Veeder-Root EMR4 User manual

Manual No: 577014-322 ●Revision: B
Technical Installation Guide
EMR4

Notice
Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of
merchantability and fitness for a particular purpose.
Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this publication.
Veeder-Root reserves the right to change system options or features, or the information contained in this publication.
This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication may be
photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root.
Contact Technical Support for additional troubleshooting information at 800-323-1799.
DAMAGE CLAIMS / LOST EQUIPMENT
Thoroughly examine all components and units as soon as they are received. If any cartons are damaged or missing, write a complete
and detailed description of the damage or shortage on the face of the freight bill. The carrier's agent must verify the inspection and sign
the description. Refuse only the damaged product, not the entire shipment.
Veeder-Root must be notified of any damages and/or shortages within 30 days of receipt of the shipment, as stated in our Terms and
Conditions.
VEEDER-ROOT’S PREFERRED CARRIER
1. Contact Veeder-Root Customer Service at 800-873-3313 with the specific part numbers and quantities that were missing or
received damaged.
2. Fax signed Bill of Lading (BOL) to Veeder-Root Customer Service at 800-234-5350.
3. Veeder-Root will file the claim with the carrier and replace the damaged/missing product at no charge to the customer. Customer
Service will work with production facility to have the replacement product shipped as soon as possible.
CUSTOMER’S PREFERRED CARRIER
1. It is the customer’s responsibility to file a claim with their carrier.
2. Customer may submit a replacement purchase order. Customer is responsible for all charges and freight associated with
replacement order. Customer Service will work with production facility to have the replacement product shipped as soon as
possible.
3. If “lost” equipment is delivered at a later date and is not needed, Veeder-Root will allow a Return to Stock without a restocking fee.
4. Veeder-Root will NOT be responsible for any compensation when a customer chooses their own carrier.
RETURN SHIPPING
For the parts return procedure, please follow the appropriate instructions in the EMR Products General Returned Goods Policy pages
in the EMR4 Products price list. Veeder-Root will not accept any return product without a Return Goods Authorization (RGA) number
clearly printed on the outside of the package.
©Veeder-Root 2018. All rights reserved.

Table of Contents
iii
Safety Information
Safety Warnings ...............................................................................................................2
Special Conditions for Safe Use .......................................................................................2
EMR4 Truck Installation
Installing The Interconnection Box (IB) .............................................................................4
Input Power – Critical Ground Connection ........................................................................4
2-Stage Solenoid Valve Connections .......................................................................8
Valve Operation With The EMR4 .............................................................................8
3-Way Safety Valve for Truck LP Gas Systems ...............................................................9
Installing The 3-way Valve........................................................................................9
Solenoid Valves......................................................................................................12
Wiring The Display Head ................................................................................................14
C&C Mode Switch ...........................................................................................................16
Installing Optional Keypad Kit - Right or Left Side ..........................................................16
IInstalling The Remote Display (Optional) ......................................................................16
Installing The Remote Pulser (Optional) .........................................................................19
Pulse Encoder Specifications .................................................................................19
EMR4 Terminal & Fueling Depot Installation
Wiring The Display Head ................................................................................................21
Installing The Interconnect Box (IB) ................................................................................22
National Electrical Code Compliance .....................................................................22
Grounding...............................................................................................................22
Wire Type for Metallic or PVC Conduit...................................................................23
Wire Length ............................................................................................................23
Mounting and Wiring the IB Unit.............................................................................23
Solenoid Valves......................................................................................................23
Power Conditioning Requirements .................................................................................26
Wire Size And/or Distance Limitations ...................................................................26
Pulse Output Limits ................................................................................................29
EMR4 – Legal Disclaimer Notice ....................................................................................29
EMR4 System Specifications
System Power .................................................................................................................30
Component Location .......................................................................................................30
Appendix A: EMR4 Safety Instructions & System Specifications
Figures
Figure 1. Example EMR4 truck Installation With 2 Display Heads And
Optional Remote Pulser ..........................................................................3
Figure 2. IB Physical Dimensions (Shown With Cover Removed) .........................6
Figure 3. EMR4 IB Box Wiring Connections ..........................................................7
Figure 4. 2-Stage Solenoid Valve ..........................................................................8
Figure 5. Connecting 3-Way Valve To Neptune Meter -
Truck LP Gas Installations ....................................................................10
Figure 6. Connecting 3-Way Valve To L.C./TCS Meter -
Truck LP Gas Installations ....................................................................11
Figure 7. Connecting 3-Way Valve To The Interconnect Box ..............................12
Figure 8. Example Wiring Connections For DC And AC Solenoid Valves ...........13
Figure 9. Display Head Cable Connections .........................................................15
Figure 10. Remote Display Assembly ....................................................................17

Table of Contents
iv
Figure 11. Remote Display Connections (Rear Cover Removed) .........................18
Figure 12. Wiring Connections In Remote Pulser (Top Cover Removed) .............19
Figure 13. Example Terminal Fueling Depot Installation With 2 Display Heads
And Optional Remote Pulser ................................................................20
Figure 14. Display Head Cable Connections .........................................................22
Figure 15. EMR4 IB Box Wiring Connections ........................................................24
Figure 16. Example Terminal Wiring Connections For DC And
AC Solenoid Valves ..............................................................................25
Figure 17. Digi-Key Power Supply Wiring Diagram ...............................................26
Figure 18. Wiring Pulse Output To A TLS-350 Console ........................................27
Figure 19. Wiring Pulse Output To A TLS-450/TLS4 Console ...............................28
Tables
Table 1. 2-Stage Solenoid Wiring ............................................................................8
Table 2. Remote Display (84559X-00X) Components ..........................................16
Table 3. System Component Dimensions ............................................................30
Table 4. Remote Pulser Dimensions ....................................................................31
Table A-1. System Component Information ........................................................... A-3
Table A-2. Remote Pulser Information ................................................................... A-3

