Toptech FCM II Installation Manual
FCM II
(Flow Control Module)
Installation Guide
Part # 2307
April 26, 2013
2
Notified Body(ies)
NMi Certin B.V., Number 0122
Hugo de Grootplein 1
3314 EG Dordrecht
The Netherlands
Notified Body(ies)
NMi Certin B.V., Number 0122
Hugo de Grootplein 1
3314 EG Dordrecht
The Netherlands
EC Declaration Of Conformity (Valid until April 20, 2016)
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)
2006/95/EC The Low Voltage Directive (and its amending directives)
Product: Distributed I/O Control System
Model name/number: FCM II
Conformity has been demonstrated with reference to the following documentation:
(MID) 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 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
IEC 61010-1: 2004 Electrical Equipment for Measurement, Control, and Laboratory Use; Part 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 instructions:
2014/32/EU The Measuring Instruments Directive (and its amending directives)
2014/30/EU The Electromagnetic Compatibility Directive (and its amending directives)
2014/35/EU The Low Voltage Directive (and its amending directives)
Product: Distributed I/O Control System
Model name/number: FCM II
Conformity has been demonstrated with reference to the following documentation:
(MID) 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 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
IEC 61010-1: 2004 Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements
Year of CE Marking: 2007
Name: William J. Porthouse Position: Director of Engineering & Production Date: 19-April-2016
FCM II Installation Guide: 20160419 - Part # 2307
ELECTRICAL CONSIDERATIONS AND REGULATORY REQUIREMENTS
Equipment Operation. If the equipment is used in a manner not specified in this installation guide,
the protection provided by the equipment may be impaired..
This equipment is suitable for use in Class I, Division 2, Groups C and D hazardous 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 before installing.
CAUTION: Use supply wires suitable for 5°C above surrounding ambient.
!!!
!
4
Copyright Notice
Copyright © 2007-2016 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 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 Flow Control
Module™, veriFID™, ACR™, ACR II™ are trademarks of Toptech Systems, Inc.
Copyright © 2016 Toptech Systems, Inc. All Rights Reserved.
FCM II Installation Guide: 20160419 - Part # 2307
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Table of Contents
Electrical Considerations and Regulatory Requirements ................................................................................3
CHAPTER 1 General ...........................................................................................................................................8
1.1 Who Should Use This Guide ...................................................................................................................8
1.2 Information Alerts: ....................................................................................................................................8
1.3 Receiving and/or Returning Equipment: ................................................................................................8
1.4 Operating Characteristics: ......................................................................................................................8
1.4.1 Electrical Ratings: ...................................................................................................................................9
1.4.2 Operating Conditions: .......................................................................................................................... 10
1.5 Electrostatic Discharge (ESD) Protection: .......................................................................................... 10
CHAPTER 2 Installation .................................................................................................................................. 11
2.1 Module Installation ................................................................................................................................ 11
2.2 Module Removal .................................................................................................................................... 11
2.3 FCM II Panels And Enclosures: ............................................................................................................ 12
2.3.1 Panel Layouts: ..................................................................................................................................... 12
2.3.2 Panel Wiring......................................................................................................................................... 12
2.3.3 Enclosure Mounting ............................................................................................................................. 12
2.4 Electrical Supply Connections ............................................................................................................. 13
2.5 Serial Communication Connection ...................................................................................................... 14
2.6 Device Address Configuration ............................................................................................................. 15
2.7 Swing Arms ............................................................................................................................................ 16
CHAPTER 3 Field Wiring ................................................................................................................................ 18
3.1 Connection Requirements .................................................................................................................... 18
3.2 FCM II Field Device Connections ......................................................................................................... 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 DC Permissive/Status Wiring (6DCIN) ............................................................................................ 28
3.2.11 DC Permissive/Status Wiring (4DCIN/4ACOUT) ............................................................................. 29
3.2.12 AC Output Wiring (4DCIN/4ACOUT) ............................................................................................... 30
3.2.13 DC Output Wiring (6DCOUT) .......................................................................................................... 31
3.2.14 3 Output Air Eliminator Wiring ......................................................................................................... 32
3.2.15 2 Output Air Eliminator Wiring ......................................................................................................... 33
3.2.16 Lectro Count Remote Display Wiring .............................................................................................. 34
CHAPTER 4 Simulation................................................................................................................................... 35
4.1 Meter Simulation .................................................................................................................................... 35
4.2 Additive Simulation ............................................................................................................................... 35
4.3 Analog Simulation ................................................................................................................................. 35
4.4 Generic I/O Simulation .......................................................................................................................... 35
