Additional Doc For EMH550 Register - MANUAL - HARDWARE - P7468 PDF

THIS IS CONFIDENTIAL INFORMATION.
THIS DRAWING AND DESIGN IS THE PROPERTY OF LIQUIP INTERNATIONAL PTY LTD.
IT MUST NOT BE COPIED OR REPRODUCED IN ANY WAY WHATSOEVER AND/OR
PASSED ON TO ANY THIRD PARTY WITHOUT WRITTEN AUTHORITY.
LIQUIP INTERNATIONAL PTY LIMITED - ENGINEERING DEPARTMENT - 13 HUME RD SMITHFIELD SYDNEY NSW AUSTRALIA 2164
PH: +61 2 9725 9000 FAX: +61 2 9609 4739 EMAIL: engineering@liquip-nsw.com.au
P7468
LIQUIP INTERNATIONAL
EMH550 SERIES
ELECTRONIC COUNTER
AND
PRESET CONTROL
FOR
FLUID METERS
Issue: B
January 2008
M:\Product-Info\EMHxxx\5-Installation-Fitting\EMH550_MANUAL_HARDWARE_P7468.doc Issue: B 25/1/08 Page 1 of 62

INFORMATION PERTAINING TO WORKING ON A TANK VEHICLE
1. Prior to working on a tank vehicle it must be degassed or certified to work on. Before working in a
tank compartment an appropriate device must be used to check for the presence of volatile gases.
2. Any work carried out on a tank vehicle must be done so in a non-hazardous area.
3. Before working on any electrical equipment on a tank vehicle power must be isolated either via the
battery isolation switch (BIS), by disconnecting the truck battery or by disconnecting the positive of
the electrical equipment.
4. Never weld on a tank vehicle unless all electronic equipment is completely disconnected electrically
from both the tanker and other equipment.
5. Hazardous conditions may be present when working with high voltage devices (such as gantry
monitors). Qualified technicians only should be servicing these devices.
6. Do not connect a battery charger or other pulsed power supply to the truck battery without first
isolating all electrical equipment as permanent damage may result.
7. Long sleeve and pants protective clothing should be worn at all times. Clothing must be non-static
generating. Any petroleum contact with skin should be washed off immediately.
8. Always follow manufacturer guidelines when working on electrical equipment. Failure to do so may
void warranty or cause damage.
INFORMATION PERTAINING TO INSTALLING EQUIPMENT ON A TANK VEHICLE
1. All electrical equipment and fittings must be suitable for use on a tanker and meet all local
regulations for operation.
2. Use high quality waterproof conduit and fittings to IP66 minimum for all wiring and junction boxes.
3. Use waterproof flexible compound such as Silastic in all glands and joints not available as waterproof
by design.
4. Mount all equipment away from direct spray areas such as behind the tyres and out of direct sunlight.
Always select the most sheltered aspect.
5. Ensure all installations adhere to appropriate safety standards and industry code of practice.
6. Coat all terminals, cable end and joints with non-conducting grease or Vaseline after final testing.
This will prevent corrosion.
7. Prior to crimping, check wiring connections are electrically correct. When crimping, make sure there
is good electrical contact between the wire strands and metal section of the crimp terminal. Pull on
the crimp to ensure a good connection has been made.
8. Cable ends may be crimped with ferrules for better connection. Do not solder the cable ends
(fatigues and corrodes). Pre-coat with non-conductive grease for corrosion protection.
9. At any point a cable is extended or joined to a standard cable assembly, all cable screens must be
connected to the chassis as well as being joined together at a star point. Insulate exposed screen
wire using heat shrink, terminate with an eye-terminal and attach to the junction box mounting screw.
If the junction box is mounted to a panel not electrically connected to the chassis, the screens must
still be joined together.
10. It is recommended the negative terminal of the battery be connected to the chassis.
11. Common grounding of a system is most important. Do not rely on common chassis grounding at
various points, run a full-length dedicated ground cable. Max resistance, battery ground to any
ground point to be 1Ω. Refer Liquip Tech Talk #48: Electrical Bonding on Tankers. The electrical
resistance between the tank and tanker chassis, prime mover chassis, or trailer undercarriage, and
between the tank and the connection of the tanker pipework to the delivery hose, shall not exceed
10Ω.

12. Always fit as much loose cable length into junction boxes and housings as practicable to allow for
future servicing.
13. When pulling multiple cables through conduit always consider using cable with one or two extra
conductors to allow for any future requirements.
14. Always completely segregate power and intrinsically safe wires into completely safe conduit and in
accordance with I.S wiring rules.
15. Carry out a complete wiring check for accuracy and continuity before connecting power to any
device.
16. All equipment must be supplied from a fused power supply.
17. Observe international and local legal requirements. In the event of conflicting instructions seek
qualified advice before proceeding.
18. Do not route communication cables past ‘noisy’ electrical apparatus such as solenoids and
alternators.
19. Check instruction manual for recommended cable type and torque settings.
20. Use specialised, genuine tools for all electrical work.
21. Mount equipment to clean, dry, bare surfaces on a metal bracket mounted to the chassis/sub-frame.
It is recommended the bracket be welded to the chassis/sub-frame to facilitate good electrical
contact.
22. Ensure adequate clearance around equipment being installed. This will provide for ease in future
maintenance.
23. When bolting equipment into place, the use of Teflon tape or anti-seize compound on threads is
advised.
24. Prior to welding a socket into a tank or pipe it is advised a pipe plug be inserted before welding to
prevent heat distortion of the socket. An anti-seize lubricant may be used to help with plug removal.
25. If possible run power wires directly from the equipment being installed to the battery isolation switch.
This will avoid the use of intermediary junction boxes ensuring proper voltage and grounding.
26. Fuses located in hazardous areas must be suited to that location.
27. Always allow suitable separation (at least 50mm) between intrinsically safe wiring and power from
line power source. Do not mix AC and DC power wiring (maintain barrier separation).

