Liquid Controls LectroCount3 Guide de référence

STANDARD BULK TRUCK SYSTEMSTANDARD BULK TRUCK SYSTEM

INSTALLATION PROCEDURESINSTALLATION PROCEDURES

LectroCount³

Table Of Contents

SECTION page

1. System Overview 3

2. Installation Overview 4

3. Parts Requirements 4

3.1 Liquid Controls Supplied Components 4

3.2 Liquid Controls Supplied Options 4

3.3 Installer Supplied Parts 4

4. Electrical Check 5

5. Truck Cab Computer Installation 6

5.1 General Requirements 6

5.2 Locating Components 6

5.3 Electrical Power Connections 7

5.3.1 Overview 7

5.3.2 Run Battery Cable 7

5.3.3 Installation of Accessory Cable 8

5.4 Truck Seat Grounding 9

5.4.1 Static Electricity and Grounding 9

5.4.2 Installation of Ground Strap Kit 10

6. Supervisory Console Grounding 12

6.1 Grounding Strap Installation 13

7. Lap Pad Connection 14

8. Printer Mounting 14

8.1 Printer Connection & Printer Dimensional Drawing 14 & 15

9. Removal of Mechanical Registration Equipment 15

10. Installation of Electronic Temperature Volume Compensator 15

10.1 Installation of Strainer Cover Mounted Thermowells 16 & 17

10.2 Installation of Pipe Mounted Thermowells 18

10.2.1 For Canadian Installations 18

11. Mounting the Remote Supervisory Control Box (RSCB) 19

11.1 Liquid Controls Meters/RSCB with Internal Pulsers 19

11.2 LC Meter with External Pulse Output Device 20

11.3 Neptune Non-Compensated Meter Retrofit Kit 21

11.4 Neptune Temperature Compensated Meter Retrofit Kit 22

11.5 RSCB Mounting Bolt Pattern 23

12. Wiring the RSCB 24

12.1 Wiring of the Valve Solenoids to the RSCB 25

12.1.1 "Diddle" Valve Wiring 26

12.1.2 Liquid Controls Dual Stage Wiring 26

12.1.3 Single Stage Valve and Three Way Solenoid Wiring 26

12.2 Wiring of the RTD Temperature Probe to the RSCB 26

12.3 POD Wiring (Pulse Output Device) 26

12.4 Internal Pulser Wiring 27

12.5 Truck Cab Cable Routing 27

12.6 Connection of the Meter Signal Cable 28

12.6.1 Single Meter Systems 28

12.6.2 Dual Meter Systems 28

13. System Start-Up 28

14. Software Part Numbering System 29

15. Troubleshooting 29 - 37

16. Wiring Diagrams 38

16.1 Mounting Arrangements for Components w/ Brackets 43

1. System Overview

The LectroCount3 On-Board Truck

Computer system works in conjunction

with many models of Positive

Displacement Flow Meters. It

accurately measures fuel deliveries,

prints priced receipts, and streamlines

driver record keeping. It can be

equipped with accessories that allow for

temperature volume compensation,

deliveries to be made (net volume), and

delivery information to be exchanged

between the truck computer and an

office computer.

The basic system consists of:

1. Remote Supervisory Control

Box/Remote Electronic Counter

Assembly (RSCB/REC) that is

mounted in place of mechanical

registration equipment on the meter.

2. Supervisory Control Module and

Printer that are mounted in the truck

cab.

3. Lap Pad operator interface.

For trucks equipped with two meters, a

dual meter configuration is available that

allows two RSCB/RECs to be connected

to a single truck computer.

This manual describes the installation of

these components and their

accessories. Read this entire

installation manual before beginning

the installation to make sure that you

understand the total scope of the

project. Specific installation

requirements will vary with the model of

truck. Meter type, configuration of

existing metering equipment, selected

options, and the type of fluid being

metered, all influence installation. Make

sure that the RSCB/REC, Electronic

Temperature Volume Compensation kit

(ETVC), pulser, and valves can be

installed in such a manner so as to not

interfere with routine service of the

meter, the strainer, and the meter

compartment door.

