Toptech MultiLoad II EXL, RCU II EXL Installation Manual
MultiLoad II & RCU II
Explosion Proof Lite (EXL)
Installation Guide
(Part # 6070)
MAY 2 0 1 9
2 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
TO P T ECH S Y STEM S
MultiLoad II & RCU II – Explosion Proof Lite (EXL)
Installation Guide
1124 Florida Central Parkway
Longwood, FL 32750
USA
Phone +1 (407).332.1774
Copyright Notice
Copyright © 2006 - 2019 Toptech Systems, 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 any claims of damage, lost data, or lost time as a result of using its products.
3 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
EU 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)
2014/34/EU The Potentially Explosive Atmospheres Directive (and its amending directives)
Product: Operator Interface/Process Control Equipment intended for use in potentially explosive
atmospheres
Model name/number: MultiLoad II EXL (MID, YES), RCU II EXL (MID, NO)
Protective Systems: Flameproof ‘d’, Intrinsic Safety ‘ib’
Notified Body(ies)
Det Norske Veritas Certification AS, Number 0575
NMi Certin B.V., Number 0122
Veritasveien 1
Hugo de Grootplein 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 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
EN 60079-0: 2012 Electrical apparatus for explosive gas atmospheres—General requirements
EN 60079-1: 2014 Electrical apparatus for explosive gas atmospheres— Flameproof enclosures ‘d’
EN 60079-11: 2012 Electrical apparatus for potentially explosive atmospheres—Intrinsic safety ‘i’
Year of CE Marking: 2007
Name: William J. Porthouse Position: Director of Engineering & Production Date: 14-May-2019
Name Plate
4 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Table of Contents
OVERVIEW ..................................................................................................................................... 8
CHAPTER 1 GENERAL INFORMATION & WARNINGS ........................................................ 10
Receiving and/or Returning Equipment ........................................................................................... 10
Safety Warnings .................................................................................................................................. 11
Electrostatic Discharge (ESD) Protection ........................................................................................ 13
FCC Note .............................................................................................................................................. 13
CHAPTER 2 OPERATING CONDITIONS AND COMPONENTS ............................................. 14
Product Outline and Dimensions ...................................................................................................... 14
MultiLoad II/ RCU II – EXL Model - Picture ................................................................................... 14
MultiLoad II/ RCU II – EXL Model – Dimensions .......................................................................... 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 Walls .................................................................................................... 20
Mounting Height Considerations ................................................................................................... 20
Recommended Wire Sizes and Torque for All Terminal Blocks .................................................... 22
Electrical Supply Connections .......................................................................................................... 22
Cable Gland Entries ...................................................................................................................... 22
AC Powered Models ..................................................................................................................... 23
DC Powered Models ..................................................................................................................... 24
Equipment Grounding ................................................................................................................... 24
5 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
CHAPTER 4 DATA COMMUNICATIONS INTERFACE ........................................................... 25
Available Communications Protocol Selection and Wire Spec ..................................................... 25
RS-422/485 ................................................................................................................................... 26
RS-232 .......................................................................................................................................... 26
Ethernet ......................................................................................................................................... 27
Communication Connection Wiring .................................................................................................. 27
FCM I/ FCM II Communications (MultiLoad II Only) - COM 0 –Port – RS485 .............................. 27
Host/TMS Communications .......................................................................................................... 28
