Veeder-Root EMR4 Technical Installation Manual

Technical Installation Guide

EMR4

Manual No: 577014-322 ● Revision: B

Notice

Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of
merchantability and fitness for a particular purpose.

Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this publication.

Veeder-Root reserves the right to change system options or features, or the information contained in this publication.

This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication may be
photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root.

Contact Technical Support for additional troubleshooting information at 800-323-1799.

DAMAGE CLAIMS / LOST EQUIPMENT

Thoroughly examine all components and units as soon as they are received. If any cartons are damaged or missing, write a complete
and detailed description of the damage or shortage on the face of the freight bill. The carrier's agent must verify the inspection and sign
the description. Refuse only the damaged product, not the entire shipment.

Veeder-Root must be notified of any damages and/or shortages within 30 days of receipt of the shipment, as stated in our Terms and
Conditions.

VEEDER-ROOT’S PREFERRED CARRIER

1. Contact Veeder-Root Customer Service at 800-873-3313 with the specific part numbers and quantities that were missing or
received damaged.

2. Fax signed Bill of Lading (BOL) to Veeder-Root Customer Service at 800-234-5350.

3. Veeder-Root will file the claim with the carrier and replace the damaged/missing product at no charge to the customer. Customer
Service will work with production facility to have the replacement product shipped as soon as possible.

CUSTOMER’S PREFERRED CARRIER

1. It is the customer’s responsibility to file a claim with their carrier.

2. Customer may submit a replacement purchase order. Customer is responsible for all charges and freight associated with
replacement order. Customer Service will work with production facility to have the replacement product shipped as soon as
possible.

3. If “lost” equipment is delivered at a later date and is not needed, Veeder-Root will allow a Return to Stock without a restocking fee.

4. Veeder-Root will NOT be responsible for any compensation when a customer chooses their own carrier.

RETURN SHIPPING

For the parts return procedure, please follow the appropriate instructions in the EMR Products General Returned Goods Policy pages
in the EMR4 Products price list. Veeder-Root will not accept any return product without a Return Goods Authorization (RGA) number
clearly printed on the outside of the package.

©Veeder-Root 2018. All rights reserved

.

Safety Information

Safety Warnings ...............................................................................................................2

Special Conditions for Safe Use .......................................................................................2

EMR4 Truck Installation

Installing The Interconnection Box (IB) .............................................................................4

Input Power – Critical Ground Connection ........................................................................4

2-Stage Solenoid Valve Connections .......................................................................8

Valve Operation With The EMR4 .............................................................................8

3-Way Safety Valve for Truck LP Gas Systems ...............................................................9

Installing The 3-way Valve........................................................................................9

Solenoid Valves......................................................................................................12

Wiring The Display Head ................................................................................................14

C&C Mode Switch ...........................................................................................................16

Installing Optional Keypad Kit - Right or Left Side ..........................................................16

IInstalling The Remote Display (Optional) ......................................................................16

Installing The Remote Pulser (Optional) .........................................................................19

Pulse Encoder Specifications.................................................................................19

EMR4 Terminal & Fueling Depot Installation

Wiring The Display Head ................................................................................................21

Installing The Interconnect Box (IB) ................................................................................22

National Electrical Code Compliance .....................................................................22

Grounding...............................................................................................................22

Wire Type for Metallic or PVC Conduit...................................................................23

Wire Length ............................................................................................................23

Mounting and Wiring the IB Unit.............................................................................23

Solenoid Valves......................................................................................................23

Power Conditioning Requirements .................................................................................26

Wire Size And/or Distance Limitations ...................................................................26

Pulse Output Limits ................................................................................................29

EMR4 – Legal Disclaimer Notice ....................................................................................29

Table of Contents

Figures

EMR4 System Specifications

System Power .................................................................................................................30

Component Location .......................................................................................................30

Appendix A: EMR4 Safety Instructions & System Specifications

Figure 1. Example EMR4 truck Installation With 2 Display Heads And

Optional Remote Pulser ..........................................................................3

Figure 2. IB Physical Dimensions (Shown With Cover Removed) .........................6

