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Toptech MultiLoad III Installation Manual

Explosion proof (ex) hardware (loaded with multiload ii+ / rcu ii+ firmware)
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MultiLoad III / RCU III
Explosion Proof (EX) Hardware
(Loaded with MultiLoad II+ / RCU II+ Firmware)
Installation Guide
M AY 26 , 20 23

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Summary of Contents for Toptech MultiLoad III

  • Page 1 MultiLoad III / RCU III Explosion Proof (EX) Hardware (Loaded with MultiLoad II+ / RCU II+ Firmware) Installation Guide M AY 26 , 20 23...
  • Page 2 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.
  • Page 3 Product: Operator Interface/Process Control Equipment intended for use in potentially explosive atmospheres Model name/number: MultiLoad III EX (MID, YES), RCU III EX (MID, NO) Flameproof ‘d’, Intrinsic Safety ‘ib’ Protective Systems: Notified Body(ies) Det Norske Veritas Certification AS, Number 0575 NMi Certin B.V., Number 0122...

  • Page 4: Table Of Contents

    Servicing and Repair ........................22 Cover Closure and Bolt Replacement ....................22 Cable Entries ............................23 Mounting the MultiLoad III/RCU III EX Hardware Enclosure ............23 Metal Plate or Rail ......................... 23 Wood ............................. 23 Concrete or Cinder Block Walls ....................23 Mounting Height Considerations ....................
  • Page 5 CONNECTING FIELD DEVICES TO INTERNAL FCMS ........38 CHAPTER 6 CONFIGURATIONS .................... 39 Weights and Measures Switch Access Control ................39 External Switch Access Control (MultiLoad III Hardware Only) ............ 39 Field Switch Access Control ......................40 Keypad ..............................41 Menus and Screens ..........................41 Field Modification and Data Entry .....................
  • Page 6 Mounting Feet Installation ........................62 Cover Replacement ..........................63 Overview Parts List and Part Numbers ..................... 66 CHAPTER 8 REVISION HISTORY ..................67 Hardware Revision ..........................67 Manual Revision ..........................67 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 7 ETHERNET CONNECTIONS FIGURE 4.3 FCM CONNECTIONS FIGURE 4.4 RS485 4-WIRE, HOST TO A SINGLE MULTILOAD III/RCU III EX HARDWARE (RECOMMENDED) FIGURE 4.5 RS485 4-WIRE, HOST TO MULTIPLE MULTILOAD III/RCU III EX HARDWARE UNITS FIGURE 4.6 RS485 2-WIRE, HOST TO A SINGLE MULTILOAD III/RCU III EX HARDWARE UNIT FIGURE 4.7...

  • Page 8: Overview

    Overview This document is designed to guide individuals installing MultiLoad III/RCU III EX Hardware 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 this guide:...
  • Page 9 Emphasizes a key product or industry term. Example: the display features a pick-list style of item selection. This guide covers RCU III/MultiLoad III EX Hardware installation information only. For information about base MultiLoad firmware, please consult the MultiLoad II+ Firmware User Guide. For information about base RCU firmware, please consult the RCU II+ Firmware User Guide.

  • Page 10: Chapter 1 General Information & Warnings

    Chapter 1 General Information & Warnings Receiving and/or Returning Equipment At receipt, the MultiLoad III/ RCU III EX Hardware should be immediately inspected after opening the packaging case. If any damage is visible, notify the carrier at once to establish liability.

  • Page 11: Safety Warnings

    ▲ PRUDENCE: Câblage de terrain doit avoir un classement de température de +75 °C ou plus. Utilisez uniquement du fil de cuivre. ▲ Consultez le manuel d'installation pour le filetage de forme et la taille du presse-étoupe. Suite à la page suivante MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 12 Matsushita Electric, model BR2032 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/BR 60079-14. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 13: Electrostatic Discharge (Esd) Protection

    The MultiLoad III/ RCU III EX Hardware contains electronic components and assemblies subject to damage by ESD. The MultiLoad III/ RCU III EX Hardware 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.