PART A
HARDWARE INFORMATION
AND
INSTALLATION

CONTENTS
1. GENERAL DESCRIPTION 6
2. MECHANICAL DESCRIPTION 7
3. PRECAUTIONS ON VEHICLE 9
4. INSTALLATION 10
5. CONNECTING A TICKET PRINTER 13
6. THE FRONT PANEL 15
7. SIMPLE FAULT FINDING 16
8. EXAMPLES OF TROUBLESHOOTING 200
9. MODE 1 - SETTING THE AVERAGE K-FACTOR (KO CAL) 233
A1 - EMH550, EMH550H ELECTRONIC REGISTER SPECIFICATIONS 255
A2 - ELECTRONIC REMOTE PULSER ERP100 277
A3 - ERP100 CONNECTION DIAGRAM 29
A4 - EMH550 WIRING DIAGRAM 300
A5 - RECOMMENDED CABLE TYPES FOR SYSTEM WIRING 323
A6 - SAMPLE DELIVERY TICKET 334
A7 - SAMPLE MANAGEMENT TICKET 345
A8 - SAMPLE SETUP TICKET 356
A9 - LIQUIP UNINTERRUPTIBLE POWER SUPPLY UPS100 (OPTIONAL) 367
A10 - KITS AND COMPONENTS TO MOUNT REGISTERS AND ELECTRONIC REMOTE PULSERS TO
VARIOUS METERS. 378
A11 - K-FACTOR AND SPEED OF EMH550 ON METERS 59
A12 - EMH550 COMPATIBILITY WITH TURBINE METERS 590
A13 – EMH550 COMPATIBILITY WITH STAR DP8340 PRINTER. 601
A14 – EMH550 MULTI-PRODUCT FEATURE. 612

1. GENERAL DESCRIPTION
The EMH550 series replaces LIQUIP’s EMH400 range of electronic registers. It features many more
functions and a greater processing power.
1.1 All of the EMH400 functions have been retained, including;
1.1.1 Connection to electronic ticket printer
1.1.2 Electronic Calibration
1.1.3 Non-linearity correction
1.1.4 Temperature compensation
1.1.5 Non volatile memory for storing set parameters.
1.2 The EMH550 has added functions such as;
1.2.1 A preset delivery/batch function that includes user selectable flow rate functions.
1.2.2 The addition of a second RS-232C port , with built-in software to communcate with a range
of devices including a range of printers, an in-cab Touch PC, remote displays, operational
commands from the truck cab, and other ports to accept information from temperature
transmitters and ‘foreign’ pulsers.
1.2.3 A self-test option that in conjunction with the Electronic Test Jig, allows the user to perform a
self test of the major components of the register. These include the Temperature reading,
the Opto board, both Communication Ports, both Relays, and the Output Pulse.
1.2.4 A separate pulse output that can be used to drive an auxilliary display.
1.2.5 A single pulse input mode that allows the EMH550 to be used with third party single wire
pulsers.
1.2.6 A programable automatic reset and print time-out.
1.2.7 Units selectable as either Litres or Gallons.
1.2.8 Selectable display resolution.
1.2.9 An accumulative total of Power Interrupts since the last management ticket.
Other programmable options detailed in “Software Settings Manual”.

Mechanically, the EMH550 can directly replace the EMH400 or the EMH300. Slight modifications need
to be made electrically as the EMH550 can support several remote devices.
The EMH550 still operates on 12 volts or 24 volts.

2. MECHANICAL DESCRIPTION
The EMH550 is a complete stand-alone unit and does not require external power control box (in opposite
to EMH500). It has been equipped with internal electronic circuit board that provides power filter and
supply, single solid-state relay for solenoid control, and some additional components for communication
ports, remote display, remote reset, remote pulser, etc. The register has two displays as standard and
can have the pulser built-in. In its simplest form it bolts on to any meter in place of the existing
mechanical counter.
2.1 Register housing.
A register mounted on a tanker may be exposed to severe environmental conditions including

exposure to water and vibration.
Water entry has been addressed primarily by eliminating the normal viewing window.
Construction is a shallow nylon body that contains all buttons and the main connection plug. A
clear high impact, polycarbonate top hat then forms the viewing windows. This means the entire
cover of the register has no potential leak points of any sort, nor any connections, so in the case
of impact damage replacement is cheap and simple.
All control buttons are of the sealed type with no through-spindle to allow leakage and the 24-pin
connecting plug and socket are a military specification waterproof type. The latter is also vibration
resistant and all connectors employed in the electronics are of the locking type to prevent
loosening. All screw fasteners are fitted with locking washers.
Pulser vibration may cause false readings if uncontrolled. Mechanically, movement of the pulse-
wheel is dampened by an internal wave spring. The primary control, however, is electronic,
employing three precisely spaced sensors that the software analyses, rejecting any spurious
counts.
All control buttons and sealed access ports for calibration purposes are mounted on the front face
for ease of use by the operator. Buttons are click-type to provide feedback to the user.
A 24-pin connector is rear-mounted and clearance is maximised by recessing the male into the
nylon housing and supplying a 90° female for the truck wiring connector.
As previously mentioned the register bolts directly onto the mounting of a Veeder Root mechanical
counter - simply fit the drive fork to suit the particular meter.
In the case of a Neptune meter, LIQUIP supply an adaptor EMH200-5 for equally simple bolt-on
conversion.
For housing diagram and specifications, refer Appendix A1. For drive forks, refer to Appendix A10.
• EMH550 is the standard version for moderate climate (-25°C to +55°C), W&M approved in the
USA, software ver.01.06.XX.
• EMH550H is the version for cold climate (-40°C to +55°C), LCD equipped with heater, W&M
approved in the USA, software ver.01.06.XX.
2.3 Remote Pulser, ERP100

It maybe preferred to have the register mounted away from the meter. In this case the register
internal opto connection to the main board must be disconnected and securely cable tied out of
harms way. The ERP100 is wired to the EMH550 via the junction box without further modification.
ERP100 is a self-contained pulser that can operate with the intrinsically safe power supply or
directly from the vehicle power of 9v to 30v.
Body mounting is the same pattern as Veeder Root pulsers for interchangeability. It can therefore
be driven off a Veeder-Root mechanical register: off the existing post-calibration gear drive train
by mounting on an adaptor plate: or by driving directly off the meter chamber main shaft.
Construction of body, cover and toothed wheel and shaft is in acetal, supported by a sealed-for-
life ball bearing. Friction damping is by an internal wave spring. The cover is screw-on for ease of
access with calibration-seal lug provided and o-ring water sealing. A maximum speed of 1,000
rpm is sufficient for all current applications when driving directly off the meter main shaft. There is
no minimum speed each tooth is counted.
For housing diagrams and specifications, refer to Appendices A3 and A4.
NOTE:
EMH550 can also work with third party remote pulsers as long as they produce output signal of
amplitude from 0V to at least +4V square or sine. Such a pulser must be connected to the input
line marked “P1”. The register must have enabled reading of the single pulse input (in the
management calibration menu “SInput=Y”).

