 3 Install the keypad bezel 4 Using a security screwdriver bit install all the bezel holding security screws 6 1 5 KEYPAD BARRIER CIRCUIT REMOVAL AND REPLACEMENT Removal 1 Disconnect the keypad cable from the display subassembly 2 Remove the four screws holding barrier circuit box 3 One by one move over the keypad wires to a new barrier circuit Installation 1 Reinstall the barrier circuit box with the three holding screws 2 Connect the keypad cable to the display subassembly MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 7 Drawings and Part Numbers 56 CHAPTER7 DRAWINGS AND PART NUMBERS 10g 26352 94 23178 1 23 36 a a i es gt ATC Hi 68 168 28 B8 218 971 dE ses vg 6 7 5 8 9 EI ke a O Figure 7 1 Unit Outline Drawing Front View 724 735 THRU M20 x 1 5 6H THD M20 x 1 50 5 PLACES 28 166901 si
19. G EQUIPMENT The MultiLoad Il should be immediately inspected after opening the packaging case If any damage is visible notify the carrier at once to establish liability Contact Toptech Account Management to initiate timely repair or replacement of the unit Account Management will issue a Return Materials Authorization RMA to return the product or parts requiring repair Do not return any material to Toptech without an RMA Account Management contact information Account Management Toptech Systems 1124 Florida Central Pkwy Longwood FL 407 332 1774 Prior to installation the MultiLoad Il should be stored in its packing case and be protected from damage due to handling and adverse weather conditions MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 1 General 10 1 3 OPERATING CHARACTERISTICS For product outline and dimensions see Appendix Figures 7 1 to 7 3 Operating voltage 85 250 Vac 47 63 Hz 300 150 mA OR Voltage Option 18 36 Vdc 600mA Operating temperature 22 F to 140 F 25 C to 60 C with Optional Heater 40 F to 140 F 40 C to 60 C Explosion proof enclosure Type 4 IP65 ETL Listed US Canada Class 1 Division 1 Groups C amp D ATEX Certified Group IIB T4 Category 2G DEMKO 06 ATEX 0619833X Weight 22 lbs 10 kg Display Color A Diagonal QVGA Optional Lockable External Switches Program Access Weights amp Measures Parameter Acces
20. S The MultiLoad Il Main Menu is shown below From this menu you select submenus MAIN MENU Diagnostics Views and Inquiries SD Card Next Prev The reverse video highlight bar indicates the current selection Press Next to select Diagnostics and then press the Enter key to go to the Diagnostics Menu DIAGNOSTIGCS ME Card Reader Meters Components Serial Ports Additives Network Test Custom Logic Keypad Display Unicode FCM Com PCM Com FCM Health PCM Health RCU Bay Preset Next Prev For menu options and function screen items pressing the Next key moves the selection bar down and pressing the Prev Previous key moves the selection bar up To return to the Main Menu press EXIT To return to any previous screen press the EXIT key MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration 5 4 FIELD MODIFICATION AND DATA ENTRY MultiLoad Il will have all fields populated with default values There are two types of fields toggle or data entry Toggle fields contain a number of choices Scroll through the choices by pressing the Enter key Data entry fields require that a value be entered into the field within a given applicable range In the example below RCU Address field is highlighted RCU GENERAL SI RCU Address 001 Card Reader DISABLD Remote Processing DISABLD Swing Arn Secondary DISABLD Password 1 HK KKK KK P
21. The MultiLoad Il SMP 18 2 5 3 DC POWERED MODELS The MultiLoad Il is optionally available with a 24 Vdc power supply The power source used to supply the MultiLoad Il must be rated 18 36 Vdc SELV Limited Energy Class 2 The rated supply input current is 600mA The supply should be protected by a 1 5 Amp fuse The 3 position terminal block is located in the right hand corner of the power supply communication board Wiring guidelines for using 24 Vdc power supply Wire gauge AWG Distance feet 24 50 22 100 20 150 TB1 18 250 Figure 2 8 DC Power Connections 16 400 2 5 4 EQUIPMENT GROUNDING A safety ground should be attached to terminal block TB1 on both ac and dc input power models to maintain electrical safety in the event of a fault condition Follow the terminal block wiring instructions in section 2 5 The required tightening torque is shown in Figure 2 3 Canadian standards require a dedicated Intrinsic Safety ground wire to be attached to the internal l S barrier Attach as show in Figure 2 9 inside the lower left of the enclosure Note that the external ground connection is not provided for the attachment of the protective conductor the safety ground Rather it is provided only as a supplemental bonding connection where Figure 2 9 Canadian LG Ground Connection local authorities permit or require such a connection for example as a means of equipotentiality The wire connection is on the bottom right exterior
22. arm Setup Products Additive Cal Remote Adtv Cal Access ID s Custom Logic Customer Logo Setup Next Prev Exit Enter 7 Press Enter and key in RCU address 001 of MultiLoad 11 RCU Il RCU GE RCU Address 001 Card Reader DISABLD Remote Processing DISABLD Swing Arm Secondary DISABLD Password 1 ATE Password d BESS ES Bote Password 3 CIS ma Password KKK KK Password 5 HK KKK Modem Dial Modem Login RCUTE TOPTECH Terminal Name Toptech Terminal Next Prev 8 Press Exit to return to the Configuration Menu 9 Select and press Enter to return to the Main Menu 10 If MultiLoad II RCU Il has Program Weights and Measures switch return the switch to Operating Mode MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration 50 5 6 VERIFY COMMUNICATIONS BETWEEN MULTILOAD Il AND I O BOARD 1 Enter program mode by pressing 00000 on the keypad then press Next key 2 Select diagnostics from main menu DEVA GENSONS al Bes ME Card Reader Meters COM Loopback Components Serial Ports Additives Network Test Custom Logic Keypad Display Unicode PCM Com FCM Health PCM Health RCU Bay Preset Next Prev 3 Select FCM COM FCM COM DIAGNOSTICS 00 0k 4 If screen display is the same as above the I O board is communicating with the MultiLoad Il 5 If I O board is not communicati