  • Page 14: Chapter 2 Operating Conditions And Components

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS Chapter Chapter 2 Operating Conditions and Components Product Outline and Dimensions MultiLoad III/RCU III EX Hardware Picture Figure 2.1 MultiLoad III/RCU III Ex Hardware MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 15: Multiload Iii/Rcu Iii Ex Hardware Dimensions

    MultiLoad III/RCU III EX Hardware Dimensions The dimensions in this section are indicated in inches and millimeters (in parenthesis). 2.1.2.1 Front View Unit Outline Drawing – Front View Figure 2.2 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 16: 2.1.2.2 Back View

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS 2.1.2.2 Back View Unit Outline Drawing – Back View Figure 2.3 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 17: 2.1.2.3 Bottom View

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS 2.1.2.3 Bottom View Unit Outline Drawing – Bottom View Figure 2.4 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 18: 2.1.2.4 Top View

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS 2.1.2.4 Top View Unit Outline Drawing – Top View MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 19: 2.1.2.5 Left Side View

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS 2.1.2.5 Left Side View Unit Outline Drawing – Left Side View Figure 2.5 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 20: 2.1.2.6 Right Side View

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS 2.1.2.6 Right Side View Unit Outline Drawing – Right Side View Figure 2.6 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 21: Operating Characteristics

    CHAPTER 2– OPERATING CONDITIONS AND COMPONENTS Operating Characteristics The MultiLoad III/RCU III EX Hardware has the following characteristics: Characteristics Description 100 - 240 Vac, 47-63 Hz, 500 – 250 mA Operating Voltage Operating Temperature -40°F to 140°F, -40°C to 60°C...

  • Page 22: Chapter 3 Installing The Multiload Iii/Rcuiii Ex Hardware

    Be sure to keep the flanges clean and free of scratches so as not to compromise the quenching ability of the flame path. All cover bolts must be tightened to maintain the explosion proof capability of the enclosure. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 23: Cable Entries

    140°F or 60°C. Exterior dimensions of the standard MultiLoad III/RCU III EX Hardware enclosure are shown in Figures 2.2 – 2.7. There is only one mounting orientation possible as shown in Figure 2.2. Seven M20x 1.5 mm cable entries are located at the bottom of the unit.

  • Page 24: Figure 3.1 Suggested Mounting Position

    CHAPTER 3– INSTALLING THE MULTILOAD III/RCUIII EX HARDWARE Figure 3.1 Suggested Mounting Position Figure 3.2 Screen Visible Area MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 25: Recommended Wire Sizes And Torque For All Terminal Blocks

    0.23 Nm +/-0.02 Nm (2 lb in +/- 0.2 lb in). Electrical Supply Connections The MultiLoad III/RCU III EX Hardware is designed to run on 100 - 240 Vac, 47-63 Hz mains power. Verify the power type before making any connections.

  • Page 26: Mains Supply Connection

    CAN/CSA-C22.2 NO. 61010-1. The disconnected device may not be blocked or be made difficult to operate by the MultiLoad III/RCU III EX Hardware or any other device. Note that installation of disconnects are typically prohibited in Class I, Division 2 locations.

  • Page 27: Equipment Battery

    Matsushita Electric, model BR2032 only. The battery must be installed with the positive battery side down and the negative battery side up. Figure 3.4 MultiLoad III/RCU III EX Hardware Main Board Battery (BT1) MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 28: Chapter 4 Data Communications Interface

    Chapter Chapter 4 Data Communications Interface The MultiLoad III/RCU III EX Hardware has six (6) communications ports (see Figure3.3), each with a specific purpose. The following section provides the information required to select and make the wiring connections to the ports: Figure 4.1...