4.2.2.2 COM 1 - RS-485 2-Wire: Host/TMS Communications .................................................................. 29
4.2.2.3 COM 1 - RS-232 - Host/TMS Communications ............................................................................ 30
4.2.2.4 Ethernet – Host/TMS Communications ......................................................................................... 31
Host Ticket Printer/Data Logger .................................................................................................... 31
4.2.3.1 COM2 – RS232 - Host Ticket Printer/Data Logger ....................................................................... 32
CHAPTER 5 CONNECTING FIELD DEVICES TO THE I/O BOARD ...................................... 34
Locating the Internal I/O Board.......................................................................................................... 34
Available I/O Points per Board........................................................................................................... 35
Terminal arrangements per Board .................................................................................................... 37
Digital Analog I/O Board (IO_DA) ................................................................................................. 37
2 Meter I/O Board (IO-2M) ............................................................................................................ 38
How to Connect and Wire Field Devices 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 Wiring .................................................................................... 48
MultiLoad II DC Output Wiring ...................................................................................................... 49
MultiLoad II 2 Output Air Eliminator Wiring ................................................................................... 50
MultiLoad II Lectro Count Remote Display Wiring ........................................................................ 51
RCU II DC Input Wiring ................................................................................................................. 52
RCU II AC Output Wiring .............................................................................................................. 53
RCU II DC Output Wiring .............................................................................................................. 54
Typical 1 Meter Application Wiring Example: IP&E Drawing (Electrical Wiring Schedule) ........... 55
CHAPTER 6 CONFIGURATIONS ............................................................................................ 56
Switch Access Control ....................................................................................................................... 56
External Switch Access Control (MultiLoad II Only) ...................................................................... 56
6.1.1.1 Magnetic Bolts Program / W&M Switches (current) ...................................................................... 57
6.1.1.2 Two (2) Rotary Program / W&M Switches (obsolete) ................................................................... 57
6.1.1.3 Single Rotary Program / W&M Switch (obsolete) ......................................................................... 58
Internal Switch Access Control ..................................................................................................... 59
Field Switch Access Control .......................................................................................................... 59
6 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
MultiLoad II/ RCU II DIV-2 Keypad ..................................................................................................... 59
Menus and Screens ............................................................................................................................ 60
Field Modification and Data Entry ..................................................................................................... 61
MultiLoad II/ RCU II Preliminary Configuration ................................................................................ 62
Verifying Communications between MultiLoad II/ RCU II and I/O Board ...................................... 65
Using I/O Diagnostics ......................................................................................................................... 66
CHAPTER 7 SERVICE AND REPAIR ....................................................................................... 67
Overview and Subassemblies............................................................................................................ 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 Replacement........................................................................ 77
Overview Parts List and Part Numbers ............................................................................................. 78
CHAPTER 8 HARDWARE REVISION HISTORY & COMPATIBILITY .................................. 79
CHAPTER 9 REVISION HISTORY .......................................................................................... 80
Hardware Revision .............................................................................................................................. 80