1
Safety Information
The following safety symbols may be used throughout this manual to alert you to important safety hazards and
precautions
EXPLOSIVE
Fuels and their vapors are extremely explo-
sive if ignited.
FLAMMABLE
Fuels and their vapors are extremely
flammable.
TURN POWER OFF
Live power to a device creates a potential
shock hazard. Turn Off power to the device
and associated accessories when servicing
the unit.
WARNING
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
NOTICE
Alerts the user to practices not related to
physical injury.
CAUTION
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.
INJURY
Careless or improper handling of materials
can result in bodily injury.
GLOVES
Wear gloves to protect hands from irri-
tation or injury.
WEAR EYE PROTECTION
Fuel spray from residual pressure in the lines
can cause serious eye injuries. Epoxy seal-
ant can cause eye injury. Always wear eye
protection when working with pressurized
lines and epoxy mixtures.
NO OPEN FLAMES
Open flames from matches, lighters,
welding torches, etc. can ignite fuels
and their vapors.
READ ALL RELATED MANUALS
Knowledge of all related procedures before
you begin work is important. Read and
understand all manuals thoroughly. If you do
not understand a procedure, ask someone
who does.
OFF
WARNING
NOTICE
CAUTION

Safety Information Safety Warnings
2
Safety Warnings
Who is allowed to work on this equipment: Only trained or authorized individuals knowledgeable in
the related procedures should install, inspect, maintain, or service this equipment.
This system operates on low dc voltage/current inputs. To avoid equipment damage:
•Disconnect the EMR power wire prior to using vehicle battery charging equipment.
• Disconnect the EMR power wire prior to jump starting the vehicle.
• Disconnect the EMR power wire prior to replacing the vehicle's battery.
•Always disconnect the IB box from truck power before welding on the truck.
If the storage tank to be fitted with an EMR4 system either contains or at any time has contained
petroleum products then the tank inspection chamber must be considered a hazardous environment
as defined in IEC EN 60079-10 Classification of Hazardous Areas. Suitable working practices for this
environment must be observed.
Special Conditions For Safe Use
All installations must be made in accordance with the accompanying Descriptive System Documentation.
WARNING
This system operates near highly combustible fuel storage tanks.
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY
PRECAUTIONS COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT,
RESULTING IN SERIOUS INJURY OR DEATH.
VEEDER-ROOT’S EMR4 PRODUCT IS NOT APPROVED FOR USE AS A
COMPONENT THAT PROVIDES LIQUID ADDITIVES TO AN AIRCRAFT FUELING
SYSTEM.
To ensure proper installation, operation, and continued safe use of this product:
1. Read and follow all instructions in this manual, including all safety
warnings.
2. Have equipment installed by a contractor trained in its proper installation
and in compliance with all applicable codes including: the National
Electrical Code; federal, state, and local codes; and other applicable safety
codes.
3. To prevent ignition of flammable or combustible atmospheres, disconnect
power before servicing.
4. Operate this equipment in accordance with the instructions in this manual.
5. Do not modify or use service parts other than those provided by Veeder-
Root. Substitution of components may impair intrinsic safety.
NOTICE

3
EMR4 Truck Installation
Installation of the EMR4 System involves installing the Display Head(s), the Interconnect Box, and any optional
devices (e.g., Remote Pulser, printer, etc.). This equipment must be installed according to the applicable
installation document. For UL/cUL installations use Control Drawing number 331940-021 and for ATEX
installations use Descriptive System Document number 331940-022. Figure 1 shows an example dual Display
Head installation.
Figure 1. Example EMR4 truck Installation With 2 Display Heads And Optional Remote Pulser
DC voltage from vehicle'saccessory
circuit - at fuse block or ACC position
of ignition switch
Display Head 1
(Meter 1)
Meter 2
Remote Display Head 2
Top mount
Remote Pulser
Front mount
Remote Pulser
TRUCK CAB
OUTSIDE TRUCK CAB
Data(RS-485)
Data(RS-485)
Power
Data
Power 12 Vdc Power 12 Vdc
5 Vdc
Pulse Input
NON-HAZARDOUS
LOCATION
(RS-232)
Printer
Quick disconnect
fittings(optional)
Temp
Probe
EPSON TM-U295 SLIP
Customer supplied wiring
The following information isfor general reference and isnot
intended to replace recommended National Electric Code (NEC)
procedures. It isimportant for the installer to understand that
wiring located in Class I, Group D, Division 1 and 2 installations,
or Class I, Zone 0, Group IIA locationsshall comply with the latest
appropriate articlesfound in the National Electric Code (NFPA
70).
Check continuity between the Display Head chassisand the IB
chassisthrough the vehicle frame. The resistance must be no
more than 1 Ohm.
24 Vdc
Truck ground
Max. cable length
35 ft. (10.6 m)
Max. cable length
1000 ft. (304.8 m)
HAZARDOUS LOCATION
OR
I.S.
I.S.
I.S.
I.S.
I.S.
I.S.
NOTE: Intrinsically safe wiring
(marked ) shall be installed
in accordance with Article 504 of
the NEC, ANSI/NFPA 70.
Intrinsic
Safety Barrier
Interconnection
Box
12 AWG U.S. (4mm2E.U.)
Barrier Ground
(See Notice 2)
Input Rating: 10-28Vdc, 5 A
1.
See
Notice 2.
See
Notice 2.
2.
NOTICE
Interlock
Switch
I.S.
ESS
Switch
I.S.

