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Toptech MultiLoad II DIV-2, Installation Manual

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Toptech MultiLoad II DIV-2 Installation Manual Download Page 74

 

65

 

Chapter 7

 

 Service and Repair   

 

Do not service MultiLoad II/ RCU II without disconnecting the supply circuit.  Keep 
the enclosure tightly closed while circuits are live. 

Using a magnetic screwdriver is very helpful in retaining the screws during removal and 
installation. 

 

 

Overview and Subassemblies   

7.1

 

 

 

Figure 7.1 

MultiLoad II (ML II) / Remote Control Unit II (RCU II) Division 2 Unit 

Chapter 

7 

DISPLAY  

KEYPAD 

 

CARD READER 
SLOT 

 

Summary of Contents for MultiLoad II DIV-2

Page 1: ...MultiLoad II RCU II DIVISION 2 DIV2 Installation Guide Part 6074...

Page 2: ...nc All Rights Reserved 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 wri...

Page 3: ...mity has been demonstrated with reference to the following documentation ATEX EC test report for Project 06NK12831 Dated 2007 01 31 MID EC type examination certificate TC7311 Compliance with the Essen...

Page 4: ...1 2 3 Bottom View 10 2 1 2 4 Side View 11 Operating Characteristics 12 2 2 Chapter 3 Installing the MultiLoad II RCUII DIV2 14 Tools Required 14 3 1 Installation 14 3 1 1 Servicing and Repair 14 3 1 2...

Page 5: ...Board 30 Where to find the internal I O board 30 5 1 Available I O points per board 31 5 2 Terminal arrangements per board 33 5 3 Digital Analog I O board IO_DA 33 5 3 1 2 Meter I O board IO 2M 34 5...

Page 6: ...agnostics 63 6 7 Chapter 7 Service and Repair 65 Overview and Subassemblies 65 7 1 CPU Subassembly Removal and Replacement 67 7 2 Display Subassembly Removal and Replacement 69 7 3 Flat Display Cable...

Page 7: ...Hardware Revision 80 9 1 Manual Revision 81 9 2...

Page 8: ...Wire Host to a Single MultiLoad II RCU II 24 Figure 4 5 RS485 4 Wire Host to Multiple MultiLoad II RCU IIs 25 Figure 4 6 RS232 Host to a Single MultiLoad II RCU II 25 Figure 4 7 RS232 Host to Multiple...

Page 9: ...tion 70 Figure 7 8 ML II RCU II Div2 Unit Cover Keypad Assembly 71 Figure 7 9 Exploded View Front Cover Assembly Slotted Card Holder with MT11 72 Figure 7 10 ML II RCU II Div2 Cover Assembly Prox Brac...

Page 10: ...V2 This chapter covers installation considerations and instructions for the Division 2 DIV2 Model 4 Data Communication Interface This chapter reviews hardware connections and communication processes 5...

Page 11: ...keypad Example Key in 00000 Italics Emphasizes a key product or industry term Example the display features a pick list style of item selection This guide covers RCU MultiLoad DIV2 installation inform...

Page 12: ...will be for the purpose of returning the product or parts requiring repair Do not return any material to Toptech without an RMA Contact Information for Americas Return Materials Department Toptech Sys...

Page 13: ...as appropriate INSTALLATIONS NORD AM RICAINES FRAN AIS Cet quipement est compatible pour une installation en Classe I Division 2 Groupes C D ou les emplacements non dangereux AVERTISSEMENT RISQUE D EX...

Page 14: ...ation of this product must be in conformity with IEC EN 60079 14 Electrostatic Discharge ESD Protection 1 3 The MultiLoad II RCU II contains electronic components and assemblies subject to damage by E...

Page 15: ...ent 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 th...

Page 16: ...pter2 OperatingConditionsandComponents Product Outline and dimensions 2 1 MultiLoad II RCU II DIV2 Model Picture 2 1 1 Figure 2 1 MultiLoad II ML II Remote Control Unit II RCU II Division 2 Unit Chapt...

Page 17: ...8 MultiLoad II RCU II DIV2 Model Dimensions 2 1 2 The dimensions in this section are indicated in inches and millimeters in parenthesis 2 1 2 1 Front View Figure 2 2 Unit Outline Drawing Front View...

Page 18: ...9 2 1 2 2 Back View Figure 2 3 Unit Outline Drawing Back View RCUII ML II Div 2 MOUNTING TEMPLATE...