Manual Revision .................................................................................................................................. 81
7 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Table of Figures
FIGURE 2.1 MULTILOAD II (ML II) / REMOTE CONTROL UNIT II (RCU II) EXPLOSION PROOF LITE (EXL) 14
FIGURE 2.2 UNIT OUTLINE DRAWING – FRONT VIEW 15
FIGURE 2.3 UNIT OUTLINE DRAWING – BACK VIEW 15
FIGURE 2.4 UNIT OUTLINE DRAWING – BOTTOM VIEW 16
FIGURE 2.5 UNIT OUTLINE DRAWING – SIDE VIEW 16
FIGURE 3.1 SUGGESTED MOUNTING POSITION 21
FIGURE 3.2 SCREEN VISIBLE AREA 21
FIGURE 3.3 MULTILOAD II/ RCU II AC POWER SUPPLY/COMM BOARD 23
FIGURE 3.4 DC POWER CONNECTIONS 24
FIGURE 4.1 FCM / PCM CONNECTIONS 27
FIGURE 4.2 RS485 4-WIRE, HOST TO A SINGLE MULTILOAD II/ RCU II (RECOMMENDED) 28
FIGURE 4.3 RS485 4-WIRE, HOST TO MULTIPLE MULTILOAD II/ RCU IIS 28
FIGURE 4.4 RS485 2-WIRE, HOST TO A SINGLE MULTILOAD II/ RCU II 29
FIGURE 4.5 RS485 4-WIRE, HOST TO MULTIPLE MULTILOAD II/ RCU IIS 29
FIGURE 4.6 RS232, HOST TO A SINGLE MULTILOAD II/ RCU II 30
FIGURE 4.7 RS232, HOST TO MULTIPLE MULTILOAD II/ RCU IIS 30
FIGURE 4.8 ETHERNET CONNECTIONS 31
FIGURE 4.9 TICKET PRINTER / DATA LOGGER CONNECTIONS WITH HANDSHAKE 32
FIGURE 4.10 TICKET PRINTER / DATA LOGGER CONNECTIONS WITHOUT 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 SWITCHES FOR PROGRAM AND W&M ACCESS (REV 1.0) 59
FIGURE 6.5 CPU DIP SWITCHES FOR PROGRAM AND W&M ACCESS (REV 2.X) 59
FIGURE 7.1 MULTILOAD II (ML II) / REMOTE CONTROL UNIT II (RCU II) EXPLOSION PROOF LITE UNIT 67
FIGURE 7.2 ML II/ RCU II EXL UNIT ASSEMBLY 68
FIGURE 7.3 CPU BOARD, POWER SUPPLY / COMM BOARD, I/O BOARD WITH CHASSIS 69
FIGURE 7.4 ML II/ RCU II EXL UNIT COVER DISPLAY ASSEMBLY 71
FIGURE 7.5 CAM LOCK UP (OPEN POSITION) 72
FIGURE 7.6 CAM LOCK DOWN (CLOSED POSITION) 72
FIGURE 7.7 DISPLAY CABLE INSERTION 72
FIGURE 7.8 ML II/ RCU II EXL UNIT COVER KEYPAD ASSEMBLY 73
FIGURE 7.9 KEYPAD BARRIER VERSION 1.1 74
FIGURE 7.10 KEYAPD BARRIER VERSION 2.0 (LED INDICATORS) 74
FIGURE 7.11 ML II/ RCU II EXL UNIT COVER WITH BARRIER VERSION 2.0 (CURRENT) 74
FIGURE 7.12 ML II/ RCU II EXL UNIT COVER WITH BARRIER VERSION 1.1 (OBSOLETE) 75
FIGURE 7.13 ML II/ RCU II EXL COVER ASSEMBLY PROX BRACKET MOUNT 76
FIGURE 7.14 ML II/ RCU II EXL W&M ASSEMBLY 77
8 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Overview
This document is designed to guide individuals installing MultiLoad II/ RCU II EXL equipment, engineering
firms developing site electrical drawings, and users troubleshooting system operations such as managers,
system administrators, technicians, and meter proving personnel.
The following table provides an informative summary of the material available in this guide:
Chapter
Topics Covered
1. General Information and Warnings
This chapter reviews safety and compliance information, as well as
instructions for receiving and returning products.
2.Operating Conditions & Components
This chapter covers product outline and dimensions, as well as
operating characteristics of the unit.
3.Installing 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 describes in detail
how to connect different field devices to the internal I/O Board.
6. Configurations
This chapter describes how to navigate the system, select field
values, perform data entry, and toggle options on and off.
7. Service and Repair
This chapter describes how to service and repair the MultiLoad/
RCUII EXL subassemblies and parts.
8. Hardware Revision History &
Compatibility
This chapter provides changes, modifications, and updates to the
hardware.
9. Revision History
This chapter provides further hardware revisions as well as
revisions made to this document.
9 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
The following keys allow the user to locate information needed in this guide:
ICON KEY
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 this symbol is displayed.
Typographical Conventions:
Boldface: 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 respective installation guides. For information about the MultiLoad register interface and Modbus
communication, please reference the MultiLoad II Communication Guide. Updated versions of all manuals,
including this one, are available on our website at http://www.toptech.com.
CHAPTER 1– GENERAL INFORMATION & WARNINGS
10 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Chapter 1 General Information & Warnings
Receiving and/or Returning Equipment
At receipt, the MultiLoad II/ RCU 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’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) 332-1774
Contact Information for EMEA and Asia:
Return Materials Department
Toptech System NVs
Nieuwe weg 1- haven 1053
2070 Zwijndrecht, BELGIUM
+32 (0)3 250 60 60
Chapter
1
CHAPTER 1– GENERAL INFORMATION & WARNINGS
11 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Safety Warnings
NORTH AMERICAN INSTALLATIONS:
▲ This equipment is suitable for use in Class I, Division 1, Groups C and D locations, OR non-
hazardous locations.
▲ WARNING: TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES,
conduit runs must have a sealing fitting connected within 18 inches of the enclosure.
