Red Seal Measurement Neptune RML2000 User manual

Neptune RML2000
Mass Flowmeter
Installation Manual
M-614(I)
RML2000
IMPORTANT: To ensure proper installation of this product, thoroughly review the information in this
revision of the manual. Information is subject to change as new features are implemented. Failure to
follow instructions may result in system malfunction.
www.redsealmeasurement.com

2
WARNINGS, CAUTIONS AND NOTES
Throughout this manual you will see WARNINGS, CAUTIONS and NOTES. They are here for your
benet and warrant attention. By paying careful attention to them you can prevent injury and
possible equipment damage.
Below are examples:
WARNINGS: INFORM THE READER OF POSSIBLE BODILY INJURY IF PROCEDURES ARE
NOT FOLLOWED EXACTLY.
CAUTIONS: Alert the reader to possible equipment damage if procedures are not followed
correctly.
NOTES: Inform the reader of a general rule for a procedure or of exception to such a rule.
NOTICE
The information contained in this document is subject to change without notice. Red Seal Technologies,
its afliates, employees, and agents and the authors of and contributors to this publication specically
disclaim all liabilities and warranties, express and implied (including warranties of merchantability and
tness for particular purpose), for the accuracy, currency, completeness and/or reliability of the information
contained herein and/or for the tness of any particular use and/or in reliance upon information contained
herein. Selection of materials and/or equipment is at the sole risk of the user of this publication.
This document contains proprietary information, which is protected by copyright. All rights reserved.
No part of this document may be reproduced without prior written consent of Red Seal Technologies.
This equipment is intended for use in Class I, Division 2, Groups A, B, C and D or non-hazardous
locations only.
WARNING - Explosion hazard; substitution of components may impair suitability for
Class I, Division 2.
WARNING - Explosion hazard; do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous.
Hazardous area approval only valid when connected to an isolated source such as a truck battery.
Power and input & output (I/O) wiring must be in accordance with Class I, Division 2 wiring
methods, Article 501-4 (b), or the National Electrical Code, NFPA 70 for installations in the U.S., or
as specied in Section 18-1J2 of the Canadian Electrical Code for installations within Canada, and
in accordance with the authority having jurisdiction.

3
Caution - This electronic device is sensitive to damage from ESD (electro-
static discharge). Observe the following precautions when servicing this
device.
1. Always use a static-dissipative wrist strap. Connect the strap to a grounded, conduc-
tive surface or to the metal chassis of the equipment under repair. Use only wrist
straps that incorporate a resistor for user safety. The resistance between the user
and ground should be between 800K ohms to 10M ohms. Do not wear a wrist strap
around exposed electrical hazards of more than 250 volts.
2. If a wrist strap is not available, ground yourself before touching electronics by touch-
ing the metal chassis of the equipment or another grounded surface. Repeat fre-
quently while working.
3. If available, use a static-dissipative work mat. Connect the mat to ground and the
wrist strap to the mat.
4. Avoid contacting the connectors or any exposed electronic component.
5. Work away from materials that may contribute to the generation of static electricity,
such as synthetic carpeting.
6. Minimize your movements to avoid building up static charge.
7. Avoid working on electronics in areas with very low humidity.
8. Do not work on electronics during periods of lightning activity.
9. Do not ship or store this device near strong electrostatic, electromagnetic, magnetic,
or radioactive elds.
ATTENTION - OBSERVE PRE-
CAUTIONS FOR HANDLING
ELECTROSTATIC SENSITIVE
DEVICES.

4

5
Amended Procedures for New Electronics
The current versions of Neptune RML Series meters (both Modbus and Pulse Output options) require Pro-
Link 3 for zeroing and conguration. ProLink 3 is compatible with all earlier releases of RML lectronics, and
will be the version used and supported by Red Seal Measurement for all RML Series meters.
ProLink 3 can be downloaded at www.redsealmeasurement.com/prolink.
The password to access the download link is NeptuneRML.
If previous versions of ProLink have been installed on a computer, they must be fully uninstalled before in-
stalling ProLink 3.
If you have any questions, please contact Red Seal Measurement Customer Service at support@red-
sealmeasurement.com, or [phone].
Prolink Update

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Installation and Zeroing
1. Power and Data Connections
1.2. Modbus Units (800 Series Core Processor)
Remove the four screws that attach the housing cover and remove the cover. Make connections to the core proces-
sor as shown below.