  • Page 29: Available Communications Protocol Selection And Wire Spec

    DC GND is available on all serial ports. Connect the MultiLoad III/RCU III EX Hardware DC GND to the signal ground of the field device. Wire used must meet the following characteristics: 24 AWG stranded.
  • Page 30 Additional wires are required for hardware handshaking when using printers and data loggers. Wire used must meet the following characteristics: 24 AWG. 3 conductors with overall shield (data only) or 8 conductors with overall shield (full handshaking). 30 pF maximum between conductors. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 31: Communication Connection Wiring

    This section describes the wiring connections for each of the communication ports to function for a specifc communication protocol. Ethernet – Host/TMS Communications The Host/TMS Computer System can be connected to the MultiLoad III/RCU III EX Hardware using Ethernet. The Ethernet Ports use HP Auto-MDIX technology. By automatically detecting the signaling on the connected device, the transceiver will configure the port direction automatically.

  • Page 32: Serial Fcm I/ Fcm Ii Communications, Com 0, Rs485

    FCM I and FCM II modules communicate with the MultiLoad III/RCU III EX Hardware using the COM0. This is a dedicated communication line. The FCMII modules linked to a specific MultiLoad III/RCU III EX Hardware are all on an RS485 bus connected to the COM 0 port.

  • Page 33: Serial Host/Tms Communications

    CHAPTER 4– DATA COMMUNICATIONS INTERFACE Serial Host/TMS Communications A host/ TMS computer system can be connected to the MultiLoad III/ RCU III EX Hardware in various ways: RS485 4-wire on COM 1 RS485 2-wire on COM 1 RS232 on COM1 Ethernet on Ethernet Port #1 4.2.3.1...

  • Page 34: 4.2.3.2 Com 1 - Rs-485 2-Wire - Host/Tms Communications

    4.2.3.2 COM 1 - RS-485 2-wire - Host/TMS Communications The Host/TMS Computer System can be connected to the MultiLoad III/RCU III EX Hardware via RS485 2-Wire on COM 1. The TD and RD pairs tied together at the Host/TMS and all MultiLoad III/RCU III EX Hardware units. Host/TMS...

  • Page 35: 4.2.3.3 Com 1 - Rs-232 - Host/Tms Communications

    Figure 4.9 RS232, Host to Multiple MultiLoad III/RCU III EX Hardware units Host Ticket Printer/Data Logger Ticket Printers or alibilog printers can be connected to the MultiLoad III/RCU III EX Hardware in the following ways: RS 232 on COM3 Ethernet on the Ethernet Port #1...

  • Page 36: 4.2.4.1 Com3 - Rs232 - Host Ticket Printer/Data Logger

    CHAPTER 4– DATA COMMUNICATIONS INTERFACE 4.2.4.1 COM3 – RS232 - Host Ticket Printer/Data Logger A Ticket Printer or Data Logger can be connected to the MultiLoad III/RCU III EX Hardware via RS232 on COM 3. The TX and RX are swapped at the MultiLoad III/RCU III EX Hardware.

  • Page 37: 4.2.4.2 Com3 - Rs232 - Ptb Protocol Host Ticket Printer/Data Logger

    4.2.4.2 COM3 – RS232 – PTB Protocol Host Ticket Printer/Data Logger A Special variant of the ticket printing equipment uses the PTB protocol. A PTB printer can be connected to the MultiLoad III/RCU III EX Hardware via RS232 on COM3. MultiLoad III/RCU III...

  • Page 38: Chapter 5 Connecting Field Devices To Internal Fcms

    Chapter 5 Connecting Field Devices to Internal FCMs Up to (4-Single Wide OR 2-Double Wide) FCM II modules can be installed inside the MultiLoad III/RCU III EX Hardware enclosure. Refer to the FCM II Installation Manual for instruction on connection to field equipment.

  • Page 39: Chapter 6 Configurations

    External Switch Access Control (MultiLoad III Hardware Only) On the left side of the MultiLoad III EX Hardware, there is a W&M Bolt Switch. W&M protection is in place when this bolt is fulling turned in. The bolt can be sealled with a wire in this position. W&M Protection is removed when this bolt is unscrewed until it stops.