4
EMR3- Truck Installations
EMR4 Truck Installation Installing The Interconnection Box (IB)
Installing The Interconnection Box (IB)
The IB box is not rated for mounting in outdoor locations. The IB box can be mounted only
in a protected enclosure or protected location.
The following information is for general reference and is not intended to replace recommended National Electric
Code (NEC) procedures. It is important for the installer to understand that electrical equipment and wiring located
in Class I, Division 1 and 2 installations shall comply with the latest appropriate articles found in the National
Electric Code (NFPA 70) and other applicable code requirements.
1. The physical dimensions of the Interconnection Box (IB) are shown in Figure 2.The IB is installed in the truck’s
cab either under the seat, mounted on the wall inside the cab, mounted to the passenger side of the “dog
house” in cab-over trucks, or mounted to a custom-made bracket that can also support the optional printer.
Use four, 3/16” (4 mm) bolts to mount the IB to the mounting surface. In the event of limited access, the front
cover of the IB can be completely removed rather than swung open, by removing four #15 Torx screws. Put
the excess coils of cable under the seat or clamp them to the IB mounting stand.
2. Figure 3 shows IB Power Side terminal wiring connections. Remove hole plugs and use cord grips for all
cables attaching to this terminal block.
Run the power cable from the truck fuse block or ignition switch to the IB. Clamp the power wire at suitable in-
tervals between the power source and the IB.
Before connecting the truck power wiring, verify the following:
a. Electrical system has a negative ground.
b. Battery terminals and cables are in good condition.
c. Alternator current output is sufficient to supply EMR4 System current requirement of 5 amperes.
3. Attach the wire from truck ground to the GND terminal of the Power Side terminal block (J8, Pin 2). Also
attach the wire from the truck’s Accessory (ACC) circuit to the Input-Pwr terminal of the terminal block (J8-Pin
1).
4. Refer to Figure 3 for the IB intrinsically safe terminal wiring connections. Remove hole plugs and use cord
grips for Display Head cable entries. The drain wire from the Display Head cable must be connected to the
chassis ground clamp in the Interconnect Box.
Input Power – Critical Ground Connection
On some vehicles, the battery minus terminal, BAT(-), may not be common with the chassis ground or the defined
vehicle ground located in either the accessory panel or in the power distribution box. In this case, directly run the
ground connection for Input Power at J8, Pin 2 (GND) terminal as shown in Figure 3, directly to the BAT(-) terminal
connection point.
Proper operation of the EMR4 hardware depends on the quality of the ground connection from the Interconnect
Box to the source of INPUT-PWR power.
If the INPUT-PWR connection is made at the accessory panel, it must be fused at 5 amps. The installer must
ensure that a minimum of 12.0 volts, between the INPUT-PWR terminal and the GND terminal, is available from
the power source. If an improper ground point is used for input power to the EMR4 there may be insufficient
power for the Display Head to operate properly resulting in various E## error codes or possibly a blank display.
Pay careful attention to the wiring labels on both the EMR4 Display Head and the Interconnect Box.
Each connection must be made according to the wiring tables listed in this manual. Use shielded
cable to connect each device to the Interconnect Box and Display Head and ensure that each cable
jacket is resistant to gas and oil.
NOTICE

5
EMR3- Truck Installations
EMR4 Truck Installation Input Power – Critical Ground Connection
Installations With High Amperage Devices
The input power for an EMR4 must be isolated from devices that use large amounts of electric current such as reel
motors. Connect the EMR4 using dedicated wiring between the voltage source and the Interconnect Box. On
vehicles with multiple voltage sources it may be necessary to use a separate battery or voltage source to power
the EMR4. Also, a battery isolator can be used between the voltage source and the IB to prevent voltage spikes
from entering the Interconnect Box when the high amperage devices are de-energized.
Recharging Vehicle Batteries
In the Interconnect Box, disconnect the wires for both the INPUT-PWR and GND Terminals while charging the
vehicle’s battery. Failure to do so can result in hardware damage to the circuit board inside the Interconnect Box.
NOTICE
NOTICE

6
EMR3- Truck Installations
EMR4 Truck Installation Input Power – Critical Ground Connection
Figure 2. IB Physical Dimensions (Shown With Cover Removed)
2X 1.5” (38mm)
1.39”
(35.3mm) 5.0”
(127mm)
7.8” (198mm) [8.5” (215.9mm) - w/cover in place]
4.04”
(103mm)
USB Port (under cover)
2.13”
(54.1mm)
0.5”
(12.7mm)
9.8”
(249mm)
1.0” (25.4mm)
SMA Connector
(under cover)
4X 1.5”
(38mm)
3X 1.375” (35mm)
4.75” (120.6mm)
REMOVE HOLE PLUG
FOR 1/2” (12.7mm)
CONDUIT OPENING
6X 1.375”
0.775”
7X 1.5”
(38MM)
3.0”
(72mm)
0.125” (3.1mm)
1.39”
(35.3mm)
1.5” (38mm)

