Toptech MultiLoad II DIV-2 User manual

MultiLoad II & RCU II
DIVISION 2 (DIV2)
Installation Guide
(Part # 6074)

MultiLoad II/ RCU II DIV-2 Installation Guide: 20181218 - Part # 6074
DECEMBER 2018 TOPTECH SYSTEMS
MultiLoadII&RCUII–Division2(DIV2)
InstallationGuide
1124 Florida Central Parkway
Longwood, FL 32750
USA
Phone [phone]
Copyright Notice
Copyright © 2006 - 2018 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.

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 DIV2 (MID, YES), RCU II DIV2 (MID, NO)
Protective Systems: Nonincendive ‘ec ic’
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:
(ATEX) EC test report for Project 06NK12831, Dated 2007-01-31
(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
EN 60079-0: 2012 Explosive atmospheres Part 0: Equipment—General requirements
EN60079-7:2015 Explosive atmospheres –Part 7: Equipment protection by increased safety «e»
EN-60079-11: 2012 Explosive atmospheres Part 11: Equipment protection by intrinsic safety "i"
Year of CE Marking: 2007
Name: William J. Porthouse Position: Director of Engineering & Production Date: 20-December-2018
Name Plate

TableofContents
Overview...........................................................................................................................1
Chapter 1 General information & Warnings............................................................3
Receiving and/or Returning Equipment .............................................................31.1 Safety Warnings................................................................................................41.2 Electrostatic Discharge (ESD) Protection...........................................................51.3 FCC Note ..........................................................................................................61.4
Chapter 2 Operating conditions and components...................................................7
Product Outline and dimensions........................................................................72.1
MultiLoadII/ RCUII –DIV2 model - Picture..................................................72.1.1 MultiLoadII/ RCUII –DIV2 model –Dimensions..........................................82.1.2
2.1.2.1 Front View................................................................................................8
2.1.2.2 Back View................................................................................................9
2.1.2.3 Bottom View...........................................................................................10
2.1.2.4 Side View...............................................................................................11
Operating Characteristics: ...............................................................................122.2
Chapter 3 Installing the MultiLoad II/RCUII DIV2..................................................14
Tools Required................................................................................................143.1
Installation ................................................................................................143.1.1 Servicing and Repair.................................................................................143.1.2
Cover Closure and Bolt Replacement..............................................................143.2 Cable Entries..................................................................................................143.3 Mounting the MultiLoad II/ RCU II DIV-2 Enclosure: ........................................143.4
Drywall......................................................................................................153.4.1 Wood........................................................................................................153.4.2 Concrete or Cinder Block Walls................................................................153.4.3 Mounting Height Considerations...............................................................153.4.4
Recommended Wire Sizes And Torque For All Terminal Blocks......................173.5 Electrical Supply Connections .........................................................................173.6
AC Powered Models.................................................................................183.6.1 DC Powered Models.................................................................................183.6.2 Equipment Grounding...............................................................................193.6.3

Chapter 4 Data Communications Interface...........................................................20
Available Communications Protocol Selection and Wire spec..........................214.1
RS-422/485 ..............................................................................................214.1.1 RS-232 .....................................................................................................214.1.2 Ethernet....................................................................................................224.1.3
Communication Connection Wiring..................................................................224.2
FCM I / FCM II Communications ( MultiLoad II Product Only) - COM 0 –4.2.1
Port –RS485.......................................................................................................22
Host/TMS Communications ......................................................................234.2.2
4.2.2.1 COM 1 - RS-485 4-wire - Host/TMS Communications............................23
4.2.2.2 COM 1 - RS-485 2-wire : Host/TMS Communications............................24
4.2.2.3 COM 1 - RS-232 - Host/TMS Communications......................................25
4.2.2.4 Ethernet –Host/TMS Communications ..................................................26
Host Ticket Printer/Data Logger................................................................274.2.3
4.2.3.1 COM2 –RS232 - Host Ticket Printer/Data Logger.................................27
Chapter 5 Connecting Field devices to the I/O Board..........................................30
Where to find the internal I/O board.................................................................305.1 Available I/O points per board..........................................................................315.2 Terminal arrangements per board....................................................................335.3
Digital Analog I/O board (IO_DA).............................................................335.3.1 2 Meter I/O board ( IO-2M)........................................................................345.3.2
How to connect and wire field devices to the I/O boards..................................355.4
MultiLoad II Flow Meter and Control Valve Wiring.....................................365.4.1 MultiLoad II Additive Wiring: Outputs........................................................375.4.2 MultiLoad II Additive Wiring: Inputs...........................................................385.4.3 MultiLoad II Analog Wiring........................................................................395.4.4
5.4.4.1 RTD Wiring ............................................................................................39
5.4.4.2 MultiLoad II 4 –20 mA Wiring ...............................................................40
MultiLoad II AC Output Wiring...................................................................415.4.5 MultiLoad II AC Input Wiring .....................................................................425.4.6 MultiLoad II DC Permissive/Status Wiring.................................................435.4.7 MultiLoad II DC Output Wiring ..................................................................445.4.8 MultiLoad II 2 Output Air Eliminator Wiring................................................455.4.9 MultiLoad II Lectro Count Remote Display Wiring ...................................465.4.10 RCU II DC Input Wiring...........................................................................475.4.11 RCU II AC Output Wiring ........................................................................485.4.12