Figure 3. EMR4 IB Box Wiring Connections ..........................................................7

Figure 4. 2-Stage Solenoid Valve ..........................................................................8

Figure 5. Connecting 3-Way Valve To Neptune Meter -

Truck LP Gas Installations ....................................................................10

Figure 6. Connecting 3-Way Valve To L.C./TCS Meter -

Truck LP Gas Installations ....................................................................11

Figure 7. Connecting 3-Way Valve To The Interconnect Box ..............................12

Figure 8. Example Wiring Connections For DC And AC Solenoid Valves ...........13

Figure 9. Display Head Cable Connections .........................................................15

Figure 10. Remote Display Assembly ....................................................................17

iii

Tables

Table of Contents

Figure 11. Remote Display Connections (Rear Cover Removed) .........................18

Figure 12. Wiring Connections In Remote Pulser (Top Cover Removed) .............19

Figure 13. Example Terminal Fueling Depot Installation With 2 Display Heads

And Optional Remote Pulser ................................................................20

Figure 14. Display Head Cable Connections .........................................................22

Figure 15. EMR4 IB Box Wiring Connections ........................................................24

Figure 16. Example Terminal Wiring Connections For DC And

AC Solenoid Valves ..............................................................................25

Figure 17. Digi-Key Power Supply Wiring Diagram ...............................................26

Figure 18. Wiring Pulse Output To A TLS-350 Console ........................................27

Figure 19. Wiring Pulse Output To A TLS-450/TLS4 Console ...............................28

Table 1. 2-Stage Solenoid Wiring ............................................................................8

Table 2. Remote Display (84559X-00X) Components ..........................................16

Table 3. System Component Dimensions ............................................................30

Table 4. Remote Pulser Dimensions ....................................................................31

Table A-1. System Component Information ...........................................................A-3

Table A-2. Remote Pulser Information ................................................................... A-3

iv

Safety Information

OFF

WARNING

NOTICE

CAUTION

The following safety symbols may be used throughout this manual to alert you to important safety hazards and
precautions

EXPLOSIVE

Fuels and their vapors are extremely explo­sive if ignited.

TURN POWER OFF

Live power to a device creates a potential
shock hazard. Turn Off power to the device
and associated accessories when servicing
the unit.

NOTICE

Alerts the user to practices not related to
physical injury.

INJURY

Careless or improper handling of materials
can result in bodily injury.

WEAR EYE PROTECTION

Fuel spray from residual pressure in the lines
can cause serious eye injuries. Epoxy seal­ant can cause eye injury. Always wear eye
protection when working with pressurized
lines and epoxy mixtures.

READ ALL RELATED MANUALS

Knowledge of all related procedures before
you begin work is important. Read and
understand all manuals thoroughly. If you do
not understand a procedure, ask someone
who does.

FLAMMABLE

Fuels and their vapors are extremely
flammable.

WARNING

Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.

CAUTION

Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.

GLOVES

Wear gloves to protect hands from irri­tation or injury.

NO OPEN FLAMES

Open flames from matches, lighters,
welding torches, etc. can ignite fuels
and their vapors.

1

Safety Information Safety Warnings

NOTICE

Safety Warnings

Who is allowed to work on this equipment: Only trained or authorized individuals knowledgeable in
the related procedures should install, inspect, maintain, or service this equipment.

WARNING

This system operates near highly combustible fuel storage tanks.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY
PRECAUTIONS COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT,
RESULTING IN SERIOUS INJURY OR DEATH.

VEEDER-ROOT’S EMR4 PRODUCT IS NOT APPROVED FOR USE AS A
COMPONENT THAT PROVIDES LIQUID ADDITIVES TO AN AIRCRAFT FUELING
SYSTEM.

To ensure proper installation, operation, and continued safe use of this product:

1. Read and follow all instructions in this manual, including all safety
warnings.

2. Have equipment installed by a contractor trained in its proper installation
and in compliance with all applicable codes including: the National
Electrical Code; federal, state, and local codes; and other applicable safety
codes.

