Toptech FCM II Installation Manual Download

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FCM II

(Flow Control Module)

Installation Guide

Part # 2307

April 26, 2013

Summary of Contents for FCM II

Page 1: ...FCM II Flow Control Module Installation Guide Part 2307 April 26 2013 ...

Page 2: ...art 1 General Requirements Year of CE Marking 2007 Name William J Porthouse Position Director of Engineering Production Date 31 Oct 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 instructi...

Page 3: ...zardous locations OR non hazardous locations only WARNING EXPLOSION HAZARD Do not disconnect equipment unless power has been removed or the area is known to be non hazardous WARNING EXPLOSION HAZARD Substitution of components may impair suitability for use in Class I Division 2 environments WARNING EXPLOSION HAZARD The area must be known to be non hazardous before servicing replacing the unit and ...

Page 4: ...mer 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 Unit of IDEX Corporation logo is a registered trademark of Toptech Systems Inc TMS TMS5 TMS6 RCU II Remote Control Unit Toptech MultiLoad II MultiLoad II RCU RCU II FCM Flo...

Page 5: ...ns 18 3 2 1 Terminal Identification 19 3 2 2 Flow Meter and Control Valve Wiring 20 3 2 3 Additive Wiring 21 3 2 4 RTD Temperature Probe Wiring 22 3 2 5 4 20mA Input Wiring LOOP CURRENT PROVIDED BY EXTERNAL POWER SUPPLY 23 3 2 6 4 20mA Input Wiring LOOP CURRENT PROVIDED BY TRANSMITTER 24 3 2 7 4 20mAOutput Wiring 25 3 2 8 AC Permissive Status Wiring 6ACIN 26 3 2 9 AC Output Wiring 6ACOUT 27 3 2 10...

Page 6: ...ts Wiring Suggestions 39 6 1 Module Dimensions 39 6 2 Standard Panel Dimensions 41 6 2 1 20 inch x 20 inch Panel 41 6 2 2 30 inch x 30 inch Panel 43 6 3 Panel Electrical Wiring Suggestions 45 6 3 1 Power and Communication Distribution 45 6 3 2 Wiring Terminal Identification 47 6 3 3 Voltage Distribution 48 CHAPTER 7 Hardware Revision History 49 CHAPTER 8 Manual Revision History 50 ...

Page 7: ...ive Status 6ACIN 26 Figure 3 10 FCM II Field Wiring AC Pump and Valve Control 6ACOUT 27 Figure 3 11 FCM II Field Wiring DC Permissive Status 6DCIN 28 Figure 3 12 FCM II Field Wiring DC Input 4DCIN 4ACOUT 29 Figure 3 13 FCM II Field Wiring AC Output 4DCIN 4ACOUT 30 Figure 3 14 FCM II Field Wiring DC Output 6DCOUT 31 Figure 3 15 FCM II Field Wiring 3 Output Air Eliminator 32 Figure 3 16 FCM II Field...

Page 8: ...ng 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 ...

Page 9: ...y 30 Vdc SELV Limited Energy FCM II Analog Min 19 Vdc Max 36 Vdc 100mA Max 4 20 mA SELV Limited Energy RTD 4 20 mA SELV Limited Energy FCM II 6 AC IN Min 19 Vdc Max 36 Vdc 100mA Max 250 Vac max Optically Isolated Contact Closure FCM II 6 AC OUT Min 19 Vdc Max 36 Vdc 100mA Max 250 Vac 350 mA max 6K Cycles Pilot Duty FCM II DC IN Min 19 Vdc Max 36 Vdc 100mA Max 30 Vdc SELV Limited Energy FCM II DC O...

Page 10: ...nstallation repair and other handling of FCM II modules summarized below 1 Service must be performed by authorized personnel only 2 The person performing the service must be grounded by an ESD grounding strap and connected to ground 3 The plastic enclosures offer a degree of protection of the inner printed circuit board assemblies against ESD However the heat venting slots and the wiring terminals...