7
EMR3- Truck Installations
EMR4 Truck Installation Input Power – Critical Ground Connection
Figure 3. EMR4 IB Box Wiring Connections
J1
J2
J3
J4
J5
J6
J7
J8
FUNCTION FUNCTION SIGNAL (COLOR) SIGNAL (COLOR)
START PULSE OUTPUT 1
START PULSE OUTPUT 2
PULSE OUTPUT 1-A
PULSE OUTPUT 2-A
PULSE OUTPUT 1-B
PULSE OUTPUT 2-B
SERIAL 232 PORT 2
SERIAL 232 PORT 1
PULSE OUTPUT 1-C
PULSE OUTPUT 2-C
PRINTER PORT
(+24V OUT, SERIAL
RS-232 PORT)
RELAY 3 FOR
DISPLAY HEAD 1
RELAY 2 FOR
DISPLAY HEAD 1
RELAY 3 FOR
DISPLAY HEAD 2
RELAY 2 FOR
DISPLAY HEAD 2
RELAY 1 FOR
DISPLAY HEAD 1
RELAY PWR
RELAY 1 FOR
DISPLAY HEAD 2
RELAY PWR
NOTE: INPUT POWER
WIRING MUST USE
DEDICATED WIRES
BETWEEN THE POWER
SOURCE AND THE I.B.
INTERCONNECT BOX WIRING DIAGRAM
INTRINSICALLY SAFE WIRING
FUNCTION SIGNAL (COLOR)
J10
(FACTORY SETTING)
*VOLTAGE SELECTABLE
ROTARY SWITCH
*VOLTAGE SELECTABLE
*VOLTAGE SELECTABLE
*VOLTAGE SELECTABLE
*VOLTAGE SELECTABLE
RELAY RATINGS:
5A@120VAC
2.5A@240VAC
24VDC, 5A MAX.
J14
USB
5
6
7
8
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
1
2
3
4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1
2
3
4
GND (BLK)
DH2-RSTOP (RED)
DH2-RSTART (WHT)
GND (GRN)
GND (GRN)
DH1-RSTOP (RED)
DH1-RSTART (WHT)
GND (BLK)
REMOTE STOP INPUT 2
REMOTE START INPUT 2
REMOTE STOP INPUT 1
REMOTE START INPUT 1
GND (WHT)
TX (BLK)
RX (GRN)
GND (GRN)
DH1-SPULSE (RED)
DH2-SPULSE (WHT)
GND (BLK)
GND (WHT)
TX (BLK)
RX (GRN)
GND (GRN)
DH1-POUT-A (RED)
DH2-POUT-A (WHT)
GND (BLK)
HALF-DUPLEX RS-485
GND (BLK)
IBNET-A (GRN)
IBNET-B (WHT)
GND (GRN)
DH1-POUT-B (RED)
DH2-POUT-B (WHT)
GND (BLK)
GND (WHT)
+24V (RED)
PRN-TX (BLK)
PRN-RX (GRN)
GND (GRN)
DH1-POUT-C (RED)
DH2-POUT-C (WHT)
GND (BLK)
DH2-R3-NO (GRN)
DH2-R3-COM (WHT)
DH2-R2-NO (RED)
DH2-R2-COM (BLK)
DH1-R3-NO (GRN)
DH1-R3-COM (WHT)
DH1-R2-NO (RED)
DH1-R2-COM (BLK)
DH1-R1-NO (GRN)
DH1-R1-COM (WHT)
INPUT-PWR (RED)
INPUT-PWR (RED)
DH2-R1-NO (GRN)
DH2-R1-COM (WHT)
INPUT-PWR (RED)
INPUT-PWR (RED)
INPUT-PWR (RED)
GND (BLK)
IB-A (GRN)
IB-B (WHT)
GND (BLK)
PWR 12V (RED)
PWR 5V (GRN)
DATA (WHT)
GND (BLK)
PWR 12V (RED)
DATA (WHT)
GND (BLK)
PWR 12V (RED)
4
3
2
1
IB-A (GRN)
IB-B (WHT)
GND (BLK)
PWR 12V (RED)
4
3
2
1
4
3
2
1
4
3
2
1
DISPLAY HEAD 1
(I.S. PROTECTED)
DISPLAY HEAD 2
(I.S. PROTECTED)
AUX 1
(I.S. PROTECTED)
AUX 2
(I.S. PROTECTED)
5VDC 24VDC
12VDC
0VDC
1
3
2
0
J13
J12
J11
CONNECTORS MAY
BE UNPLUGGED FOR
FIELD WIRING
WARNING
This system operates on low DC voltage/current
inputs.To avoid equipment damage, disconnect
the EMR4 input power plug (J8) prior to
performing ANY of the following truck mainte-
nance issues:
• Using vehicle battery charging equipment
• Jump starting the vehicle
• Replacing the vehicle’s battery
• Welding on the truck
12/24V INPUT
FOR USE WITH PERIPHERAL
EQUIPMENT SPECIFIED IN THE
INSTALLATION INSTRUCTIONS.
LED INDICATORS
COMM (D10) : EMR4 STATUS
STATUS (D12) : WIFI STATUS
LINK (D15) : WIFI LINK INDICATION
SEE MANUAL FOR DETAILS
FOR SUPPLY CONNECTION,
USE WIRES RATED FOR A
MINIMUM OF 90°C.
CHASSIS-GND (GRN)
CHASSIS-GND (GRN)
TRUCK BATTERY / TERMINAL UPS:
10-28VDC, 5A MAX.
RELAY GROUND
BARRIER GROUND WIRE