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1.2. Pulse Output Units (2400S Core Processor)
Remove the four screws that attach the housing cover and remove the cover. The 2400s requires the upper disc to
be removed before power or pulse connections can be made to the electronics. Loosen the two Philips screws on
the disc and pull disc straight up.
There is a plastic cover over the power terminals on the processor. Loosen the retaining screw and ip the cover up
to expose the power terminals. Connect power leads. Connect the pulse output wiring to terminals 3 and 4 (channel
B) on the terminal strip adjacent to the power connection. Reinstall the upper disc.

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2. Zeroing the meter
Before performing the zeroing procedure:
1. Power the meter for at least 30 minutes to warm up the electronics.
2. Circulate product thru the meter for 5 – 10 minutes to remove vapor and allow meter to reach a steady tempera-
ture.
3. Close the valve downstream of the meter rst, vapor return line valve second, and nally close the valve upstream
of the meter. All three should be closed as quickly as possible, to assure the meter is completely lled with LPG.
4. Disengage the truck PTO.
2.1 Modbus Units
Using ProLink 3:
1. Power up the meter, allow to stabilize for approx. 20 minutes. Run process uid through meter until temperature
equalizes. Shut off ow and ensure it is completely stopped.
2. Attach temporary RS485 connection to SP terminals on user interface module (see section II above). Establish a
connection in ProLink 3.
3. In ProLink 3: “Device Tools” > “Calibration” > “Zero Verication and Calibration”.
4. Perform Auto Zero, or select other options as desired.
5. LED on user interface module turns red during calibration, and turns green afterward for a good zero. If it remains
red, calibration is unsuccessful and troubleshooting must be done.
2.2 Pulse Output Units
Using the “Zero” button:
1. Remove the four screws that secure the cover of the electronics housing. Remove the cover.
2. Power up the meter, allow to stabilize for approximately 20 minutes. Run process uid through meter until tem-
perature equalizes. Shut off ow and ensure it is completely stopped.
3. Press the zero button with a pointed tool and hold it until the status LED on the user interface module ashes yel-
low. (See picture below for location of button.)
4. If the status LED shows solid green or solid yellow, the zero was successful. If it is red, the zero is not successful
and should be repeated.
(Note that the zeroing time cannot be changed when using the zero button; if a different time is desired, you must
use ProLink).

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2.2 Pulse Output Units (continued)
Using ProLink 3:
To communicate with the unit via the ProLink 3 conguration program, connect the RS-485 adapter to the A & B ter-
minals of the service port (labeled SP). Then follow the instructions for “Using Prolink 3” in Section 2, Modbus Units.

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0. AMMENDED PROCEDURES FOR NEW ELECTRONICS 5
1. FUNCTIONAL OVERVIEW 12
2. SPECIFICATIONS AND APPROVALS 13
2.1 RML2000 Specications 13
2.2. E4000 Specications
2.3. Custody Transfer Approval 15
2.4. Safety Approvals 15
3. SYSTEM COMPONENTS 16
3.1. RML2000 Coriolis Mass Flowmeter 16
3.2. E4000 Register Head 16
3.3. Display 17
3.4. Keypad 17
3.5. Electronic Temperature Compensation (Optional) 17
3.6. Valve control 18
3.7. Junction Box 18
3.7. Printer 19
3.8 Mobile Computer 19
4. INSTALLATION 20
4.1. Introduction 20
4.2. Check Parts 20
4.3. Truck Preparation 20
4.4. Installing the RML2000 Mass Flowmeter 20
4.5. Installing a Retrot RML2000 Mass Flowmeter 21
4.6. Positioning the E4000 Register Head 21
4.7 Installing the RTD 22
4.8 Wiring the RTD 22
Table of Contents