Page 11: ...by sliding adjacent FCM II s together until the bus connectors click into place see Figure 2 3 below 2 2 MODULE REMOVAL Module removal is the reverse of installation Power must be removed from the modules Then spread the module to be removed from adjacent modules on either side Disengage the spring loaded bottom catch by inserting a Flat Head screwdriver and sliding the catch away from the rail an...

Page 12: ...ield connections 1 Connect a safety ground to the panel A copper post is provided for this 2 Wiring must enter the enclosure through conduit entries All conduits must be terminated at the enclosure by use of appropriately rated conduit hubs or glands 3 Avoid routing AC and DC wiring in the same conduit in order to minimize the disruption of DC and analog voltage circuits by line voltage transients...

Page 13: ... 2 Toptech recommends using stranded 16 to 18 AWG 1 3 to 0 8 mm 2 for power See section 2 5 regarding the choice of communication wire The required screw tightening torque is 2 to 4 Lb in 0 2 to 0 5 Nm For terminal assignments see Figure 2 4 below Wires must be stripped and inserted into terminal block leaving no bare conductor exposed Only one of each of the three possible 24 VDC DC COMMON pairs ...

Page 14: ...22 485 communications protocol is designed for multi point i e computer to multiple 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 TDB and a receive pair of wires RDA RDB Figure 2 4 shows the terminal assignments for the bus RS 485 serial connection Either...

Page 15: ... and the location of DIP switches used to set the module s serial address The table below provides the settings for FCM addresses 0 31 Port 0 Status Port 1 Status Port 2 Status Port 3 Status Port 4 Status Port 5 Status Port 6 Status Port 7 Status TX Status RX Status FCM 5V Power FCM 12V Output FCM Address Dip Switches Figure 2 5 Module Status Configuration Setting and Identification ...

Page 16: ...0 0 0 1 0 1 1 0 23 0 0 0 1 0 1 1 1 24 0 0 0 1 1 0 0 0 25 0 0 0 1 1 0 0 1 26 0 0 0 1 1 0 1 0 27 0 0 0 1 1 0 1 1 28 0 0 0 1 1 1 0 0 29 0 0 0 1 1 1 0 1 30 0 0 0 1 1 1 1 0 31 0 0 0 1 1 1 1 1 Figure 2 6 DIP Switch Configuration Settings 2 7 SWING ARMS An industry practice of sharing loading equipment between two adjacent lanes is termed a swing arm The reference indicates the actual practice in which o...

Page 17: ...ntrol of the relay coils is to be wired by the customer to the arm ring switch Note the voltage available and match it to the relay coil voltage rating If DC voltage is used a reverse biased diode is recommended to snub ringing voltage when the coil opens Although star wiring of FCM IIs is discouraged star wiring of the shared modules is necessary since switching of shared upstream modules would r...

Page 18: ...ignments are given later in this chapter 3 2 FCM II FIELD DEVICE CONNECTIONS FCM II consists of 6 different module types see Electrical Ratings in section 1 1 1 1 4DCIN 4ACOUT 4 DC Inputs 5 30 VDC 4 AC Outputs 12 250 VAC 12 Vdc Power Supply 167 mA Max 2 6ACIN 6 AC Input 90 140 VAC or 180 250 VAC 3 6ACOUT 6 AC Outputs 12 250VAC 4 6DCIN 6 DC Inputs 5 30 VDC 5 6DCOUT 6 DC Outputs 0 30 VDC 6 ANALOG 4D...

Page 19: ...19 Part 2307 Figure 3 1 FCM II Single And Double Module Comparison 3 2 1 TERMINAL IDENTIFICATION All DC Field Wiring Connections Power COM Connection Bus Power COM Connection Bus All AC Field Wiring Connections Figure 3 2 FCM II Field Wiring Terminal Locations ...

Page 20: ...ve Solenoids MUST be controlled by the Ground Overfill monitor In the event of a Ground loss or Overfill detection this voltage must be switched off to ensure a failsafe shutdown of the product flow D4 D3 D2 D1 12Vdc Top Side Bottom Row E4 E3 E2 E1 Top Side Middle Row Port 5 Port 4 In Out In Out A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 In Out In Out B1 B2 B3 B4 Bottom Side Middle Row Port ...

