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Toptech MultiLoad II EXL Installation Manual Download Page 78

CHAPTER 7

–

 SERVICE AND REPAIR 

78

 

MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070

 

 

Overview Parts List and Part Numbers 

 

The Toptech replacement part numbers are shown in the table below:  

 

Part 

Part Number 

 

Part 

Part Number 

EXL Display Assembly 

 

1667

 

 

AC Power Supply Board :

 

 

EXL Prox Card Reader 

 

1669

 

 

Revision 1.0, 1.1

 

obsolete

 

EXL Keypad

 

1638

 

 

Revision 1.2

 

4728

 

EXL Keypad Barrier (1.1)

 

obsolete

 

 

DC Power Supply Board :

 

 

EXL Keypad Barrier (2.0)

 

2710

 

 

Revision 1.0, 1.1

 

obsolete

 

 

 

 

Revision 1.2

 

4729

 

Magnetic Switch Assembly 

 

1900

 

 

I/O Board :

 

 

Magnetic Bolt Assembly 

 

1901

 

 

Digital/ Analog I/O, revision 1.3

 

4718

 

Display Interface Cable 

 

1250

 

 

2 Meter I/O Board, revision 1.2

 

4723

 

EXL backlight power cable

 

1663

 

 

CPU Board :

 

 

 

 

 

Revision 1.0, 2.0

 

obsolete

 

 

 

 

Revision 2.1

 

4727

 

 

 

Summary of Contents for MultiLoad II EXL

Page 1: ...MultiLoad II RCU II Explosion Proof Lite EXL Installation Guide Part 6070 MAY 2019 ...

Page 2: ...ms Inc 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 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 an...

Page 3: ...tplein 1 1322 Høvik Norway 3314 EG Dordrecht The Netherlands Conformity has been demonstrated with reference to the following documentation EC type examination certificate Presafe 17 ATEX 9557X IECEx CoC IECEx PRE 17 0013X 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 Ge...

Page 4: ...sions 15 2 1 2 1 Front View 15 2 1 2 2 Back View 15 2 1 2 3 Bottom View 16 2 1 2 4 Side View 16 Operating Characteristics 17 CHAPTER 3 INSTALLING THE MULTILOAD II RCUII EXL 19 Tools Required 19 Installation 19 Servicing and Repair 19 Cover Closure and Bolt Replacement 19 Cable Entries 20 Mounting the MultiLoad II RCU II DIV 2 Enclosure 20 Metal Plate or Rail 20 Wood 20 Concrete or Cinder Block Wal...

Page 5: ...ces to the I O Boards 39 MultiLoad II Flow Meter and Control Valve Wiring 40 MultiLoad II Additive Wiring Outputs 41 MultiLoad II Additive Wiring Inputs 42 MultiLoad II Analog Wiring 43 5 4 4 1 RTD Wiring 43 5 4 4 2 MultiLoad II 4 20 mA Input Wiring 44 5 4 4 3 MultiLoad II 4 20 mA Output Wiring 45 MultiLoad II AC Output Wiring 46 MultiLoad II AC Input Wiring 47 MultiLoad II DC Permissive Status Wi...

Page 6: ...mblies 67 CPU Subassembly Removal and Replacement 69 Display Subassembly Removal and Replacement 71 Flat Display Cable Connector Remove and Connect 72 Keypad Removal and Replacement 73 Keypad Barrier Removal and Replacement 74 Keypad Barrier Version 2 0 LED indicators 74 Keypad Barrier Version 1 1 no LED indicators 75 Card Reader Removal and Replacement 76 W M Switch Assembly Removal and Replaceme...

Page 7: ...UT HANDSHAKE 32 FIGURE 4 11 PTB PRINTER CONNECTION WITH HANDSHAKE 33 FIGURE 4 12 PTB PRINTER CONFIGURATION 33 FIGURE 5 1 DIGITAL ANALOG I O BOARD TERMINAL BLOCK ASSIGNMENTS 37 FIGURE 5 2 2 METER I O BOARD TERMINAL BLOCK ASSIGNMENTS 38 FIGURE 6 1 TYPE 3 PROGRAM W M SWITCH WITH MAGNETIC BOLTS 57 FIGURE 6 1 TYPE 1 PROGRAM W M SWITCHES 57 FIGURE 6 2 TYPE 2 PROGRAM W M SWITCHES 58 FIGURE 6 4 CPU DIP SW...