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4.9 Installing the Single Stage LPG Solenoid Valve 23
4.10 Wiring the Single Stage LPG Solenoid Valve 23
4.12 Wiring the Dual Stage LPG Valve 24
4.11 Installing the Dual-Stage LPG Valve 24
4.13 Installing the Junction Box and Printer 26
4.14 Wiring the E4000 Register Head 26
4.15 Wiring the Junction Box 28
4.15 Wiring the RML2000 Meter to the E4000 Register 30
4.16 Installing the Printer 31
4.17 Connecting Power to the Junction Box 31
4.15 Connecting a Mobile Computer 33
5. START UP AND CALIBRATION 34
5.1 Route Mode 34
5.2 Conguring the E4000 36
5.3 Conguring and Zeroing the RML2000 38
5.4 Calibrating the E4000 volumetric K-Factor 44
6. INSTALLATION CHECKLISTS 51
7. E4000 INITIALIZATION PROCEDURE 53
8. INTRODUCTION TO RESPONSIBLE RECYCLING (R2) 55
9. POWER/DATA CABLE WIRE COLOR CONVERSION CHART 57

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1. FUNCTIONAL OVERVIEW
The RML2000 Coriolis metering system for LP gas delivery trucks consists of two main elements:
• The RML2000 Coriolis mass meter complete with vapor release and differential valve
• The E4000 Electronic Register system
The Coriolis meter is a true mass ow meter in that it directly measures the mass ow rate of the product
passing through the sensor. The sensor consists of a vibrating U-tube arrangement, which tends to ex
under the action of uid ow. The degree of exing of the tube is measured and is directly proportional to
the mass ow rate. The Coriolis meter vibration frequency is related to the density of the product in the
tubes. The combination of a direct mass and density reading allows the meter electronics to calculate
the gross volume of propane delivered through the meter. The resultant volume measurement is highly
accurate and the meter has the operational advantage compared to traditional volumetric meters of having
no moving parts.
The E4000 electronic register system automates delivery and invoicing operations for deliveries of
LPG, distillate fuels and other commercially distributed liquids from owmeters on bulk delivery trucks.
The register displays the delivered volume on the owmeter at the rear of the truck as is traditional with
mechanical registers in this application. Electronic temperature compensation allows deliveries to be made
in gross or net volumes according to local practice. A printer in the cab provides a simple volume delivery
ticket or, using the E4000’s pricing capability, a complete priced invoice as a record of the transaction.
Tickets are time and date stamped for security. An end of shift report can be conveniently generated to
totalize the day’s deliveries by product. This allows administrative staff to reconcile individual tickets with
the shift as a whole. Delivery data is held for up to 100 deliveries in battery-backed memory. (Battery life is
approximately 10 years.)
The driver controls the E4000 from a push button panel on the front of the register. This allows yes/no
type decisions to be made and numerical values to be entered that are associated with delivery functions.
The buttons are used to navigate menus that appear on the display screen, guiding the user to perform
the required function. This interactive approach makes the register easy to operate by inexperienced
personnel.
The E4000 can control a security valve to prevent fraudulent LPG deliveries being made without the
register recording them. The solenoid valve is used with the LPG meter’s existing differential valve to
prevent ow. For both LPG, an optional driver-programmable 2-stage preset valve allows the delivered
amount to be set at a predetermined volume or monetary amount, subject to volume measurement
resolution.
The E4000 adapts mechanically to Neptune and other manufacturers’ tank truck owmeters. Temperature
compensation is achieved via an RTD probe installed in the owmeter that directly contacts the delivered
product and measures its temperature. The ability to accept an electrical pulse input allows the E4000 to
work with the RML2000 mass owmeter.
The E4000 is designed to interface with the latest mobile computing products. Mobile computers bring
customer database and delivery information from the ofce onto the truck. The register updates the
customer record as deliveries are made during the shift. Formatted tickets can be printed that include
customer information that has been downloaded from the computer. At the end of the shift, captured
delivery information is carried back to the ofce in the computer to be downloaded to the main customer
accounts database.
The E4000 features a calibrated pulse output which can be used to interface with remote meter displays
and/or remote control truck delivery systems.