Page 19: ...ttom View 2 1 2 3 1 2 Hole Base 2 x 1 NTP Aluminum HUBS Figure 2 4 Unit Outline Drawing Bottom View 2 Hole Base 2 1 2 3 2 5 Hole Base Europe 3xM20 and 2xM25 Figure 2 5 Unit Outline Drawing Bottom View...

Page 20: ...11 2 1 2 4 Side View Figure 2 6 Unit Outline Drawing Side View...

Page 21: ...Internal I O Options Two versions of an optional internal I O board are available the Digital Analog I O board the 2 Meter I O board The quantity and electrical ratings of each I O are described in t...

Page 22: ...T 230 50 0 36 5 1 78 8 2 85 120 60 0 32 5 1 62 8 2 60 ACIN 230 50 0 73 0 2 1 46 120 60 0 44 0 2 0 89 DCOUT 5 0 02 3 0 07 2 0 05 12 0 02 3 0 07 2 0 05 24 0 02 3 0 07 2 0 05 30 0 02 3 0 07 2 0 05 DCIN 5...

Page 23: ...r starting one or two of the right corner screws This is done to assist the alignment of the cover and base holes for starting the screws The enclosure cover is secured to the housing by four 6mm slot...

Page 24: ...ing the 14 x 1 M6 x 40 mm wood screws for the four sheet metal screws Do not use the self tapping nylon inserts Concrete or Cinder Block Walls 3 4 3 Follow the instructions above for Drywall installat...

Page 25: ...16 Figure 3 1 Suggested Mounting Position Figure 3 2 Screen Visible Area...

Page 26: ...d holes blanking elements appropriate for the type enclosure must be used Do not route AC and DC wiring in the same conduit All wiring must enter the MultiLoad II RCU II enclosure through conduit via...

Page 27: ...sion 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 bottom corner of the Power Supply Communication board as shown in figure...

Page 28: ...ent of a fault condition Follow the terminal block wiring instructions in section 3 6 Keep the required tightening torque in mind section 3 5 The external ground connection is not provided for the att...

Page 29: ...S 232 TB4 RS 485 Comm Port 2 RS 232 or RS 485 2 wire Ticket Printer Data Logger TB5 Ethernet 10 100MBPS Host Communication TMS J3 Cat 5 or higher Cable If a service loop is used the maximum wire lengt...

Page 30: ...situations where this is not the case 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 II RCU II...

Page 31: ...ng standard T568B Cat5 cable or greater Communication Connection Wiring 4 2 This section describes the wiring connections for each of the communication ports in order to function for a specifc communi...

Page 32: ...the MultiLoad II RCU II via RS485 4 wire on COM 1 The TD and RD pairs are swapped at the Host TMS Figure 4 2 RS485 4 Wire Host to a Single MultiLoad II RCU II recommended MultiLoad II RCUII can be mu...

Page 33: ...System can be connected to the MultiLoad II RCU II via RS485 2 Wire on COM 1 The TD and RD pairs tied together at the Host TMS and all MultiLoad II RCU IIs Figure 4 4 RS485 2 Wire Host to a Single Mu...

Page 34: ...st TMS Communications The Host TMS Computer System can be connected to the MultiLoad II RCU II via RS232 on COM 1 The TX and RX are swapped at the Host TMS Figure 4 6 RS232 Host to a Single MultiLoad...

Page 35: ...utomatically 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 longer has to b...

Page 36: ...be connected to the MultiLoad II RCU II via RS232 on COM 2 The TX and RX are swapped at the MultiLoad II RCU II Handshake lines MUST be connected or terminated or a printer error will be reported Mult...

Page 37: ...the PTB protocol A PTB printer can be connected to the MultiLoad II RCU II via RS232 on COM 2 or COM1 Figure 4 11 PTB Printer Connection with Handshake MultiLoad II RCU II COM 2 Printer Logger RS232 D...

Page 38: ...29 COMMUNICATION SETUP COM 1 Baud Rate 9600 Parity Even Data Bits 7 Data Stop Bits 1 Stop Multidrop Single Type PTB Next Prev Exit Enter...

Page 39: ...ats its I O in two groups corresponding to two different meters In the 2 Meter I O wiring diagrams that follow FCM 0 ports correspond to the first meter and FCM 1ports correspond to the second meter F...