Page 8: ...talling the MultiLoad II RCUII EXL This chapter covers installation considerations and instructions for the the Explosion Proof Lite EXL Model 4 Data Communication Interface This chapter reviews hardware connections and communication processes 5 Connecting Field Devices to the Internal I O Board This chapter covers the available I O points per board the terminal arrangements per board and then des...

Page 9: ...ldface Indicates what is pressed 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 This guide covers RCU MultiLoad EXL installation information only For information about base MultiLoad firmware please consult the MultiLoad II User Guide For information about wiring other models please consult the r...

Page 10: ...Contact Toptech s Return Materials Department to initiate timely repair or replacement of the unit A Return Materials Authorization RMA 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 Systems Inc 1124 Florida Central Pkwy Longwood FL 32750 USA 1 407 3...

Page 11: ...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 AMÉRICAINE...

Page 12: ...ION COVER BOLTS MUST HAVE A YIELD STRESS OF AT LEAST 700 N mm 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 atmosphere is present WARNING All unused conduit entries must be s...

Page 13: ...r 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 FCC Note This equipment complies with the limits for a Class A Digital Device pursuant t...

Page 14: ... II Explosion Proof Lite EXL Installation Guide Part 6070 Chapter 2 Operating Conditions and Components Product Outline and Dimensions MultiLoad II RCU II EXL Model Picture Figure 2 1 MultiLoad II ML II Remote Control Unit II RCU II Explosion Proof Lite EXL Chapter 2 ...

Page 15: ...Lite EXL Installation Guide Part 6070 MultiLoad II RCU II EXL Model Dimensions 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 2 1 2 2 Back View Figure 2 3 Unit Outline Drawing Back View ...

Page 16: ...NDITIONS AND COMPONENTS 16 MultiLoad II RCU II Explosion Proof Lite EXL Installation Guide Part 6070 2 1 2 3 Bottom View Figure 2 4 Unit Outline Drawing Bottom View 2 1 2 4 Side View Figure 2 5 Unit Outline Drawing Side View ...

Page 17: ... 2 User Selectable RS 232 or RS 485 1 Ethernet port 10 100 Mbps 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 the table below Type I O Digital Analog I O Quantity Location 2 Meter I O Quantity Location Electrical Rating AC Outputs 5 TB1 8 TB2 TB3 1...

Page 18: ...O I O TOTAL Dissipation I O TOTAL Dissipation V Hz W W W ACOUT 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 0 00 6 0 03 6 0 03 15 0 06 6 0 33 6 0 33 24 0 16 6 0 97 6 0 97 30 0 23 6 1 41 6 1 41 4 20 mA Input 0 03 1 0 03 0 I O points dissipating 1 ...

Page 19: ...e housing by twenty 10mm hex cap screws An 8mm 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 Dr...

Page 20: ...ons for three typical surfaces metal wood or concrete solid block Metal Plate or Rail Use four hex head 3 8 OD M10 bolts with a 3 8 flat washer 3 4 OD M10 20mm OD under the head of the bolt Tighten with four 3 8 M10 hex nuts Wood Use four hex head 2 x 3 8 OD M10 x 50 mm lag bolts with a 3 8 flat washer 3 4 OD M10 20 mm OD under the head of the bolt Or you may drill through holes in the wood and as...

Page 21: ...CHAPTER 3 INSTALLING THE MULTILOAD II RCUII EXL 21 MultiLoad II RCU II Explosion Proof Lite EXL Installation Guide Part 6070 Figure 3 1 Suggested Mounting Position Figure 3 2 Screen Visible Area ...

Page 22: ...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 and suitable for ...

Page 23: ... The disconnected device may not be blocked or be made difficult to operate by the MultiLoad II RCU II or any other device Note that installation of disconnects are typically prohibited in Class I Division 1 or 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 bottom corner of the Power Supply Communication board as ...

Page 24: ... 24 Vdc power supply Wire gauge AWG Distance feet 24 50 22 100 20 150 18 250 16 400 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 3 6 Keep the required tightening torque in mind section 3 5 The external ground c...

Page 25: ... 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 length in the service loop should not exceed 3 inches 75mm 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 Default settings in MultiLo...

Page 26: ...he 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 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 con...