23. ased DC power supply option DC INT rev 1 0 07 03 2008 Added alternate LTC cross for AD reference and changed capacitors on I O board 08 25 2009 Added display heater option 08 25 2009 Alternate cast enclosure with alternate cement 01 09 2009 Released magnetic switches for configuration amp weights and measures 03 25 2010 Changed regulatory agency from UL to CSA 02 08 2011 Released new CPU board CPU rev 2 0 and Ethernet update on power supply com boards AC INT rev 1 1 DC INT rev 1 1 02 08 2011 Released 2 Meter I O board option IO 2M rev 1 0 03 08 2011 Changed regulatory agency from CSA to Intertek 01 17 2012 Replaced relay assemblies on I O board with discrete triacs IO_DA rev 1 2 MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 9 Manual Revision History CHAPTER 9 MANUAL REVISION HISTORY Revision Date Description 1 0 08 27 2007 Release 1 1 08 21 2008 Added additional UL required warnings 1 2 12 19 2008 Added instructions required by update from UL508 to UL61010 1 that customer is required to use a Class 2 power source when using the DC power supply described wiring partitions described three types of PGM W amp M switches shaft and magnetic bolts first release of magnetic switch construction added table of torque requirements for all terminal
24. assword 2 kkkkkkk Password 3 KEREKEK Password 4 kk kk kkk Password 5 Ra Rika Modem Dial Modem Login RCUTE TOPTECH Terminal Name Toptech Terminal Next Prev Exit Press ENTER to choose the field A blinking cursor indicates data can be entered RCU G RCU Address Card Reader DISABLD Remote Processing DISABLD Swing Arm Secondary DISABLD Password 1 KK RK KKK Password 2 KKKKKKX Password 3 KK KK KKK Password 4 HR RH XX Password 5 HR I XX Modem Dial Modem Login RCUTE TOPTECH Terminal Name Toptech Terminal MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration Type in the new value e g 123 and press ENTER The new value displays on the screen RCU G RCU Address 1234 Card Reader DISABLD Remote Processing DISABLD Swing Arn Secondary DISABLD Password 1 KKKKKKX Password 2 KKKKKKX Password 3 KOR RK KK Password 4 KR KKK Password 5 HR RH XX Modem Dial Modem Login RCUTE TOPTECH Terminal Name Toptech Terminal Next Prev Exit Enter Using this same screen as an example the Remote Processing line is selected and ENTER is pressed use the NEXT or PREV keys to toggle between the values ENABLED and DISABLD as shown below You must then press ENTER to accept the desired choice RCU GE RCU Address 123 Card Reader DISABLD Swing Arm S
25. atmosph re explosive peut tre pr sente AVERTISSEMENT Toutes les entr es du bo tier inutilis es doivent tre scell es avec un bouchon de conduit PRUDENCE La pile peut exploser si elle est maltrait e NE PAS RECHARGER NE PAS DEMONTER ET NE PAS JETER DANS LE FEU PRUDENCE C blage de terrain doit avoir un classement de temp rature de 75 C ou plus Consultez le manuel d installation pour le filetage de forme et la taille du presse toupe Une pile est soud e la carte processeur pour la conservation des donn es de l heure et de la date Cette pile devrait durer pendant plus que dix ans Veuillez retourner la carte processeur Toptech Systems pour le remplacement de la pile Remplacez la pile avec Matsushita Electric mod le BR2477A seulement Utiliser une autre pile peut pr senter un risque d incendie ou d explosion L installation de ce produit doit se conformer avec NFPA 70 ou CSA C22 1 comme appropri e MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 A ATEX AND IECEx INSTALLATIONS A This equipment is suitable for use in Ex Zone Group IIB locations or non hazardous locations THE LETTER X TO THE RIGHT OF THE CERTIFICATE NUMBER INDICATES THE FOLLOWING SPECIAL CONDITIONS FOR SAFE USE A CERTAIN FLAMEPROOF JOINTS ARE OTHER THAN THE MINIMUM OR MAXIMUM DIMENSIONS GIVEN IN IEC EN BR 60079 1 CLAUSE 5 PLEASE CONSULT TOPTECH SYSTEMS IF DIMENSIONAL INFORMATION IS REQUIRED
26. d 0139 28 S 1 128 80 Figure 7 2 Unit Outline Drawing Bottom View MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 7 Drawings and Part Numbers 57 cal 58 51 la 012 701 i 84 Figure 7 3 Unit Outline Drawing Side View MAGNETIC SWITCH ASSEMBLY MAGNETIC BOLT ASSEMBLY 1901 TT PN 1900 TT PN BACKLIGHT POWER CABLE CONNECTION DISPLAY INTERFACE BOARD TO POWER SUPPLY BOARD TT PN 1662 CPU TT PN 4712 POWER SUPPLY TT PN 4714 d I O BOARD TT PN 4718 DISPLAY INTERFACE CABLE TT PN 1518 CONNECTION DISPLAY INTERFACE BOARD TO MICROPROCESSOR BOARD DISPLAY ASSEMBLY TT PN 4721 BARRIER ASSEMBLY TT PN 4725 MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 7 Drawings and Part Numbers 58 BACKLIGHT POWER CABLE d A CPU POWER SUPPLY TA il 1 0 BOARD D Li DISPLAY INTERFACE CABLE DISPLAY assematy 1 BARRIER ASSEMBLY 2 Figure 7 4 Replacement Parts SMP Base Drawing NOTE TT PN Toptech Part Number MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 7 Drawings and Part Numbers 59 COVER NOTE IT IS NOT NECESSARY TO REMOVE THE COVER TO REPLACE THE DISPLAY KEYPAD OR BARRIER DISPLAY ASSEMBLY TT PN 4721 KI a KEYPAD BARRIER ASSEMBLY TT PN 4725 E KEYPAD ASSEMBLY o TI PN