3. To prevent ignition of flammable or combustible atmospheres, disconnect
power before servicing.

4. Operate this equipment in accordance with the instructions in this manual.

5. Do not modify or use service parts other than those provided by Veeder­Root. Substitution of components may impair intrinsic safety.

This system operates on low dc voltage/current inputs. To avoid equipment damage:

•

Dis

connect the EMR power wire prior to using vehicle battery charging equipment.

• Disconnect the EMR po

• Disconnect the EMR po

Always dis

•

If the storage tank to

connect the IB box from truck power before welding on the truck.

be fitted with an EMR4 system either contains or at any time has contained

wer wire prior to jump starting the vehicle.

wer wire prior to replacing the vehicle's battery.

petroleum products then the tank inspection chamber must be considered a hazardous environment
as defined in IEC EN 60079-10 Classification of Hazardous Areas. Suitable working practices for this
environment must be observed.

Special Conditions For Safe Use

All installations must be made in accordance with the accompanying Descriptive System Documentation.

2

EMR4 Truck Installation

DC voltage from vehicle's accessory
circuit - at fuse block or ACC position
of ignition switch

Display Head 1

(Meter 1)

Meter 2

Remote Display Head 2

Top mount

Remote Pulser

Front mount

Remote Pulser

TRUCK CAB

OUTSIDE TRUCK CAB

Data (RS-485)

Data (RS-485)

Power

Data

Power 12 Vdc

Power 12 Vdc

5 Vdc

Pulse Input

NON-HAZARDOUS

LOCATION

(RS-232)

Printer

Quick disconnect
fittings (optional)

Temp

Probe

EPSON TM-U295 SLIP

Customer supplied wiring

The following information is for general reference and is not
intended to replace recommended National Electric Code (NEC)
procedures. It is important for the installer to understand that
wiring located in Class I, Group D, Division 1 and 2 installations,
or Class I, Zone 0, Group IIA locations shall comply with the latest
appropriate articles found in the National Electric Code (NFPA

70).

Check continuity between the Display Head chassis and the IB
chassis through the vehicle fra

me. The resistance must be no

more than 1 Ohm.

24 Vdc

Truck ground

Max. cable length
35 ft. (10.6 m)

Max. cable length
1000 ft. (304.8 m)

HAZARDOUS LOCATION

OR

I.S.

I.S.

I.S.

I.S.

I.S.

I.S.

NOTE: Intrinsically safe wiring
(marked ) shall be installed
in accordance with Article 504 of
the NEC, ANSI/NFPA 70.

Intrinsic

Safety Barrier

Interconnection

Box

12 AWG U.S. (4mm2 E.U.)

Barrier Ground

(See Notice 2)

Input Rating: 10-28 Vdc, 5 A

1.

See

Notice 2.

See

Notice 2.

2.

NOTICE

Interlock

Switch

I.S.

ESS

Switch

I.S.

Installation of the EMR4 System involves installing the Display Head(s), the Interconnect Box, and any optional
devices (e.g., Remote Pulser, printer, etc.). This equipment must be installed according to the applicable
installation document. For UL/cUL installations use Control Drawing number 331940-021 and for ATEX
installations use Descriptive System Document number 331940-022. Figure 1 shows an example dual Display
Head installation.

Figure 1. Example EMR4 truck Installation With 2 Display Heads And Optional Remote Pulser

3

EMR4 Truck Installation Installing The Interconnection Box (IB)

NOTICE

EMR3 - Truck Installations

Installing The Interconnection Box (IB)

The IB box is not rated for mounting in outdoor locations. The IB box can be mounted only
in a protected enclosure or protected location.

The following information is for general reference and is not intended to replace recommended National Electric
Code (NEC) procedures. It is important for the installer to understand that electrical equipment and wiring located
in Class I, Division 1 and 2 installations shall comply with the latest appropriate articles found in the National
Electric Code (NFPA 70) and other applicable code requirements.