▲ WARNING: TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES,
disconnect from the supply circuit before opening enclosure. Keep tightly closed when
circuits are live.
▲ WARNING: Substitution of components may impair intrinsic safety.
▲ WARNING: Do not open when an explosive gas atmosphere is present.
▲ WARNING: All unused conduit entries must be sealed with a conduit plug which
satisfies the flameproof “d” method of protection.
▲ CAUTION: Battery may explode if mistreated. DO NOT RECHARGE, DISASSEMBLE, OR
DISPOSE OF IN FIRE.
▲ CAUTION: Field wiring must have a temperature rating of +75 °C or greater.
▲ Consult installation manual for required cable entry size and thread.
▲ A battery is soldered to the processor board for retention of data, time, and date. This battery
should last more than ten years. Please return the board to Toptech Systems for battery
replacement. This battery must be replaced with Matsushita Electric, model BR2477A only. Use
of another battery may present a risk of fire or explosion.
▲ The installation of this product must be in conformity with NFPA 70 (US National Electric Code)
or CSA C22.1 (Canadian Electrical Code) as appropriate.
INSTALLATIONS NORD-AMÉRICAINES (FRANÇAIS)
▲ Cet équipement est compatible pour une installation en Classe I, Division 1, Groupes C & D ou
les emplacements non dangereux.
▲ AVERTISSEMENT: RISQUE D'EXPLOSION Les scellements des conduits doit être
installé à moins de 18 pouces du boîtier.
▲ AVERTISSEMENT: RISQUE D'EXPLOSION Couper le courant avant d'enlever le
couvercle. Garder le couvercle bien fermé tant que les circuits sont sous tension.
▲ AVERTISSEMENT: La substitution de composants peut compromettre la sécurité
intrinsèque.
▲ AVERTISSEMENT: Ne pas ouvrir si une atmosphère explosive peut être présente.
▲ AVERTISSEMENT: Toutes les entrées du boîtier inutilisées doivent être scellées avec un
bouchon de conduit.
▲ PRUDENCE: La pile peut exploser si elle est maltraitée. NE PAS RECHARGER, NE PAS
DÉMONTER, ET NE PAS JETER DANS LE FEU.
▲ PRUDENCE: Câblage de terrain doit avoir un classement de température de +75 °C ou
plus.
▲ Consultez le manuel d'installation pour le filetage de forme et la taille du presse-étoupe.
Suite à la page suivante
CHAPTER 1– GENERAL INFORMATION & WARNINGS
12 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
INSTALLATIONS NORD-AMÉRICAINES (FRANÇAIS, suite de la page précédente)
▲ Une pile est soudée à la carte processeur pour la conservation des données, de l'heure, et de la
date. Cette pile devrait durer pendant plus que dix ans. Veuillez retourner la carte processeur
à Toptech Systems pour le remplacement de la pile. Remplacez la pile avec Matsushita
Electric, modèle BR2477A seulement. Utiliser une autre pile peut présenter un risque
d'incendie ou d'explosion.
▲ L’installation de ce produit doit se conformer avec NFPA 70 ou CSA C22.1 comme appropriée.
ATEX AND IECEX INSTALLATIONS:
▲ This equipment is suitable for use in Ex Zone I Group IIB locations or non-hazardous locations.
THE LETTER “X” TO THE RIGHT OF THE CERTIFICATE NUMBER INDICATES THE
FOLLOWING SPECIAL CONDITIONS FOR SAFE USE:
▲ CERTAIN FLAMEPROOF JOINTS ARE OTHER THAN THE MINIMUM OR MAXIMUM
DIMENSIONS GIVEN IN IEC/EN/BR 60079-1, CLAUSE 5. PLEASE CONSULT TOPTECH
SYSTEMS IF DIMENSIONAL INFORMATION IS REQUIRED.
▲ MAXIMUM SPECIFIED GAP OF FLANGE JOINT IS 0.08mm.
▲ AMBIENT TEMPERATURE RANGE IS BETWEEN -40°C AND +60°C.
▲ CAUTION: COVER BOLTS MUST HAVE A YIELD STRESS OF AT LEAST 700 N/mm².
