M-614(I)

RML2000

Neptune RML2000
Mass Flowmeter
Installation Manual

IMPORTANT: To ensure proper installation of this product, thoroughly review the information in this
revision of the manual. Information is subject to change as new features are implemented. Failure to
follow instructions may result in system malfunction.

www.redsealmeasurement.com
 WARNINGS, CAUTIONS AND NOTES
Throughout this manual you will see WARNINGS, CAUTIONS and NOTES. They are here for your
benefit and warrant attention. By paying careful attention to them you can prevent injury and
possible equipment damage.

Below are examples:

WARNINGS: INFORM THE READER OF POSSIBLE BODILY INJURY IF PROCEDURES ARE

NOT FOLLOWED EXACTLY.

CAUTIONS: Alert the reader to possible equipment damage if procedures are not followed
correctly.

NOTES: Inform the reader of a general rule for a procedure or of exception to such a rule.

NOTICE

The information contained in this document is subject to change without notice. Red Seal Technologies,
its affiliates, employees, and agents and the authors of and contributors to this publication specifically
disclaim all liabilities and warranties, express and implied (including warranties of merchantability and
fitness for particular purpose), for the accuracy, currency, completeness and/or reliability of the information
contained herein and/or for the fitness of any particular use and/or in reliance upon information contained
herein. Selection of materials and/or equipment is at the sole risk of the user of this publication.

This document contains proprietary information, which is protected by copyright. All rights reserved.
No part of this document may be reproduced without prior written consent of Red Seal Technologies.

This equipment is intended for use in Class I, Division 2, Groups A, B, C and D or non-hazardous
locations only.

WARNING - Explosion hazard; substitution of components may impair suitability for

Class I, Division 2.

WARNING - Explosion hazard; do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous.

Hazardous area approval only valid when connected to an isolated source such as a truck battery.

Power and input & output (I/O) wiring must be in accordance with Class I, Division 2 wiring
methods, Article 501-4 (b), or the National Electrical Code, NFPA 70 for installations in the U.S., or
as specified in Section 18-1J2 of the Canadian Electrical Code for installations within Canada, and
in accordance with the authority having jurisdiction.

2
 ATTENTION - OBSERVE PRE-
CAUTIONS FOR HANDLING
ELECTROSTATIC SENSITIVE
DEVICES.

Caution - This electronic device is sensitive to damage from ESD (electro-

static discharge). Observe the following precautions when servicing this
device.

1. Always use a static-dissipative wrist strap. Connect the strap to a grounded, conduc-
tive surface or to the metal chassis of the equipment under repair. Use only wrist
straps that incorporate a resistor for user safety. The resistance between the user
and ground should be between 800K ohms to 10M ohms. Do not wear a wrist strap
around exposed electrical hazards of more than 250 volts.
2. If a wrist strap is not available, ground yourself before touching electronics by touch-
ing the metal chassis of the equipment or another grounded surface. Repeat fre-
quently while working.
3. If available, use a static-dissipative work mat. Connect the mat to ground and the
wrist strap to the mat.
4. Avoid contacting the connectors or any exposed electronic component.
5. Work away from materials that may contribute to the generation of static electricity,
such as synthetic carpeting.
6. Minimize your movements to avoid building up static charge.
7. Avoid working on electronics in areas with very low humidity.
8. Do not work on electronics during periods of lightning activity.
9. Do not ship or store this device near strong electrostatic, electromagnetic, magnetic,
or radioactive fields.

3
4
 Amended Procedures for New Electronics

Prolink Update

The current versions of Neptune RML Series meters (both Modbus and Pulse Output options) require Pro-
Link 3 for zeroing and configuration. ProLink 3 is compatible with all earlier releases of RML lectronics, and
will be the version used and supported by Red Seal Measurement for all RML Series meters.

ProLink 3 can be downloaded at www.redsealmeasurement.com/prolink.

The password to access the download link is NeptuneRML.

If previous versions of ProLink have been installed on a computer, they must be fully uninstalled before in-
stalling ProLink 3.

If you have any questions, please contact Red Seal Measurement Customer Service at support@red-
sealmeasurement.com, or (800) 833-3357.

5
Installation and Zeroing

1. Power and Data Connections

1.2. Modbus Units (800 Series Core Processor)

Remove the four screws that attach the housing cover and remove the cover. Make connections to the core proces-
sor as shown below.

