Toptech FCM II User manual

FCM II
(Flow Control Module)
Installation Guide
Part # 2307
April 26, 2013

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FCM II Installation Guide: 20160419 - Part # 2307
EC Declaration Of Conformity (Valid until April 20, 2016)
The signatory, representing the manufacturer, declares that the products listed below are in conformity with the essential requirements of the
following EC Directive(s) when installed in accordance with the product installation instructions:
2004/22/EC The Measuring Instruments Directive (and its amending directives)
2004/108/EC The Electromagnetic Compatibility Directive (and its amending directives)
2006/95/EC The Low Voltage Directive (and its amending directives)
Product: Distributed I/O Control System
Model name/number: FCM II
Notified Body(ies)
NMi Certin B.V., Number 0122
Hugo de Grootplein 1
3314 EG Dordrecht
The Netherlands
Conformity has been demonstrated with reference to the following documentation:
(MID) EC type-examination certificate TC7311
Compliance with the Essential Health and Safety Requirements has been assessed by reference to the following standards:
WELMEC guide 8.8 General and Administrative Aspects of the Voluntary System of Modular Evaluation of Measuring
instruments under MID
OIML R117-1:2007(E) Dynamic measuring systems for liquids other than water
EN 61000-6-4: 2007 Generic emissions for industrial operating environments
EN 61000-6-2: 2005 Generic immunity for industrial operating environments
IEC 61010-1: 2004 Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements
Year of CE Marking: 2007
Name: William J. Porthouse Position: Director of Engineering & Production Date: 31-Oct-2012
EC Declaration Of Conformity
The signatory, representing the manufacturer, declares that the products listed below are in conformity with the essential requirements of the
following EC Directive(s) when installed in accordance with the product installation instructions:
2014/32/EU The Measuring Instruments Directive (and its amending directives)
2014/30/EU The Electromagnetic Compatibility Directive (and its amending directives)
2014/35/EU The Low Voltage Directive (and its amending directives)
Product: Distributed I/O Control System
Model name/number: FCM II
Notified Body(ies)
NMi Certin B.V., Number 0122
Hugo de Grootplein 1
3314 EG Dordrecht
The Netherlands
Conformity has been demonstrated with reference to the following documentation:
(MID) EC type-examination certificate TC7311
Compliance with the Essential Health and Safety Requirements has been assessed by reference to the following standards:
WELMEC guide 8.8 General and Administrative Aspects of the Voluntary System of Modular Evaluation of Measuring
instruments under MID
OIML R117-1:2007(E) Dynamic measuring systems for liquids other than water
EN 61000-6-4: 2007 Generic emissions for industrial operating environments
EN 61000-6-2: 2005 Generic immunity for industrial operating environments
IEC 61010-1: 2004 Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements
Year of CE Marking: 2007
Name: William J. Porthouse Position: Director of Engineering & Production Date: 19-April-2016

ELECTRICAL CONSIDERATIONS AND REGULATORY REQUIREMENTS

Equipment Operation. If the equipment is used in a manner not specified in this installation guide,
the protection provided by the equipment may be impaired..

This equipment is suitable for use in Class I, Division 2, Groups C and D hazardous locations OR
non-hazardous locations only.
WARNING: EXPLOSION HAZARD, Do not disconnect equipment unless power has been
removed or the area is known to be non-hazardous.
WARNING: EXPLOSION HAZARD, Substitution of components may impair suitability for use in
Class I, Division 2 environments.
WARNING: EXPLOSION HAZARD, The area must be known to be non-hazardous before
servicing/replacing the unit and before installing.
CAUTION: Use supply wires suitable for 5°C above surrounding ambient.
!
!
!
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FCM II Installation Guide: 20160419 - Part # 2307
Copyright Notice
Copyright © 2007-2016 Toptech Systems, Inc.
The information contained in this document is proprietary and confidential. No part of this document may be copied, reproduced, or
transmitted in any medium without the express written permission of Toptech Systems, Inc.
Disclaimer
Toptech Systems assumes no responsibility for damages resulting from installation or use of its products. Toptech Systems will not be liable
for any claims of damage, lost data, or lost time as a result of using its products.
A Unit of IDEX Corporation
logo is a registered trademark of Toptech Systems, Inc.
TMS™, TMS5™, TMS6™, RCU II Remote Control Unit™, Toptech MultiLoad II™, MultiLoad II -RCU™, RCU II™, FCM Flow Control
Module™, veriFID™, ACR™, ACR II™are trademarks of Toptech Systems, Inc.
Copyright © 2016 Toptech Systems, Inc. All Rights Reserved.