The conduit and wiring for the above

components need to be routed with

similar concerns in mind. If a dual meter

system is being installed, the

RSCB/REC, ETVC, pulser, and valve

work must be duplicated for the second

meter.

NOTE: Power, input and output (I/O) wiring must be in accordance with

Class I, Division 2, wiring methods in Article 501-4(b) of the National

Electrical Code, NFPA 70 and in accordance with the authority having

jurisdiction.

WARNING: Explosion Hazard - Substitution of Components May

Impair Suitability for Class I, Division 2.

WARNING: Explosion Hazard - When in Hazardous Locations, Turn

Off Power Before Replacing or Wiring Modules;

WARNING: Explosion Hazard - Do NOT Disconnect Equipment

Unless Power Has Been Switched Off or the Area is

Known to be Non-hazardous.

2. Installation Overview

qEnsure that the truck electrical

system meets specifications and

can provide at least 5 Amps for

the LectroCount3with all truck

accessories operating.

qElectrically ground the truck

seats.

qMount supervisory control

module and printer in cab.

qInstall battery/accessory cables.

qInstall odometer kit (optional).

qRemove any existing mechanical

registration equipment.

qRemove any existing manual

preset valve.

qInstall an electronically controlled

security valve or solenoid kit.

qMount RSCB / REC

qInstall pulser assembly (optional)

qInstall Electronic Temperature

Volume Compensation Kit

(optional).

qRoute Meter Signal Cable to

truck cab.

3. Parts Requirements

3.1 LIQUID CONTROLS SUPPLIED COMPONENTS

qRSCB / REC

qMeter Signal Cable (pre-wired to RSCB)

qBattery/Accessory Cable

qSupervisory Control Module

qLap Pad (driver key pad)

qTicket Printer with cables

3.2 LIQUID CONTROLS SUPPLIED OPTIONS

qETVC Kit

qPulse Output Device (pulser)

qOdometer Pulser

qDual Meter Switch Box

qRAM Interface Module

qTwo Stage Valve or 3-Way Solenoid

3.3 INSTALLER SUPPLIED PARTS

qProtective Sheathing/Conduit for cables

qAll Fittings

qHardware for Truck Computer Mounting Brackets

4. Electrical Check

Before beginning to install the LectroCount3, it is essential that you complete the

following checklist. If the vehicle electrical system cannot meet the following

requirements, corrective action must be taken before installing the LectroCount3. This

checklist is also included with the system. That copy should be filled out and filed with

the distributor or truck builder. NOTE: Contact the factory if the truck has a positive

ground.

The truck system must meet the following requirements:

qBattery terminals and cables must be in good condition with clean, corrosion free

connections.

qBattery must be charged in accordance with manufacturer’s specifications.

qThe alternator must be large enough to meet the total demands of the truck,

including the LectroCount3. LectroCount3requires 5A minimum for proper

operation. A typical alternator size is 90 amperes.

qIf the truck has a history of electrical problems, make sure that these problems

have been corrected before installing the LectroCount3.

qInspect all truck electrical/electronic equipment for proper installation.

qDetermine if the truck is positive or negative ground. (If the system is positive

ground, contact the factory).

qBe sure that the radio antennas were installed in accordance with the

manufacturer’s specifications to prevent RF interference.

To ensure that these requirements are met, check the voltage across the battery

terminals under the following conditions:

LectroCount3

Vehicle Inspection Check List

With the truck running at low idle, and all accessories off, the voltage should be between

12.6 and 18 VDC.

With all the accessories (lights, heater, radio, and radio mike) on, the voltage must be

between 12.6 and 18 VDC. If the voltage drops significantly when the accessories

are turned on, it may indicate that the alternator will not be able to support the

LectroCount3.

Extend the delivery hose to its full length, engage the hose reel and measure the voltage

as the hose is reeled in. It shouldn’t drop below 10VDC.