27. econdary DISABLD Password 1 KK RK KKK Password 2 KK KKK KK Password 3 KKKKEKE Password 4 KKKKKKE Password 5 KKRKIKK Modem Dial Modem Login RCUTE TOPTECH Terminal Name Toptech Terminal MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration 48 5 5 MULTILOAD Il PRELIMINARY CONFIGURATION 1 Energize the MultiLoad Il 2 When the MultiLoad Il is first energized the Card in screen appears indicating Operating Mode For Access Insert Driver Card 3 Go to program mode by entering 00000 on the keypad then press Next A MultiLoad Il must have the Program switch set to allow access to Program Mode See section 5 1 00000 is the factory default access code See the MultiLoad II User Guide RCU General setup section for changing or adding new access codes IR Note that unlike MultiLoad Il Program switches or CPU DIP switches never deny access to RCU II Program Mode The program mode main menu displays MAIN MENU Diagnostics Views and Inquiries Sh Carad Next Prev 5 Press Enter to access the Configuration menu MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration 6 Press Enter to access RCU General Setup RCU Setup CON FATC URA Tr ON Communication Network RCU Setup Equipment Setup Al
28. ee 10 1 4 Electrostatic Discharge ESD Protection ii 11 1 5 Lu 82 62 Le 11 CHAPTER 2 Installing The MultiLoad Il SMP is sinrsnnrrrsnersssnensnnenenensnneeseneenenenes 12 2 1 Tools E UC E 12 Pa Ba Oe EE EE 12 2 12 Servicing and Aepair niniin iti i ie ai iet den arie 12 2 2 Cover Closure and Bolt Replacement sine 12 2 3 Mounting The MultiLoad Il SMP Enclosure eennnennnnes 12 2 3 1 Metal Plate or EE 12 Pato AA WOOO EE 12 2 3 3 Concrete Solid Block or Brick Walls i 13 2 3 4 Mounting Height Considerations ss 13 2 4 Recommended Wire Sizes And Torque For All Terminal Blocks rreiiiieee 14 2 5 Electrical Supply Connections aan 15 2 5 1 Cable Gland Entries aa a i i 15 Tee e EE 16 2 5 3 DG Powered Mod ls rimes nine aaea aa EENS AER Dates 18 2 514 Equipment Grounding Uma maam JA bag unan nbang bh akan fus 18 CHAPTER 3 Data Communications Interface 19 3 1 Communications Protocol Selection and Connection aaa 20 31 1 AS A422 488 ss een i era ita ai 20 Ka Aa ae Presents ai ai 20 3 1 3 FCM I FCM IV PCM Communications COM 0 RS 485 ue 21 3 1 4 Host TMS Communications COM 1 RS 485 Awirel so nnnssnana 22 3 1 5 Host TMS Communications COM 1 RS 485 2wirel nnaman nanwwana nanana ananawwanano wana snananannaanwana no nnnnanana 23 3 1 6 Host TMS Communications COM 1 RS 232
29. er Data Logger Connections with Handehake 01 nwwa anna wanawawannananasanananaanananann 25 Ticket Printer Data Logger Connections without Handshake 00 2a aw wananawanaananaaananananananwnann 25 Ethernet C nnections iaia aad ala ini na le mh 26 UO Board Terminal Block AssignmentSs i 28 MultiLoad Il Digital Analog UO Board Field Wiring Flow Meter and Control Valve 29 MultiLoad II Digital Analog I O Board Field Wiring RTD 31 MultiLoad II Digital Analog I O Board Field Wiring 4 20MA Input 32 MultiLoad II Digital Analog I O Board Field Wiring 4 20MA Input 33 MultiLoad II Digital Analog I O Board Field Wiring 4 20MA Output 34 MultiLoad II Digital Analog I O Board Field Wiring AC Pump and Valve Control 35 MultiLoad Il Digital Analog I O Board Field Wiring DC Permissive Status 36 MultiLoad II Digital Analog I O Board Field Wiring DC Output 37 MultiLoad II Digital Analog I O Board Field Wiring 2 Output Air Elmminaior 38 MultiLoad Il Digital Analog I O Board Field Wiring Lectro Count 39 Type 1 Program W amp M Switches iii 42 Type 2 Program W amp M Switches iii 42 Type 3 Program W amp M Switches iii 43 CPU DIP Switches for Program and W amp M Access rev 1 0 44 CPU DIP Switches for Program and W amp M Access rev 2 0 44 Cam lock in the Open Up position sisi 52 Display Cable In
30. es the connection of REF to COM and REF to V should be as close as possible to the probe within inches MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 32 4 1 4 MULTILOAD II 4 20MA INPUT WIRING LOOP CURRENT PROVIDED BY EXTERNAL POWER SUPPLY 4 20mA Transmitter External Power Supply Terminal Number NOTE The receiver does not contain a voltage source The loop must be powered either by the transmitter or by an external power supply The I O Board adds 75 Ohms to the loop Figure 4 4 MultiLoad Il Digital Analog UO Board Field Wiring 4 20mA Input MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 4 1 5 MULTILOAD II 4 20MA INPUT WIRING LOOP CURRENT PROVIDED BY TRANSMITTER External Power Supply Terminal Number NOTE The receiver does not contain a voltage source The loop must be powered either by the transmitter or by an external power supply The I O Board adds 75 Ohms to the loop Figure 4 5 MultiLoad Il Digital Analog UO Board Field Wiring 4 20mA Input MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 33 Chapter 4 I O Configuration 34 4 1 6 MULTILOAD II 4 20MAOUTPUT WIRING Return 4 20mA Receiver Terminal A Number B2A 12Vd Bo LT aa agd Ju Terminal Number Figure 4 6 MultiLoad Il Di