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2. SPECIFICATIONS AND APPROVALS
2.1 RML2000 Specications
Device Type:
• 1” Coriolis Mass Flow Transducer
Wetted Parts:
• 316L Stainless Steel
Sensor Housing:
• 304L Stainless Steel
Line Size:
• 2” (51mm)
Flowrate:
• NCWM Approved Volumetric Flowrate 8-82 GPM
Weight:
• 28lb (13kg)
Operating Temperature Range:
• -40 – 150OF (-40 – 65OC)
Pressure Rating:
• 350psi (24bar)
Power:
• 12 to 24vDC (19Volts supplied from E4000 Junction Box).
• If power to puck drops below 9-10 Volts, pulses will stop during ow. Pulse output will restart once 12
volts is reached and the puck has completed the 20-40 second recovery period.
Dimensions:

14
2.2. E4000 Specications
Display
• 143 x 19 mm text area
• 2 lines, 20 characters per line
• 8.3 x 5.9 mm character area
Power Rating (supply from isolating or battery source)
• 9-16 VDC, 14.6 VDC nominal
• 0.25 Amps (0.63 Amps with optional display heater)
Relay Rating
• Number of Relays: 2
• Type: Normally open
• Contact Style: Form C contacts
• Contact Ratings: 230 VAC @ 3 amps
30 VDC @ 3 amps
LPG Single-Stage Valve (3/8” NPT)
• 0.8 Amp
• 12 VDC
• 9.5 Watts
LPG Dual-Stage Valve
• High Flow 3/8” Low Flow 3/8”
• 0.8 Amp 0.8 Amp
• 12 VDC 12 VDC
• 9.5 Watts 10 Watts
RTD Temperature Probe
• Platinum
• 4 wire
• Resistance at 32 F, 100 Ohms +/- 0.12%
Pulse Input
• Number of inputs: one
• Congurations supported: single input, single, dual or quad channel (menu selectable)
• Input Impedance: 10K Ohms nominal to common
• Trigger levels:
• Logic on: 3 to 30 VDC
• Logic off: 0 to 1 VDC
Communication to Printer and Computer
• RS232
Power to Electronics Module
• 19 Volts

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Printer
• Epson TM-U295 Dot Matrix (Can also be used with Blaster printer)
• Ticket Type: Blank / Pre-Printed up to 3 ply
• Ticket Size: 102 mm x 257 mm (4 x 10”)
• Power: 24 VDC +/- 2.4 VDC
• Ribbon: Epson ERC—27
Size
• 9.0 in x 8.9 in x 6.3 in (229 mm x 227 mm x 161 mm)
Weight
• 5.4 lbs (2.45 kg)
Operating Temperature Range
• 0 OF to 131 OF (-18 OC to 55 OC)
• -40 OF to 104 OF (-40 OC to 40 OC) with optional display heater
Enclosure Rating
• NEMA 3R, NEMA 4
Meter Performance
• Accuracy: ±0.1% of rate
• Repeatability: ±0.05% of rate
2.3. Custody Transfer Approval
NTEP Approval to NIST Handbook 44 and NCWM Publication 14
• E4000 – Certicate 02-105
• RML2000 – Certicate 06-009
2.4. Safety Approvals
E4000:
UL Suitable for use in Class 1, Division 2, Group A, B, C and D or non-Hazardous locations only.
The E4000 Electronic Register is UL approved when installed and operated in accordance with this
manual. Modications to the unit or deviations from specied usage may invalidate the UL certication.
RML2000:
CSA (C/US) suitable for use in Class I, Division 2, Group A, B, C and D or non-Hazardous locations only.
Evaluated to applicable CSA and ANSI/UL standards for use in Canada and the US.