  • Page 40: Field Switch Access Control

    Field Switch Access Control The MultiLoad III EX Hardware also can a accept field input for the W&M access. Review the “MultiLoad II/II+ Firmware User Guide” for more information. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 41: Keypad

    CHAPTER 6– CONFIGURATIONS Keypad The MultiLoad III/RCU III EX Hardware keypad has 55 keys, including alpha, numeric, and function keys, which are used to: Select menu items and fields Enter data in fields Initiate actions Return to previous screens Numeric keys (1 through 9 and 0) are used to enter numeric data. Alpha keys are used to enter text.

  • Page 42: Field Modification And Data Entry

    Processing Mode: Remote Swing Arm Secondary: DISABLD Terminal Name: Toptech Terminal Security Accounts Exit Type in the new value (e.g. 123) and press Enter. The new value displays on the screen. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 43 OK to accept the desired choice. RCU GENERAL SETUP RCU Address: Card Reader: DISABLD Processing Mode: Remote Swing Arm Secondary: DISABLD Terminal Name: Toptech Terminal Security Accounts Exit MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 44: Multiload Ii+/Rcu Ii+ Firmware Preliminary Configuration

    MultiLoad II+/RCU II+ Firmware Preliminary Configuration Power-on the MultiLoad III/RCU III EX Hardware. When the MultiLoad III EX Hardware is first powered-on, running MultiLoad II+ Firmware, the card– in screen appears, indicating the Operating Mode. When the RCU III EX Hardware is first powered-on, running RCU II+ Firmware, the “System Unavailable”...
  • Page 45 Factory Defaults Down Exit RCU II+ Firmware M A I N M E N U Configuration Diagnostics Factory Defaults SD Card Down Exit Press OK to access the Configuration menu. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 46 RCU II+ Firmware C O N F I G U R A T I O N M E N U Communication Network RCU Setup Customer Logo Setup Date & Time Down Exit MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 47 CHAPTER 6– CONFIGURATIONS Press Enter and key in RCU Address (001, or as desired) for the MultiLoad III/RCU III EX Hardware: MultiLoad II+ Firmware RCU GENERAL SETUP RCU Address: Card Reader: DISABLD Processing Mode: Remote Swing Arm Secondary: DISABLD Terminal Name: Toptech Terminal...

  • Page 48: Verifying Communications With Fcms

    RCU II+ Firmware D I A G N O S T I C S M E N U Card Reader COM Loopback Serial Ports Network Test Keypad Display Unicode Down Exit MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 49 (bits), 1 Stop (bit), Single, and I/O Board (type of serial device). This is correctly set in the factory when an RCU II is assembled, but it is possible for the settings to be updated by the installer. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 50: Using I/O Diagnostics

    OFF state. Activate each input from the field. If the circuit is connected properly, the state change can be observed. For the counter inputs, the totals will accrue if they are receiving pulses. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 51: Chapter 7 Service And Repair

    Chapter Chapter 7 Service and Repair Do not service MultiLoad III/RCU III EX Hardware without disconnecting the supply circuit. Keep the enclosure tightly closed while circuits are live. Using a magnetic screwdriver is very helpful in retaining the screws during removal and installation.

  • Page 52: Figure 7.2 Subassembly Identification

    CHAPTER 7– SERVICE AND REPAIR The MultiLoad III/RCU III EX Hardware has been constructed with replaceable sub-assemblies that are available from Toptech. These include: 1. Main Board Subassembly 2. Display Subassembly 3. Keypad Barrier 4. Card Reader Subassembly 5. FCMII 24V Power Supply 6.