▲ 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 sealed with a conduit plug which
satisfies the flameproof “d” method of protection. Blanking elements must be removable
with the aid of a tool, ATEX certified, suitable for Gas Group IIB and suitable for an
ambient temperature range of -40 C to +60 C.
▲ CAUTION: Battery may explode if mistreated. DO NOT RECHARGE, DISASSEMBLE, OR
DISPOSE OF IN FIRE.
▲ CAUTION: Field wiring must have a temperature rating of +75 °C or greater. It must also
have a temperature rating for the lowest expected minimum ambient temperature.
▲ Consult installation manual for required cable entry size and thread.
▲ A battery is soldered to the processor board for retention of data, time, and date. This battery
should last more than ten years. Please return the board to Toptech Systems for battery
replacement. This battery must be replaced with Matsushita Electric, model BR2477A only. Use
of another battery may present a risk of fire or explosion.
▲ The installation of this product must be in conformity with IEC/EN/BR 60079-14
CHAPTER 1– GENERAL INFORMATION & WARNINGS
13 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Electrostatic Discharge (ESD) Protection
The MultiLoad II/ RCU II contains electronic components and assemblies subject to damage by ESD.
The MultiLoad II/ RCU II was designed to protect against ESD while the unit is closed and in normal
operation. Proper handling procedures must be observed during the removal, installation, repair and
other handling of printed circuit board assemblies, electronic devices and components. This includes:
1) Service to 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) While performing maintenance or repair, touch an unpainted metal of the MultiLoad II/ RCU
II surface prior to touching or handling any printed circuit boards or electronic components.
4) Printed circuit board assemblies must be placed in and transported in conductive bags or
other conductive containers.
5) Printed circuit boards must not be removed from the conductive container until time of use.
6) All other “best” practices for protecting devices from ESD must be observed.
FCC Note
This equipment complies with the limits for a Class A Digital Device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with the instruction manual,
may cause harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct the
interference at their expense.
Modifications not approved by the manufacturer could void the user's authority to operate the
equipment under FCC rules.
CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS
14 MultiLoad II/ RCU 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
CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS
15 MultiLoad II/ RCU II Explosion Proof 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
CHAPTER 2– OPERATING CONDITIONS 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
CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS
17 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Operating Characteristics
The MultiLoad II/ RCU II – Explosion Proof Lite (EXL) Model has the following characteristics:
Characteristics
Description
Operating Voltage
85 - 250 Vac, 47-63 Hz, 300 – 150 mA
Voltage Option
9 - 30 Vdc, 600mA
Operating Temperature
40°F to 140°F, -40°C to 60°C
Enclosure
Type 4, IP65
ETL Listed (US, Canada) Class I, Division 1, Groups C & D, T4
Weight
24 lbs : 11 kg
Display
Color 8.4” Diagonal VGA
Prox Card Reader
Captive or Non-captive: supports TWIC
Lockable External W&M Bolts
Program Access, Weights & Measures Parameter Access (on MultiLoad
only)
Keypad
47 Key Alpha/ Numeric Membrane Switch Keypad
Communications
3 serial ports (1 RS-485, 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)
12 - 250 Vac rms, 500 mA (per point), TB1
AC Inputs
0
2 (TB1)
90 - 250Vac
DC Outputs:
3 (TB3)
2 (TB9)
0 - 30 Vdc, 600 mA (per point), TB3
DC Inputs:
5 (TB2-Right)
(2 High Speed)
6 (TB7, TB8)
(4 High Speed)
5 - 30Vdc, TB2B
Dual Channel flow meter inputs (1-5000Hz)
Miscellaneous signal inputs
12Vdc Source:
167mA Max Load
(TB2-Left)
250mA Max Load
(TB6)
Isolated Power Supply
Power for flow meter pulsers or preamps
RTD Input:
1 (TB4)
2 (TB4, TB5)
100-ohm platinum, four wire
Coefficient 0.00385 Ohm/Ohm/°C
Analog Input
1 (TB5)
0
4 - 20mA, 1.5V maximum burden
Analog Output
1 (TB6)
0
4 - 20mA, Requires 12Vdc – 30Vdc Supply
CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS
18 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Internal I/O Heat Dissipation:
I/O TYPE
Voltage
Freq
Dissipation
per Point
Digital/ Analog I/O
2 Meter I/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 mW or less are not reported.
CHAPTER 3– INSTALLING THE MULTILOAD II/RCUII EXL
19 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Chapter 3 Installing the MultiLoad II/RCUII EXL
Tools Required
Installation
- -8 mm hex wrench required for tightening cover bolts.