RCU II DC Output Wiring ........................................................................495.4.13 Typical 1 meter application wiring example IP&E Drawing (electrical wiring5.4.14
schedule).............................................................................................................50
Chapter 6 Configurations.....................................................................................51
Switch Access Control.....................................................................................516.1
External Switch Access Control (MultiLoad II Only) ..................................516.1.1 External Type 1 Program / W&M switches................................................526.1.2 External Type 2 Program / W&M switches................................................526.1.3 External Type 3 Program / W&M switches................................................546.1.4 Internal Switch Access Control .................................................................546.1.5
MultiLoad II/ RCU II DIV-2 Keypad ..................................................................566.2 Menus and Screens.........................................................................................576.3 Field Modification and Data Entry....................................................................586.4 MultiLoad II/ RCU II Preliminary Configuration.................................................596.5 Verify Communications Between MultiLoad II/ RCU II And I/O Board..............626.6 Using I/O Diagnostics......................................................................................636.7
Chapter 7 Service and Repair..............................................................................65
Overview and Subassemblies..........................................................................657.1 CPU Subassembly Removal and Replacement:..............................................677.2 Display Subassembly Removal and Replacement:..........................................69
7.3
Flat Display Cable connector : Remove and Connect..............................697.3.1
Keypad Removal and Replacement:................................................................707.4 Card Reader Removal and Replacement ........................................................717.5
Slotted Card Holder Mounted Prox Reader Removal and Replacement:7.5.1
(Current Model)...................................................................................................71
Bracket Mounted (Obsolete) Prox Reader Removal and Replacement:....727.5.2 Slotted Card Holder Mounted Prox Reader HID (Obsolete) Removal and7.5.3
Replacement:......................................................................................................73
Slotted Card Holder Mounted TWIC Reader (Obsolete) Removal and7.5.4
Replacement:......................................................................................................74
W&M switch assembly Removal and Replacement.........................................757.6 Ice Shield Removal and Replacement:............................................................767.7 Overview Parts List and Partnumbers :............................................................777.8
Chapter 8 Hardware Revision History & Compatibilty..........................................79
Chapter 9 Revision History ..................................................................................80

Hardware Revision ..........................................................................................809.1 Manual Revision..............................................................................................819.2

TableofFigures
Figure 2.1 MultiLoad II (ML II) / Remote Control Unit II (RCU II) Division 2 Unit ............7
Figure 2.2 Unit Outline Drawing –Front View.......................................................................8
Figure 2.3 Unit Outline Drawing –Back View.......................................................................9
Figure 2.4 Unit Outline Drawing –Bottom View -2 Hole Base.........................................10
Figure 2.5 Unit Outline Drawing –Bottom View - 5 Hole Base........................................10
Figure 2.6 Unit Outline Drawing –Side View......................................................................11
Figure 3.1 Suggested Mounting Position.............................................................................16
Figure 3.2 Screen Visible Area..............................................................................................16
Figure 3.3 MultiLoad II/ RCU II AC Power Supply/Comm Board.....................................18
Figure 3.4 DC Power Connections .......................................................................................19
Figure 4.1 FCM / PCM Connections.....................................................................................23
Figure 4.2 RS485 4-Wire, Host to a Single MultiLoad II/ RCU II (recommended)........23
Figure 4.3 RS485 4-Wire, Host to Multiple MultiLoad II/ RCU IIs....................................24
Figure 4.4 RS485 2-Wire, Host to a Single MultiLoad II/ RCU II......................................24
Figure 4.5 RS485 4-Wire, Host to Multiple MultiLoad II/ RCU IIs....................................25
Figure 4.6 RS232, Host to a Single MultiLoad II/ RCU II ..................................................25
Figure 4.7 RS232, Host to Multiple MultiLoad II/ RCU IIs.................................................26
Figure 4.8 Ethernet Connections ..........................................................................................26
Figure 4.9 Ticket Printer / Data Logger Connections with Handshake...........................27
Figure 4.10 Ticket Printer / Data Logger Connections without Handshake.....................28
Figure 4.11 PTB Printer Connection with Handshake.........................................................28
Figure 5.2 2 Meter I/O Board Terminal Block Assignments..............................................34
Figure 6.1 Type 1 Program / W&M Switches......................................................................52
Figure 6.2 Type 2 Program / W&M Switches......................................................................52
Figure 6.3 Type 3 Program / W&M Switch with Magnetic Bolts.......................................54
Figure 6.4 CPU DIP Switches for Program and W&M Access (rev 1.0).........................56
Figure 6.5 CPU DIP Switches for Program and W&M Access (rev 2.0) Field Switch Access Control
(MultiLoad II Only) .......................................................................................................................56
Figure 7.1 MultiLoad II (ML II) / Remote Control Unit II (RCU II) Division 2 Unit ..........65