31. gital Analog I O Board Field Wiring 4 20mA Output Note The 4 20mA output requires a power source 12 30vdc The 12vdc output can be used as shown here MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 35 4 1 7 MULTILOAD II AC OUTPUT WIRING Component Pump Run Additive Pump Run Open Block Valve O EA GJ DH EA ei jen jen ef KO Bay Active O00000 2gaaaamama O le Line Neutral SS SS SS SA SKK SK Terminal Number Figure 4 7 MultiLoad Il Digital Analog UO Board Field Wiring AC Pump and Valve Control Note This shows a typical configuration AC outputs can be assigned to any unused AC output MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 4 1 8 MULTILOAD II DC PERMISSIVE STATUS WIRING KE Ei ni a L t Ground Overfill VRU VCU Block Valve Status Pump Status Power SS SS SS SS ZS SN Pea Terminal Terminal Number Number 5 30 Vdc Figure 4 8 MultiLoad Il Digital Analog I O Board Field Wiring DC Permissive Status Note This shows a typical configuration DC Permissive Status inputs can be assigned to any unused DC input Note The Digital Analog I O board lacks AC inputs MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configura
32. gures 7 1 through 7 3 There is only one mounting orientation possible as shown in Figure 7 1 Five M20x 1 5 mm cable entries are located at the bottom of the enclosure Appropriate fasteners must be selected to support the minimum weight of 22 lbs 10 kg Toptech offers the following mounting suggestions for three typical surfaces metal wood or concrete cinder block 2 3 1 METAL PLATE OR RAIL Use four hex head 5 16 OD M8 bolts with a 5 16 flat washer OD M8 18mm OD under the head of the bolt Fasten with four 5 16 M8 hex nuts 2 3 2 Woo Use four hex head 2 X 5 16 OD M8 x 50 mm lag bolts with a 5 16 flat washer 34 OD M8 18 mm OD under the head of the bolt Or you may drill through holes in the wood and assemble as with the metal plate using four hex head 5 16 OD M8 bolts with a 5 16 flat washer 34 OD M8 18mm OD under the head of the bolt Fasten with four 5 16 M8 hex nuts MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing The MultiLoad Il SMP 2 3 3 CONCRETE SOLID BLOCK OR BRICK WALLS Use four a x 2 1 4 Tapcon 5 8 diameter hex flange head masonry fasteners with a 4 flat washer 44 OD under the head of the screw Drill pilot holes for the Tapcons using a 3 16 masonry drill bit 2 3 4 MOUNTING HEIGHT CONSIDERATIONS When mounting the enclosure be aware of the limitations that the cover places on screen visibil
33. iple devices also called multi dropped communications up to 4 000 feet 1 220 Meters RS 422 requires 4 wires 2 twisted pair for full duplex communications and utilizes a transmit pair of wires TDA amp TDB and a receive pair of wires RDA amp RDB RS 485 requires 2 wires 1 twisted pair for half duplex communications and utilizes a single pair of wires TDA RDA amp TDB RDB for transmit and receive This manual will typically refer to both RS 422 and RS 485 as simply RS485 2 wire or RS485 4 wire Although a ground wire is not required the common mode voltage between the MultiLoad Il and the field device must be within 7Vdc to 12Vdc To correct situations where this is not the case Li the DC common is available on COM 0 and COM 1 by using TB2 pin five revision 1 1 Power Supply Comm boards only and TB 3 pin three Connect the MultiLoad Il DC common to the signal ground of the field device Wire used must meet the following characteristics 24 AWG stranded 4 wire two twisted pair with overall shield 2 wire one twisted pair with overall shield 30 pF maximum between conductors 1 000 ohm impedance Maximum length 4 000 feet 1 220 Meters Maximum stub length 15 feet All exposed shields must be properly insulated to prevent short circuits All shields must be continuous soldered and properly insulated 3 1 2 RS 232 RS 232 protocol is designed for point to point e computer to a single device
34. itch on revision 2 0 CPU boards Li A switch input is active when either the DIP switch OR the external switch is active ON position moved left prior to sealing the MultiLoad Il SMP enclosure This will ensure that W amp M D Your Weights and Measures inspector may wish to verify that DIP switch 4 bottom switch is in the off parameters are secure EAA PIE A Figure 5 4 CPU DIP Switches for Program Figure 5 5 CPU DIP Switches for Program and W amp M Access rev 1 0 and W amp M Access rev 2 0 5 1 6 FIELD SWITCH ACCESS CONTROL The MultiLoad Il SMP also has the ability to accept field inputs for the Program Mode and W amp M Access switches See the MultiLoad II User Guide for more information 5 2 MULTILOAD Il RCU Il EXL KEYPAD The MultiLoad Il SMP keypad has 18 keys including numeric and function keys used to Select menu items and fields Enter data in fields Initiate actions Return to previous screens MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 44 Chapter 5 Configuration 45 Numeric keys 1 through 9 and 0 are used to enter numeric data Alpha keys are used to enter text and also to select deselect alpha character entry The decimal point is used to enter numeric field data with a decimal point CLR key is used to clear data entered in error The CLR key is a backspace key erasing characters as the cursor moves backward 5 3 MENUS AND SCREEN
35. ity Because the display is inset about an inch 25mm from the surface of Div 2 and SMP units and the screen is inset an inch and one half 39mm in the EXL unit the enclosure should be mounted so that top of the screen s visible area is at eye level of the tallest operator Figure 2 1 shows the visible area at arm s length and the distance from the ground to the top mounting hole location for a six foot 1 8m tall user Figure 2 2 shows the offset of the top of the screen s visible area from the top mounting bolt and the depth of the screen within the unit 4 19in 106 48mm a kw 1 06in 26 93mm F 0 95in 24 17mm TS E LE UU fei Figure 2 2 Screen Visible Area 68 In 1 72m t Figure 2 1 Suggested Mounting Position MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing The MultiLoad Il SMP 14 2 4 RECOMMENDED WIRE SIZES AND TORQUE FOR ALL TERMINAL BLOCKS Three sizes of terminal blocks are used in the MultiLoad Il products 7 62 mm pitch supply power 5 08 mm pitch line voltage switching and 3 81 mm pitch serial communication analog or dc voltages All sizes orientations and manufacturer brands have different torque and wire size specifications Please follow the recommendations in Figure 2 1 below The manufacturer may be determined by looking for the logo molded into the terminal block u