6
1.2. Pulse Output Units (2400S Core Processor)
Remove the four screws that attach the housing cover and remove the cover. The 2400s requires the upper disc to
be removed before power or pulse connections can be made to the electronics. Loosen the two Philips screws on
the disc and pull disc straight up.

There is a plastic cover over the power terminals on the processor. Loosen the retaining screw and flip the cover up
to expose the power terminals. Connect power leads. Connect the pulse output wiring to terminals 3 and 4 (channel
B) on the terminal strip adjacent to the power connection. Reinstall the upper disc.

7
2. Zeroing the meter
Before performing the zeroing procedure:
1. Power the meter for at least 30 minutes to warm up the electronics.
2. Circulate product thru the meter for 5 – 10 minutes to remove vapor and allow meter to reach a steady tempera-
ture.
3. Close the valve downstream of the meter first, vapor return line valve second, and finally close the valve upstream
of the meter. All three should be closed as quickly as possible, to assure the meter is completely filled with LPG.
4. Disengage the truck PTO.

2.1 Modbus Units

Using ProLink 3:
1. Power up the meter, allow to stabilize for approx. 20 minutes. Run process fluid through meter until temperature
equalizes. Shut off flow and ensure it is completely stopped.
2. Attach temporary RS485 connection to SP terminals on user interface module (see section II above). Establish a
connection in ProLink 3.
3. In ProLink 3: “Device Tools” > “Calibration” > “Zero Verification and Calibration”.
4. Perform Auto Zero, or select other options as desired.
5. LED on user interface module turns red during calibration, and turns green afterward for a good zero. If it remains
red, calibration is unsuccessful and troubleshooting must be done.

2.2 Pulse Output Units

Using the “Zero” button:
1. Remove the four screws that secure the cover of the electronics housing. Remove the cover.
2. Power up the meter, allow to stabilize for approximately 20 minutes. Run process fluid through meter until tem-
perature equalizes. Shut off flow and ensure it is completely stopped.
3. Press the zero button with a pointed tool and hold it until the status LED on the user interface module flashes yel-
low. (See picture below for location of button.)
4. If the status LED shows solid green or solid yellow, the zero was successful. If it is red, the zero is not successful
and should be repeated.
(Note that the zeroing time cannot be changed when using the zero button; if a different time is desired, you must
use ProLink).

8
2.2 Pulse Output Units (continued)
Using ProLink 3:

To communicate with the unit via the ProLink 3 configuration program, connect the RS-485 adapter to the A & B ter-
minals of the service port (labeled SP). Then follow the instructions for “Using Prolink 3” in Section 2, Modbus Units.

9
 Table of Contents

0. AMMENDED PROCEDURES FOR NEW ELECTRONICS 5

1. FUNCTIONAL OVERVIEW 12

2. SPECIFICATIONS AND APPROVALS 13

2.1 RML2000 Specifications 13
2.2. E4000 Specifications
2.3. Custody Transfer Approval 15
2.4. Safety Approvals 15

3. SYSTEM COMPONENTS 16
3.1. RML2000 Coriolis Mass Flowmeter 16
3.2. E4000 Register Head 16
3.3. Display 17
3.4. Keypad 17
3.5. Electronic Temperature Compensation (Optional) 17
3.6. Valve control 18
3.7. Junction Box 18
3.7. Printer 19
3.8 Mobile Computer 19

4. INSTALLATION 20
4.1. Introduction 20
4.2. Check Parts 20
4.3. Truck Preparation 20
4.4. Installing the RML2000 Mass Flowmeter 20
4.5. Installing a Retrofit RML2000 Mass Flowmeter 21
4.6. Positioning the E4000 Register Head 21
4.7 Installing the RTD 22
4.8 Wiring the RTD 22
10
4.9 Installing the Single Stage LPG Solenoid Valve 23
4.10 Wiring the Single Stage LPG Solenoid Valve 23
4.12 Wiring the Dual Stage LPG Valve 24
4.11 Installing the Dual-Stage LPG Valve 24
4.13 Installing the Junction Box and Printer 26
4.14 Wiring the E4000 Register Head 26
4.15 Wiring the Junction Box 28
4.15 Wiring the RML2000 Meter to the E4000 Register 30
4.16 Installing the Printer 31
4.17 Connecting Power to the Junction Box 31
4.15 Connecting a Mobile Computer 33