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FCM II Installation Guide: 20160419 - Part # 2307
Table of Contents
Electrical Considerations and Regulatory Requirements ................................................................................3
CHAPTER 1 General...........................................................................................................................................8
1.1 Who Should Use This Guide ...................................................................................................................8
1.2 Information Alerts:....................................................................................................................................8
1.3 Receiving and/or Returning Equipment:................................................................................................8
1.4 Operating Characteristics: ......................................................................................................................8
1.4.1 Electrical Ratings:...................................................................................................................................9
1.4.2 Operating Conditions:.......................................................................................................................... 10
1.5 Electrostatic Discharge (ESD) Protection:.......................................................................................... 10
CHAPTER 2 Installation.................................................................................................................................. 11
2.1 Module Installation ................................................................................................................................ 11
2.2 Module Removal.................................................................................................................................... 11
2.3 FCM II Panels And Enclosures:............................................................................................................ 12
2.3.1 Panel Layouts:..................................................................................................................................... 12
2.3.2 Panel Wiring......................................................................................................................................... 12
2.3.3 Enclosure Mounting............................................................................................................................. 12
2.4 Electrical Supply Connections............................................................................................................. 13
2.5 Serial Communication Connection...................................................................................................... 14
2.6 Device Address Configuration............................................................................................................. 15
2.7 Swing Arms............................................................................................................................................ 16
CHAPTER 3 Field Wiring ................................................................................................................................ 18
3.1 Connection Requirements.................................................................................................................... 18
3.2 FCM II Field Device Connections......................................................................................................... 18
3.2.1 Terminal Identification.......................................................................................................................... 19
3.2.2 Flow Meter and Control Valve Wiring.................................................................................................. 20
3.2.3 Additive Wiring..................................................................................................................................... 21
3.2.4 RTD Temperature Probe Wiring.......................................................................................................... 22
3.2.5 4-20mA Input Wiring: LOOP CURRENT PROVIDED BY EXTERNAL POWER SUPPLY ................. 23
3.2.6 4-20mA Input Wiring: LOOP CURRENT PROVIDED BY TRANSMITTER......................................... 24
3.2.7 4-20mAOutput Wiring.......................................................................................................................... 25
3.2.8 AC Permissive/Status Wiring (6ACIN)................................................................................................. 26
3.2.9 AC Output Wiring (6ACOUT).............................................................................................................. 27
3.2.10 DC Permissive/Status Wiring (6DCIN) ............................................................................................ 28
3.2.11 DC Permissive/Status Wiring (4DCIN/4ACOUT)............................................................................. 29
3.2.12 AC Output Wiring (4DCIN/4ACOUT)............................................................................................... 30
3.2.13 DC Output Wiring (6DCOUT) .......................................................................................................... 31
3.2.14 3 Output Air Eliminator Wiring ......................................................................................................... 32
3.2.15 2 Output Air Eliminator Wiring ......................................................................................................... 33
3.2.16 Lectro Count Remote Display Wiring .............................................................................................. 34
CHAPTER 4 Simulation................................................................................................................................... 35
4.1 Meter Simulation.................................................................................................................................... 35
4.2 Additive Simulation ............................................................................................................................... 35
4.3 Analog Simulation ................................................................................................................................. 35
4.4 Generic I/O Simulation .......................................................................................................................... 35
CHAPTER 5 Troubleshooting ........................................................................................................................ 36
5.1Is The Module Powered?....................................................................................................................... 36
5.2 Is The Module Communicating? .......................................................................................................... 36
5.3 Are The Inputs Functioning?................................................................................................................ 37
5.4 Are The Outputs Functioning?............................................................................................................. 37