8
EMR3- Truck Installations
EMR4 Truck Installation Input Power – Critical Ground Connection
2-STAGE SOLENOID VALVE CONNECTIONS
A 2-stage solenoid flow valve is shown in Figure 4 and wiring connections in Table 1.
Figure 4. 2-Stage Solenoid Valve
VALVE OPERATION WITH THE EMR4
Full Flow
The valve is normally closed. When the START button is pushed on the EMR4 display, both relays for that head are
energized, opening the solenoid-operated valves. The Fast Flow solenoid valve allows the main valve diaphragm to
open via the pump pressure pushing on the diaphragm. Full flow is obtained. The Slow Flow solenoid valve allows
flow around the main diaphragm valve. When the FINISH button is pushed on the EMR4 display, both relays are
de-energized, the solenoid valves close stopping flow.
Preset
The valve is normally closed. When the START button is pushed on the EMR4 display, both relays for that head are
energized, opening the solenoid valves and fast/full flow is obtained.
• First Stage Knockoff - When the first stage/slow flow point is reached (1st stage knockoff), the fast flow/relay 1
de-energizes and the spring assisted main diaphragm of the valve closes as the pressure equalizes. The single
flow/relay 2 bypass remains open for slow flow.
Table 1. 2-Stage Solenoid Wiring
Display Head Relay Function
Diagram In
Installation Manual Setup Manual
Head 1
DH1-R2 COM Relay Control
Set Advance Stop
(2nd Stage
Knockoff)
N.O.
DH1-R1
COM Relay Control
Set Slow Flow
(1st Stage
Knockoff)
N.O.
Head 2
DH2-R2 COM Relay Control
Set Advance Stop
(2nd Stage
Knockoff)
N.O.
DH2-R1
COM Relay Control
Set Slow Flow
(1st Stage
Knockoff)
N.O.
Single Flow In IB
(Relay 2)
Flow
(Solenoid Valve
Number Begins
With 7221)
(Solenoid Valve
Number Begins
With 7121)
Fast Flow In IB
(Relay 1)
DH 1
Relays
C
N.O.
Single
Flow
C
N.O.
Fast
Flow
DH 2
Relays
C
N.O.
Single
Flow
C
N.O.
Fast
Flow

9
EMR3- Truck Installations
EMR4 Truck Installation 3-Way Safety Valve for Truck LP Gas Systems
• Second Stage Knockoff - When the advance stop (2nd stage knockoff) point is reached, the single flow/relay 2
de-energizes and the single flow/bypass valve closes stopping flow.
Knockoff Control Adjustments - The ‘volume to go’ adjustments are made underRELAY CONTROL in setup
mode. The 1st stage defaults to 5 and the 2nd stage defaults to 0.1. Adjustments to these knockoff points,
particularly the 2nd stage/stop point may be required to accommodate the specific systems dynamics.
3-Way Safety Valve For Truck LP Gas Systems
The 3-Way Safety Valve is not intended for flow control or preset control.
INSTALLING THE 3-WAY VALVE
On the male pipe threads, use a pipe sealant when installing fittings or conduit to either
the valve or the junction box.
1. On the valve, install a rigid metal conduit nipple in the threaded opening, provided for the solenoid wiring. Run
the two red wires from the 3-way valve, through the nipple and into a metal junction box. Mechanically attach
the valve/nipple combination to junction box as shown in Figure 5. Even though the 3-way valve will operate
in any position, it will last longer and perform best if mounted vertically upright (port 3 up). Secure the
junction box to the vehicle's frame.
2. Run a 2-wire shielded cable from the Relay Terminals located at J7 in the IB Box, located in the truck cab, to
the 3-way valve junction box. Pass the cable through a cord grip fitting in one of the J-box openings. Cut off 1-
inch (25.4 mm) of the cable’s shield and jacket, then strip off 1/2-inch (12.7 mm) of each wire’s insulation.
WARNING
The Three-Way Safety Valve is installed and operated in the highly
combustible environment of an LPG tank.
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY
PRECAUTIONS COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT,
RESULTING IN SERIOUS INJURY OR DEATH.
1. It is essential that you carefully read and follow the warnings and
instructions in this manual to protect yourself and others from serious
injury due to fire, explosion, or electrical shock. LPG systems shall be
installed in accordance with the national standards and regulations that
apply.
2. Comply with all federal, state, and local codes, and other applicable
safety codes. All wiring must comply with standard electrical practices,
the local authority, and the latest editions of the National Electrical Code
(NFPA 70) and other applicable code requirements. All work on LPG
systems must comply with NFPA 58, Liquefied Petroleum Gas Code and
other applicable code requirements.
3. LPG tanks must be depressurized (drained) and free of liquid and
combustible vapors before work begins.
4. Flow control valves connected to the EMR4 must be UL Listed. Also, flow
control valves must be suitable for the intended application, i.e.,
gasoline, fuel oil, LPG and must be rated for use in a Class 1, Division 1,
Group C or Group D Hazardous Location. For LPG applications, such as
propane, each valve must have a minimum pressure rating of 350 psi.
NOTICE