Page 40: ...RATING SYMBOL QUANTITY QUANTITY AC Outputs 5 8 12 250 Vac rms 500 mA per point TB1 AC Inputs 0 2 90 250Vac DC Outputs 3 2 0 30 Vdc 600 mA per point TB3 DC Inputs 5 6 5 30Vdc TB2B Dual Channel flow met...

Page 41: ...t A 0 If a product meter pulser is used PORT 4 is dedicated to the A channel single or optional quadrature DC Input B 90 If a product meter pulser is used PORT 5 is dedicated to the B channel of optio...

Page 42: ...Pt F 5V 12V TB2A TB2B TB1 1 6 TB3 1 6 TB6 1 4 TB4 10 1 IO_DA RTD 4 20 mA IN PORT 4 PORT 5 PORT 6 PORT 7 PORT 9 PORT 10 PORT 11 PORT 12 PORT 0 PORT 1 PORT 2 PORT 3 PORT 8 4 20 mA OUT A 0 B 90 i 4 20mA...

Page 43: ...TD METER 1 RTD 12 Vdc METER 0 PORT 4 METER 0 PORT 5 6 METER 0 PORT 7 METER 1 PORT 4 METER 1 PORT 5 6 METER 1 PORT 7 METER 0 PORT 10 METER 1 PORT 10 METER 0 PORT 8 METER 1 PORT 8 METER 1 PORT 0 METER 1...

Page 44: ...you an example of how certain types of I O need to get wired into the various boards MultiLoad II Wiring Examples o Flow Meter and Control Valve o Additive o RTD o Analog In Analog Out o AC Output Wi...

Page 45: ...NE IN 1 IO_2M TB3 PORT 0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB2 1 2 3 4 5 6 7 8 9 10 IO_DA TB2B PORT 4 PORT 5 PORT 6 PORT 7 PORT 9 1 2 3 4 5 6 7 8 9 10 IO_DA TB2A 12Vdc 1 2 3...

Page 46: ...0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB3 PORT 0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB2 PORT 3 PORT 2 OUT PORT 2 IN LINE IN PORT 3 OUT PORT 3 OUT PO...

Page 47: ...PORT 6 PORT 7 PORT 7 1 2 3 4 IO_2M TB6 12Vdc 1 2 3 4 IO_2M TB6 12Vdc 1 2 3 4 5 6 7 8 9 10 12Vdc IO_DA TB2A 1 k 1 4W 1 k 1 4W 1 k 1 4W 1 k 1 4W 12Vdc Note Most additive injection meters only provide an...

Page 48: ...R RTD R RTD COM RTD V RTD R RTD R RTD COM RTD V RTD R RTD R RTD COM V 1 R 2 R 3 COM 4 IO_DA TB4 RTD V 1 R 2 R 3 COM 4 IO_2M TB5 RTD V 1 R 2 R 3 COM 4 IO_2M TB4 RTD Note All 4 wires MUST be run to the...

Page 49: ...mA OUT V 4 20 mA OUT I 4 20 mA OUT V 4 20 mA OUT GND I 1 I 2 V 1 COM 2 IOUT 3 N A 4 4 20 mA OUT IO_DA TB6 4 20 mA IN 1 2 3 4 5 6 IO_DA TB2A 12Vdc I I 4 20 mA I I 4 20 mA i 4 20mA 0 Vdc 12 30 Vdc i 4...

Page 50: ...PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB3 PORT 0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB2 IN 10 OUT 9 IN 8 OUT 7 IN 6 OUT 5 IN 4 OUT 3 IN 2 OUT 1 PORT 8 IO_DA TB1 PORT 0 PO...

Page 51: ...ETER 0 METER 1 PORT 8 PORT 8 N PORT 8 N PORT 8 L PORT 8 L PORT 8 PORT 8 PORT 8 L PORT 8 N L 1 N 2 L 3 N 4 IO_2M TB1 PORT 1 8 L 1 N 2 L 3 N 4 IO_2M TB1 PORT 0 8 L N L N L N Note This shows a typical co...

Page 52: ...6 PORT 9 IO_DA ONLY PORT 6 PORT 7 PORT 9 PORT 6 PORT 7 PORT 9 1 2 3 4 5 6 7 8 9 10 IO_DA TB2B PORT 4 PORT 5 PORT 6 PORT 7 PORT 9 1 2 3 4 5 6 PORT 5 PORT 7 IO_2M TB7 PORT 4 1 2 3 4 5 6 PORT 5 PORT 7 IO...