3. PRECAUTIONS ON VEHICLE
Attention to details during installation is essential for correct operation of the unit. The following points
are emphasised in order to minimise any problems from “spikes” in the power supply or stray signals
which may be picked up from equipment such as the alternator or starter motor.
3.1 Take your power supply from the battery isolation switch, not from an intermediate source.
3.2 Run power supply in separate conduit to other equipment such as C.B. radio or solenoids.
3.3 Run power supply and signal conduits well clear of equipments such as the alternator and starter
motor.
3.4 Use only soldered joints or tool-crimped connections.
3.5 Do not weld on the vehicle with the register connected.
NOTE:
For further recommendation refer to the Information Pertaining to working on a Tank Vehicle at the start
of this manual.
3.6 When ever possible place the register in a shaded position on the truck. This will increase the life
span of the register displays and make them more readable.
Similarly use common sense in siting equipment away from positions exposed to flying stones,
heavy water spray and so on.
3.7 The construction of the EMH550 is rated to IP66 in its present format. Should improved water
sealing be required, we recommend the use of Dow Corning Silastic 1080 translucent silicone
sealant or equivalent on the base and the lid when reassembling after wiring. Follow the
manufacturer’s instructions and use Dow Corning OS2 or equivalent for cleaning before and after
the application.

4. INSTALLATION
• The EMH550 can be fitted to a tanker or gantry in a variety of ways and with a choice of ancillaries.
4.1.1 As a stand-alone unit

Remove the existing mechanical counter and bolt the EMH550 with built in pulser and the
corresponding adaptor. It can be used as a counter only or with the preset batch operation.
4.1.2 Remote Pulser and Separate Counter

The remote pulser can be mounted directly off the meter drive shaft, on the normal drive off
the calibration gear output or off the side of the register. An indicator can then be mounted
where most convenient, whether used as a simple counter or with the preset batch
operation.
Refer Appendix A10 for various mounting kits for Remote Pulser and stand alone mounting.
4.1.3 Tankerside or rear external mounting is standard, where the driver can see and use the
register as usual. The EMH550 is weather proof, vibration resistant and EMC tested.
4.2 All external devices are connected to the EMH550 directly. This includes the connection of
communication devices such as Ticket Printers or a Touch PC; as well as the connection of a
Remote Pulser ERP100; or a Remote Reset (bidirectional); a Temperature Probe; Calibrated
Pulse Output; and Air Solenoid. A detailed wiring diagram is given in Appendix A5, and
recommended cables in Appendix A5.
The EMH550, along with the communication and connections between the other devices, are
tested before leaving LIQUIP.

4.3 Pre-Delivery Test Sequence

Following installation, check the Register before attaching it in its final position:
4.3.1 Turn the Isolation Switch on the truck to ON. The register should light up and display the
company name on the bottom display and the dispensed volume on the top display (which
should read 0.0 at this stage).
4.3.2 Turn the shaft by hand to check the register is functioning and the display is changing.
4.3.3 Start the Engine. The volume dispensed and the accumulative total should read as before.
Again rotate the shaft by hand and check that the Register is counting.
4.3.4 To ensure the register will still work with various equipment on the truck, turn on and operate
(if available):
• Engage/disengage P.T.O.
• Switch lights on/off
• Switch radio on/off
• Switch on and operate CB.
• Switch on and operate telephone
• Switch on and operate remote transmitter
• Turn engine on/off.
Check the register at each operation and ensure that there is no change in the reading
unless the shaft is rotated by hand. At the end of these tests, print a Delivery Ticket,
Management Ticket, and Setup Ticket to check the printer (refer to front panel operation
section 6).
4.3.5 Bolt the register into place.
4.3.6 Before lead sealing the MODE and CAL buttons, run through all modes to ensure that all the
required features are enabled and those that are not required are disabled.
Note: If the top cover of the EMH550 is removed, care must be taken when screwing the cover screws
back into place. These are self-tapping screws. Make sure the screw are aligned with the thread that has
already been made and do not over tighten the screws. Stripped threads are not covered under
warranty.

4.4 EMH400 To EMH550 Conversion Wiring
When replacing an EMH300 or EMH400 with an EMH550, electrical modifications must be made due to
the difference in wiring. This difference in wiring is due to the EMH550’s ability to simultaneously handle
multiple external devices.
When replacing an older model Register with a new EMH550, there is no need to re-calibrate if the
existing K-factor (or K-factors in the case of non-linearity) is known. The following conversion can be
performed:
K550 = K302 × 3/2 = K400 × 1/2
Enter this new K-factor into the EMH550 by following the procedure outlined in calibration instructions.

5. CONNECTING A TICKET PRINTER

Installation and configuring a ticket printer is dependent on the model of the printer. The EMH550 can
support the:
• TM-295,
• CTM-290,
• Liquip Blaster Printer.
All ticket printers are available in +24V only; therefore a voltage doubler will need to be used if run off a
+12V source.
Note: Always mount the ticket printer in the cabin.
5.1 Installing the TM-295 and CTM-290
5.1.1 Turn the Ticket Printer OFF and set the DIP switches as described below for the appropriate
printer (for different settings refer to software details). These switches are located under the
base of the printer.
ON
1 2 3 4 5 6 7 8 9 10
FIGURE 5.1 - DIP SWITCH SETTINGS FOR THE TM-295 TICKET PRINTER
(FOR 1200 BAUD RATE)
ON
1 2 3 4 5 6 7 8 9 10
FIGURE 5.2 - DIP SWITCH SETTINGS FOR THE CTM-290 TICKET PRINTER
(FOR 1200 BAUD RATE AND U.K. CHARACTER SET)
5.1.2 Check that your Ticket Printer has an ink ribbon fitted.
5.1.3 Set up the comm ports and the printer type in the register (refer to software).