Page 21: ...e Valve Solenoid 1 Additive Meter Pulser or Switch 2 Additive Meter Pulser or Switch 3 Additive Meter Pulser or Switch 4 Additive Meter Pulser or Switch Port 0 Output Port 1 Output Port 3 Output Port 2 Output Port 7 Input Port 6 Input Port 5 Input Port 4 Input 12V Gnd D4 D3 D2 D1 12Vdc Top Side Bottom Row In Out In Out B1 B2 B3 B4 Bottom Side Middle Row Port 3 Port 2 A B E D F Terminal Number E4 E...

Page 22: ... II For 3 wire and 2 wire probes the connection of REF to COM and REF to V should be as close as possible to the probe within inches White Red Red White Red 2 Wire RTD Connection White Red 3 Wire RTD Connection Red Com R R V D4 D3 D2 D1 RTD Top Side Bottom Row NC NC I I E4 E3 E2 E1 Top Side Middle Row 4 20 mA IN Iout Rtn Com V F4 F3 F2 F1 Top Side Top Row 4 20 mA OUT E D F Terminal Number 1 2 3 4 ...

Page 23: ...p Row 4 20 mA OUT Terminal Number Com R R V D4 D3 D2 D1 RTD Top Side Bottom Row NC NC I I E4 E3 E2 E1 Top Side Middle Row 4 20 mA IN E D F 1 2 3 4 1 2 3 4 1 2 3 4 External Power Supply I Figure 3 6 FCM II Field Wiring 4 20mA Input 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 l...

Page 24: ...umber Com R R V D4 D3 D2 D1 RTD Top Side Bottom Row NC NC I I E4 E3 E2 E1 Top Side Middle Row 4 20 mA IN E D F 1 2 3 4 1 2 3 4 1 2 3 4 External Power Supply I I I 4 20mA Transmitter V V Figure 3 7 FCM II Field Wiring 4 20mA Input 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 lo...

Page 25: ...sed as shown here Com R R V D4 D3 D2 D1 RTD Top Side Bottom Row NC NC I I E4 E3 E2 E1 Top Side Middle Row 4 20 mA IN Iout Rtn Com V F4 F3 F2 F1 Top Side Top Row 4 20 mA OUT Terminal Number E D F E D F D4 D3 D2 D1 Top Side Bottom Row 12Vdc E4 E3 E2 E1 Top Side Middle Row Port 5 Port 4 F4 F3 F2 F1 Top Side Top Row Port 7 Port 6 1 2 3 4 1 2 3 4 1 2 3 4 Figure 3 8 FCM II Field Wiring 4 20mA Output ...

Page 26: ...unused AC inputs Pump Status Etc Port 5 Input Port 4 Input Port 3 Input Port 2 Input Port 1 Input Port 0 Input Caution The 6ACIN module is available in 90 140 VAC and 180 250 VAC models VERIFY MODULE VOLTAGE LISTED L N L N A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 L N L N B1 B2 B3 B4 Bottom Side Middle Row Port 2 Port 3 L N L N C1 C2 C3 C4 Bottom Side Top Row Port 4 Port 5 Terminal Number 1...

Page 27: ...Block Valve2 Open Line Neutral Note This shows a typical configuration AC ouputs can be assigned to any unused AC outputs In Out In Out A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 In Out In Out B1 B2 B3 B4 Port 3 Port 2 Bottom Side Middle Row In Out In Out B1 B2 B3 B4 Bottom Side Top Row Port 4 Port 5 A B C Terminal Number 1 2 3 4 Figure 3 10 FCM II Field Wiring AC Pump and Valve Control 6ACO...

Page 28: ...ical configuration DC Permissive Status inputs can be assigned to any unused DC inputs Pump Status Etc Port 0 Input Port 1 Input Port 2 Input Port 3 Input Port 4 Input Port 5 Input Terminal Number E D F D4 D3 D2 D1 Top Side Bottom Row Port 1 Port 0 E4 E3 E2 E1 Top Side Middle Row Port 3 Port 2 F4 F3 F2 F1 Top Side Top Row Port 5 Port 4 1 2 3 4 Figure 3 11 FCM II Field Wiring DC Permissive Status 6...