  • Page 53: Main Board Replacement

    Verify no cables are pinched under the PCBA. Once all screws are in place, tighten all screws to secure the PCBA to the chassis. 3. Carefully reconnect the cables that were disconnected for Removal. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 54: Display Subassembly Replacement

    5. Remove the 4 side screws that secure the display subassembly to the mounting bracket. 6. Remove the display assembly from the mounting bracket. Fig. 7.5 7. If the display is not being replace immediately, reinstall the mounting brackets. Fig. 7.6 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 55: Figure 7.4 Display Assembly Removed From The Mounting Bracket

    5. Reinstall the mounting brackets with the display assembly into the cover. Note: do not tighten screws until all screws have been installed. 6. Carefully reconnect the display cable the CPU board. Figure 7.4 Display Assembly removed from the Mounting Bracket MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 56 CHAPTER 7– SERVICE AND REPAIR Figure 7.6 Mounting Bracket reinstalled without Display Subassembly MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 57: Keypad Barrier Replacement

    Keypad Barrier Replacement Removal: Note: Power MUST be moved when removing or installing the keypad barrier or electrical damage to the keypad barrier will result. 1. Disconnect the external keypad barrier cable by pressing the tab to release. 2. Remove the three screws using a #2 Philps screwdriver and lift away the keypad barrier. 3.

  • Page 58: Card Reader Replacement

    5. Reinstall the card reader gasket and cover. Using a screw align the two upper holes of the gasket and cover first then the remaining screw. Figure 7.6 Exploded View of Card Reader MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 59: Fcm Power Supply Replacement

    3. Attach the Mains AC Input wires to the FCM Power Supply noting the polarity of Line and Neutral wires. 4. Reconnect Mains AC Power. Figure 7.7 Removal of FCM Power Supply MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 60: Keypad Replacement

    6. Install the keypad bracket and retaining screws. Note: Do not overtighten the mouting screws or the mounting plate can become deformed. Figure 7.7 Keypad Assembly Removal MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 61: Figure 7.8 Keypad Assembly Installation Prep

    CHAPTER 7– SERVICE AND REPAIR Remove paper backing Figure 7.8 Keypad Assembly Installation Prep MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 62: Mounting Feet Installation

    Mounting Feet Installation Mounting Foot Installation 1. The MultiLoad III EX Hardware mounting feet are not preassembled. 2. Align the mounting feet with the predrilled and tapped holes. 3. Using a #2 Philips screwdriver and provide screws install the mounting feet.

  • Page 63: Cover Replacement

    CHAPTER 7– SERVICE AND REPAIR Cover Replacement Removal: 1. Using a 10mm HEX driver remove all the cover bolts and open the MultiLoad III/RCU III EX Hardware. 2. Remove the tie wraps securing the display cable to base. 3. Disconnect the Display Cable from the main board by pressing the tab to release.

  • Page 64: Figure 7.11 Install Top Right Screw And Remove Lower Hinge Knuckle

    CHAPTER 7– SERVICE AND REPAIR Figure 7.11 Install Top Right Screw and remove lower hinge knuckle. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 65: Figure 7.12 Remove Top Right Screw And Lift Cover Off

    CHAPTER 7– SERVICE AND REPAIR Figure 7.12 Remove Top Right Screw and lift cover off. MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

  • Page 66: Overview Parts List And Part Numbers

    CHAPTER 7– SERVICE AND REPAIR Overview Parts List and Part Numbers The Toptech replacement part numbers are shown in the table below: Part Part Number Part Part Number ML3 Main Board Assembly TT#2827 ML3 Display Assembly TT#3043 ML3 Backup Board V2...

  • Page 67: Chapter 8 Revision History

    CHAPTER 8– REVISION HISTORY Chapter Chapter 8 Revision History Hardware Revision Date Description Initial Product Release Manual Revision Revision Date Description Initial Manual Release MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...
  • Page 68 1124 Florida Central Parkway Longwood, FL 32750, USA Phone: +1 (407) 332-1774 Europe office: Toptech Systems NV Nieuwe Weg 1 2070 Zwijndrecht (Antwerp), Belgium Phone: +32 (0)3 250 60 60 MultiLoad III/RCU III Hardware - Explosion Proof (EX) Installation Guide...

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