5.2 Installing the Liquip Blaster Printer
5.2.1 The Liquip Blaster Printer has no DIP switches therefore once it is wired up, you only have to
setup the register (refer to software).
5.2.2 N.B.: Always set the EMH550 to 9600 baud rate when using the Liquip Blaster Printer.
5.3 Checking the Operation of Your Printer (typical)
5.3.1 Supply power to the Register and Ticket Printer, checking for the GREEN (POWER) LED on
the printer.
5.3.2 Press the RELEASE button and note that the GREEN (RELEASE) LED appears. Insert the
ticket so that the top of the top line is aligned with the arrow on the side of the printer.
NOTE: If the ticket is inserted correctly, the RED (PAPER OUT) LED will go out, however, if
the RED LED remains ON, remove and insert the ticket again until NO RED LED is visible.
5.3.3 Perform a delivery run or simply rotate the Register by hand. Print a Delivery Ticket by
presing RESET not sooner than 6 seconds after the end of the delivery (refer to Front Panel
Operation section 7.3).
5.3.4 Press the RELEASE button on the ticket printer to release the ticket from the printer.
Compare this ticket to the example ticket which can be found in Appendix A6.
5.4 Connecting multiple registers to one printer.

Connect wires in the following way:
• EMH's transmit wires joined together to the receive input of the printer,
• EMH's receive wires joined together to the transmit output of the printer,
• EMH's ground wires joined together to the ground input of the printer,
• Do NOT join shields of communication cables – each individual cable must have its shield
connected to the ground inside the junction box ONLY.

6. THE FRONT PANEL

The front panel consists of the two displays, BATCH, STOP/START, TOTAL, RESET and the MODE
and CAL buttons.
6.1 When TOTAL is pressed while in the standby mode the accumulative total will be displayed on the
top display. Pressing TOTAL immediately followed by STOP/START will show decimal part of the
accumulative total.
6.2 While in standby, pressing BATCH will allow the user to change the batch size only if this option
has been enabled in the Management Menu. To changing the batch size from the front panel refer
to software. If this option has not been enabled, pressing BATCH will be of no consequence.
BATCH pressed during delivery will show the preset volume setup for the current delivery.
6.3 Pressing RESET while in the standby mode will print out a delivery report and reset the register to
zero.
6.4 Pressing TOTAL immediately followed by RESET while in standby mode will print a management
ticket. This will reset the power interrupts and the delivery number to zero, however, will not reset
the register to zero.
6.5 When a pipeline valve is fitted, pressing STOP/START will begin a delivery if one is not already in
progress, otherwise it will stop a delivery. A delivery can be restarted from the point at which it was
stopped simply by pressing STOP/START. The preset ramping is not used as the register can
control only one solenoid. It can however provide restriction of flow rate by switching the solenoid
on/off with short pulses.
6.6 Pressing TOTAL five times in five seconds allows the user to change the Specific Gravity value,
view the Temperature Probe reading, change the Time and Date, and view the Meter Number.
Refer software for details.
6.7 During a delivery, the top display will show the volume delivered so far, while the bottom display
will show the volume left to dispense according to the preset batch size. If no batch size has been
entered, then the bottom display will show the company name.
6.8 Pressing RESET while a delivery is in progress will display the current flow rate for 5 seconds
before returning to the volume display.
6.9 Pressing TOTAL while performing a delivery will display the accumulative total. This figure will be
continuously changing as a delivery is in progress.
6.10 Pressing TOTAL twice while either in standby mode or while a delivery is in progress will display
the unconverted volume for five seconds.

7. SIMPLE FAULT FINDING

Problem Probable Cause Corrective Action
Display lights up but there are no Faulty display Notify Liquip
digits shown.
Display does not light up or cuts 1. No power to display. 1a. Display not connected to main PCB.
out. 1b. Faulty display.
2. No power to register. 2a. Register not connected to EJB101.
2b. D-connector not connected to PCB correctly.
2c. Power not on.
Button not working when display 1. No power to button. 1a. Button not connected.
is on. 2. Button faulty.
Pulser reading incorrect volume. 1. Incorrect K-factor 1. Correct K-factor.
2. Drive shaft incorrectly connected. 2. Check drive shaft.
3. Problem with opto board. 3. Notify Liquip.
No power to register. 1. Faulty wiring. 1. Check wiring.
2. Faulty in-line fuse. 2. Check fuse.

ERROR MESSAGES
ITEM MESSAGES DESCRIPTION COMMENTS/ACTIONS
1. “ “ on top left of Remains steady when temperature conversion is enabled and - Check the temperature of the product.
upper display indicates volume converted to +15 deg C. - Check the wiring between the register and the
When blinking, either temperature probe.
- Temperature probe is disconnected (or connection may be - Check the functionality of the temperature probe.
intermittent)
- Temperature probe is faulty
- Probe is functioning correctly, but product temperature exceeds
+65 deg C.
2. “ | “ on top left of When Steady, indicates Special operation, Mode 1 is active and - Special function, uncompensated volume is
upper display temperature compensation is enabled. displayed. All calculations are based on
When blinking, either uncompensated volume
- Temperature probe is disconnected (or connection may be
intermittent)
- Temperature probe is faulty
- Probe is functioning correctly, but product temperature exceeds
+65 deg C.
3. “no probe” When displaying the temperature of the product and this message - Check the temperature of the product
appears, then either - Check the wiring between the register and the
- The temperature probe is disconnected temperature probe.
- The temperature probe is faulty - Check the functionality of the temperature probe.
- The temperature of the product exceeds approx. +65°C.

4. “ data error” Some of the data stored in the memory was corrupted and replaced - Check your power supply for glitches, spikes, etc.,
with a default value. and then restore your original settings using the
calibration menus.
5. “error” K-factor value has been set up outside the permissive range (1.0000 - Recalibrate ensuring that the k-factor is within the
- 999.9999) during manual or automatic calibration. permitted range.
6. “correctn” During the calibration of non-linearity correction flow rates, Fa to Fh - Recalibrate ensuring that Fa ≤ Fb ≤ Fc.....≤ Fh.
have not been set up in ascending order and the register has - Make sure that Kb<Ka+0.25% if Kb>Ka and
rearranged them automatically, or resulting K-factors differed by Kb>Ka-0.25% if Kb<Ka, etc… and Kh<Kg+0.25%
more than ± 0.25% and the register has adjusted them automatically. if Kh>Kg and Kh>Kg-0.25% if Kh<Kg.
7. “port1” or “port2” When handshaking is enabled and you are trying to print a docket on - Load a sheet of paper (larger in size if necessary)
“no paper” the Epson printer connected to either comm. Port 1 or 2. into the printer.
- No paper is inserted in the printer
- The paper is not the correct size
8. “port1” or “port2” Appears if handshaking is enabled and attempting to print on the - Check that the printer or Touch-PC is switched on
“comm err” Epson printer or communicate with the Touch-PC then either: - Check that the printer or Touch-PC is physically
- The printer or Touch-PC is switched off connected to the port specified in the Comm menu
- The printer or Touch-PC is not connected to the specified port - Check the wiring between the register and the
- The connection between the register and the printer or Touch-PC is printer or Touch-PC.
faulty. - Enter calibration mode and check setup for the
- Wrong setup in calibration for the communication port. communication port.
9. “port1” or “port2” When handshaking is enabled and you are printing a docket on the - Check that the printer is switched on
“prnt err” Liquip Blaster printer, then - Check that the printer is physically connected to the