1. The physical dimensions of the Interconnection Box (IB) are shown in Figure 2.The IB is installed in the truck’s
cab either under the seat, mounted on the wall inside the cab, mounted to the passenger si

e” in cab-over trucks, or mounted to a custom-made bracket that can also suppor

hous

ur, 3/16” (4 mm) bolts to mount the IB to the mounting surface. In the event of limited access, the front

Use fo
cover of the IB can be completely removed rather than swung open, by removing four #15 Torx screws. Put
the excess coils of cable under the seat or clamp them to the IB mounting stand.

2. Figure 3 shows IB Power Side terminal wiring connections. Remove hole plugs and use

ables attaching to this terminal block.

c

he power cable from the truck fuse block or ignition switch to the IB. Clamp the power wire at suitable in-

Run t

tervals between the power source

fore connecting the truck power wiring, verify the following:

Be

and the IB.

de of the “dog

t the optional printer.

cord grips for all

ctrical system has a negative ground.

a. Ele

b. Bat

tery terminals and cables are in good condition.

c. Alternato

3. Attach the wire from truck ground to the GND terminal of the Power Side terminal block (J8, Pin 2).
attach the wire from the truck’s Accessory (ACC) circuit to the Input-Pwr terminal of the terminal block (J8-Pin

1).

4.

Refer to Figure 3 for the IB intrinsically safe terminal wiring connections. Remove hole plugs

ps for Display Head cable entries. The drain wire from the Display Head cable must be conne

gri

assis ground clamp in the Interconnect Box.

ch

r current output is sufficient to supply EMR4 System current requirement of 5 amperes.

Also

and use cord

cted to the

Input Power – Critical Ground Connection

On some vehicles, the battery minus terminal, BAT(-), may not be common with the chassis ground or the defined
vehicle ground located in either the accessory panel or in the power distribution box. In this case, directly run the
ground connection for Input Power at J8, Pin 2 (GND) terminal as shown in Figure 3, directly to the BAT(-) terminal
connection point.

Proper operation of the EMR4 hardware depends on the quality of the ground connection from the Interconnect
Box to the source of INPUT-PWR power.

If the INPUT-PWR connection is made at the accessory panel, it must be fused at 5 amps. The installer must
ensure that a minimum of 12.0 volts, between the INPUT-PWR terminal and the GND terminal, is available from
the power source. If an improper ground point is used for input power to the EMR4 there may be insufficient
power for the Display Head to operate properly resulting in various E## error codes or possibly a blank display.

Pay careful attention to the wiring labels on both the EMR4 Display Head and the Interconnect Box.
Each connection must be made according to the wiring tables listed in this manual. Use shielded
cable to connect each device to the Interconnect Box and Display Head and ensure that each cable
jacket is resistant to gas and oil.

4

EMR4 Truck Installation Input Power – Critical Ground Connection

NOTICE

NOTICE

EMR3 - Truck Installations

Installations With High Amperage Devices

The input power for an EMR4 must be isolated from devices that use large amounts of electric current such as reel
motors. Connect the EMR4 using dedicated wiring between the voltage source and the Interconnect Box. On
vehicles with multiple voltage sources it may be necessary to use a separate battery or voltage source to power
the EMR4. Also, a battery isolator can be used between the voltage source and the IB to prevent voltage spikes
from entering the Interconnect Box when the high amperage devices are de-energized.

Recharging Vehicle Batteries

In the Interconnect Box, disconnect the wires for both the INPUT-PWR and GND Terminals while charging the
vehicle’s battery. Failure to do so can result in hardware damage to the circuit board inside the Interconnect Box.

5

EMR4 Truck Installation Input Power – Critical Ground Connection

2X 1.5” (38mm)

1.39”

(35.3mm)

5.0”

(127mm)

7.8” (198mm) [8.5” (215.9mm) - w/cover in place]

4.04”

(103mm)

USB Port (under cover)

2.13”

(54.1mm)

0.5”

(12.7mm)

9.8”

(249mm)

1.0” (25.4mm)

SMA Connector

(under cover)

4X 1.5”

(38mm)

3X 1.375” (35mm)

4.75” (120.6mm)

REMOVE HOLE PLUG
FOR 1/2” (12.7mm)
CONDUIT OPENING

6X 1.375”

0.775”