Page 27: ... T568B Cat5 cable or greater Communication Connection Wiring This section describes the wiring connections for each of the communication ports in order to function for a specifc communication protocol FCM I FCM II Communications MultiLoad II Only COM 0 Port RS485 FCM I FCM II and PCM modules communicate with the MultiLoad II using the COM0 This is a dedicated communication line The FCMII modules l...

Page 28: ...r system can be connected to 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 multridropped on the same communication line using a RS485 4 Wire on COM 1 to communicate to a host system Figure 4 3 RS485 4 Wire Host to Multiple MultiLoad II RCU IIs TDA T...

Page 29: ... RD pairs tied together at the Host TMS and all MultiLoad II RCU IIs Figure 4 4 RS485 2 Wire Host to a Single MultiLoad II RCU II MultILoad II RCU II can be multidropped on the same communication line using RS485 2 Wire on COM 1 Figure 4 5 RS485 4 Wire Host to Multiple MultiLoad II RCU IIs TDA TDB RDA RDB RDA RDB TDA TDB MultiLoad II RCU II COM 1 Host TMS RS485 TDA TDB RDA RDB RDA RDB TDA TDB RDA ...

Page 30: ...iLoad 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 II RCU II MultiLoad II RCUII has the ability to multi drop onto a RS232 line on COM 1 Figure 4 7 RS232 Host to Multiple MultiLoad II RCU IIs TX RX RX TX GND GND TX RX RX TX GND GND RX TX GND MultiLoad II RCU II COM 1 Host TMS RS232 MultiLoad II RCU II 1 COM Host TMS RS232 MultiL...

Page 31: ...vice the transceiver will configure the port settings automatically Thus the choice of a straight through or cross over cable no longer has to be made either will work Ethernet is available on MultiLoad II RCUII with revision 2 0 or higher CPU boards Figure 4 8 Ethernet Connections Host Ticket Printer Data Logger Ticket Printers or alibilog printers can be connected to the MultiLoad II RCU II in t...

Page 32: ...TS DSR and DCD for active signals Figure 4 9 Ticket Printer Data Logger Connections with Handshake Figure 4 10 Ticket Printer Data Logger Connections without Handshake When Print or Alibi Log is configured to be on COM 2 the CTS handshake line MUST be connected or a printer error will occur preventing loading MultiLoad II RCU II COM 2 Printer Logger RS232 DB25 Connector RX CTS TX GND DSR N C DCD N...

Page 33: ...d II RCU II via RS232 on COM 2 or COM1 Figure 4 11 PTB Printer Connection with Handshake Figure 4 12 PTB Printer Configuration MultiLoad II RCU II COM 2 PTB Printer Logger RS232 DB25 Connector RX CTS TX GND DSR N C DCD N C RTS N C DTR 2 TX 20 DTR 3 RX 7 GND 4 RTS 5 CTS N C 6 DSR N C 8 DCD N C COMMUNICATION SETUP COM 1 Baud Rate 9600 Parity Even Data Bits 7 Data Stop Bits 1 Stop Multidrop Single Ty...

Page 34: ...and 5 2 show the board s terminal arrangements The 2 Meter I O board treats 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 For more information please consult the MultiLoad II Users Guide Locating the Internal I O Board The I O board is mounted above t...

Page 35: ...BOARD I O BOARD 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 meter inputs 1 5000Hz Miscellaneous signal inputs 12Vdc Source 167mA Max Load 250mA Max Load Isolated Power Supply Power for flow meter pulsers or preamp RTD Input 1 2 100 ohm platinum fo...

Page 36: ...nal inputs DC Input 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 optional quadrature DC Input 1 If an additive injection control is used the numbered DC input must be paired with the corresponding numbered AC output AC Input L N All AC inputs may be us...

Page 37: ...ments per Board Digital Analog I O Board IO_DA 1 10 100Ω C 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 0 Vdc 12 30 Vdc i 4 20mA Figure 5 1 Digital Analog I O Board Terminal Block Assignments ...

Page 38: ... TB8 TB9 TB3 TB2 TB1 A 0 1 6 1 4 1 4 1 4 1 4 5 1 4 1 METER 0 RTD 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 PORT 1 METER 1 PORT 2 METER 1 PORT 3 LINE METER 0 PORT 0 METER 0 PORT 1 METER 0 PORT 2 METER 0 PORT 3 LINE IO_2M Figure 5 2 2 Meter I O B...