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FCM II Installation Guide: 20160419 - Part # 2307
5.5 Are RTD Errors Present?...................................................................................................................... 38
5.6 Are Other Errors Present?.................................................................................................................... 38
5.7 Is Technical Assistance Available?..................................................................................................... 38
CHAPTER 6 Dimensions, Panel Layouts, Wiring Suggestions.................................................................. 39
6.1 Module Dimensions............................................................................................................................... 39
6.2 Standard Panel Dimensions................................................................................................................. 41
6.2.1 20 inch x 20 inch Panel........................................................................................................................ 41
6.2.2 30 inch x 30 inch Panel........................................................................................................................ 43
6.3 Panel Electrical Wiring Suggestions ................................................................................................... 45
6.3.1 Power and Communication Distribution .............................................................................................. 45
6.3.2 Wiring Terminal Identification .............................................................................................................. 47
6.3.3 Voltage Distribution.............................................................................................................................. 48
CHAPTER 7 Hardware Revision History....................................................................................................... 49
CHAPTER 8 Manual Revision History........................................................................................................... 50

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FCM II Installation Guide: 20160419 - Part # 2307
Table of Figures
Figure 1.1 FCM II Module Comparison .............................................................................................................9
Figure 1.2 FCM II Module Electrical Ratings....................................................................................................9
Figure 2.1 Engage Top Foot on Rail .............................................................................................................. 11
Figure 2.2 Snap Metal Foot to Rail................................................................................................................. 11
Figure 2.3 Slide Modules Together ................................................................................................................ 12
Figure 2.4 Power / Com Connection Bus ...................................................................................................... 13
Figure 2.5 Module Status, Configuration Setting and Identification .......................................................... 15
Figure 2.6 DIP Switch Configuration Settings .............................................................................................. 16
Figure 2.7 Swing Arm Wiring of Shared FCM IIs .......................................................................................... 17
Figure 3.1 FCM II Single And Double Module Comparison ......................................................................... 19
Figure 3.2 FCM II Field Wiring Terminal Locations ...................................................................................... 19
Figure 3.3 FCM II Field Wiring: Flow Meter and Control Valve ................................................................... 20
Figure 3.4 FCM II Field Wiring: Additive Meters and Injection Valves ....................................................... 21
Figure 3.5 FCM II Field Wiring: RTD............................................................................................................... 22
Figure 3.6 FCM II Field Wiring: 4-20mA Input ............................................................................................... 23
Figure 3.7 FCM II Field Wiring: 4-20mA Input ............................................................................................... 24
Figure 3.8 FCM II Field Wiring: 4-20mA Output ............................................................................................ 25
Figure 3.9 FCM II Field Wiring: AC Permissive/Status (6ACIN) .................................................................. 26
Figure 3.10 FCM II Field Wiring: AC Pump and Valve Control (6ACOUT)......................................................... 27
Figure 3.11 FCM II Field Wiring: DC Permissive/Status (6DCIN) .................................................................. 28
Figure 3.12 FCM II Field Wiring: DC Input (4DCIN/4ACOUT)......................................................................... 29
Figure 3.13 FCM II Field Wiring: AC Output (4DCIN/4ACOUT)...................................................................... 30
Figure 3.14 FCM II Field Wiring: DC Output (6DCOUT).................................................................................. 31
Figure 3.15 FCM II Field Wiring: 3 Output Air Eliminator............................................................................... 32
Figure 3.16 FCM II Field Wiring: 2 Output Air Eliminator............................................................................... 33
Figure 3.17 FCM II Field Wiring: Lectro Count Remote Display ................................................................... 34
Figure 5.1 FCM II Module Front Panel............................................................................................................ 36
Figure 6.1 FCM II Single Module Dimensions .................................................................................................. 39
Figure 6.2 FCM II Double Module Dimensions................................................................................................. 40
Figure 6.3 20 Inch x 20 Inch Panel Layout .................................................................................................... 41
Figure 6.4 20 Inch x 20 Inch Enclosure Dimensions.................................................................................... 42
Figure 6.5 30 Inch x 30 Inch Panel Layout .................................................................................................... 43
Figure 6.6 30 Inch x 30 Inch Enclosure Dimensions.................................................................................... 44
Figure 6.7 FCM II Power and Serial Communication Panel Wiring: Single Row....................................... 45
Figure 6.8 FCM II Power and Serial Communication Panel Wiring: Two Rows, Two Serial Ports .......... 46
Figure 6.9 FCM II Power and Serial Communication Panel Wiring: Two Rows, One Serial Port ............ 47
Figure 6.10 FCM II Field Terminal Block Labels ............................................................................................. 48

Chapter 1 –General
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FCM II Installation Guide: 20160419 - Part # 2307
!
CHAPTER 1 GENERAL
1.1 WHO SHOULD USE THIS GUIDE
This guide is intended for individuals installing FCM II panels, engineering firms fabricating FCM II panels, and
users troubleshooting system operation such as managers, system administrators, technicians, and meter proving
personnel.
1.2 INFORMATION ALERTS:

Important information to enhance understanding and make better use of the product.