Servicing and Repair
- #2 Philips screwdriver for circuit board removal.
- ¼” socket wrench for CPU circuit board removal and a 5/16” socket wrench for display board
removal.
- - Torx T10 for removal of keypad bezel security screws.
Cover Closure and Bolt Replacement
The enclosure cover is secured to the 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. Dry stainless steel fasteners can gall or seize in aluminum, so please be
sure to use a petrolatum or a similar lubricant.
Be sure to keep the flanges clean and free of scratches so as not to compromise the quenching
ability of the flame path.
All cover bolts must be tightened to maintain the explosion proof capability of the enclosure.
Chapter
3
CHAPTER 3– INSTALLING THE MULTILOAD II/RCUII EXL
20 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Cable Entries
Five M20 x 1.5 mm apertures in the enclosure bottom are provided for the installation of cable glands.
A gland with the correct corresponding thread must be installed in the opening.
WARNING: If there are unused holes, blanking elements satisfying the flameproof “d” method
of protection must be used. Blanking elements must be removable with the aid of a tool, ATEX
certified, suitable for Gas Group IIB and suitable for an ambient temperature range of -40 C to
+60 C.
Mounting the MultiLoad II/ RCU II DIV-2 Enclosure
The EXL enclosure should be located in a shaded area. Direct sunlight can increase internal
temperature to greater than 140°F or 60°C.
Exterior dimensions of the standard MultiLoad II/ RCU II Explosion Proof Lite (EXL) enclosure are
shown in Figures 2.2 – 2.5. There is only one mounting orientation possible as shown in Figure 2.2.
Five M20x 1.5 mm cable entries are located at the bottom of the unit.
Appropriate fasteners must be selected to support the minimum weight of 33 lbs. (15 kg). Toptech
offers the following mounting suggestions 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 assemble as with the metal plate
using four hex head 3/8” OD (M10) bolts with a 3/8” flat washer, 3/4” OD (M10, 20 mm OD) under the head
of the bolt. Tighten with four 3/8” (M10) hex nuts.
Concrete or Cinder Block Walls
Use four Sleeve, Bolt and Stud Anchors, Hex Nut 3/8“OD, 2 1/4“long or a metric equivalent.
Mounting Height Considerations
When mounting the enclosure, be aware of the limitations that the cover places on screen visibility.
Because the display is inset about an inch [25mm] from the surface of EXL and SMP units and the
screen is inset an inch-and-one-half [39mm] in the EXL unit, the enclosure should be mounted so that
top of the screen’s visible area is at eye level of the tallest operator. Figure 3.1 shows the visible area
at arm’s length and the distance from the ground to the top mounting hole location for a six foot [1.8m]
tall user. Figure 3.2 shows the offset of the top of the screen’s visible area from the top mounting bolt
and the depth of the screen within the unit.
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
CHAPTER 3– INSTALLING THE MULTILOAD II/RCUII EXL
22 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Recommended Wire Sizes and Torque for All Terminal Blocks
Three sizes of terminal blocks are used in the MultiLoad II/ RCU II products: 7.62 mm pitch (supply
power), 5.08 mm pitch (line voltage switching), and 3.81 mm pitch (serial communication, analog or dc
voltages). The 7.62 and 5.08 mm terminal blocks have an allowable wire size of 24 AWG – 12 AWG
and should be tightened to 0.55 Nm +/-0.05 Nm (5 lb in +/- 0.4 lb in).
The 3.81 mm terminal blocks have an allowable wire size of 28 AWG – 16 AWG and should be
tightened to 0.23 Nm +/-0.02 Nm (2 lb in +/- 0.2 lb in).