With the truck running at high idle, and all accessories off, check the voltage. Again it

should be between 12.6 and 18 VDC.

Repeat the hose reel test with the truck at high idle. Make sure that the voltage does not

drop below 10 VDC.

5. Truck Cab Computer Installation

5.1 GENERAL REQUIREMENTS

A minimal truck cab computer system

includes:

1. A supervisory control module (SCM)

that is mounted between two right

angle brackets

2. A dot matrix ticket printer

3. A Lap Pad (key pad/display).

Systems equipped with the RAM card

option will have a RAM interface module

mounted atop the supervisory control

module. Dual meter systems will have a

Dual Meter Switch mounted below the

SCM. (See Figure to the right)

The truck computers are shipped with

the components and brackets

assembled. The installer has to bolt the

brackets to the cab floor, ground the

SCM to the truck electrical system, and

route the power and signal cables to the

appropriate connectors on the SCM and

Dual Meter Switch.

The printer also needs to be mounted in

the truck cab, usually on top of the SCM

“stack”. The Lap Pad is secured in a

holder on the side of one of the

brackets.

5.2 LOCATING COMPONENTS

The SCM bracket should be mounted in

a location where:

qBoth the front and back can be

accessed to connect cables

qThe Lap Pad and printer will be

accessible to the driver.

qThe Supervisory Control Module

fuses can be replaced.

qThere is enough room to insert and

remove a RAM card from the RAM

interface module. (RAM systems

only)

Truck Cab

Component Configuration

Single Meter/Non-RAM Configuration

Single Meter / RAM Configuration

Dual Meter / RAM System

5.3 ELECTRICAL POWER CONNECTIONS

5.3.1 Overview

The LectroCount3 is designed to run only

when the ignition switch is in the “on” or

“accessory” position. This prevents the

LectroCount3from being damaged by

the voltage spikes or electrical noise

that occur when the starter is engaged,

or from draining the truck battery power

when the truck isn’t running.

Voltage from the battery is switched by

a relay that is controlled by the truck’s

accessory circuit. It is vital that the

battery and accessory cables be

properly connected and fused, and that

the SCM is properly grounded.

5.3.2 Run Battery Cable

(Part Number 81232)

The battery cable is supplied with

heavy-duty ring terminals that must be

installed directly to the battery posts.

Make sure that the truck’s electrical

system has been properly checked.

Clean the battery terminals for a

good electrical connection.

qRemove the ATO 7.5 amp fuse from

the battery cable’s black splash-

proof fuse holder so that the wire is

not live while the cable is routed and

terminated.

qAttach the black cable to the

negative (-) terminal of the battery.

qConnect the orange cable terminal

to the positive (+) terminal of the

battery.

qOn truck systems with several

batteries connected in parallel, the

last battery in the system usually has

the least number of connections and

will be the best location to attach the

battery cable.

qRoute the cable to the supervisory

control module in the truck cab.

qSeal any holes that you may have

made in the cab wall.

(continued next page)

qMake sure that you route the cable

in such a manner so as not to

interfere with the operation or

maintenance of the truck.

qThe wires will be connected to a

three pin terminal block on the back

of the SCM.

qThe block can be removed from the

SCM to ease the process.

qUse a 1/8” screwdriver to back off

the terminal block screws.

qStrip 7/32” of insulation from the

wires.

qConnect the white wire to Pin 2 on

the block and connect the black wire

to Pin 3.

qMake sure that the screws are re-

tightened and that no loose strands

of wire are exposed.

5.3.3 Install Accessory Cable

(Part Number 80747)

The accessory cable consists of a RED and a BLACK conductor in a shielded cable.

The conductors are both connected to the same ring terminal on one end. They are not

terminated on the other end.