Page 39: ...the I O boards This is not an exhaustive listing but intended to provide you an example of how certain types of I O need to get wired into the various boards MultiLoad II Wiring Examples Flow Meter and Control Valve Additive RTD Analog In Analog Out AC Output Wiring AC Input Wiring DC Input Wiring Permissives Status DC Output Wiring 2 Output Air Eliminator Wiring Remote Display Wiring RCUII Wiring...

Page 40: ...PORT 8 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 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 4 5 6 IO_2M TB7 PORT 4 PORT 5 PORT 7 1 2 3 4 12Vdc IO_2M TB6 1 2 3 4 5 6 IO_2M TB8 PORT 4 PORT 5 PORT 7 1 2 3 4 12Vdc IO_2M TB6 PORT 4 POR...

Page 41: ... IN 2 OUT 1 PORT 2 IO_DA TB1 PORT 0 PORT 1 PORT 3 PORT 8 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 PORT 3 PORT 2 OUT PORT 2 IN LINE IN PORT 3 OUT PORT 3 OUT PORT 3 IN Output Port Input Port Injector 1 0 7 Injector 2 1 6 Injector 3 2 5 Injector 4 3 4 Note The output port that is selected will dicta...

Page 42: ...ORT 4 PORT 5 PORT 7 PORT 7 IO_DA ONLY PORT 7 PORT 7 PORT 6 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 kΩ 1 4W 1 kΩ 1 4W 1 kΩ 1 4W 1 kΩ 1 4W 12Vdc Note Most additive injection meters only provide an Open Collector pull down type output Typically a 1 000 Ohm watt pull up resistor needs to be added in the pulser junction box to pull th...

Page 43: ...100Ω C Pt F α 0 00385 100 Ω α 0 00385 100 Ω α 0 00385 100 Ω RTD RTD 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 sensor Do not simply jumper REF to COM or REF to V at the FCM II For 3 wire and 2 wire probes the connection of REF to COM and REF t...

Page 44: ...N I 4 20 mA IN I 4 20 mA IN I 4 20 mA IN I 4 20 mA IN i 4 20mA 4 20 mA IN I 4 20 mA IN I 4 20 mA INVALCO WCM 7300 LOOP 24 GND 24 4 20 mA 4728 BS W 4 20 mA IN EXT Note The 4 20 mA 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 Note 4 20 mA IN I MUST CONNECT TO LOOP SUPPLY Note A sepa...

Page 45: ...0 mA OUT I 4 20 mA OUT GND 4 20 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 20mA 0 Vdc 12 30 Vdc 12 30 Vdc 4 20 mA OUT 4 20 mA OUT Note The 4 20mA output requires a power source 12 30vdc The 12vdc output can be used as shown here ...

Page 46: ...L N N O N C C PORT 3 PORT 2 PORT 8 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 PORT 8 IO_DA TB1 PORT 0 PORT 1 PORT 2 PORT 3 IO_DA ONLY PORT 2 IN LINE IN PORT 3 IN LINE IN PORT 8 IN PORT 2 OUT PORT 3 OUT PORT 8 OUT COM IN X M L N L N L N L N Not...

Page 47: ...d II AC Input Wiring L N 15A I O DIGITAL ANALOG I O 2 METER METER 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 configuration AC Permissive Status inputs can be assigned to any unused AC input ...

Page 48: ...ETER 1 PORT 5 PORT 4 PORT 5 PORT 4 PORT 5 PORT 4 PORT 7 PORT 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_2M TB8 PORT 4 IO_DA ONLY 5 30 Vdc M L N L N Note This shows a typical configuration DC Permissive Status inputs can be assigned to any unu...

Page 49: ...RT 12 IN PORT 12 OUT IO_DA ONLY M N 5 30 Vdc PORT 10 OUT PORT 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 OUT PORT 1 10 IN PORT 0 10 OUT PORT 10 PORT 10 L N Note This shows a typical configuration DC outputs can be assigned to any unused DC outp...

Page 50: ... 2 OUT 1 PORT 2 PORT 3 IO_DA TB1 PORT 0 PORT 1 PORT 8 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 L N L N N L 1 2 3 Note With only two states 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 use...

Page 51: ...6 IO_DA TB3 PORT 10 PORT 11 PORT 12 PORT 10 PORT 0 10 OUT PORT 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 12Vdc 12V common can be supplied by an external source Note I O DIGITAL ANALOG Only Connect Port 10 to Lectro Count output pulse Connect Port 11...