10
EMR3- Truck Installations
EMR4 Truck Installation 3-Way Safety Valve for Truck LP Gas Systems
3. Using the wire nuts, connect the stripped wires from the IB box to the 3-way valve wires (see Figure 5). There
is no polarity to the 3-way valve’s wiring. Seal the wire nuts with epoxy sealant using one bag for both wire nut
connections and place bag in junction box (see Figure 5).
Epoxy sealant is irritating to eyes, respiratory system, and skin. Can cause allergic skin
reaction. Contains: epoxy resin and cycloaliphatic epoxycarboxylate. Precautions: Wear
suitable protective clothing, gloves, eye, and face protection. Use only in well ventilated
areas. Wash thoroughly before eating, drinking, or smoking.
Figure 5. Connecting 3-Way Valve To Neptune Meter - Truck LP Gas Installations
4. Tighten the cable bushing nuts on the cord grip to ensure a watertight seal at the cable’s entry.
5. Remove the protective closures from the 3-way valve ports.
Neptune meters:
Connect a hose from line pressure to port 3 (normally open port) of the 3-way valve (see Figure 5). On some
systems, line pressure is available at an opening in the vapor eliminator housing. Connect another hose from
the 3-way valve’s port 1 (normally closed port) to the air eliminator. Connect a third hose from the 3-way
valve’s port 2 (common port) to the differential valve.
L.C./TCS Meters:
Connect a hose from the air eliminator to port 3 (normally open port) of the 3-way valve (see Figure 6). Con-
nect another hose from the 3-way valve’s port 1 (normally closed port) to the strainer cover. Connect a third
hose from the 3-way valve’s port 2 (common port) to the differential valve.
CAUTION
Rigid Metal
Junction Box
Shrink wrapped diode
Shielded 2-Wire Cable
V-R PN 848100-250
Cord Grip
V-R PN 331028-001
Port 1
(N.C.)
Port 3
(N.O.)
Port 2
(COM)
Hose Connections
are 1/4'' NPT
Connect to Line
Pressure
Connect to
Differential
Valve
12 Vdc 10 Watts
3-Way Solenoid Valve
Connect to
Air Eliminator
Connect wires
in IB unit
1/2'' NPT
Nipple or Conduit
758-23.eps
Black
White (+)
To
3-Way
valve
To
IB unit
Red
Red
Wire nuts
Instructions:
NOTE: When temperature isbelow 50°F (10°C), keep
resin in awarm place prior to mixing (e.g., in an inside
pocket next to body).
1. Attach red wiresfrom 3-way valve to black and white
(+) wire from IB unit with wire nutsas shown in A.
Connect diode white wire to red/white (+) pair.
Connect diode black wire to red/black pair.
2. Open epoxy package, and remove resin pak.
3. Holding resin pak as shown in B, bend pak along long
length.
4. Asshown in C, firmly squeeze the RED SIDE of the
resin, forcing it through the center seal and into
BLACK SIDE.
5. Mix thoroughly to auniform color by squeezing
contentsback and forth 25-30 times.
6. Squeeze mixed, warm resin into one end of bag and
cutoff other end.
7. Slowly insert wiring connectionsinto sealing pack until
they fit snugly against the opposite end.
8. Twist open end of bag and use tie wrap to close it off,
or wrap open end of bag with vinyl electrical tape (not
included) and position the taped end up until the resin
jells.
9. Place epoxy pack into junction box and screw on
cover as shown in D.
C
A
D
B
Diode
(+)

11
EMR3- Truck Installations
EMR4 Truck Installation 3-Way Safety Valve for Truck LP Gas Systems
Figure 6. Connecting 3-Way Valve To L.C./TCS Meter - Truck LP Gas Installations
6. At the IB Box, connect the 3-way valve solenoid and a jumper to J7 and J8 as shown in Figure 7.
Connect to Air
Eliminator
Connect to
Differential
Valve
Connect to
Strainer
Cover
758-24.eps
BC
Instructions:
NOTE: When temperature isbelow 50°F (10°C), keep
resin in awarm place prior to mixing (e.g., in an inside
pocket next to body).
1. Attach red wiresfrom 3-way valve to black and white
(+) wire from IB unit with wire nutsas shown in A.
Connect diode white wire to red/white (+) pair.
Connect diode black wire to red/black pair.
2. Open epoxy package, and remove resin pak.
3. Holding resin pak as shown in B, bend pak along long
length.
4. Asshown in C, firmly squeeze the RED SIDE of the
resin, forcing it through the center seal and into
BLACK SIDE.
5. Mix thoroughly to auniform color by squeezing
contentsback and forth 25-30 times.
6. Squeeze mixed, warm resin into one end of bag and
cutoff other end.
7. Slowly insert wiring connectionsinto sealing pack until
they fit snugly against the opposite end.
8. Twist open end of bag and use tie wrap to close it off,
or wrap open end of bag with vinyl electrical tape (not
included) and position the taped end up until the resin
jells.
9. Place epoxy pack into junction box and screw on
cover as shown in D.
Rigid Metal
Junction Box
Shrink wrapped diode
Shielded 2-Wire Cable
V-R PN 848100-250
Cord Grip
V-R PN 331028-001
Port 1
(N.C.)
Port 3
(N.O.)
Port 2
(COM)
Hose Connections
are 1/4'' NPT
12 Vdc 10 Watts
3-Way Solenoid Valve
Connect wires
in IB unit
1/2'' NPT
Nipple or Conduit
Black
White (+)
To
3-Way
valve
To
IB unit
Red
Red
Wire nuts
A
D
Diode
(+)