Page 53: ...10 IN PORT 1 10 IN 1 OUT 2 IN 3 OUT 4 IN 5 OUT 6 IO_DA TB3 PORT 10 PORT 11 PORT 12 COM IN X IN 1 OUT 2 IN 3 OUT 4 IO_2M TB9 PORT 0 10 IN 1 OUT 2 IN 3 OUT 4 IO_2M TB9 PORT 1 10 PORT 0 10 IN PORT 1 10...

Page 54: ...OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB3 PORT 0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB2 L N L N N L 1 2 3 Note With only two states returned from the a...

Page 55: ...RT 0 10 IN PORT 10 OUT PORT 10 IN IN 1 OUT 2 IN 3 OUT 4 IO_2M TB9 PORT 0 10 IN 1 OUT 2 IN 3 OUT 4 IO_2M TB9 PORT 1 10 500 mA RESET 12 V COM COUNT 12 Vdc Note Use only model E1613 The Lectro Count 12Vd...

Page 56: ...TER 1 PORT 5 PORT 4 5V 12V PORT 4 1 2 3 4 5 6 7 8 9 10 IO_DA TB2A 12Vdc 1 2 3 4 12Vdc IO_2M TB6 1 2 3 4 12Vdc IO_2M TB6 PORT 4 A 0 1 2 3 4 5 6 IO_2M TB7 PORT 4 PORT 5 PORT 7 1 2 3 4 5 6 IO_2M TB8 PORT...

Page 57: ...PORT 0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB3 PORT 0 OUT 5 PORT 1 OUT 4 PORT 2 OUT 3 PORT 3 OUT 2 LINE IN 1 IO_2M TB2 IN 10 OUT 9 IN 8 OUT 7 IN 6 OUT 5 IN 4 OUT 3 IN 2 OUT 1...

Page 58: ...10 IN 1 OUT 2 IN 3 OUT 4 IN 5 OUT 6 IO_DA TB3 PORT 10 PORT 11 PORT 12 IN 1 OUT 2 IN 3 OUT 4 IO_2M TB9 PORT 0 10 IN 1 OUT 2 IN 3 OUT 4 IO_2M TB9 PORT 1 10 PORT 0 10 IN PORT 1 10 OUT PORT 1 10 IN PORT...

Page 59: ...50 Typical 1 Meter Application Wiring Example IP E Drawing Electrical Wiring Schedule 5 4 14...

Page 60: ...ch into the active position 2 At the idle card in screen enter the security code default security code is 000000 and press the Next key External Switch Access Control MultiLoad II Only 6 1 1 One acces...

Page 61: ...xternal 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 M or Program to indicate their re...

Page 62: ...53 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...

Page 63: ...U board also provide the closure of the program mode W M switch contacts When the MultiLoad II RCU II does not have the external Program Mode W M switch installed it is necessary to use these DIP swit...

Page 64: ...55...

Page 65: ...ss switches Review the MultiLoad II User Guide for more information RCU II INPUTS RECEIVED FROM EXTERNAL FIELD DEVICES CANNOT BE CONFIGURED TO CONTROL PROGRAM MODE ACCESS WEIGHTS AND MEASURES FUNCTION...

Page 66: ...n Press Next to select Diagnostics and then press the Enter key to go to the Diagnostics Menu For menu options and function screen items pressing the Next key moves the selection bar down and pressing...

Page 67: ...o the field within a given applicable range In the example below RCU Address field is highlighted Press ENTER to choose the field A blinking cursor indicates that data can be entered Type in the new v...

Page 68: ...When the MultiLoad II is first powered on the card in screen appears indicating Operating Mode An RCU II may initially display System Unavailable because it is unconnected to a host system RCU GENERA...

Page 69: ...User Guide RCU General Setup section for changing or adding new access codes Note that unlike MultiLoad II Program switches or CPU DIP switches never deny access to RCU II Program Mode 4 The program...

Page 70: ...Additive Cal Remote Adtv Cal Access ID s Custom Logic Customer Logo Setup Next Prev Exit Enter C O N F I G U R A T I O N M E N U Communication Network RCU Setup Customer Logo Setup Date Time Next Pre...

Page 71: ...I O Board Com ERR for the RCU II D I A G N O S T I C S M E N U Card Reader COM Loopback Serial Ports Network Test Keypad Display Unicode RCU Next Prev Exit Enter 000 FCM COM DIAGNOSTICS 00 Ok Exit RCU...