Page 52: ...ng VCC A B GND B A I O DIGITAL ANALOG I O 2 METER METER 0 METER 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 4 PORT 5 PORT 7 1 2 3 4 5 6 7 8 9 10 IO_DA TB2B PORT 4 PORT 5 PORT 6 PORT 7 PORT 9 12 Vdc ...

Page 53: ...0 IN PORT 0 OUT PORT 1 OUT LINE IN PORT 1 IN LINE IN PORT 0 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 PORT 8 IO_DA TB1 PORT 0 PORT 1 PORT 2 PORT 3 L N N O N C C N L L N L N Note This shows a typical configuration AC outputs can be assigned to...

Page 54: ...ORT 10 OUT PORT 10 IN PORT 0 10 PORT 10 OUT PORT 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 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 0 10 OUT PORT 10 PORT 10 N O N C C N L 5 30 Vdc L N Note This shows a typical configuration DC outputs can be assigned to any unused DC out...

Page 55: ...ER 5 CONNECTING FIELD DEVICES TO THE I O BOARD 55 MultiLoad II RCU II Explosion Proof Lite EXL Installation Guide Part 6070 Typical 1 Meter Application Wiring Example IP E Drawing Electrical Wiring Schedule ...

Page 56: ... 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 Next key External Switch Access Control MultiLoad II Only 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 cont...

Page 57: ...s a small hole that can be sealed with 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 M or Program adjacent to each bolt to indicate the bolt function Figure 6 1 Type 3 Program W M Switch with Magnetic Bolts Do not use a wrench to tighten the bolts Insert the bolts and hand tighten only Over tightening will da...

Page 58: ...ndividual 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 is denied and Weights and Measures access is denied B First cover open Program access is allowed and Weights and Measures access is denied C Both covers open Program access is allowed and Weights and Measures access is allowed Figure 6...

Page 59: ...he W M access switch In the example in Figure 6 4 below the program mode switch is currently active while the W M switch is not active Figure 6 5 shows the location of the DIP switch on revision 2 x CPU boards A switch input is active when either the DIP switch OR the external switch is active ON Figure 6 4 CPU DIP Switches for Program and W M Access rev 1 0 Figure 6 5 CPU DIP Switches for Program...

Page 60: ...tion 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 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 M A I N M E N U Configuration Diagnostics Views and Inqui...

Page 61: ...into 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 value e g 123 and press Enter The new value displays on the screen RCU GENERAL SETUP RCU Address 001 Card Reader DISABLD Processing Mode Remote Swing Arn Secondary DISABLD Terminal Name Toptech Term...

Page 62: ...onfiguration 1 Power on the MultiLoad II RCU II 2 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 GENERAL SETUP RCU Address 123 Card Reader DISABLD Processing Mode Remote Swing Arn Secondary DISABLD Terminal Name Toptech Terminal Security Accounts Next Pr...

Page 63: ...tup 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 mode main menu displays the following MultiLoad II RCU II 5 Press Enter to access the Configuration menu 6 Press Enter to access RCU General Setup RCU Setup For Access Insert Driver Card M A I N M E N U Configuration Diagnosti...

Page 64: ...twork RCU General Setup RCU Setup Security Setup Equipment Setup FCm Type Setup Alarm Setup Products 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 Date Time Printing Trace Reports 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 Prev Exit Enter...

Page 65: ...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 RCU II is assembled but it is possible for the settings to be updated by the installer D I A G N O S T I C S M E N U Card Reader Preset COM Loopback Meters Serial Ports Components PTB Serial Test Additives Network Test Sampler Keypad Custom Logic Display Modbus Device Unicode Threa...

Page 66: ...output under test If the connection has been made properly the field device will actuate NOTE If numbers do not appear next to the outputs enter Configurations RCU Setup and change the password from the default 00000 Inputs Each input is listed on the screen adjacent to its status Each input will be in either the ON or OFF state Activate each input from the field If the circuit is connected proper...

Page 67: ...U 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 Figure 7 1 MultiLoad II ML II Remote Control Unit II RCU II Explosion Proof Lite Unit Chapter 7 DISPLAY DISPLAY KEYPAD CARD READER SLOT ...