5. START UP AND CALIBRATION 34

5.1 Route Mode 34
5.2 Configuring the E4000 36
5.3 Configuring and Zeroing the RML2000 38
5.4 Calibrating the E4000 volumetric K-Factor 44

6. INSTALLATION CHECKLISTS 51

7. E4000 INITIALIZATION PROCEDURE 53

8. INTRODUCTION TO RESPONSIBLE RECYCLING (R2) 55

9. POWER/DATA CABLE WIRE COLOR CONVERSION CHART 57

11
1. FUNCTIONAL OVERVIEW
The RML2000 Coriolis metering system for LP gas delivery trucks consists of two main elements:
• The RML2000 Coriolis mass meter complete with vapor release and differential valve
• The E4000 Electronic Register system

The Coriolis meter is a true mass flow meter in that it directly measures the mass flow rate of the product
passing through the sensor. The sensor consists of a vibrating U-tube arrangement, which tends to flex
under the action of fluid flow. The degree of flexing of the tube is measured and is directly proportional to
the mass flow rate. The Coriolis meter vibration frequency is related to the density of the product in the
tubes. The combination of a direct mass and density reading allows the meter electronics to calculate
the gross volume of propane delivered through the meter. The resultant volume measurement is highly
accurate and the meter has the operational advantage compared to traditional volumetric meters of having
no moving parts.

The E4000 electronic register system automates delivery and invoicing operations for deliveries of
LPG, distillate fuels and other commercially distributed liquids from flowmeters on bulk delivery trucks.
The register displays the delivered volume on the flowmeter at the rear of the truck as is traditional with
mechanical registers in this application. Electronic temperature compensation allows deliveries to be made
in gross or net volumes according to local practice. A printer in the cab provides a simple volume delivery
ticket or, using the E4000’s pricing capability, a complete priced invoice as a record of the transaction.
Tickets are time and date stamped for security. An end of shift report can be conveniently generated to
totalize the day’s deliveries by product. This allows administrative staff to reconcile individual tickets with
the shift as a whole. Delivery data is held for up to 100 deliveries in battery-backed memory. (Battery life is
approximately 10 years.)

The driver controls the E4000 from a push button panel on the front of the register. This allows yes/no
type decisions to be made and numerical values to be entered that are associated with delivery functions.
The buttons are used to navigate menus that appear on the display screen, guiding the user to perform
the required function. This interactive approach makes the register easy to operate by inexperienced
personnel.

The E4000 can control a security valve to prevent fraudulent LPG deliveries being made without the
register recording them. The solenoid valve is used with the LPG meter’s existing differential valve to
prevent flow. For both LPG, an optional driver-programmable 2-stage preset valve allows the delivered
amount to be set at a predetermined volume or monetary amount, subject to volume measurement
resolution.

The E4000 adapts mechanically to Neptune and other manufacturers’ tank truck flowmeters. Temperature
compensation is achieved via an RTD probe installed in the flowmeter that directly contacts the delivered
product and measures its temperature. The ability to accept an electrical pulse input allows the E4000 to
work with the RML2000 mass flowmeter.

The E4000 is designed to interface with the latest mobile computing products. Mobile computers bring
customer database and delivery information from the office onto the truck. The register updates the
customer record as deliveries are made during the shift. Formatted tickets can be printed that include
customer information that has been downloaded from the computer. At the end of the shift, captured
delivery information is carried back to the office in the computer to be downloaded to the main customer
accounts database.

The E4000 features a calibrated pulse output which can be used to interface with remote meter displays
and/or remote control truck delivery systems.

12
2. SPECIFICATIONS AND APPROVALS
2.1 RML2000 Specifications
Device Type:
• 1” Coriolis Mass Flow Transducer

Wetted Parts:
• 316L Stainless Steel

Sensor Housing:
• 304L Stainless Steel

Line Size:
• 2” (51mm)

Flowrate:
• NCWM Approved Volumetric Flowrate 8-82 GPM

Weight:
• 28lb (13kg)

Operating Temperature Range:

• -40 – 150OF (-40 – 65OC)

Pressure Rating:
• 350psi (24bar)

Power:
• 12 to 24vDC (19Volts supplied from E4000 Junction Box).
• If power to puck drops below 9-10 Volts, pulses will stop during flow. Pulse output will restart once 12
volts is reached and the puck has completed the 20-40 second recovery period.