CHAPTER 5 Troubleshooting ........................................................................................................................ 36
5.1 Is The Module Powered?....................................................................................................................... 36
5.2 Is The Module Communicating? .......................................................................................................... 36
5.3 Are The Inputs Functioning? ................................................................................................................ 37
5.4 Are The Outputs Functioning? ............................................................................................................. 37
FCM II Installation Guide: 20160419 - Part # 2307
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5.5 Are RTD Errors Present? ...................................................................................................................... 38
5.6 Are Other Errors Present? .................................................................................................................... 38
5.7 Is Technical Assistance Available? ..................................................................................................... 38
CHAPTER 6 Dimensions, Panel Layouts, 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
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Table of Figures
Figure 1.1 FCM II Module Comparison .............................................................................................................9
Figure 1.2 FCM II Module Electrical Ratings ....................................................................................................9
Figure 2.1 Engage Top Foot on Rail .............................................................................................................. 11
Figure 2.2 Snap Metal Foot to Rail ................................................................................................................. 11
Figure 2.3 Slide Modules Together ................................................................................................................ 12
Figure 2.4 Power / Com Connection Bus ...................................................................................................... 13
Figure 2.5 Module Status, Configuration Setting and Identification .......................................................... 15
Figure 2.6 DIP Switch Configuration Settings .............................................................................................. 16
Figure 2.7 Swing Arm Wiring of Shared FCM IIs .......................................................................................... 17
Figure 3.1 FCM II Single And Double Module Comparison ......................................................................... 19
Figure 3.2 FCM II Field Wiring Terminal Locations ...................................................................................... 19
Figure 3.3 FCM II Field Wiring: Flow Meter and Control Valve ................................................................... 20
Figure 3.4 FCM II Field Wiring: Additive Meters and Injection Valves ....................................................... 21
Figure 3.5 FCM II Field Wiring: RTD ............................................................................................................... 22
Figure 3.6 FCM II Field Wiring: 4-20mA Input ............................................................................................... 23
Figure 3.7 FCM II Field Wiring: 4-20mA Input ............................................................................................... 24
Figure 3.8 FCM II Field Wiring: 4-20mA Output ............................................................................................ 25
Figure 3.9 FCM II Field Wiring: AC Permissive/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 Wiring: 2 Output Air Eliminator ............................................................................... 33
Figure 3.17 FCM II Field Wiring: Lectro Count Remote Display ................................................................... 34
Figure 5.1 FCM II Module Front Panel ............................................................................................................ 36
Figure 6.1 FCM II Single Module Dimensions .................................................................................................. 39
Figure 6.2 FCM II Double Module Dimensions ................................................................................................. 40
Figure 6.3 20 Inch x 20 Inch Panel Layout .................................................................................................... 41
Figure 6.4 20 Inch x 20 Inch Enclosure Dimensions .................................................................................... 42
Figure 6.5 30 Inch x 30 Inch Panel Layout .................................................................................................... 43
Figure 6.6 30 Inch x 30 Inch Enclosure Dimensions .................................................................................... 44
Figure 6.7 FCM II Power and Serial Communication Panel Wiring: Single Row ....................................... 45
Figure 6.8 FCM II Power and Serial Communication Panel Wiring: Two Rows, Two Serial Ports .......... 46
Figure 6.9 FCM II Power and Serial Communication Panel Wiring: Two Rows, One Serial Port ............ 47
Figure 6.10 FCM II Field Terminal Block Labels ............................................................................................. 48
FCM II Installation Guide: 20160419 - Part # 2307
Chapter 1 – General
8
!
Important information to enhance understanding and make better use of the product.
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.
CHAPTER 1 GENERAL
1.1 WHO SHOULD USE THIS GUIDE
This guide is intended for individuals installing FCM II panels, engineering firms fabricating FCM II panels, and
users troubleshooting system operation such as managers, system administrators, technicians, and meter proving
personnel.
1.2 INFORMATION ALERTS:
1.3 RECEIVING AND/OR RETURNING EQUIPMENT:
The FCM II 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
1.4 OPERATING CHARACTERISTICS:
FCM II is available in six varieties (see Figures 1.1 and 1.2 below). This modular construction simplifies the
process of FCM mapping to field devices by appropriating each FCM II model with just the right amount of I/O for
its designated purpose. In addition, FCM IIs are DIN rail (35mm) mountable and require no wiring between units;
24Vdc and serial communications are bussed. This substantially simplifies installation and wiring.
FCM II Installation Guide: 20160419 - Part # 2307
Chapter 1 – General
9
Module
Supply
Voltage
Electrical Ratings
Auxiliary
Power Supply
Outputs
Inputs
FCM II 4DC IN/
4AC OUT
Min. 19 Vdc
Max. 36 Vdc
100mA Max
12 Vdc
167 mA Max
250 Vac
350 mA max.
6K Cycles, Pilot Duty
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 OUT
Min. 19 Vdc
Max. 36 Vdc
100mA Max
30 Vdc
250mA max.
6K Cycles, Pilot Duty
Figure 1.1 FCM II Module Comparison
1.4.1 ELECTRICAL RATINGS:
Figure 1.2 FCM II Module Electrical Ratings
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Chapter 1 – General
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1.4.2 OPERATING CONDITIONS:
Operating temperature (surrounding air temperature) -40°F to 140°F (-40°C to 60°C).
Environmental Ratings: None. FCM II modules are classified as open equipment must be placed in a
suitable Type 4 (or IP 65) or better enclosure.