36. l SMP CHAPTER 2 INSTALLING THE MULTILOAD Il SMP 2 1 TOOLS REQUIRED 2 1 1 INSTALLATION 6 mm hex wrench required for tightening cover bolts 2 1 2 SERVICING AND REPAIR 4 Philips screwdriver for circuit board removal a socket wrench for CPU circuit board removal 5 16 socket wrench for display board removal Torx T15 for removal of keypad bezel security screws 2 2 COVER CLOSURE AND BOLT REPLACEMENT The enclosure cover is secured to the housing by twelve 8mm hex cap screws A 6mm Allen head wrench is required to remove the screws After the bolts are removed the front cover will swing left and hang from its hinges To close the cover gently lift on the bottom right corner when in position and start one or two of the lower right corner bolts This is done to assist in alignment of the cover and base holes for starting the bolts Dry stainless steel fasteners can gall or seize in aluminum so please be sure to use a petrolatum or similar lubricant Be sure to keep the flanges clean and free of scratches and nicks so as not to compromise the quenching ability of the flame path A All cover bolts must be tightened to maintain the explosion proof capability of the enclosure 2 3 MOUNTING THE MULTILOAD Il SMP ENCLOSURE The SMP enclosure should be located in a shaded area Direct sunlight can increase internal temperature to greater than 140 F or 60 C Exterior dimensions of the enclosure are shown in Fi
37. ming the service must be grounded by an ESD grounding strap and connected to ground 3 While performing maintenance or repair touch an unpainted metal of the MultiLoad Il surface prior to touching or handling any printed circuit boards or electronic components 4 Printed circuit board assemblies must be placed in and transported in conductive bags or other conductive containers 5 Printed circuit boards must not be removed from the conductive container until time of use 6 All other best practices for protecting devices from ESD must be observed 1 5 FCC NOTE This equipment complies with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense Modifications not expressly approved by the manufacturer could void the user s authority to operate the equipment under FCC rules MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing The MultiLoad I
38. nfiguration NOTE 184 185 and T84 ONLY ON BOARD ASSEMBLY DIGITAL ANALOG I O 2 W ISOLATED SUPPLY AVAILABLE FOR PULSERS 3 SWITCHED DC OUTPUTS 0 30 Vde 0 6A PULSERS 28 V R R GND 5 AC OUTPUTS 12 250 Vac H 0 5 A RMS V GND TRIACS v NO ORIENTATION ON PINS 12V 12V E 12V 12V 12V 12V COM 12V COM 12V COM 12V COM 12V COM OUTI le t feefee CC IG SANI t HHH Si Figure 4 1 UO Board Terminal Block Assignments MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 4 1 1 MULTILOAD II FLOW METER AND CONTROL VALVE WIRING Meter Pulser Pulse A Optional Pulse B Port 5 Input pple ley ly N O Digital Valve Solenoid Port 2 Output Port 3 Output N C Digital Valve Solenoid Gnd Overfill Switched Neutral Line ba a Terminal A Terminal Number Number Figure 4 2 MultiLoad Il Digital Analog UO Board Field Wiring Flow Meter and Control Valve Caution Line voltage used to drive the Digital Valve Solenoids MUST be controlled by the Ground or Overfill monitor In the event of a Ground loss or Overiill detection this voltage must be switched off to ensure a failsafe shutdown of the product flow MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 4 1 2 MULTILOAD Il ADDITIVE WIRING Gnd 4
39. ng the message 00 ERR appears 6 If 00 ERR or I O Board Com ERR appears verify the communication parameters for Com0 within the Communication Setup Menu This menu is located under the Configuration Menu The Com0 communication settings required for the I O board are 57 6 K Baud None Parity 8 Data bits 1 Stop bit Single and I O Board type of serial device This is correctly set in the factory when an SMP is assembled but it is possible for the settings to be updated by the installer MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration 5 7 USING I O DIAGNOSTICS MultiLoad Il Consult MultiLoad Il User manual for diagnostics functions MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 51 Chapter 6 Service and Repair 52 CHAPTER 6 SERVICE AND REPAIR 6 1 MODULAR DESIGN The MultiLoad Il SMP has been constructed with replaceable modules or sub assemblies that are available from Toptech see Appendix for part numbers These include e CPU Subassembly CPU Chassis CPU Board Power Supply COM Board UO Board e Display Subassembly Active Matrix Display and Display Board e Keypad e Keypad Barrier Circuit The following sections describe how to remove and replace each subassembly and where possible how to further disassemble the subassembly NOTE Do not service MultiLoad Il RCU Il without disconnecting the s