Figure 7.2 ML II/ RCU II Div2 Unit Assembly Slotted Card Holder with MT11 ..............66
Figure 7.3 CPU Board, Power Supply / Comm Board, I/O Board with Chassis............67
Figure 7.4 ML II/ RCU II Div2 Unit Cover Display Assembly............................................69
Figure 7-5 Cam lock in the Open (Up) position Figure 7-6 Cam lock in the closed (down)70
Figure 7-7 Display Cable Insertion........................................................................................70
Figure 7.8 ML II/ RCU II Div2 Unit Cover Keypad Assembly............................................71
Figure 7.9 Exploded View Front Cover Assembly: Slotted Card Holder with MT11.....72
Figure 7.10 ML II/ RCU II Div2 Cover Assembly Prox Bracket Mount Thinline II (Obsolete) 73
Figure 7.11 ML II/ RCU II Div2 Cover with Slotted Card Holder Thinline II (Obsolete)..74
Figure 7.12 ML II/ RCU II Div2 Unit Assembly Prox/TWIC Slotted Card Holder RP15 (Obsolete)
75
Figure 7.13 ML II/ RCU II DIV2 W&M Assembly..................................................................76
Figure 7.14 Ice Shield Assembly Installation Slotted Card Holder....................................77

1
Overview
This document is designed to guide individuals installing MultiLoad II/ RCU II DIV2 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 thematerial available in thisguide:
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 –
DIV2
This chapter covers installation considerations and instructions for the
Division 2 (DIV2) 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 Boards.
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 DIV-2 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.

2
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 DIV2 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.

3
Chapter1 GeneralInformation&Warnings
Receiving and/or Returning Equipment1.1
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
[phone]
Contact Information for EMEA and Asia:
Return Materials Department
Toptech System NVs
Nieuwe weg 1- haven 1053
2070 Zwijndrecht, BELGIUM
[phone]
Prior to installation, the MultiLoad II/ RCU II should be stored in its packing case and be protected from
damage due to handling and adverse weather conditions.
Chapter
1

4
Safety Warnings1.2
NORTH AMERICAN INSTALLATIONS:
▲This equipment is suitable for use in Class I, Division 2, Groups C and D locations, OR non-
hazardous locations.
▲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
Class I, Division 2.
▲WARNING: EXPLOSION HAZARD. The area must be known to be non-hazardous before
servicing/replacing the unit and before installing.
▲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.
▲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 2, Groupes C & D ou
les emplacements non dangereux..
▲AVERTISSEMENT: RISQUE D'EXPLOSION. Avant de déconnecter l’ équipement, couper
le courant ou s’assurer que l’emplacement est designe non dangereux.
▲AVERTISSEMENT: RISQUE D'EXPLOSION. La substitution de composants peut render
ce materiel inacceptable pour les emplacements de Classe I, Division 2.
▲AVERTISSEMENT: RISQUE D'EXPLOSION. Avant réparer ou remplacer l’équipement et
avant d’installer s’assurer que l’emplacement est designe non dangereux.
▲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.
▲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 le Code National d'Électricité, NFPA 70 ou le
Code Canadien d'Électricité, CSA C22.1 comme appropriée.

5
ATEX AND IECEX INSTALLATIONS:
▲This equipment is suitable for use in EX Zone 2 Group IIB Locations, OR non-hazardous
locations.
▲WARNING: Do not open when an explosive atmosphere may be present.
▲WARNING: Do not disconnect equipment unless power has been removed or the area is
known to be non-hazardous.
▲WARNING: EXPLOSION HAZARD. The area must be known to be non-hazardous before
servicing/replacing the unit and before installing.
▲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.
▲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 60079-14.
Electrostatic Discharge (ESD) Protection1.3
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.

6
FCC Note1.4
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 theirexpense.
Modifications not approved by the manufacturer could void the user's authority to operate the
equipment under FCC rules.

7
Chapter2 OperatingConditionsandComponents
Product Outline and dimensions2.1
MultiLoad II/ RCU II –DIV2 Model - Picture 2.1.1
Figure 2.1 MultiLoad II (ML II) / Remote Control Unit II (RCU II) Division 2 Unit
Chapter
2

8
MultiLoad II/ RCU II –DIV2 Model –Dimensions 2.1.2
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

9
2.1.2.2 Back View
Figure 2.3 Unit Outline Drawing –Back View
RCUII/ ML II Div 2
MOUNTING TEMPLATE

10
2.1.2.3 Bottom View
2.1.2.3.1 2- Hole Base
2 x 1” NTP Aluminum HUBS
Figure 2.4 Unit Outline Drawing –Bottom View -2 Hole Base
2.1.2.3.2 5- Hole Base (Europe)
3xM20 and 2xM25
Figure 2.5 Unit Outline Drawing –Bottom View - 5 Hole Base

11
2.1.2.4 Side View
Figure 2.6 Unit Outline Drawing –Side View