For product outline and dimensions see Figure 6.1 and Figure 6.2.
1.5 ELECTROSTATIC DISCHARGE (ESD) PROTECTION:
The FCM II contains electronic components and assemblies subject to damage by ESD. The FCM II was
designed to protect against ESD while the unit is mounted on an electrical panel and in normal operation. Proper
handling procedures must be observed during the removal, installation, 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 blocks do allow a possible path
for ESD when not fastened to the electrical panel. Therefore, a servicing technician is advised to
touch unpainted metal of the electrical panel prior to installing or replacing FCM II modules.
4) FCM II modules must be placed in and transported in conductive bags or other conductive containers.
5) FCM II modules 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.
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Chapter 2 – Installation
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CHAPTER 2 INSTALLATION
2.1 MODULE INSTALLATION
FCM II modules are easily attached to 35mm DIN rails by tilting the top edge toward the panel and catching the
top edge on the rail (see Figure 2.1 below). Then the module is swung back down until the spring loaded metal
foot catches on the bottom edge of the rail (see Figure 2.2 below). The 24 Vdc power and RS-485
communication is connected 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 ¼” Flat Head screwdriver and sliding the catch away from the rail and tilting the module top toward the
panel. With the bottom edge disconnected, the top foot may by moved off of the rail to free the module. Do not
attempt to open the module’s plastic housing.
Figure 2.1 Engage Top Foot on Rail
FCM II Installation Guide: 20160419 - Part # 2307
Figure 2.2 Snap Metal Foot to Rail
Chapter 2 – Installation
12
Figure 2.3 Slide Modules Together
2.3 FCM II PANELS AND ENCLOSURES:
2.3.1 PANEL LAYOUTS:
Toptech Systems assembles standard panel layouts which are shown in Chapter 6. These include a 20 inch by
20 inch panel with a single DIN rail of FCM IIs or a 30 inch by 30 inch panel with two DIN rails of FCM IIs.
Exterior dimensions of the panel’s associated enclosures are also shown in Chapter 6.
2.3.2 PANEL WIRING
The following guidelines are recommended when installing panels at a facility and making field 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 and surges.
4. Wiring must comply with all local electrical codes.
2.3.3 ENCLOSURE MOUNTING
Mounting instructions are provided with all panel assemblies shipped by Toptech. Whether installing a Toptech
supplied FCM II enclosure, or installing a customer sourced enclosure, follow the manufacturer’s mounting
instructions in order not to invalidate regulatory requirements.
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Chapter 2 – Installation
13
2.4 ELECTRICAL SUPPLY CONNECTIONS
FCM IIs require a supply of 19 – 36 Vdc, 100mA to power each module (200mA for a double). The power must
be from an isolated, SELV (Safety Extra Low Voltage) power supply, rated 36 VDC max.
Although the ten position power/communication bus terminal block is rated for solid or stranded copper wire 14 to
30 AWG [2.1 to 0.05 mm2], Toptech recommends using stranded 16 to 18 AWG [1.3 to 0.8 mm2] 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 ¼” and inserted into terminal
block leaving no bare conductor exposed. Only one of each of the three possible 24 VDC+/DC COMMON pairs
need be used; the rest are provided for bus capacity.
24 VDC + 24 VDC +
24 VDC + 24 VDC +
24 VDC + 24 VDC +
DC Common DC Common
DC Common DC Common
DC Common DC Common
RDA RDA
RDB RDB
TDA TDA
TDB TDB
Figure 2.4 Power / Com Connection Bus
FCM II Installation Guide: 20160419 - Part # 2307
Chapter 2 – Installation
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!
!
Note 1: If a disconnecting device is used, ensure that it is not blocked by FCMs or any other
device which would make it difficult to operate. If used, do not place the disconnect in a
Class I, Division 2 location.
Note 2: Do not place a thermal magnetic circuit breaker in a Class I, Division 2 location.
The installer should provide over current protection between the branch circuit and the supply according to the
power supply manufacturer’s recommendations; usually either an appropriately sized s low-blow fuse or a
characteristic B thermal magnetic circuit breaker. Because the primary side of the power supply is overcurrent
protected, it is not necessary to fuse the 24 Vdc output, unless it is used to supply power to field devices located
outside of the panel housing the FCM IIs.
2.5 SERIAL COMMUNICATION CONNECTION
RS-422/485 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 end may be connected
to a MultiLoad or other serial device as the bus supplies the serial connection to all modules that are joined
together. The TD and RD pairs are swapped at the MultiLoad II. Although the ten position terminal block is rated
for 14 to 30 AWG [2.1 to 0.05 mm2], a reliable serial connection will be achieved by the use of cable meeting the
following:
24 AWG [0.2 mm2] stranded.
4-wire, two 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.
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Chapter 2 – Installation
15
2.6 DEVICE ADDRESS CONFIGURATION
Figure 2.5 shows the locations of I/O, power, and communication status indicators 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
FCM II Installation Guide: 20160419 - Part # 2307
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