Page 29: ... Input Port 5 Input Port 6 Input Port 7 Input Note Ports 4 7 can be used for general DC inputs when not configured for additive or component meter input L N L N A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 L N L N B1 B2 B3 B4 Bottom Side Middle Row Port 2 Port 3 A B E D F Terminal Number D4 D3 D2 D1 Top Side Bottom Row 12Vdc E4 E3 E2 E1 Top Side Middle Row Port 5 Port 4 F4 F3 F2 F1 Top Side To...

Page 30: ...Output Port 1 Output Port 2 Output Note Ports 0 3 can be used for general AC outputs when not configured for additive or digital valve control D4 D3 D2 D1 Top Side Bottom Row 12Vdc A B E D F Terminal Number E4 E3 E2 E1 Top Side Middle Row Port 5 Port 4 F4 F3 F2 F1 Top Side Top Row Port 7 Port 6 In Out In Out A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 In Out In Out B1 B2 B3 B4 Port 3 Port 2 B...

Page 31: ...e assigned to any unused DC outputs Any DC output port can be configured as an output pulse Pulse Out Etc Port 0 Output Port 1 Output Port 2 Output Port 3 Output Port 4 Output Port 5 Output E D F Terminal Number In Out In Out D4 D3 D2 D1 Top Side Bottom Row Port 1 Port 0 In Out In Out E4 E3 E2 E1 Top Side Middle Row Port 3 Port 2 In Out In Out F4 F3 F2 F1 Top Side Top Row Port 5 Port 4 1 2 3 4 Fig...

Page 32: ...is removed the flow rate will drop to the Alt High Flow Rate Note 1 When the level drops below Low Low the power will be removed from the digital valves stopping flow before the air eliminator is completely drained L N L N A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 L N L N B1 B2 B3 B4 Bottom Side Middle Row Port 2 Port 3 L N L N C1 C2 C3 C4 Bottom Side Top Row Port 4 Port 5 A B Terminal Numb...

Page 33: ...ates returned from the air eliminator flow must be completely stopped to purge air To purge air by only slowing the rate a 3 output air eliminator head must be used Note 1 When the level drops below Low the power will be removed from the digital valves stopping flow before the air eliminator is completely drained A B Terminal Number In Out In Out A1 A2 A3 A4 Bottom Side Bottom Row Port 0 Port 1 In...

Page 34: ...r Reset Pulse Green E D F 1 2 3 4 Ground Common Black E4 E3 E2 E1 Top Side Middle Row Port 5 Port 4 F4 F3 F2 F1 Top Side Top Row Port 7 Port 6 E D F 1 2 3 4 12VDC Red Output Pulse Port Batch Authorized Inverse Port MODEL E1613 Note 1 Use only model E1613 External Power Supply Terminal Number Figure 3 17 FCM II Field Wiring Lectro Count Remote Display ...

Page 35: ...behave as if pulses were actually received on Port 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 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...

Page 36: ...e dc inputs The modules must be powered from the BUS rail with a DC voltage source of 19 36 Vdc If required verify the output voltage and current capacity of the power supply used to power the FCM IIs 5 2 IS THE MODULE COMMUNICATING The quickest check that an FCM II module is communicating with a MultiLoad or other serial device is to look for the module s front panel TX LED to flash The RX LED on...

Page 37: ...correctly and that two devices do not share a duplicate address If all modules have an ERR state check the bus communication wiring see section 2 5 5 3 ARE THE INPUTS FUNCTIONING An input LED will only illuminate when a voltage of 5 30 Vdc appears across the input s terminal pair If a problem occurs verify the wiring shown in chapter 3 5 4 ARE THE OUTPUTS FUNCTIONING The output LED will illuminate...