Indicates potential damage to hardware or loss of data.
Potential for property damage or that personal injury may occur. Pay close attention and follow
instructions when you see this symbol.
1.3 RECEIVING AND/OR RETURNING EQUIPMENT:
The FCM II should be immediately inspected after opening the packaging case. If any damage is visible notify the
carrier at once to establish liability. Contact Toptech Account Management to initiate timely repair or replacement
of the unit.
Account Management will issue a Return Materials Authorization (RMA) to return the product or parts requiring
repair. Do not return any material to Toptech without an RMA.
Account Management contact information:
Account Management
Toptech Systems
1124 Florida central Pkwy
Longwood, FL
[phone]
1.4 OPERATING CHARACTERISTICS:
FCM II is available in six varieties (see Figures 1.1 and 1.2 below). This modular construction simplifies the
process of FCM mapping to field devices by appropriating each FCM II model with just the right amount of I/O for
its designated purpose. In addition, FCM IIs are DIN rail (35mm) mountable and require no wiring between units;
24Vdc and serial communications are bussed. This substantially simplifies installation and wiring.

Chapter 1 –General
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FCM II Installation Guide: 20160419 - Part # 2307
Figure 1.1 FCM II Module Comparison
1.4.1 ELECTRICAL RATINGS:
Module
Supply
Voltage
Electrical Ratings
Auxiliary
Power Supply
Outputs
Inputs
FCM II 4DC IN/
4AC OUT
Min. 19 Vdc
Max. 36 Vdc
100mA Max
12 Vdc
167 mA Max
250 Vac
350 mA max.
6K Cycles, Pilot Duty
30 Vdc
SELV
Limited Energy
FCM II Analog
Min. 19 Vdc
Max. 36 Vdc
100mA Max
--
4-20 mA
SELV
Limited Energy
RTD, 4-20 mA
SELV
Limited Energy
FCM II 6 AC IN
Min. 19 Vdc
Max. 36 Vdc
100mA Max
--
--
250 Vac max.
Optically Isolated
Contact Closure
FCM II 6 AC OUT
Min. 19 Vdc
Max. 36 Vdc
100mA Max
--
250 Vac
350 mA max.
6K Cycles, Pilot Duty
--
FCM II DC IN
Min. 19 Vdc
Max. 36 Vdc
100mA Max
--
--
30 Vdc
SELV
Limited Energy
FCM II DC OUT
Min. 19 Vdc
Max. 36 Vdc
100mA Max
30 Vdc
250mA max.
6K Cycles, Pilot Duty
Figure 1.2 FCM II Module Electrical Ratings

Chapter 1 –General
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FCM II Installation Guide: 20160419 - Part # 2307
1.4.2 OPERATING CONDITIONS:
Operating temperature (surrounding air temperature) -40°F to 140°F (-40°C to 60°C).
Environmental Ratings: None. FCM II modules are classified as open equipment must be placed in a
suitable Type 4 (or IP 65) or better enclosure.
For product outline and dimensions see Figure 6.1 and Figure 6.2.
1.5 ELECTROSTATIC DISCHARGE (ESD) PROTECTION:
The FCM II contains electronic components and assemblies subject to damage by ESD. The FCM II was
designed to protect against ESD while the unit is mounted on an electrical panel and in normal operation. Proper
handling procedures must be observed during the removal, installation, repair and other handling of FCM II
modules summarized below.
1) Service must be performed by authorized personnel only.
2) The person performing the service must be grounded by an ESD grounding strap and connected to
ground.
3) The plastic enclosures offer a degree of protection of the inner printed circuit board assemblies
against ESD. However, the heat venting slots and the wiring terminals blocks do allow a possible path
for ESD when not fastened to the electrical panel. Therefore, a servicing technician is advised to
touch unpainted metal of the electrical panel prior to installing or replacing FCM II modules.
4) FCM II modules must be placed in and transported in conductive bags or other conductive containers.
5) FCM II modules must not be removed from the conductive container until time of use.
6) All other “best” practices for protecting devices from ESD must be observed.