The accessory cable must be wired to the truck’s accessory circuit. The power to this

circuit should be:

qOFF when the ignition is off or the engine is cranking,

qON when the truck is running or the ignition switch is in the “accessory”

position:

Key Switch OFF 0VDC

Key Switch ON 12 VDC (battery voltage)

Key Switch ACCESSORY 12 VDC (battery voltage)

Key Switch or starter button CRANKING 0 VDC

qCheck the voltage using an accurate multi-meter.

qBe sure to use a good ground to avoid false readings.

qThe voltage should drop momentarily to 0 as the engine is cranked.

If the ignition switch is accessible:

qConnect the ring terminal on the

accessory cable to the accessory

stud on the switch.

qIt is usually best to install the ring

terminal over the stud and the nut

that hold the existing accessory

wires in place.

qAn additional nut should then be

used to hold the LC accessory cable

on the stud.

If the ignition switch is not

accessible:

qInstall a voltage tap on the

accessory fuse.

qRemove the ring terminal from the

accessory cable.

qConnect both the red and black

conductors in the cable to the fuse

tap.

qTrim back the drain wire and foil

shield at the outer insulation on the

cable.

qUse electrical tape or heat

shrinkable tubing to insulate the

edge of the shield.

qRoute the cable to the rear of the

supervisory control module.

qTrim the cable to the appropriate

length and strip back the outer

insulation, foil shield, and drain wire.

qUse electrical tape or heat

shrinkable tubing to insulate the

edge of the shield.

qRemove 7/32” of insulation from

both the red and black conductors,

twist the wires together, and insert

them in Pin 1 of the three pin

terminal block.

qTighten the terminal block screw

using 1/8” flat blade screwdriver.

qPlug the terminal black back into the

SCM.

5.4 TRUCK SEAT GROUNDING

5.4.1 Static Electricity and Grounding

Static electricity can build up on drivers

and truck seats, especially during cold,

dry weather. Adjustable, shock-

absorbing seats add to the problem

because they isolate the seat cushion

from an electrical ground. If the static is

discharged on or near the LectroCount3,

it can cause the truck computer to reset

and/or cause a number of other hard to

trace faults. The discharge can occur

when the driver touches the

LectroCount3 or a part of the truck that

provides a good ground path.

WARNING

To prevent the occurrence of electrostatic discharge (ESD), it is

mandatory that the truck seat(s) be properly grounded. This allows

the static electricity to “bleed off’ the driver and seat before it can

build up to the point where a discharge can interfere with the

operation of the LectroCount3(or cause an explosion in hazardous

environments!)

5.4.2 Installation of Ground Strap Kit

qLocate a good ground point near the back of the seat frame. The bottom of the seat

base bracket is usually a good spot.

qDrill a 9/32” hole in the seat frame near the back of the base.

qAttach one end of the ground strap to the bracket using the lock washer, flat washer

and nut provided. The lock washer should penetrate any paint on the bracket to

ensure a good electrical connection.

qAttach the other end of the strap to a metal part of the seat frame at a point where it

contacts the seat cushion. Make sure that there are no intervening pivot points,

guides, adjustment mechanisms, etc., which could interfere with the ground path

between the seat cushion and the ground strap.

qIf the seat cushion has a wooden base, use a wood screw and washer to attach the

strap lug to the bottom of the seat at a point where the seat fabric is attached to the

wood. There must be good contact between the seat fabric and ground strap lug.

qMake sure that the strap is positioned so that it doesn’t interfere with the movement

of the seat or is exposed to physical damage.

Checking for a good ground

The resistance should be checked. Use a multi-meter to test the resistance between a

bare spot on the seat frame and PIN 3 on the SCM power connector.

(The ground terminal should be connected directly to the negative terminal of the battery

on a negative ground system)

The test should be done with all accessories, including the dome light, turned OFF. This

will prevent other currents from distorting the measurement.

If the resistance is less than 3 ohms:

The system is grounded sufficiently and no further action is necessary.

If the resistance is greater than 3 ohms:

Locate a better ground on the base of the seat or at some other point in the cab.

“Fan fold” the excess ground strap and tie it with a wire tie to the back of the seat frame.

Make sure that you have left enough slack in the strap to accommodate the seat’s full

range of adjustment.

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