Page 38: ...r replacement 5 6 ARE OTHER ERRORS PRESENT Please consult the MultiLoad User Manual for further errors that are not covered here The MultiLoad User Manual describes in great detail how to configure an FCM II panel for most kinds of control applications as well as how to troubleshoot those setups 5 7 IS TECHNICAL ASSISTANCE AVAILABLE Technical assistance may be obtained during business hours or dur...

Page 39: ...pter 6 Dimensions Panel Layouts Wiring 39 FCM II Installation Guide 20160419 Part 2307 CHAPTER 6 DIMENSIONS PANEL LAYOUTS WIRING SUGGESTIONS 6 1 MODULE DIMENSIONS Figure 6 1 FCM II Single Module Dimensions ...

Page 40: ...Chapter 6 Dimensions Panel Layouts Wiring 40 FCM II Installation Guide 20160419 Part 2307 Figure 6 2 FCM II Double Module Dimensions ...

Page 41: ...INCH X 20 INCH PANEL Figure 6 3 20 Inch x 20 Inch Panel Layout The maximum number of FCM IIs on this panel is the equivalent of 12 single wide modules Toptech recommends mounting the power supply on the DIN rail with the FCM IIs as most DIN rail power supplies require vertical mounting and top bottom clearance for proper cooling ...

Page 42: ...Chapter 6 Dimensions Panel Layouts Wiring 42 FCM II Installation Guide 20160419 Part 2307 Figure 6 4 20 Inch x 20 Inch Enclosure Dimensions ...

Page 43: ...h Panel Layout The maximum number of FCM IIs on this panel is the equivalent of 18 single wide modules per row 36 total Toptech recommends mounting the power supply on the DIN rail with the FCM IIs as most DIN rail power supplies require vertical mounting and top bottom clearance for proper cooling Each row of FCM IIs requires its own power supply ...

Page 44: ...Chapter 6 Dimensions Panel Layouts Wiring 44 FCM II Installation Guide 20160419 Part 2307 Figure 6 6 30 Inch x 30 Inch Enclosure Dimensions ...

Page 45: ...which side of a DIN rail assembly the power and communication cable should attach left side female plug or right side male plug Note also that star wiring should be avoided so communication cable extension to adjacent rows ought to use the opposite end of the joined modules than the end from which communication enters Toptech also recommends using one power supply for each DIN rail assembly See Fi...

Page 46: ...Chapter 6 Dimensions Panel Layouts Wiring 46 FCM II Installation Guide 20160419 Part 2307 Figure 6 8 FCM II Power and Serial Communication Panel Wiring Two Rows Two Serial Ports ...

Page 47: ... they staircase to the top Numbers one through 4 are arranged from left to right when viewing the plug from its wire entry side To differentiate terminals of different modules Toptech recommends a module slot number identification scheme where module is the FCM s address slot is either 0 or 1 depending on whether the terminals are attached to the left or right board in a double wide housing and nu...

Page 48: ... recommends the installation of bussed DIN mounted terminal blocks to distribute Neutrals and dc commons Two ac line voltages are also distributed through the panels One is normal 120V line voltage switched to additive injectors motor operated valves VRU VCOs and pump run signals The second line voltage to be distributed is the Ground Overfill output required by digital control valves Note Do not ...

Page 49: ...se with C US UL Listing 11 26 2008 Modification of board to board header updating i2c expansion analog 4IN 4OUT 09 21 2011 Approved alternate bottom terminal block 05 11 2012 Replaced AC relay assemblies with discrete triacs 4IN 4OUT 6ACOUT 05 11 2012 Replaced DC relay assemblies with discrete MOSFETs 6DCOUT 10 01 2014 Improved RTD filtering IO_DA rev 1 3 IO_2M rev 1 2 ...

Page 50: ...tion from chapter 4 of MultiLoad II install guide to its own install guide 1 1 06 23 2011 Added Swing Arm configuration 04 26 2013 Added LectroCount wiring 04 26 2013 Dropped revision number control control by release date 04 26 2013 Added 12Vdc supply load rating 04 26 2013 Updated European DOC 04 19 2016 Revised Declaration of Conformity new directive dates in effect 4 20 2016 ...

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