7X 1.5”
(38MM)

3.0”

(72mm)

0.125” (3.1mm)

1.39”

(35.3mm)

1.5” (38mm)

EMR3 - Truck Installations

Figure 2. IB Physical Dimensions (Shown With Cover Removed)

6

EMR4 Truck Installation Input Power – Critical Ground Connection

J1

J2

J3

J4

J5

J6

J7

J8

FUNCTION

FUNCTION

SIGNAL (COLOR)

SIGNAL (COLOR)

START PULSE OUTPUT 1
START PULSE OUTPUT 2

PULSE OUTPUT 1-A
PULSE OUTPUT 2-A

PULSE OUTPUT 1-B
PULSE OUTPUT 2-B

SERIAL 232 PORT 2

SERIAL 232 PORT 1

PULSE OUTPUT 1-C
PULSE OUTPUT 2-C

PRINTER PORT

(+24V OUT, SERIAL

RS-232 PORT)

RELAY 3 FOR

DISPLAY HEAD 1

RELAY 2 FOR

DISPLAY HEAD 1

RELAY 3 FOR

DISPLAY HEAD 2

RELAY 2 FOR

DISPLAY HEAD 2

RELAY 1 FOR

DISPLAY HEAD 1

RELAY PWR

RELAY 1 FOR

DISPLAY HEAD 2

RELAY PWR

NOTE: INPUT POWER
WIRING MUST USE
DEDICATED WIRES
BETWEEN THE POWER
SOURCE AND THE I.B.

INTERCONNECT BOX WIRING DIAGRAM

INTRINSICALLY SAFE WIRING

FUNCTION

SIGNAL (COLOR)

J10

(FACTORY SETTING)

*VOLTAGE SELECTABLE

RO

TARY SWITCH

*VOLTAGE SELECTABLE

*VOLTAGE SELECTABLE

*VOLTAGE SELECTABLE

*VOLTAGE SELECTABLE

RELAY RATINGS:

5A@120VAC

2.5A@240VAC

24VDC, 5A MAX.

J14

USB

5

6

7

8

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

1

2

3

4

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

1

2

3

4

GND (BLK)

DH2-RSTOP (RED)

DH2-RSTART (WHT)

GND (GRN)

GND (GRN)
DH1-RSTOP (RED)
DH1-RSTART (WHT)
GND (BLK)

REMOTE STOP INPUT 2

REMOTE START INPUT 2

REMOTE STOP INPUT 1

REMOTE START INPUT 1

GND (WHT)

TX (BLK)

RX (GRN)

GND (GRN)
DH1-SPULSE (RED)
DH2-SPULSE (WHT)
GND (BLK)

GND (WHT)

TX (BLK)

RX (GRN)

GND (GRN)
DH1-POUT-A (RED)
DH2-POUT-A (WHT)
GND (BLK)

HALF-DUPLEX RS-485

GND (BLK)

IBNET-A (GRN)

IBNET-B (WHT)

GND (GRN)
DH1-POUT-B (RED)
DH2-POUT-B (WHT)
GND (BLK)

GND (WHT)

+24V (RED)

PRN-TX (BLK)

PRN-RX (GRN)

GND (GRN)
DH1-POUT-C (RED)
DH2-POUT-C (WHT)
GND (BLK)

DH2-R3-NO (GRN)
DH2-R3-COM (WHT)
DH2-R2-NO (RED)
DH2-R2-COM (BLK)

DH1-R3-NO (GRN)

DH1-R3-COM (WHT)

DH1-R2-NO (RED)

DH1-R2-COM (BLK)

DH1-R1-NO (GRN)

DH1-R1-COM (WHT)

INPUT-PWR (RED)
INPUT-PWR (RED)

DH2-R1-NO (GRN)
DH2-R1-COM (WHT)
INPUT-PWR (RED)
INPUT-PWR (RED)

INPUT-PWR (RED)

GND (BLK)

IB-A (GRN)
IB-B (WHT)
GND (BLK)
PWR 12V (RED)

PWR 5V (GRN)
DATA (WHT)
GND (BLK)
PWR 12V (RED)