40. onfiguration 42 5 1 2 EXTERNAL TYPE 1 PROGRAM W amp M SWITCHES This design consists of two separate external rotary switches one for Program Mode Access and one for W amp M change access Each switch has external fold down cover that can be locked or sealed with a wire and lead seal to prevent moving the switch into the active state Each cover will also be stamped as W amp M or Program to indicate function O tr Figure 5 1 Type 1 Program W amp M Switches 5 1 3 EXTERNAL TYPE 2 PROGRAM W amp M SWITCHES This design consists of a single 3 position external rotary switch with two individual covers which may be locked and sealed with a wire and lead seal The covers limit the switch rotation to three positions A Two covers closed Program access denied and Weights and Measures access denied B First cover open Program access allowed and Weights and Measures access denied C Both covers open Program access allowed and Weights and Measures access allowed Figure 5 2 Type 2 Program W amp M Switches MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 5 Configuration 5 1 4 EXTERNAL TYPE 3 PROGRAM W amp M SWITCHES The third design consists of two separate external magnetic bolts one for Program Mode Access and one for W amp M change access Program or W amp M access is achieved by removing the corresponding bolt Each bolt has a small hole that can be sealed with
41. or explosion A The installation of this product must be in conformity with IEC EN 60079 14 MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Copyright Notice Copyright 2006 2012 Toptech Systems Inc The information contained in this document is proprietary and confidential No part of this document may be copied reproduced or transmitted in any medium without the express written permission of Toptech Systems Inc Disclaimer Toptech Systems assumes no responsibility for damages resulting from installation or use of its products Toptech Systems will not be liable for any claims of damage lost data or lost time as a result of using its products a Toptech Gab Systems Inc Ze logo is a registered trademark of Toptech Systems Inc TMS TMS5 TMS6 RCU Il Remote Control Unit Toptech MultiLoad II MultiLoad Il RCU FCM Flow Control Module are trademarks of Toptech Systems Inc Copyright 2012 Toptech Systems Inc AII Rights Reserved MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Table of Contents Safety Warnings Avertissements de S curit 3 CHAPTER 1 EE 9 1 1 Who Should Use This Guide snnnnnnenennsnnnnnnenenneensnennnennnes 9 1 2 lnf rmation E 1 ener 9 12 1 Typographical Conventions assimiler lier unies 9 1 2 2 Receiving and or Returning Equipment seen 9 1 3 Operating Characteristics e
42. releasing the cam lock and display power cable Disconnect the W amp M Access Program Mode switch cable from the CPU board Remove the four chassis mounting screws not the mounting screws for the I O board or Power Supply COM board 7 Carefully remove the CPU chassis from inside the base by removing the CPU board side of the chassis first Installation 1 Carefully insert the CPU chassis back into the enclosure 2 Install the chassis mounding screws 3 Connect the W amp M Access Program Mode switch cable to the CPU board 4 Reconnect the display power cable and the flat display cable remember to secure the cam lock 5 Connect the Mains Power to the Power Supply COM board 6 Connectall Serial Communications to the Power Supply COM board 7 Connect all field wiring to the I O board 6 1 3 DISPLAY SUBASSEMBLY REMOVAL AND REPLACEMENT Removal 1 Disconnect the flat display cable after releasing the cam lock display power cable and the keypad cable 2 While supporting the display subassembly remove the four mounting screws 3 Do not attempt to disassemble the display subassembly Return entire subassembly to Toptech for repair after receiving an RMA number Installation 1 While supporting the display subassembly install the four mounting screws 2 Connect the keypad cable display power cable and the flat display cable 3 Verify routing and clearance of the cable MultiLoad Il Single Meter Preset SMP Installation Guide 201
43. reset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface 25 3 1 7 HOST TICKET PRINTER DATA LOGGER COM 2 RS 232 A Ticket Printer or Data Logger can be connected to the MultiLoad Il via RS232 on COM 2 The TX and RX are swapped at the MultiLoad Il Handshake lines MUST be connected or terminated or a Printer Error will be reported MultiLoad Il will monitor CTS DSR and DCD for active signals MultiLoad II Printer Logger RS232 RCU Il COM 2 DB25 Connector RX 2 TX CTS 20 DTR TX 3 RX GND 7 GND DSR 4 RTS N C DCD 5 CTS N C 6 DSR N C 8 DCD N C Figure 3 8 Ticket Printer Data Logger Connections with Handshake MultiLoad II Printer Logger RS232 RCU Il COM 2 DB25 Connector RX 2 TX CTS 20 DTR TX 3 RX GND 7 GND DSR 4 RTS DCD 5 CTS RTS 6 DSR N C DTR Figure 3 9 Ticket Printer Data Logger Connections without Handshake MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 3 Data Communications Interface 3 1 8 ETHERNET Ethernet wiring standard T568B Cat5 cable or greater Figure 3 10 illustrates the required connections for Ethernet The Ethernet controller on revision 2 0 CPU boards uses HP Auto MDIX technology By automatically detecting the signaling on the connected device the transceiver will configure the port settings automatically Thus the choice of a straight through or cross over cable no