- The printer is switched off port specified in the Comm menu
- The printer is not connected to the specified port - Check the paper in the printer.
- The connection between the printer and the register is faulty - Enter calibration mode and check setup for the
- Indexing has been enabled, but there is no paper, or a paper jam communication port.
has occurred in the printer.
- Incorrect setup in calibration for the communication port.
10. “opto off” - Neither the internal pulser nor the remote pulser are connected or - Check system wiring configuration
properly selected - Replace remote pulser or register (when using the
- The connection between the register and either the remote pulser internal pulser).
or internal pulser, is faulty
- Either the remote pulser board or the internal pulser board is faulty.
11. “opto fty” - The connection between the register and either the remote pulser - Check system wiring configuration
or internal pulser, is faulty - Replace remote pulser or register (when using the
- Either the remote pulser board or the internal pulser board is faulty. internal pulser).
12. “wrng dir” The shaft is rotating in the opposite direction to that setup in the - Change the direction of rotation in the
Management Menu. Management Menu.
NOTES: The register has got in-built protection against exceeding of maximum capacity of the counter. If delivery passes 90 percent of
maximum capacity of the counter, i.e. 90000 litres when operating at its standard resolution of 0.1L, the register will shut the control relay down
to terminate current delivery and will not allow starting a new one until the volume is cleared. The display panel will blink to draw attention of the
operator.

8. EXAMPLES OF TROUBLESHOOTING
8.1 Temperature Probe
The EMH550 is designed to work with the Temperature Probe (Part No: 4155). No calibration needs
to be performed by the user, as the register is already preset with the following data:
At 15°C, Probe resistance = 105.775Ω

At 45°C, Probe resistance = 117.325Ω.
Using the graph on the following page and the following procedure, the user can test the accuracy
and the functionality of any given probe.
8.1.1 Test Procedure:-

1. Remove the plug from the rear of the EMH550.
2. With a resistance meter (multimeter set to ohms and properly zeroed), measure the
resistance between pins N and P on the plug. (Do not put the meter across any pins in
the socket of the register or any wires while the plug is connected as this may damage
the register
3. Record this measurement.
4. Determine the temperature of the probe by using a thermometer to measure the
probes environment, i.e. if the probe is immersed in a liquid, measure the temperature
of the liquid.
5. Record this result.
6. Using the Figure, draw a vertical line from the horizontal axis using the value from step
3.
7. Draw a horizontal line from the vertical axis using the value from step 5.
8. If the two lines intersect on the line, the probe is reading correctly and its accuracy can
be derived from its deviation from the nominal value. If the lines do not intersect on the
line, repeat the test and check your calculations. If the reading is confirmed to be
wrong, the probe or its wiring is faulty and further investigation will be required.

FIGURE - TEMPERATURE VS PROBE RESISTANCE

8.2 Ticket Printers and Touch PC
If a Ticket Printer or Touch PC is connected to one of the Communication Ports and does not function
correctly;
8.2.1 Check that the register has been setup correctly (refer to software for Comm Port setup
procedure).
8.2.2 If using a TM-295 or CTM-290, check that the correct DIP switch settings have been
selected.
8.2.3 Check that power connections are correct, note that all printers operate from +24V.
8.2.4 If using a TM-295 or CTM-290, check that the ribbon is correctly installed. The Liquip
Blaster Printer has a thermal head.
8.3 Opto Board
8.3.1 A failure of the opto-board or wiring between opto and main board will be accompanied by
a message on the Register’s display of “OPTO OFF”. A defect causing missing pulses will
cause display of “OPTO FLTY”.
8.3.2 If installing the EMH550 for the first time, check that switch 4 on the DIP Switch on the
main board is ON. This enables the opto-board.
8.3.3 An intermittent failure will give an incorrect reading. This may be due to a component
failure on the board or to a misaligned sensor. Display will be “OPTO FLTY”.
8.4 Remote Pulser
The EMH550 is designed to work with LIQUIP’s ERP100 Electronic Remote Pulser. This is an
electronic pulse transmitter and drive unit that is used when the register is located away from the
meter (such as on the back of a truck). The Remote Pulser serves the same purpose as the opto-
board in the EMH550. Due to its similar design and construction, operation and diagnosis is as
above.

9. MODE 1 - Setting the Average K-factor (KO CAL)

This mode allows the user to manually set or to automatically calculate the K factor. It is required that
a volume be dispensed into a certified measuring container and that this value then be compared to
the reading on the register.
9.1 From the delivery mode, press CAL to enter into the main menu.
9.2 K0 CAL? N, will appear with the cursor flashing on the N. This indicates that this option can be
changed. If you are already in the main menu, toggle through the options by pressing TOTAL
until this option is reached.
9.3 Press TOTAL to toggle this option to Y (for yes). This allows the user to change the K factor.
9.4 Press STOP/START to enter this option.
9.5 XXX.XXXX appears on the display with the cursor flashing on the left most digit.
9.6 To enter a new K factor manually:-
9.6.1 The new K-factor to be entered must firstly be calculated.
New K-factor = (Register Reading) × (Old K-factor)
Measuring Container Reading
9.6.2 The user can change the value of the first digit by pressing TOTAL.
9.6.3 Press RESET to toggle to the next digit and so on for each digit.
9.6.4 When the K factor has been set, press STOP/START to save this option.
9.6.5 Press MODE. The display will now read K0 ACN? N, with the cursor flashing on the N. This
option is asking the user if they want to automatically calculate the K factor. Since the K factor
has already been manually set, leave this option as N (for no).
9.6.6 Press MODE to return to the Main Menu.
9.7 To automatically calculate the K factor, follow steps 9.1 to 9.5, then:
9.7.1 Press MODE. The display will now show K0 ACN? N, with the cursor flashing on the N. This
indicates that this option can be changed.