Electrical Supply Connections
The MultiLoad II/ RCU II may be equipped for either 85 -250Vac or 24Vdc operation. Verify the
power type before making any connections.
To reduce the risk of ignition in hazardous atmospheres, conduit runs must have seals Installed
within 18 inches (45 cm) of the enclosure.
Field wiring must have a temperature rating of 75°C or greater.
Cable Gland Entries
Five M20 x 1.5 mm apertures in the enclosure bottom are provided for the installation of cable glands.
A gland with the correct corresponding thread must be installed in the opening.
WARNING: If there are unused holes, blanking elements satisfying the flameproof “d” method of
protection must be used. Blanking elements must be removable with the aid of a tool, ATEX
certified, suitable for Gas Group IIB and suitable for an ambient temperature range of -40 C to +60 C.
Do not route AC and DC wiring in the same conduit.
All wiring must enter the MultiLoad II/ RCU II enclosure through conduit fittings or cable glands in the
bottom of the enclosure. All conduit fittings or cable glands used must be appropriately-rated.
Wires must be stripped ¼” and fully inserted into terminal block with no bare conductor exposed.
Review section 3.5 for recommended wire size and torque values.
Both ac and dc input models require a safety ground connection as described in section 3.6.4 below.
A service loop is recommended for all wires and cables entering the enclosure.
Do not allow service loop cables to overlap the circuit boards. Coil any cable length in the
bottom of the enclosure. Keep AC wiring separated from all other wiring in the enclosure.
Wiring must comply with all local electrical codes.
CHAPTER 3– INSTALLING THE MULTILOAD II/RCUII EXL
23 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
AC Powered Models
Provide over current protection using a 15 Amp circuit breaker or equivalent. The breaker also serves
as a means of disconnection from the operating supply as required by UL/ISA/IEC 61010-1 and
CAN/CSA-C22.2 NO. 61010-1. 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
shown in figure 3.3. Select supply wire rated 300V or better with a flammability rating of at least VW-1.
Figure 3.3 MultiLoad II/ RCU II AC Power Supply/Comm Board
CHAPTER 3– INSTALLING THE MULTILOAD II/RCUII EXL
24 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
DC Powered Models
The MultiLoad II/ and RCU II is optionally available with a 24 Vdc power supply. The power source
used to supply the MutliLoad II/RCUII must be rated 9 – 30 Vdc SELV, Limited Energy (Class 2). The
rated supply input current is 600mA. The supply should be protected by a 1.5 Amp fuse.
The 4-position terminal block is located in the right-hand corner of the power supply/communication
board. The left-most terminal position is a spare and will not be used.
Figure 3.4 DC Power Connections
Wiring guidelines for using 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 connection is not provided for the attachment of the protective conductor (the
safety ground). Rather, it is provided only as a supplemental bonding connection where local
authorities permit or require such a connection: for example, as a means of equipotentiality. The wire
connection is on the bottom right exterior surface. The following wire sizes may be used: 10 AWG
(5.26 mm2) or 11 AWG (4.17 mm2).
Do not connect the power supply dc common to earth ground.
CHAPTER 4– DATA COMMUNICATIONS INTERFACE
25 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Chapter 4 Data Communications Interface
The MultiLoad II/ RCU II has four (4) communications ports (see Figure3.3), each with a specific
purpose. The following section provides the information required to select and make the wiring
connections to the ports:
Communication
Port
Interface Type
Typical Function
Terminal (Figure 3.3)
Comm. Port 0
RS-485
Internal I/O board /
FCM I / FCM II / PCM
Communication
TB2
Comm. Port 1
RS-232 or RS-485
Host Communication (TMS) /
Printer
TB3 RS-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 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 MultiLoad are: COM O – FCM ; COM 1- HOST , and COM2 – NA.See
the user guide for more details.
Only one port may be defined as an FCM, Print or Alibi Log, otherwise, a ‘Port Usage
Conflict(s)’ message will display upon re-boot. See the user guide for more details.
Available Communications Protocol Selection and Wire Spec
This section describes the available communication protocols for MultiLoadII/RCU II.
Chapter
4
Loading...