44. rt 4 A quadrature meter will be simulated if the Quad Check Enable parameter is set in MultiLoad and the secondary meter channel will be assigned to Port 5 When ports 2 amp 3 are both activated product flow will ramp up When port 2 is active and port 3 is inactive flow will remain constant When both ports are inactive flow rate will ramp down to zero 4 2 2 ADDITIVE SIMULATION Up to 4 channels of additive control Solenoid or Piston type may also be simulated If an additive meter is selected it will be simulated with a 100 Hz pulser input 4 2 3 ANALOG SIMULATION If analog functions are enabled in MultiLoad such as RTD temperature input or 4 20mA current input the simulator places fixed analog values into these input registers For the RTD the fixed temperature is 28 5 C For the 4 20mA current input the value is fixed at 12 800mA The later input provides simulation of a density or pressure sensor input 4 2 4 GENERIC O SIMULATION O lines not used for Product or Additive simulation are available as general purpose DC inputs or AC outputs Do not make connections to field terminals UNEXPECTED OPERATION MAY RESULT The I O is close looped in logic MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 40 Chapter 5 Configuration 41 CHAPTER 5 CONFIGURATION The following describes how to navigate the system select field values perform data entry and toggle options on and off
45. s ss 42 5 1 4 External Type 3 Program W amp M switches ss 43 5 15 Internal Switch ACCESS Control Cotes iia ii ANNA PAA GANA 44 5 1 6 Field Switch Access Control TEE 44 5 2 MultiLoad WU RCU Il EXL Keypad ss na aBaN ANAKAN KNANKN NAAN AN ANAN KAANAK ANAKAN ANAN ANAKAN ANAKAN nunnan nnne KAANAK ANAN 44 5 3 Menus and Screens ille duateacecdceadveduad seserseod ecudeiesuecssadeecuacensqaacs di ie de seu 45 5 4 Field Modification and Data Entry aaa 46 5 5 MultiLoad Il Preliminary Configuration sssssisneennnnnnenesnnnennennnns 48 5 6 Verify Communications Between MultiLoad Il And I O Board An 50 5 7 Using VO KE Ile LA NANA i iena rare ile 51 CHAPTER 6 Service and Repat sssri gaei asnon EEGENEN Sen 52 6 1 Modular Desigh 53 252 Seege iaia vieni dE 52 6 1 1 Operating the Flat Display Cable Connectors sr 52 6 1 2 CPU Subassembly Removal and Replacement sr 54 6 1 3 Display Subassembly Removal and Replacement sawaan anananannaanwnnasanananana 54 6 1 4 Keypad Removal and Replacement sise 55 6 1 5 Keypad Barrier Circuit Removal and Hepnlacement ana waannwaanawawana sawan anananannasawanasnanananana 55 CHAPTER 7 Drawings and Part Numbers 111 NN 56 CHAPTER 8 Hardware Revision History na naan an 61 CHAPTER 9 Manual Revision History ss esssnnnnnnneenennnneenennnnennnes 62 MultiLoad Il Single Me
46. s Keypad 18 Key Numeric Membrane Switch Keypad Communications 3 serial ports 1 RS 232 1 RS 485 1 User Selectable RS 232 or RS 485 1 Ethernet port 10 100 MBPS Internal UO Board Type and Electrical Ratings TYPE I O DIGITAL ANALOG I O ELECTRICAL RATING QUANTITY LOCATION AC Outputs 5 TB1 12 250 Vac rms 500 mA per point TB1 DC Outputs 3 TB3 0 30 Vdc 600 mA per point TB3 DC Inputs 5 TB2 Right 5 30Vdc TB2B 2 High Speed Dual Channel flow meter inputs 1 5000Hz Miscellaneous signal inputs 12Vdc Source 167mA Max Load Isolated Power Supply TB2 Left Power for flow meter pulsers or preamps RTD Input 1 TB4 100 ohm platinum four wire Coefficient 0 00385 Ohm Ohm C Analog Input 1 TB5 4 20mA 1 5V maximum burden Analog Output 1 TB6 4 20mA Requires 12Vdc 30Vdc Supply MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 1 General 1 4 ELECTROSTATIC DISCHARGE ESD PROTECTION The MultiLoad Il contains electronic components and assemblies subject to damage by ESD The MultiLoad Il was designed to protect against ESD while the unit is closed and in normal operation Proper handling procedures must be observed during the removal installation repair and other handling of printed circuit board assemblies electronic devices and components to include 1 Service to be performed by authorized personnel only 2 The person perfor
47. sertion ai 53 Cam lock in the closed down position 53 Unit Outline Drawing Front View i 56 Unit Outline Drawing Bottom View anna aa wana GN ANNG NN AG GG NNNGGNNANGENANGG KNANG GNNNNGANaKGG KN nGK0nnaKa0nKKNG 56 Unit Outline Drawing Side View 57 Replacement Parts SMP Base Drawing sir 58 Exploded view front panel assembly ss 59 Power Supply Comm Board amp I O Board Chassis i 60 MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 1 General CHAPTER 1 GENERAL 1 1 WHO SHOULD USE THIS GUIDE This guide is intended for individuals installing MultiLoad Il equipment engineering firms developing site electrical drawings and users troubleshooting system operation such as managers system administrators technicians and meter proving personnel 1 2 INFORMATION ALERTS Important information to enhance understanding and make better use of the product HI Indicates potential damage to hardware or loss of data Potential for property damage or that personal injury may occur Pay close attention and follow instructions when you see this symbol 1 2 1 TYPOGRAPHICAL CONVENTIONS Boldface Indicates what you are to press on the keypad Example Key in 00000 Italics Emphasizes a key product or industry term Example the display features a pick list style of item selection 1 2 2 RECEIVING AND OR RETURNIN
48. sually on the side Recommended Block Pitch tion Wire Size Screw Torque AWG ll eg a a a alt MG 8 4 8 1 1 1 1 1 TB1 I O Board A0 A0 19 3 31 TB2 TB5 Power Supply Board TB3 TB6 I O Board 30 i Ka 30 14 0 2 0 5 On Shore 26 16 0 Technology Figure 2 3 MultiLoad Il Terminal Block Recommended Wire Size and Screw Torque TB2A TB2B I O Board ca 7 7 4 3 7 6 7 6 7 6 5 0 5 0 5 0 3 8 3 8 3 8 3 8 8 3 5 5 7 3 5 1 7 2 4 2 7 MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 2 Installing The MultiLoad Il SMP 15 2 5 ELECTRICAL SUPPLY CONNECTIONS The SMP may be equipped for either 85 250Vac or 24Vdc operation Verify the power type before making any connections within 18 inches 45 cm of the enclosure A To reduce the risk of ignition in hazardous atmospheres conduit runs must have seals Installed A Field wiring must have a temperature rating of 75 C or greater 2 5 1 CABLE GLANDENTRIES Five M20 x 1 5 mm apertures in the enclosure bottom are provided for the installation of cable glands A gland with the correct corresponding thread must be installed in the opening WARNING If there are unused holes blanking elements satisfying the flameproof d method of protection must be used Blanking elements must be removable with the aid of a tool ATEX certified suitable for Gas Group IIB