9.7.2 Press TOTAL to toggle this option to Y (for yes).
9.7.3 Press STOP/START to enter this option.
9.7.4 The display will now show XXXXX.X with the cursor flashing on the left most digit. This is the
volume which was dispensed in the previous delivery, according to the register. This value may
differ to the reading on the approved test tank. Enter the true value of the delivery according to
the reading of the test tank.
9.7.5 Press TOTAL to set the first digit.
9.7.6 Press RESET to select the next digit, and so on until the true volume reading has been
entered.
9.7.7 Press STOP/START to enter this value.
9.7.8 The register will now calculate the new K factor. This new K factor will momentarily be
displayed, followed by WAIT, then SAVED, before returning the display to the previously
dispensed volume measured by the register. Note that in this procedure, the user was not
asked to perform any calculations.
9.7.9 Press MODE to return to the Main Menu.
9.8 Press CAL to return to delivery mode.
9.9 It is recommended that a re-test be done using at least three calibration runs to verify the
result. If recalibration is required, repeat steps 9.1 to 9.6 (manual calculation), or steps 9.1 to
9.7 (for automatic calculation).

A1 - EMH550, EMH550H ELECTRONIC REGISTER SPECIFICATIONS

Microprocessor: 32 bit µP running at 16.7MHz
Program Memory: 256K × 16 bits EPROM
Operating Temperature: -25°C to +55°C, or -40°C to +55°C (model "H")
Size: 212 x 212 x 165mm
Weight: approx. 2.2kg
Displays: 2 x 8 digits, 15mm high
Power: 10Vdc - 30Vdc @ 400mA max. polarity protected
Temperature Compensation: -15 to +55°C for all products
Temperature Probe: PT100 100Ω@0°C
Product Density: 0.550 - 0.600 kg/l for LPG,

0.653 - 1.075 kg/l for other products
Communication: 2 x RS232C Ports can be used to communicate with a PC or other

serial device such as a modem or printer.
PC: Software is written for Touch-PC on-line communication.

Commands that can be interrogated include: resetting the meter,
pre-setting the batch quantity and requesting the current delivery
quantity. Refer software section for detail.
Printer: Epson CTM-290 or TM-295, Liquip Blaster.
Pulse Input: Will accept 3-channel pulses of 60° (Electrical) separation from
ERP100 pulser or single pulse from foreign pulser.
Pulse Output: This is an Open Drain, active-low output, signal calibrated to 10

pulses/litre, where the pulse width can be set up to either 2 ms or
0.2 ms, (either 166Hz or 1.66kHz max. frequency).
Two Stage Solenoid Output: Current source, 1A max, unregulated voltage - internally taken from
the power input. Solenoid to be connected between this output and
the Ground. Additional in-line fuse (1A, antisurge) is strongly
recommended.
External Reset: This is an input/output signal.


A2 - ELECTRONIC REMOTE PULSER ERP100
Power Consumption: +9 to +30Vdc; 100mA
Output Voltage Internally pull up to +5V through 4.7kΩ. However, it can be pulled up
to 30Vdc, maximum load current 100mA.
Rotation Bi-directional.
Input Shaft Speed: 1000 rpm maximum.
Torque: 120 g-cm maximum.
Output Pulse: Three channels lagging each other by 60 degrees, with a 50% duty
cycle and 25 evenly spaced slots allowing 150 changes of state per
revolution.
Operating Temperature: -40°C to +80°C.
Weight: 300g for assembly less terminator.
Materials: Housing & drive are acetal, Buna nitrile seals

Brackets and screws Zinc Plated or 304 Stainless steel.
Associated Equipment: EMH400 and EMH550 series electronic registers

EJB101 Power Junction Box.


A3 - ERP100 CONNECTION DIAGRAM

A4 - EMH550 WIRING DIAGRAM
NOTE: EMH550 and EMH600 wiring diagrams are identical.


A5 - RECOMMENDED CABLE TYPES FOR SYSTEM WIRING
ITEM USAGE CABLE TYPE COMMENTS
1. EMH550 to junction 25 Core, 25 x 7/0 Foil shielded with Supplied

box drain wire, 10.7mm N.O.D.
Polyurethane sheath
2. Power Supply 2 Core Shielded (16 x 0.2) Foil Rated @ 24Vdc5A or

shielded with drain wire. (Red/Black) 12Vdc 5A
3. RS232 Port 1 or 2 4 core 24AWG 7 x 0.2 Foil shielded Wire colours inside are
with drain wire blue, white, red and black
COMM 1 : Sheath Black
COMM 2 : Sheath BLUE
4. Temperature Probe N/A
5. Hi-Speed Pulser 5 core 24 AWG (7 x 0.2) foil shielded

cable with drain wire
6. Remote reset Single core cable (7 x 0.2) Standard cable
7. Pulse Output Single core cable (7 x 0.2) Standard cable
8. Solenoid (each) 2 Core Shielded (16 x 0.2) Foil

shielded with drain wire. (Red/Black)

A6 - SAMPLE DELIVERY TICKET
LIQUIP
DATE 08/01/99
TIME 14:02
CONVERTED TO +15°C
ACCUM. TOTAL 00545750.1 LITRES
QUANTITY 01009.6 LITRES
METER NUMBER 0000
DELIVERY NUMBER 86
NOTE: If temperature compensation has not been enabled, “converted to +15°C” will not appear on
the delivery ticket.

A7 - SAMPLE MANAGEMENT TICKET
LIQUIP
DATE 08/10/97
TIME 14:03
DENSITY 0.000 kg/L

K-FACTOR 015.0000
NON-LINEARITY CONVERTION
Fa=00100 Ka=015.0752
Fb=00250 Kb=015.1135
Fc=00000 Kc=015.0000
Fd=00000 Kd=015.0000
Fe=00000 Ke=015.0000
Ff=00000 Kf=015.0000
Fg=00000 Kg=015.0000
Fh=00000 Kh=015.0000
ACCUM. TOTAL 0054750.1 LITRES

TOTAL DELIVERIES 86
POWER INTERRUPTS 071
METER NUMBER 0000
NOTE: If the non-linearity function is disabled, i.e. Fa=00000, then the ticket would read
NO NON-LINEARITY CORRECTION
and the values of Fa to Fh and Ka to Kh would not appear.