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3. SYSTEM COMPONENTS
3.1. RML2000 Coriolis Mass Flowmeter
The Coriolis meter is mounted in a similar position to
a traditional volumetric meter at the rear of the truck.
The meter is connected in line via 2” 300 lb pressure
rated anges to the vapor release and differential
valve.
The meter is constructed from stainless steel and
consists of a double U-tube arrangement enclosed in
a rectangular case. The drive coil, used to vibrate the
tubes, and the sensor coils which measure the exing
of the tubes under ow conditions, are mounted inside
the box.
The instrument electronics are enclosed within the
small junction box at the top of the meter. Power and
communication connections to the register are made
here. The only means of communicating directly to the
Coriolis meter is to connect a computer to these same terminals. The computer is only required to “zero”
the meter as part of the calibration process, to be discussed later in this manual.
Once the junction box lid is closed, there are no operator controls on the meter; all functions are per-
formed at the E4000 register head.
3.2. E4000 Register Head
The E4000 electronic register is designed and eld proven to
withstand the harsh environment on tank trucks. The enclosure
is plastic with a NEMA 3 rating.
The E4000 can be mounted directly on the positive displace-
ment owmeter so that the mechanical drive of the meter rotates
an optical pulse encoder mounted in the register. Alternately,
the register can be mounted wherever required when receiving
a pulse output from a meter. Counting the pulses indicates the
amount of product measured by the owmeter during a delivery.
An optional temperature compensation kit can be added to the
base unit.
An operator communicates with the register via an LCD screen and a 4 button control panel. Internally
mounted relays operate electrical solenoid valves to control the ow of product. Delivery ticket information
is transmitted through the power/data cable from the rear of the register to a cab mounted junction box,
then to the ticket printer or hand-held computer.
Power and data connections are made to terminal strips inside the register and junction box. Congura-
tion parameters are programmed into the register manually by the buttons or from an external computer
using the E4000 conguration program.
An internal calibration switch is positioned inside the register to allow access to the Weights and Measures
conguration menu, and is mechanically sealed on the outside of the register.
Figure 3-1. RML2000 Tube Conguration
Figure 3-2. E4000 Register Head

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3.3. Display
The 2x20 character LCD display is primarily intended to
show the volume of product being delivered. The two-line
display conguration also allows two parameters to be shown
simultaneously, such as delivered volume and price during
delivery or net and gross volume during calibration. The
display is also the method by which the E4000 communicates
instructions to operators as they navigate through the
software menus.
3.4. Keypad
The 4 button keypad is the method used to enter conguration data and select function options for the
E4000 register.
START/ENTER Conrms/accepts selected option on display
^ Increments the displayed character through the available character set
> Moves cursor to the right .
STOP/CANCEL Terminates delivery or exits current selection.
Pressing the up arrow on the control panel will scroll the selected character through a complete ASCI
character set (upper and lower case letters, all numerals and symbols). A space character is also included
in the character set. It is the fth character after the lowercase z and is located between the right facing
arrow and the exclamation point:
→, [space], !
Access the Weights and Measures functions by depressing the internal switch beneath the seal screw on
the side of the register and pressing the > button simultaneously.
3.5. Electronic Temperature Compensation (Optional)
A temperature probe is available as an option for electronic temperature correction of the delivered volume
of product. This correction is mandatory for some products under Weights and Measures legislation in
certain states and countries. The probe is a 100 ohm RTD. The E4000 measures the product temperature
during delivery and uses the approved API volume correction table for the product at that temperature.
The resulting calculation when applied to the gross volume gives a net volume corrected to 60 OF or 15 OC
depending on the chosen units or product (505 LPG/510 LPG).
The use of electronic temperature correction has been shown to reduce the amount of unmeasured
product by approximately 1% versus mechanical ATC. For uids without a recognized correction table,
approved formulas or expansion factors are used to calculate net volume. The RTD probe can be installed
in a Neptune meter, replacing the mechanical ATC bellows, or in the strainer cover.
Figure 3-3. LCD Display
Figure 3-4. E4000 Keypad