49. ter Preset SMP Installation Guide 20121031 Part 6067 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 6 1 Figure 6 2 Figure 6 3 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Table of Figures Suggested M unting Poso Nia an iii 13 Screen Vis De ALC A EE 13 MultiLoad Il Terminal Block Recommended Wire Size and Screw Torque 14 MultiLoad Il AC Power Supply Comm Board 16 AC Supply Terminal Block Access iii 17 Removal of AC Wiring Side Partition ss 17 Replacement of AC Wiring Side Partition sur 17 DC e ee ee 18 Canadian l S Ground Connection sisi 18 FEM POM Connections aka maana A KANNADA DAN deeg eege amine els 21 RS485 4 Wire Host to a Single MultiLoad Il recommended wananwwanaawanananananaananuwanan 22 RS485 4 Wire Host to Multiple MultiLoad IIS ann 22 RS485 2 Wire Host to a Single MultiLoad 11 23 RS485 4 Wire Host to Multiple MultiLoad ls 23 RS232 Host to a Single MultiLoad Il iii 24 RS232 Host to Multiple MultiLoad US nranasan 24 Ticket Print
50. tion 37 4 1 9 MULTILOAD II DC OUTPUT WIRING pub ely alot ah o i E Lei g i Port 10 Output Open Block Port 11 Output Common Pulse Out AA ZS SN Terminal Number Figure 4 9 MultiLoad Il Digital Analog UO Board Field Wiring DC Output Note This shows a typical configuration DC outputs can be assigned to any unused DC output Note For WO Board firmware v036 or greater any DC output port can be configured as an output pulse MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 4 I O Configuration 38 4 1 10 MULTILOAD II 2 OUTPUT AIR ELIMINATOR WIRING f N O Digital i Valve Solenoid EH EH 5 Let ni N C Digital Valve Solenoid d IPA HA CEE ELIEL EL e ice ai a Neutral Air Eliminator SEA g Top Float wi Switch v Gnd Overfill Switched Line Air Purge Neutral Valve Terminal Solenoid Number Figure 4 10 MultiLoad Il Digital Analog I O Board Field Wiring 2 Output Air Eliminator air To purge air by only slowing the rate a 3 output air eliminator head must be used Note When the level drops below Low the power will be removed from the digital valves stopping flow Note With only two states returned from the air eliminator flow must be completely stopped to purge IN before the air eliminator is completely drained MultiLoad Il Single Meter Preset SMP Installation Guide 20121031
51. tmosphere is present WARNING All unused conduit entries must be sealed with a conduit plug which satisfies the flameproof d method of protection CAUTION Battery may explode if mistreated DO NOT RECHARGE DISASSEMBLE OR DISPOSE OF IN FIRE CAUTION Field wiring must have a temperature rating of 75 C or greater Consult installation manual for required cable entry size and thread A battery is soldered to the processor board for retention of data time and date This battery should last more than ten years Please return the board to Toptech Systems for battery replacement This battery must be replaced with Matsushita Electric model BR2477A only Use of another battery may present a risk of fire or explosion The installation of this product must be in conformity with NFPA 70 US National Electric Code or CSA C22 1 Canadian Electrical Code as appropriate INSTALLATIONS NORD AMERICAINES FRANGAIS Cet quipement est compatible pour une installation en Classe Division 1 Groupes C amp D ou les emplacements non dangereux AVERTISSEMENT RISQUE D EXPLOSION Les scellements des conduits doit tre install a moins de 18 pouces du boitier AVERTISSEMENT RISQUE D EXPLOSION Couper le courant avant d enlever le couvercle Garder le couvercle bien ferm tant que les circuits sont sous tension AVERTISSEMENT La substitution de composants peut compromettre la s curit intrins que AVERTISSEMENT Ne pas ouvrir si une
52. upply circuit Keep enclosure tightly closed while circuits are live 6 1 1 OPERATING THE FLAT DISPLAY CABLE CONNECTORS Removal 1 To remove the Display Cable rotate the cam to the open up position see Figure 6 1 2 Genily pull the cable straight out free of the connector Installation 1 To install the display cable make sure the cam is in the open up position 2 Gently insert the cable with the dark insulated side towards the cam see Figure 6 2 When inserting the cable make sure that it is not tilted to one side or the other and that the bottom of the cable is completely seating in the connector 3 Rotate the cam to the closed down position to lock in place see Figure 6 3 Figure 6 1 Cam lock in the Open Up position MultiLoad Il Single Meter Preset SMP Installation Guide 20121031 Part 6067 Chapter 6 Service and Repair Figure 6 3 Cam lock in the closed down position MultiLoad II Single Meter Preset SMP Installation Guide 20121031 Part 6067 53 Chapter 6 Service and Repair 54 6 1 2 CPU SUBASSEMBLY REMOVAL AND REPLACEMENT NOTE Using a magnetic screwdriver is very helpful in retaining the screws during removal and installation Removal D HE ri Disconnect all field wiring from the I O board Disconnect all Serial Communications from the Power Supply COM board Disconnect Mains Power from the Power Supply COM board Disconnect the flat display cable after

20121031 MLII_SMP_Installation Guide

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