Toptech MultiLoad II EXL User manual

MultiLoad II & RCU II
Explosion Proof Lite (EXL)
Installation Guide
(Part # 6070)
MAY 2 0 1 9

2MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
TO PT EC H SYS T EM S
MultiLoadII&RCUII–ExplosionProofLite(EXL)
InstallationGuide
1124 Florida Central Parkway
Longwood, FL 32750
USA
Phone [phone]
Copyright Notice
Copyright © 2006 - 2019 Toptech Systems, Inc. All Rights Reserved.
The information contained in this document is proprietary and confidential. No part of this document may be copied, reproduced, or
transmitted in any medium without the express written permission of Toptech Systems, Inc.
Disclaimer
Toptech Systems assumes no responsibility for damages resulting from installation or use of its products. Toptech Systems will not be
liable for any claims of damage, lost data, or lost time as a result of using its products.

3MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
EU Declaration of Conformity
The signatory, representing the manufacturer, declares that the products listed below are in conformity with the essential requirements of
the following EC Directive(s) when installed in accordance with the product installation instructions:
2014/32/EU The Measuring Instruments Directive (and its amending directives)
2014/30/EU The Electromagnetic Compatibility Directive (and its amending directives)
2014/34/EU The Potentially Explosive Atmospheres Directive (and its amending directives)
Product: Operator Interface/Process Control Equipment intended for use in potentially explosive
atmospheres
Model name/number: MultiLoad II EXL (MID, YES), RCU II EXL (MID, NO)
Protective Systems: Flameproof ‘d’, Intrinsic Safety ‘ib’
Notified Body(ies)
Det Norske Veritas Certification AS, Number 0575
NMi Certin B.V., Number 0122
Veritasveien 1
Hugo de Grootplein 1
1322 Høvik, Norway
3314 EG Dordrecht
The Netherlands
Conformity has been demonstrated with reference to the following documentation:
EC type-examination certificate : Presafe 17 ATEX 9557X
IECEx CoC : IECEx PRE 17.0013X
EC type-examination certificate : TC7311
Compliance with the Essential Health and Safety Requirements has been assessed by reference to the following standards:
WELMEC guide 8.8 General and Administrative Aspects of the Voluntary System of Modular Evaluation of Measuring
instruments under MID
OIML R117-1:2007(E) Dynamic measuring systems for liquids other than water
EN 61000-6-4: 2007 Generic emissions for industrial operating environments
EN 61000-6-2: 2005 Generic immunity for industrial operating environments
EN 60079-0: 2012 Electrical apparatus for explosive gas atmospheres—General requirements
EN 60079-1: 2014 Electrical apparatus for explosive gas atmospheres—Flameproof enclosures ‘d’
EN 60079-11: 2012 Electrical apparatus for potentially explosive atmospheres—Intrinsic safety ‘i’
Year of CE Marking: 2007
Name: William J. Porthouse Position: Director of Engineering & Production Date: 14-May-2019
Name Plate

4MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
TableofContents
OVERVIEW..................................................................................................................................... 8
CHAPTER 1 GENERAL INFORMATION & WARNINGS ........................................................ 10
Receiving and/or Returning Equipment ........................................................................................... 10
Safety Warnings.................................................................................................................................. 11
Electrostatic Discharge (ESD) Protection ........................................................................................ 13
FCC Note.............................................................................................................................................. 13
CHAPTER 2 OPERATING CONDITIONS AND COMPONENTS............................................. 14
Product Outline and Dimensions ...................................................................................................... 14
MultiLoad II/ RCU II –EXL Model - Picture................................................................................... 14
MultiLoad II/ RCU II –EXL Model –Dimensions .......................................................................... 15
2.1.2.1 Front View ..................................................................................................................................... 15
2.1.2.2 Back View...................................................................................................................................... 15
2.1.2.3 Bottom View.................................................................................................................................. 16
2.1.2.4 Side View ...................................................................................................................................... 16
Operating Characteristics .................................................................................................................. 17
CHAPTER 3 INSTALLING THE MULTILOAD II/RCUII EXL................................................ 19
Tools Required.................................................................................................................................... 19
Installation..................................................................................................................................... 19
Servicing and Repair..................................................................................................................... 19
Cover Closure and Bolt Replacement............................................................................................... 19
Cable Entries ....................................................................................................................................... 20
Mounting the MultiLoad II/ RCU II DIV-2 Enclosure......................................................................... 20
Metal Plate or Rail......................................................................................................................... 20
Wood............................................................................................................................................. 20
Concrete or Cinder Block Walls.................................................................................................... 20
Mounting Height Considerations................................................................................................... 20
Recommended Wire Sizes and Torque for All Terminal Blocks .................................................... 22
Electrical Supply Connections .......................................................................................................... 22
Cable Gland Entries...................................................................................................................... 22
AC Powered Models ..................................................................................................................... 23
DC Powered Models ..................................................................................................................... 24
Equipment Grounding ................................................................................................................... 24

5MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
CHAPTER 4 DATA COMMUNICATIONS INTERFACE ........................................................... 25
Available Communications Protocol Selection and Wire Spec ..................................................... 25
RS-422/485................................................................................................................................... 26
RS-232.......................................................................................................................................... 26
Ethernet......................................................................................................................................... 27
Communication Connection Wiring.................................................................................................. 27
FCM I/ FCM II Communications (MultiLoad II Only) - COM 0 –Port –RS485.............................. 27
Host/TMS Communications .......................................................................................................... 28
4.2.2.2 COM 1 - RS-485 2-Wire: Host/TMS Communications.................................................................. 29
4.2.2.3 COM 1 - RS-232 - Host/TMS Communications ............................................................................ 30
4.2.2.4 Ethernet –Host/TMS Communications......................................................................................... 31
Host Ticket Printer/Data Logger.................................................................................................... 31
4.2.3.1 COM2 –RS232 - Host Ticket Printer/Data Logger....................................................................... 32
CHAPTER 5 CONNECTING FIELD DEVICES TO THE I/O BOARD...................................... 34
Locating the Internal I/O Board.......................................................................................................... 34
Available I/O Points per Board........................................................................................................... 35
Terminal arrangements per Board .................................................................................................... 37
Digital Analog I/O Board (IO_DA) ................................................................................................. 37
2 Meter I/O Board (IO-2M) ............................................................................................................ 38
How to Connect and Wire Field Devices to the I/O Boards ............................................................ 39
MultiLoad II Flow Meter and Control Valve Wiring .................................................................. 40
MultiLoad II Additive Wiring: Outputs............................................................................................ 41
MultiLoad II Additive Wiring: Inputs............................................................................................... 42
MultiLoad II Analog Wiring............................................................................................................ 43
5.4.4.1 RTD Wiring.................................................................................................................................... 43
5.4.4.2 MultiLoad II 4 –20 mA Input Wiring.............................................................................................. 44
5.4.4.3 MultiLoad II 4 –20 mA Output Wiring........................................................................................... 45
MultiLoad II AC Output Wiring....................................................................................................... 46
MultiLoad II AC Input Wiring ......................................................................................................... 47
MultiLoad II DC Permissive/Status Wiring .................................................................................... 48
MultiLoad II DC Output Wiring ...................................................................................................... 49
MultiLoad II 2 Output Air Eliminator Wiring................................................................................... 50
MultiLoad II Lectro Count Remote Display Wiring........................................................................ 51
RCU II DC Input Wiring................................................................................................................. 52
RCU II AC Output Wiring .............................................................................................................. 53
RCU II DC Output Wiring .............................................................................................................. 54
Typical 1 Meter Application Wiring Example: IP&E Drawing (Electrical Wiring Schedule)........... 55
CHAPTER 6 CONFIGURATIONS ............................................................................................ 56
Switch Access Control ....................................................................................................................... 56
External Switch Access Control (MultiLoad II Only)...................................................................... 56
6.1.1.1 Magnetic Bolts Program / W&M Switches (current)...................................................................... 57
6.1.1.2 Two (2) Rotary Program / W&M Switches (obsolete) ................................................................... 57
6.1.1.3 Single Rotary Program / W&M Switch (obsolete) ......................................................................... 58
Internal Switch Access Control ..................................................................................................... 59
Field Switch Access Control.......................................................................................................... 59

6MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
MultiLoad II/ RCU II DIV-2 Keypad..................................................................................................... 59
Menus and Screens ............................................................................................................................ 60
Field Modification and Data Entry..................................................................................................... 61
MultiLoad II/ RCU II Preliminary Configuration................................................................................ 62
Verifying Communications between MultiLoad II/ RCU II and I/O Board ...................................... 65
Using I/O Diagnostics......................................................................................................................... 66
CHAPTER 7 SERVICE AND REPAIR....................................................................................... 67
Overview and Subassemblies............................................................................................................ 67
CPU Subassembly Removal and Replacement ............................................................................... 69
Display Subassembly Removal and Replacement .......................................................................... 71
Flat Display Cable Connector: Remove and Connect ................................................................. 72
Keypad Removal and Replacement .................................................................................................. 73
Keypad Barrier Removal and Replacement ..................................................................................... 74
Keypad Barrier Version 2.0 (LED indicators)................................................................................ 74
Keypad Barrier Version 1.1 (no LED indicators)........................................................................... 75
Card Reader Removal and Replacement.......................................................................................... 76
W&M Switch Assembly Removal and Replacement........................................................................ 77
Overview Parts List and Part Numbers............................................................................................. 78
CHAPTER 8 HARDWARE REVISION HISTORY & COMPATIBILITY.................................. 79
CHAPTER 9 REVISION HISTORY .......................................................................................... 80
Hardware Revision.............................................................................................................................. 80
Manual Revision.................................................................................................................................. 81

7MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
TableofFigures
FIGURE 2.1 MULTILOAD II (ML II) / REMOTE CONTROL UNIT II (RCU II) EXPLOSION PROOF LITE (EXL) 14
FIGURE 2.2 UNIT OUTLINE DRAWING –FRONT VIEW 15
FIGURE 2.3 UNIT OUTLINE DRAWING –BACK VIEW 15
FIGURE 2.4 UNIT OUTLINE DRAWING –BOTTOM VIEW 16
FIGURE 2.5 UNIT OUTLINE DRAWING –SIDE VIEW 16
FIGURE 3.1 SUGGESTED MOUNTING POSITION 21
FIGURE 3.2 SCREEN VISIBLE AREA 21
FIGURE 3.3 MULTILOAD II/ RCU II AC POWER SUPPLY/COMM BOARD 23
FIGURE 3.4 DC POWER CONNECTIONS 24
FIGURE 4.1 FCM / PCM CONNECTIONS 27
FIGURE 4.2 RS485 4-WIRE, HOST TO A SINGLE MULTILOAD II/ RCU II (RECOMMENDED) 28
FIGURE 4.3 RS485 4-WIRE, HOST TO MULTIPLE MULTILOAD II/ RCU IIS 28
FIGURE 4.4 RS485 2-WIRE, HOST TO A SINGLE MULTILOAD II/ RCU II 29
FIGURE 4.5 RS485 4-WIRE, HOST TO MULTIPLE MULTILOAD II/ RCU IIS 29
FIGURE 4.6 RS232, HOST TO A SINGLE MULTILOAD II/ RCU II 30
FIGURE 4.7 RS232, HOST TO MULTIPLE MULTILOAD II/ RCU IIS 30
FIGURE 4.8 ETHERNET CONNECTIONS 31
FIGURE 4.9 TICKET PRINTER / DATA LOGGER CONNECTIONS WITH HANDSHAKE 32
FIGURE 4.10 TICKET PRINTER / DATA LOGGER CONNECTIONS WITHOUT HANDSHAKE 32
FIGURE 4.11 PTB PRINTER CONNECTION WITH HANDSHAKE 33
FIGURE 4.12 PTB PRINTER CONFIGURATION 33
FIGURE 5.1 DIGITAL/ ANALOG I/O BOARD TERMINAL BLOCK ASSIGNMENTS 37
FIGURE 5.2 2 METER I/O BOARD TERMINAL BLOCK ASSIGNMENTS 38
FIGURE 6.1 TYPE 3 PROGRAM / W&M SWITCH WITH MAGNETIC BOLTS 57
FIGURE 6.1 TYPE 1 PROGRAM / W&M SWITCHES 57
FIGURE 6.2 TYPE 2 PROGRAM / W&M SWITCHES 58
FIGURE 6.4 CPU DIP SWITCHES FOR PROGRAM AND W&M ACCESS (REV 1.0) 59
FIGURE 6.5 CPU DIP SWITCHES FOR PROGRAM AND W&M ACCESS (REV 2.X) 59
FIGURE 7.1 MULTILOAD II (ML II) / REMOTE CONTROL UNIT II (RCU II) EXPLOSION PROOF LITE UNIT 67
FIGURE 7.2 ML II/ RCU II EXL UNIT ASSEMBLY 68
FIGURE 7.3 CPU BOARD, POWER SUPPLY / COMM BOARD, I/O BOARD WITH CHASSIS 69
FIGURE 7.4 ML II/ RCU II EXL UNIT COVER DISPLAY ASSEMBLY 71
FIGURE 7.5 CAM LOCK UP (OPEN POSITION) 72
FIGURE 7.6 CAM LOCK DOWN (CLOSED POSITION) 72
FIGURE 7.7 DISPLAY CABLE INSERTION 72
FIGURE 7.8 ML II/ RCU II EXL UNIT COVER KEYPAD ASSEMBLY 73
FIGURE 7.9 KEYPAD BARRIER VERSION 1.1 74
FIGURE 7.10 KEYAPD BARRIER VERSION 2.0 (LED INDICATORS) 74
FIGURE 7.11 ML II/ RCU II EXL UNIT COVER WITH BARRIER VERSION 2.0 (CURRENT) 74
FIGURE 7.12 ML II/ RCU II EXL UNIT COVER WITH BARRIER VERSION 1.1 (OBSOLETE) 75
FIGURE 7.13 ML II/ RCU II EXL COVER ASSEMBLY PROX BRACKET MOUNT 76
FIGURE 7.14 ML II/ RCU II EXL W&M ASSEMBLY 77

8MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Overview
This document is designed to guide individuals installing MultiLoad II/ RCU II EXL equipment, engineering
firms developing site electrical drawings, and users troubleshooting system operations such as managers,
system administrators, technicians, and meter proving personnel.
The following table provides an informative summary of the material available in 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 –EXL
This chapter covers installation considerations and instructions for
the the Explosion Proof Lite (EXL) Model.
4.Data Communication Interface
This chapter reviews hardware connections and communication
processes.
5.Connecting Field Devices to the Internal
I/O Board
This chapter covers the available I/O points per board, the
terminal arrangements per board, and then describes in detail
how to connect different field devices to the internal I/O Board.
6. Configurations
This chapter describes how to navigate the system, select field
values, perform data entry, and toggle options on and off.
7. Service and Repair
This chapter describes how to service and repair the MultiLoad/
RCUII EXL subassemblies and parts.
8. Hardware Revision History &
Compatibility
This chapter provides changes, modifications, and updates to the
hardware.
9. Revision History
This chapter provides further hardware revisions as well as
revisions made to this document.

9MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
The following keys allow the user to locate information needed in this guide:
ICON KEY
Important information to enhance understanding and make better use of the product.
Indicates potential damage to hardware or loss of data.
Potential for property damage or that personal injury may occur. Pay close attention and
follow instructions when this symbol is displayed.
Typographical Conventions:
Boldface: Indicates what is pressed on the keypad. Example: Key in 00000.
Italics: Emphasizes a key product or industry term.
Example: the display features a pick-list style of item selection.
This guide covers RCU/MultiLoad EXL installation information only. For information about base MultiLoad
firmware, please consult the MultiLoad II User Guide. For information about wiring other models, please
consult the respective installation guides. For information about the MultiLoad register interface and Modbus
communication, please reference the MultiLoad II Communication Guide. Updated versions of all manuals,
including this one, are available on our websiteathttp://www.toptech.com.

CHAPTER 1–GENERAL INFORMATION & WARNINGS
10 MultiLoad II/ RCU II Explosion Proof Lite (EXL) Installation Guide - Part # 6070
Chapter 1 General Information & Warnings
Receiving and/or Returning Equipment
At receipt, the MultiLoad II/ RCU II should be immediately inspected after opening the packaging case.
If any damage is visible, notify the carrier at once to establish liability.
Contact Toptech’s Return Materials Department to initiate timely repair or replacement of the unit.
A Return Materials Authorization (RMA) will be for the purpose of returning the product or parts
requiring repair. Do not return any material to Toptech without an RMA.
Contact Information for Americas:
Return Materials Department
Toptech Systems, Inc.
1124 Florida Central Pkwy
Longwood, FL 32750 USA
[phone]
Contact Information for EMEA and Asia:
Return Materials Department
Toptech System NVs
Nieuwe weg 1- haven 1053
2070 Zwijndrecht, BELGIUM
[phone]
Chapter
1