A8 - SAMPLE SETUP TICKET
-----------SETUP ver.01.06.01--------------
COMPANY NAME......................LIQUIP
METER NUMBER......................0000
DATE.....................................02/11/2005
DATE_FORMAT........................DD/MM/YY
TIME......................................14:08
K0-FACTOR.............................015.0000
PRODUCT TYPE.......................LPG
DENSITY MAN.ENTERED......……0.000 kg/L
TEMPERATURE CONV............…DISABLED
UNCONVERTED VOL.............….N/A
UNITS.....................................LITRES
RESOLUTION..........................0.1 L
ACCUM. TOTAL....................…00545750.1 L
POWER INTERRUPTS...............000
DIR OF ROTATION...................ANTICLOCKWISE
SINGLE PULSE IN....................DISABLED
REMOTE DENS.CAL..............….ENABLED
REMOTE CLK CAL…..............….ENABLED
REMOTE BATCH CAL............….ENABLED
PULSE OUTPUT.....................…HIGH SPEED
RESET TIMEOUT..................….000 SEC

REMOTE RESET.......................ENABLED
PRESET VOLUME...................…01000.0 L
RAMP UP..............................…040 L
RAMP DOWN...........................060 L
FLOW RATE START...............….10000 LPM
FLOW RATE MAX...................…10000 LPM
FLOW RATE STOP..................…10000 LPM
N/PULSE TIMEOUT.................…20 SEC
OVERSHOOT............................00.0 L
PRINT DELAY…......................….N/A
AIR BLOW……….....................….N/A
PORT 1....................................TOUCH-PC, 1200 , ACK
PORT 2....................................CTM-290 , 1200 , ACK
INDEX-PORT 1..........................N/A
INDEX-PORT 2..........................NO
DEL.TICK.COPIES..................….N/A
SPECIAL DOCKETS.................….N/A,N
DATA BLOCK….......................…N/A,N/A
SPACE LINES…..........................N/A,N/A
NEGATIVE ACK.............…..........Y,N/A
EMH400 EMULATION......…....…..N,N/A
NON-LIN CORRECTN.......….....….DISABLED
Fa..........00000, Ka-FACTOR..........015.0000
Fb..........00000, Kb-FACTOR..........015.0000
Fc..........00000, Kc-FACTOR….….…015.0000
Fd..........00000, Kd-FACTOR..........015.0000
Fe..........00000, Ke-FACTOR..........015.0000
Ff........…00000, Kf-FACTOR..…..…..015.0000
Fg..........00000, Kg-FACTOR..........015.0000
Fh..........00000, Kh-FACTOR..........015.0000
NOTE: The first line of the docket shows current version of the software.
A9 - Liquip Uninterruptible Power Supply UPS100 (Optional)

Liquip uninterruptible power supply unit, UPS100, has been designed to maintain a continuous supply
of power to the EMH550 register.
Version UPS100-240 operates with 240Vac mains voltage, UPS100-110 with 110Vac mains voltage.
The unit can function in a temperature range of -30°C to +50°C.
The internal lead-acid battery is capable of supplying power to the EMH550 system for up to 2 1/2
hours after mains power shut down.
The battery requires a charging time of 10 - 12 hours to reach its full charge; otherwise the period of
battery backup for the system will be shorter.
The power output connector is protected by a 1A antisurge fuse and can be switched off without
interrupting the charging of the internal battery.
The unit is equipped with a voltage free relay contact set, activated immediately after mains power
shut down and protected by a 1A antisurge fuse. It can be used with other remote alarm equipment,
for example; lights, siren, radio modem, computer system, etc.
The three indicators on the front panel are as follows:

• “ALARM” is on when mains power is shut down and the UPS100 is supplying power from the
internal battery.
• “CHARGED” is on when the internal battery is fully charged and no power is drawn from the
power output terminal.
• “CHARGING” is on when the internal battery is being charged and/or power is drawn from the
power output terminal.

A10 - Kits and Components to Mount Registers and Electronic Remote

Pulsers to Various Meters.
Mounting of Electronic Registers to Meters with calibrators.

1. Top mount to LC meter with calibrator.
2. Top mount to Neptune meter.
3. Top mount to SBM meter.
4. Top mount to Smith meter.
Mounting of Electronic Registers to Meters without calibrators.

5. Top mount to LC meter - to suit hexagon drive.
6. Top mount to LC meter - to suit old drive.
7. Top mount to Sampi meter.
Mounting of Electronic Remote Pulsers to Meters with calibrators.

8. Top mount to LC meter with calibrator.
9. Top mount to Neptune meter.
10. Top mount to SBM meter.
11. Top mount to Smith meter.
Mounting of Electronic Remote Pulsers to Meters without calibrators.

12. Top mount to LC meter - to suit hexagon drive.
13. Top mount to LC meter - to suit old drive.
14. Top mount to Sampi meter.
Mounting of Electronic Remote Pulsers onto the front of Meters driving straight of rotor shaft.
15. Direct mount to SBM meter.
16. Direct mount to LC meter.
17. Mounting of Registers to LC meters.
Notes:
1. Sampi Meters use the similar kits as per the old style LC Meters for top mounting except for the
adaptor bracket. Direct mounting is also similar except for the drive dog.
2. Many LC meters have non-detachable calibration covers, in which the adaptor bracket will not fit
due to the SBM mounting holes on the adaptor bracket. There are two versions of LC M5 & M7
meters, (with and without detachable covers). The mounting will only fit detachable covers.
3. Various models of Sampi meters may have problems when the ERP100 is directly mounted to the
front of the meter. Consult Liquip if direct mounting is required.





















A11 - K-Factor and speed of EMH550 on Meters
1. LC Meters & Speeds –

Meter characteristics are as follows;
US Gallons Litres
M5 M7 M5 M7
Max flow rate 60 100 228 l/m 380 l/m
Max RPM of main output shaft. 245 555 245 555
Revolutions per gallon 4.079 5.555 - -
Revolutions per litre - - 1.0775 1.4674
Pulses per rev of pulser wheel. 150 150 150 150
K Factors (nominal) 612 833 162 220
If vertical drive used with 1:2 bevel gears then: -

RPM of vertical shaft 122 278 122 278
K Factors (nominal) 306 416 81 110
Oilmeter/Avery Hardoll/Satam meters
Litres
SBM75 SBM150
Max flow rate l/min 550 1550
Max RPM of main output shaft. 300 430
Revolutions per litre 0.6 0.287
Pulses per rev of pulser wheel. 150 150
K factor (nominal) (from 150 pulses X (revs/min / litres/min) 90 43
2. Neptune Meters.
These meters do not have calibrators in the driveline and the EMH550 simply replaces
the Neptune register.