12
EMR3- Truck Installations
EMR4 Truck Installation 3-Way Safety Valve for Truck LP Gas Systems
Figure 7. Connecting 3-Way Valve To The Interconnect Box
SOLENOID VALVES
Figure 8 illustrates wiring examples when connecting DC or AC solenoid valves to the IB box.
Wire nut
Red
Red
Black
Black
White
White
Wire nut
3-Way Valve
Solenoid
Cord
Grip
Nipple
J-Box
Suppression Diodes can only be
used with DC powered solenoids.
Suppressor diode
V/R Kit P/N 846000-022
Suppressor Diode Ratings:
Output Current of 1.0 Amp,
Maximum reverse voltage 420 Volts Interconnect Box
Power-Side Terminals
J7
J8
DH1-R1-NO
DH1-R1-COM
INPUT-PWR
INPUT-PWR
DH2-R1-NO
DH2-R1-COM
INPUT-PWR
INPUT-PWR
INPUT-PWR
GND
CHASSIS-GND
CHASSIS-GND
Note: Use either INPUT-PWR terminal
to provide power to valve
Note: Use either CHASSIS-GND terminal
to provide return for valve
Note: Use DH2-R1-NO and DH2-R1-COM
if using Display Head 2 to control valve
NOTICE

13
EMR3- Truck Installations
EMR4 Truck Installation 3-Way Safety Valve for Truck LP Gas Systems
Figure 8. Example Wiring Connections For DC And AC Solenoid Valves
DC Solenoid
valve
Rigid conduit
Seal off
J-Box
Rigid
conduit
L
N
Supply
120/240 Vac
1
Interconnect Box
Power Side terminals
AC Solenoid
valve
Rigid conduit
Sealoff
AC Solenoid Wiring
DC Solenoid Wiring
Wire nut
Red
Red
Black
Black
White
White
Wire nut
Suppressor diode
V/R Kit P/N 846000-022
Suppressor Diode Ratings:
Output Current of 1.0 Amp,
Maximum reverse voltage 420 Volts
Suppression Diodes can only be
used with DC powered solenoids. Interconnect Box
Power-Side Terminals
J7
J8
DH1-R1-NO
DH1-R1-COM
INPUT-PWR
INPUT-PWR
DH2-R1-NO
DH2-R1-COM
INPUT-PWR
INPUT-PWR
INPUT-PWR
GND
CHASSIS-GND
CHASSIS-GND
Note: Use either INPUT-PWR terminal
to provide power to valve
Note: Use either CHASSIS-GND terminal
to provide return for valve
Note: Use DH2-R1-NO and DH2-R1-COM
if using Display Head 2 to control valve
Note: Use DH2-R1-NO and DH2-R1-COM
if using Display Head 2 to control valve
J7
DH1-R1-NO
DH1-R1-COM
INPUT-PWR
INPUT-PWR
DH2-R1-NO
DH2-R1-COM
INPUT-PWR
INPUT-PWR
NOTICE

14
EMR3- Truck Installations
EMR4 Truck Installation Wiring The Display Head
Wiring The Display Head
1. With the Display Head cover still off, remove the nut and bushing from the top side panel cord grip connector.
Note: the maximum cable length between the Interconnect Box and the Display Head is 1000 feet (304.8
meters).
2. Slide the cord grip nut and then the bushing over the IB cable leads. Pull enough cable through so that the
leads reach the terminal block on the display assembly and can be tie wrapped to the pulse encoder mounting
base as shown in Figure 9. Slide the tapered end of the bushing into the cord grip, then screw on the cord
grip nut and tighten securely.
3. Attach the four-wire IB cable to the terminal block where shown in Figure 9. Attach the drain wire of the IB
cable to a grounding lug on the Pulse Encoder mounting base.
When stripping wire for terminal block connections, be careful not to nick the individual strands. Also, be sure
to tighten each terminal so the wire can not be pulled out. A failure to follow either of these instructions can re-
sult in signal loss and faulty operation.
4. If you have the optional temperature probe and/or ESS switch, remove the lower cord grip nut and slide it,
then the tapered bushing, over the temperature probe and/or ESS switch cable. Pull enough cable through so
that the leads reach the terminal block on the display assembly and can be tie wrapped to the pulse encoder
mounting base as shown in Figure 9. Slide the bushing into the cord grip and then screw the cord grip nut
onto the cord grip and tighten securely. Attach the shield of the temperature probe cable and/or ESS switch
cable to a grounding lug on the pulse encoder mounting base.
5. Attach each wire (no polarity) of the 2-conductor temperature probe and/or ESS switch cable(s) where shown
on the terminal block label.
6. Tie wrap the IB, ESS switch, and temp probe (if installed) cables to the Pulse Encoder mounting base.
7. For transfer Interlock applications, attach the two wires in the switch cable where shown on the terminal block
label and tie wrap the cable to the pulse encoder’s mounting base.
8. Replace the Display Head cover and screw in the four cover retaining bolts just enough to hold them in (the
cover will be removed later for system calibration).
9. Using the tie wraps from the installation kit, attach the 4-wire cable from the Display Head to the Interconnect
Box along the inside of the truck frame, to existing piping, or to the reel motor cable back to the cab. Avoid
sharp bends and placements where vibration might wear through the cable. Allow ample cable length to
compensate for tilt-cab trucks and to avoid putting additional stress on the assembly. Running the cable
through a split loom or tubing will offer added protection from weather and abrasion. Use a rubber grommet or
cord grip to line the hole where cable passes through truck cab wall or floor. Tractor-trailer installations will
require detachable plugs, and either a separate tensioning device much like that used to protect air lines, or
perhaps attach the cable to one of the existing air lines with tie wraps.
10. Check continuity between the Display Head chassis and IB chassis through the vehicle frame. This resistance
must be less than 1 ohm.