Page 68: ...de CPU Subassembly CPU Chassis CPU Board Power Supply COM Board I O Board 1 Display Subassembly Active Matrix Display and Display Board 2 Keypad 3 Keypad Barrier Circuit 4 Prox Reader 5 W MS Subassembly 6 The following sections describe how to remove and replace each subassembly and when applicable how to further disassemble the subassembly Figure 7 2 ML II RCU II EXL Unit Assembly 5 1 BACKLIGHT P...

Page 69: ...d the CPU mounted Optionally an I O board can be added 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 Power Supply Board 4728 DC Power Supply Board 4729 CPU Board 4727 I O Boards Digital Analog I O Board 4718 2 Meter I O Board 4723 POWER SUPPLY COMMU...

Page 70: ... 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 M Access Program Mode switch cable to the CPU board 4 Rec...

Page 71: ... 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 ...

Page 72: ... 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 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 Rotate the cam to the closed down position to lock in place see...

Page 73: ... depressing the connector latch to remove the cable Installation 1 Connect the keypad cable to the back of the keypad 2 Slide the keypad wires to the side of the connector install the keypad The wires must be to the side of the connector for the keypad to sit flush all the way around the edge Place a weighted object on top of the keypad to hold it down and in place for installing the new gasket 3 ...

Page 74: ...sion 1 1 Figure 7 10 Keyapd Barrier Version 2 0 LED indicators Keypad Barrier Version 2 0 LED indicators Removal 1 Remove the outside connector plug from the barrier side header 2 Remove the four screws holding barrier circuit box 3 Remove the inside connector plug from the barrier circuit board header Installation 4 Reinstall the inside connector plug to the barrier circuit board header 5 Reinsta...

Page 75: ...n 2 0 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 four holding screws 2 Connect the keypad cable to the display subassembly Figure 7 12 ML II RCU II EXL Unit Cover with Barrier Version 1 1 Obsolete ...

Page 76: ...XL Prox Card Reader 1669 Removal 1 Disconnect the prox reader cable from the display subassembly 2 Remove the two nuts holding prox reader 3 Remove the prox reader Installation 1 Reinstall the prox reader with the two nuts 2 Connect the prox reader cable to the display subassembly Figure 7 13 ML II RCU II EXL Cover Assembly Prox Bracket Mount PROX READER ...

Page 77: ... from the CPU board Carefully depress the locking mechanism on the connector and gently pull 2 Remove the two screws securing the switch board assembly 3 Remove the board Installation 1 Install the new switch assembly using the same screws Install with the cut corners facing outward DO NOT over tighten and simply secure gently Over tightening will crack the ferrite rings damaging the switch 2 Rein...

Page 78: ...Supply Board EXL Prox Card Reader 1669 Revision 1 0 1 1 obsolete EXL Keypad 1638 Revision 1 2 4728 EXL Keypad Barrier 1 1 obsolete DC Power Supply Board EXL Keypad Barrier 2 0 2710 Revision 1 0 1 1 obsolete Revision 1 2 4729 Magnetic Switch Assembly 1900 I O Board Magnetic Bolt Assembly 1901 Digital Analog I O revision 1 3 4718 Display Interface Cable 1250 2 Meter I O Board revision 1 2 4723 EXL b...

Page 79: ...CHAPTER 8 HARDWARE REVISION HISTORY COMPATIBILITY 79 MultiLoad II RCU II Explosion Proof Lite EXL Installation Guide Part 6070 Chapter 8 Hardware Revision History Compatibility Chapter 8 ...

Page 80: ... 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 04 08 2011 IECEx certificate issued 01 17 2012 Replaced relay assemblies on I O board with discrete triacs IO_DA rev 1 2 IO_2M rev 1 1 06 07 2013 Added 2 wire 485...

Page 81: ...CU 02 26 2009 Release of RCU II EXL Installation Guide 1 4 ML 10 02 2009 Added operating characteristics summary changed format to mirror the new MultiLoad II format in the I O section 1 5 02 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 combined RCU II EXL and ML II EXL i...

Page 82: ...Manual update formatting changes restructuring Updated Chapter 5 I O wiring figures to support multilingual support improved mechanical drawings updated Declaration of Conformity and included I O heat dissipation chapter 7 updated and completed 05 13 2019 Updated version date spelling grammar Declaration of Conformity and basic formatting changes 05 13 2019 Updated 4 20 mA input wiring see 5 4 4 2...

Page 83: ...llation Guide Part 6070 Toptech Systems 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 32 0 3 250 60 60 ...

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