A12 - EMH550 Compatibility with Turbine Meters
Electrical compatibility of EMH550 with the turbine meter depends on the type of proximity
sensor used in it. If it sends out an electrical signal of amplitude 0V to at least +4V (with
square or sine wave shape), no interface is necessary and the user need only select the
“single pulse input” in the calibration menu of the register.
If the signal from the proximity switch is not amplified, a special interface (amplifier) is
required for the register.
Using a standard turbine meter (with k-factor 224.30 P/L) at the maximum flow rate of
250LPM there is a frequency of pulses: 250x224.3/60 = 934.6Hz. This is well below the limit
for the EMH550 register, which can work up to 2550Hz.

A13 – EMH550 Compatibility with STAR DP8340 printer.

With minor modifications to the wiring and correct settings the EMH550 register will also work
with STAR DP8340 line printer.
Interface Wiring
F-GND 1
TXD 2 TXD
RXD 3 RXD
RTS 4
CTS 5
DSR 6
S-GND 7 S-GND
DTR 20
DP8340S EMH500
Interface Conector Interface Conector
OFF--ON
DIP-SW1-1
SW1-2
SW1-3 EMH500 - Comms Settings
SW1-4
SW1-5 Dip Switchs all set to ON Set printer typr to TM295.
SW1-6 Factory Default
Baud Rate 9600
SW1-7
ACK N
SW1-8
IND N
DIP-SW2-1
SW2-2
SW2-3
SW2-4

A14 – EMH550 multi-product feature.
The EMH550/550H register can be supplied with special version of software (series 01.05.XX)
that allows for use with the same meter calibrated for several different products and individual
K-factors selected by specific product name.
Such system must be equipped with a ticket printer and power-operated valve in the outlet line
between the meter and the hose reel, controlled by electric signal from the register relay – a
simple fully open or fully closed ball valve is recommended.
Typical operating procedure involves tasks in the following order:

• Select product (outlet powered valve closed),
• Press [Start] button (outlet powered valve closed), register requests for confirmation of
product name,
• Press [Start] again to confirm,
• Outlet powered valve opens and delivery can commence,
• Delivery
• Delivery stops when trigger nozzle is closed,
• Press [Reset] button to end delivery, print ticket, reset display to zero,
• Outlet powered valve closes.
NOTES:
• In order to select the product the operator should press TOTAL button 5 times in 5 seconds while the
register is in standby mode and it has been reset i.e. delivery docket printed, indicator shows 0.0
litres.The register will display “Product:” shortly followed by the product name as per internally stored
data base. The operator can select the product by pressing the TOTAL button and accept the choice
by pressing the START button.
• As long as the delivery has not been started the operator can select different product. Delivery is
started as soon as the indicator shows volume bigger than 0.0 litres. Once it happens the operator
cannot select another product. The delivery must be completed and the docket printed.
• There is possibility of checking which product has been selected if the register is in standby mode
but delivery not completed i.e. product flow has stopped but the docket has not been printed yet – in
this case the operator can press the TOTAL button 5 times in 5 second and the register will show on
the display the current product name for this delivery.
• There is no option of showing the product name while the product is flowing.
Ref. Software settings manual for more details.

PART B
SOFTWARE

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THIS IS CONFIDENTIAL INFORMATION.

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INFORMATION PERTAINING TO WORKING ON A TANK VEHICLE

INFORMATION PERTAINING TO INSTALLING EQUIPMENT ON A TANK VEHICLE

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5. CONNECTING A TICKET PRINTER 13

6. THE FRONT PANEL 15

7. SIMPLE FAULT FINDING 16

8. EXAMPLES OF TROUBLESHOOTING 200

9. MODE 1 - SETTING THE AVERAGE K-FACTOR (KO CAL) 233

A1 - EMH550, EMH550H ELECTRONIC REGISTER SPECIFICATIONS 255

A2 - ELECTRONIC REMOTE PULSER ERP100 277

A3 - ERP100 CONNECTION DIAGRAM 29

A4 - EMH550 WIRING DIAGRAM 300

A5 - RECOMMENDED CABLE TYPES FOR SYSTEM WIRING 323

A6 - SAMPLE DELIVERY TICKET 334

A7 - SAMPLE MANAGEMENT TICKET 345

A8 - SAMPLE SETUP TICKET 356

A9 - LIQUIP UNINTERRUPTIBLE POWER SUPPLY UPS100 (OPTIONAL) 367

A11 - K-FACTOR AND SPEED OF EMH550 ON METERS 59

A12 - EMH550 COMPATIBILITY WITH TURBINE METERS 590

A13 – EMH550 COMPATIBILITY WITH STAR DP8340 PRINTER. 601

A14 – EMH550 MULTI-PRODUCT FEATURE. 612

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1.1 All of the EMH400 functions have been retained, including;

1.1.1 Connection to electronic ticket printer

1.1.2 Electronic Calibration

1.1.3 Non-linearity correction

1.1.4 Temperature compensation

1.1.5 Non volatile memory for storing set parameters.

1.2 The EMH550 has added functions such as;

1.2.6 A programable automatic reset and print time-out.

1.2.7 Units selectable as either Litres or Gallons.

1.2.8 Selectable display resolution.

Other programmable options detailed in “Software Settings Manual”.

The EMH550 still operates on 12 volts or 24 volts.

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2.1 Register housing.

A register mounted on a tanker may be exposed to severe environmental conditions including

2.3 Remote Pulser, ERP100

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For housing diagrams and specifications, refer to Appendices A3 and A4.

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3.4 Use only soldered joints or tool-crimped connections.

3.5 Do not weld on the vehicle with the register connected.

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4.1.1 As a stand-alone unit

4.1.2 Remote Pulser and Separate Counter

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4.3 Pre-Delivery Test Sequence

4.3.5 Bolt the register into place.

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4.4 EMH400 To EMH550 Conversion Wiring

K550 = K302 × 3/2 = K400 × 1/2

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