15
EMR3- Truck Installations
EMR4 Truck Installation Wiring The Display Head
Figure 9. Display Head Cable Connections
ENS1J-489ENS1J-489
-L00100-L00100
BOURNSBOURNS
VR ENCODERVR ENCODER
P/NP/N
331884-001331884-001
331933-001331933-001
I.S.I.S.
Intrinsically-safe inputs from
Interconnect Box, emergency stop switch,
interlock switch, temperature probe,
and optional series 8452 remote pulser
Route cables as shown to
avoid interference with flexible
encoder shaft. Use tie wraps
to attach cables to base.
Pulse encoder
Optional keypad
Encoder shaft
spring
C&C
Jumper
Display head
terminal block
Attach optional remote
pulser, temperature probe,
interlock switch, IB cable and
ESS switch cable shields to
grounding lug on base.
9/64” (3.5mm) max.
Note: Maximum screwdriver
size for attaching wires to
terminal block.
C&C Switch - Removal of corner
bolt releases actuator lever of C&C
switch allowing entry into C&C Mode
#6 Self tapping
screws (3) Rubber gasket (1)
INTERCONNECT BOX 1000 RPM ENCODER OPTIONAL KEYPAD TEMP PRB
INTER LO CK
STOP SWC & C SW
BLK
GND
RED
PWR
YEL
+
YEL
GND
WHT
+
BLK
GND
GRN
CHA
WHT
CHB
BLK
GND RED
+5V
WHT
+
BLK
GND
WHT
+
BLK
GND
ORA
KP8
BLU
KP7
YEL
KP6
GRN
KP5
WHT
KP4
BLK
KP3
RED
KP2
NOT
USED
GRN
IB-A
WHT
IB-B

16
EMR3- Truck Installations
EMR4 Truck Installation C&C Mode Switch
C&C Mode Switch
The C&C corner switch assembly (P/N 845900-018) that fits into one corner of the Display Head’s housing (see
Figure9). To enter C&C mode, remove the corner bolt fromthe Display Head’s cover. To exit C&C mode, replace
the bolt. When using the corner switch, remove the C&C jumper.
Installing Optional Keypad Kit - Right Or Left Side
Figure9 shows the installation and wiring of the optional keypad. To attach the keypad housing mounting screws,
you will need to pull/slide up the display assembly away from the Display Head. Insert the keypad wires through
the center hole in the gasket, slide the gasket down against the keypad and align its three holes with the mounting
holes in the keypad. Hold the keypad against the Display Head and screw in the 3 mounting screws, replace the
display assembly and then connect the keypad wiring to theterminal block as shown in Figure9. The screws are
self-tapping. The user may want to pre-tap the holes using the screw to ease installation.
Installing The Remote Display (Optional)
The Remote Display consists of the items listed in Table 2:
Figure 10 shows the Remote Display assembly and Figure 11 shows how to wire the display to the Interconnect
Box. You can mount the display on a wall or dashboard of a truck, a wall in a building, or outside in a hazardous
location. Use appropriate fasteners in any of the pre-drilled holes in the base of the optional bracket when
attaching the bracket to the mounting surface. Adjust the angle of the display by loosening the side bolts and
rotating the unit to the desired position.
Following wiring routing precautions and procedures discussed earlier (page 14) for the meter mounted Display
Head, connect the Remote Display to the Interconnect Box. Wiring connections at the Remote Display are shown
in Figure 11. Install optional cord grip fitting in rear of Remote Display for cable egress. Wiring connections at the
IB are to the identical terminals of the unused Display Head terminal block.
Table 2. Remote Display (84559X-00X) Components
Description V-R P/N
Remote Display install kit 330020-430
Opt. Mounting Bracket kit 845900-024
Opt. 4 conductor cable - 6 ft (1.83 m) 846000-107
Opt. 4 conductor cable - 35 ft (10.67 m) 846000-106
Opt. 4 conductor cable - 50 ft (15.24 m) 846000-100
Opt. 4 conductor cable - 100 ft (30.48 m) 846000-101
Opt. 4 conductor cable - 200 ft (60.96 m) 846000-102
Opt. 4 conductor cable - 300 ft (91.44 m) 846000-103
Opt. 4 conductor cable - 400 ft (121.92 m) 846000-104
Opt. 4 conductor cable - 500 ft (152.4 m) 846000-105