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3.6. Valve control
Red Seal provides an optional single stage solenoid valve (gure 3-4) to control the opening and closing
of the differential valve on LPG meters. The valve is opened only when the E4000 is powered and the
start button has been pressed to commence a delivery. The valve will close whenever the stop button is
pressed during a delivery or power is lost to the register.
Dual stage valves are also available for making preset deliveries of LPG. The E4000 has 2 relays which
control the two-stage shut off either by volume or monetary amount. The rst stage reduces ow by 90%
to slowly bring delivered volume up to the preset amount. The second stage shuts off ow when the preset
amount is reached without hydraulic shock to the delivery system.
Figure 3-5. Single Stage LPG Valve Figure 3-6. Dual Stage LPG Valve
Caution: All valves supplied with the E4000 (security valves and dual-stage preset) are wired with
an in-line TVS (transient voltage suppressor) to protect the E4000 from harmful voltage spikes. If
an E4000 is installed on another manufacturer’s meter with a different solenoid valve (or a Neptune
meter using another manufacturer’s valve), an appropriate TVS must be installed. Contact custom-
er service for details.
3.7. Junction Box
The junction box, located in the vehicle cab, houses a
PC board and serves as the connection point for the
E4000 peripherals mounted in the cab. The power to
the E4000 and printer is distributed from here. Data
passes through the junction box on its way to the printer.
The RS232 data link from the E4000 to any peripheral-
computing device such as a Hand held or Laptop is
made here. The same RS232 connector is used for
downloading the E4000 conguration parameters from a
laptop using the E4000 Conguration Program.
Figure 3-7. Junction Box

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3.7. Printer
The E4000 printer is an Epson TM-U295 single feed style dot-
matrix printer which uses a standard 4-1/8” wide truck meter
delivery ticket , Neptune or Veeder Root. The printer is intended
for internal use only and should be mounted in the cab of the
truck. A data cable is supplied with the printer kit. The printer
power cable comes with the Junction Box. The junction box steps
up truck voltage from 12V to 24V to power the printer. The E4000
can also be used with a Blaster printer or an EPSON TM-U220D
roll printer.
3.8 Mobile Computer
The E4000 has been specically designed to operate with a mobile
computer such as a laptop, hand-held or PDA. The computer plugs
directly into the 9-pin RS-232 serial connector on the junction box that is
not occupied by the printer.
There are two modes of operation with an external computer:
1. The computer is running the E4000 Conguration Program and is temporarily connected to the junction
box to change non metrological parameters and update stand alone pricing.
2. The computer has fuel delivery application software running and carries customer account information
required by the driver during a shift. The computer interacts digitally with the E4000, extracts volume data
and uses this to calculate the customer invoice and update the account records. The mobile computer
updates the company database when returned to the ofce at the end of the shift.
Figure 3-8. Printer

20
4. INSTALLATION
4.1. Introduction
Before attempting to install an RML2000/E4000 system, read this manual! To simplify installation and
reduce the time required, follow the directions provided in this document. Each installation will vary
depending on the layout and overall condition of the truck, the uid being measured, and the installer’s
experience with electronic registers and owmeters.
WARNING: LPG systems should be installed in accordance with national standards ref: NFPA
58. Power, input and output (I/O) wiring must be in accordance with Class I, Division 2 wiring
methods Article 501-4(b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as
specied in Section 18-1J2 of the Canadian Electrical Code for installations within Canada and in
accordance with the authority having jurisdiction.
4.2. Check Parts
Before commencing installation, unpack the entire contents of the E4000 packaging. Lay out the parts as
they would be installed on the truck. This will highlight any missing or incorrectly ordered/supplied parts.
Verifying that all the necessary parts are available in advance will reduce the truck downtime and avoid
any wasted truck preparation work.
4.3. Truck Preparation
Before commencing the installation:
Check that the condition of the truck battery is within the E4000 specications.
Disconnect the battery.
Close the manual supply valves and bleed down the meter.
Disconnect the pressure line from the top of the differential valve.
Warning: Pressure must be completely relieved before proceeding.
4.4. Installing the RML2000 Mass Flowmeter
The unit must be mounted using the approved bracket available from Red Seal (or a similarly fabricated
bracket that will hold the unit securely, place no stress on the meter, and transmit minimal vibration). The
four bolts securing the clamps which hold the meter should be torqued to 55-65 ft-lbs. The bolts attaching
the top plate (for mounting the register) should be torqued to 15-17 ft-lbs.
The unit should be mounted horizontally so that the electronics module faces outward (gure 4-1).
Figure 4-1. RML2000 in Bracket