DATA (WHT)
GND (BLK)
PWR 12V (RED)

4

3

2

1

IB-A (GRN)
IB-B (WHT)
GND (BLK)
PWR 12V (RED)

4

3

2

1

4

3

2

1

4

3

2

1

DISPLAY HEAD 1
(I.S. PROTECTED)

DISPLAY HEAD 2
(I.S. PROTECTED)

AUX 1

(I.S. PROTECTED)

AUX 2

(I.S. PROTECTED)

5VDC 24VDC

12VDC

0VDC

1

3

2

0

J13

J12

J11

CONNECTORS MAY

BE UNPLUGGED FOR

FIELD WIRING

WARNING

This system operates on low DC voltage/current
inputs.To avoid equipment damage, disconnect
the EMR4 input power plug (J8) prior to
performing ANY of the following truck mainte­nance issues:

• Using vehic

le battery charging equipment

• Jump starting the vehicle

• Replacing the vehic

le’s battery

• Welding on the truck

12/24V INPUT

FOR USE WITH PERIPHERAL
EQUIPMENT SPECIFIED IN THE
INSTALLATION INSTRUCTIONS.

LED INDICATORS

COMM (D10) : EMR4 STATUS
STATUS (D12) : WIFI STATUS
LINK (D15) : WIFI LINK INDICATION

SEE MANUAL FOR DETAILS

FOR SUPPLY CONNECTION,

USE WIRES RATED FOR A

MINIMUM OF 90°C.

CHASSIS-GND (GRN)
CHASSIS-GND (GRN)

TRUCK BATTERY / TERMINAL UPS:

10-28VDC, 5A MAX.

RELAY GROUND

BARRIER GROUND WIRE

EMR3 - Truck Installations

Figure 3. EMR4 IB Box Wiring Connections

7

EMR4 Truck Installation Input Power – Critical Ground Connection

DH 1

Relays

C
N.O.

Single
Flow

C
N.O.

Fast
Flow

DH 2

Relays

C
N.O.

Single
Flow

C
N.O.

Fast
Flow

EMR3 - Truck Installations

2-STAGE SOLENOID VALVE CONNECTIONS

A 2-stage solenoid flow valve is shown in Figure 4 and wiring connections in Table 1.

Single Flow In IB

(Relay 2)

(Solenoid Valve
Number Begins
With 7221)

Display Head Relay Function

Head 1

Head 2

Flow

Figure 4. 2-Stage Solenoid Valve

Table 1. 2-Stage Solenoid Wiring

Diagram In

Installation Manual Setup Manual

DH1-R2

DH1-R1

DH2-R2

DH2-R1

COM

N.O.

COM

N.O.

COM

N.O.

COM

N.O.

Fast Flow In IB
(Relay 1)

(Solenoid Valve
Number Begins
With 7121)

Relay Control

Set Advance Stop

Relay Control

Set Slow Flow

Relay Control

Set Advance Stop

Relay Control

Set Slow Flow

(2nd Stage

Knockoff)

(1st Stage
Knockoff)

(2nd Stage

Knockoff)

(1st Stage
Knockoff)

VALVE OPERATION WITH THE EMR4

Full Flow

The valve is normally closed. When the START button is pushed on the EMR4 display, both relays for that head are
energized, opening the solenoid-operated valves. The Fast Flow solenoid valve allows the main valve diaphragm to
open via the pump pressure pushing on the diaphragm. Full flow is obtained. The Slow Flow solenoid valve allows
flow around the main diaphragm valve. When the FINISH button is pushed on the EMR4 display, both relays are
de-energized, the solenoid valves close stopping flow.

Preset

The valve is normally closed. When the START button is pushed on the EMR4 display, both relays for that head are
energized, opening the solenoid valves and fast/full flow is obtained.

• First Stage Knockoff - When the first stage/slow flow point is reached (1st stage knockoff), the fast flow/relay
de-en

ergizes and the spring assisted main diaphragm of the valve closes as the pressure equalizes. The si

y 2 bypass remains open for slow flow.

8

flow/rela

1

ngle