Page 72: ...e MultiLoad II User Manual for diagnostics functions RCU II Each output is listed on the screen adjacent to a number Press a number on the keypad that corresponds to the output under test If the conne...

Page 73: ...64...

Page 74: ...eep the enclosure tightly closed while circuits are live Using a magnetic screwdriver is very helpful in retaining the screws during removal and installation Overview and Subassemblies 7 1 Figure 7 1...

Page 75: ...oard 1 Display Subassembly Active Matrix Display and Display Board 2 Keypad 3 Prox Reader 4 W MS Subassembly 5 Iceshield The following sections describe how to remove and replace each subassembly and...

Page 76: ...ded to this subassembly The CPU subassembly is comprised of different Toptech Parts Figure 7 3 CPU Board Power Supply Comm Board I O Board with Chassis Part numbers Power Supply Communication board AC...

Page 77: ...nting 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...

Page 78: ...rews 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 insta...

Page 79: ...e with the dark insulated side towards the cam see Figure 7 6 When inserting the cable ensure that it is not tilted to one side and that the bottom of the cable is completely seated in the connector 3...

Page 80: ...iver carefully pry out the keypad Installation 1 Carefully install the keypad into the cover 2 Install the keypad plate and retaining screws 3 Reconnect the keypad cable to the keypad Figure 7 8 ML II...

Page 81: ...tom of the card reader onto the bottom of the back plate Align the top hole of the reader with the threaded insert on the back plate Reinstall the flat head screw and tighten 3 Align the assembly back...

Page 82: ...ver Assembly Prox Bracket Mount Thinline II Obsolete Slotted Card Holder Mounted Prox Reader HID Obsolete Removal and Replacement 7 5 3 Replacement part number 4726 Removal 1 Disconnect the prox reade...

Page 83: ...tted Card Holder Mounted TWIC Reader Obsolete Removal and Replacement 7 5 4 Replacement part number 4726 Removal 1 Disconnect the prox reader cable from the display subassembly 2 Remove the 2 screws a...

Page 84: ...M Switch Assembly Removal and Replacement 7 6 Part Number W M Assembly Board 1900 W M Bolt 1901 This assembly is only found for MultiLoad II DIV2 devices Removal 1 Unplug the cable from the CPU board...

Page 85: ...ement 7 7 Part Number Ice Shield 2443 The ice shield is a current standard on MultILoad II and RCUII slotted card readers For installations having freezing temperatures with precipitation for extended...

Page 86: ...ard Holder Overview Parts List and Part Numbers 7 8 The Toptech replacement part numbers are shown in the table below Part Part Number Part Part Number DIV 2 Display Assembly 4720 AC Power Supply Boar...

Page 87: ...terface Cable 1250 Revision 1 1 4729 Backlight power cable 2224 Ice Shield 2443 I O Board Digital Analog I O revision 1 1 4718 2 Meter I O Board revision 1 0 4723 CPU Board Revision 1 0 obsolete Revis...

Page 88: ...79 Chapter8 HardwareRevisionHistory Compatibility Chapter 8...

Page 89: ...ence and changed capacitors on I O board 12 19 2008 Began casting enclosure 12 19 2008 Released magnetic switches for configuration weights and measures 12 19 2008 Prox mounting cup changed from insid...

Page 90: ...ated AC INT rev 1 2 DC INT rev 1 2 10 01 2014 Improved RTD filtering IO_DA rev 1 3 IO_2M rev 1 2 09 24 2015 Released SCS_IO board rev 1 0 Manual Revision 9 2 Revision Date Description RCU 07 18 2006 O...

Page 91: ...format 1 5 ML 10 02 2009 Removed FCM diagrams from chapter 4 and placed them in separate FCM manual 1 6 2 18 2011 Added wiring diagrams for 2 Meter I O board added wiring diagrams for Lectro Count ad...

Page 92: ...83 12 20 2018 Updated Chapter 5 I O wiring figures to support multilingual support improved mechanical drawings updated Declaration of Conformity and included I O heat dissipation...

Page 93: ...North America office Toptech Systems Inc 1124 Florida Central Parkway Longwood FL 32750 USA Phone 1 407 332 1774 Europe office Toptech Systems NV Nieuwe Weg 1 2070 Zwijndrecht Antwerp Belgium Phone 3...

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