Dimensions:

13
2.2. E4000 Specifications
Display
• 143 x 19 mm text area
• 2 lines, 20 characters per line
• 8.3 x 5.9 mm character area

Power Rating (supply from isolating or battery source)

• 9-16 VDC, 14.6 VDC nominal
• 0.25 Amps (0.63 Amps with optional display heater)

Relay Rating
• Number of Relays: 2
• Type: Normally open
• Contact Style: Form C contacts
• Contact Ratings: 230 VAC @ 3 amps
30 VDC @ 3 amps

LPG Single-Stage Valve (3/8” NPT)

• 0.8 Amp
• 12 VDC
• 9.5 Watts

LPG Dual-Stage Valve

• High Flow 3/8” Low Flow 3/8”
• 0.8 Amp 0.8 Amp
• 12 VDC 12 VDC
• 9.5 Watts 10 Watts

RTD Temperature Probe

• Platinum
• 4 wire
• Resistance at 32 F, 100 Ohms +/- 0.12%

Pulse Input
• Number of inputs: one
• Configurations supported: single input, single, dual or quad channel (menu selectable)
• Input Impedance: 10K Ohms nominal to common
• Trigger levels:
• Logic on: 3 to 30 VDC
• Logic off: 0 to 1 VDC

Communication to Printer and Computer

• RS232

Power to Electronics Module

• 19 Volts

14
Printer
• Epson TM-U295 Dot Matrix (Can also be used with Blaster printer)
• Ticket Type: Blank / Pre-Printed up to 3 ply
• Ticket Size: 102 mm x 257 mm (4 x 10”)
• Power: 24 VDC +/- 2.4 VDC
• Ribbon: Epson ERC—27

Size
• 9.0 in x 8.9 in x 6.3 in (229 mm x 227 mm x 161 mm)

Weight
• 5.4 lbs (2.45 kg)

Operating Temperature Range

• 0 OF to 131 OF (-18 OC to 55 OC)
• -40 OF to 104 OF (-40 OC to 40 OC) with optional display heater

Enclosure Rating
• NEMA 3R, NEMA 4

Meter Performance
• Accuracy: ±0.1% of rate
• Repeatability: ±0.05% of rate

2.3. Custody Transfer Approval

NTEP Approval to NIST Handbook 44 and NCWM Publication 14
• E4000 – Certificate 02-105
• RML2000 – Certificate 06-009

2.4. Safety Approvals

E4000:
UL Suitable for use in Class 1, Division 2, Group A, B, C and D or non-Hazardous locations only.

RML2000:
CSA (C/US) suitable for use in Class I, Division 2, Group A, B, C and D or non-Hazardous locations only.
Evaluated to applicable CSA and ANSI/UL standards for use in Canada and the US.

15
3. SYSTEM COMPONENTS
3.1. RML2000 Coriolis Mass Flowmeter
The Coriolis meter is mounted in a similar position to
a traditional volumetric meter at the rear of the truck.
The meter is connected in line via 2” 300 lb pressure
rated flanges to the vapor release and differential
valve.

The meter is constructed from stainless steel and

consists of a double U-tube arrangement enclosed in
a rectangular case. The drive coil, used to vibrate the
tubes, and the sensor coils which measure the flexing
of the tubes under flow conditions, are mounted inside
the box.

The instrument electronics are enclosed within the

small junction box at the top of the meter. Power and
communication connections to the register are made Figure 3-1. RML2000 Tube Configuration
here. The only means of communicating directly to the
Coriolis meter is to connect a computer to these same terminals. The computer is only required to “zero”
the meter as part of the calibration process, to be discussed later in this manual.

Once the junction box lid is closed, there are no operator controls on the meter; all functions are per-
formed at the E4000 register head.

3.2. E4000 Register Head

The E4000 electronic register is designed and field proven to
withstand the harsh environment on tank trucks. The enclosure
is plastic with a NEMA 3 rating.

The E4000 can be mounted directly on the positive displace-

ment flowmeter so that the mechanical drive of the meter rotates
an optical pulse encoder mounted in the register. Alternately,
the register can be mounted wherever required when receiving
a pulse output from a meter. Counting the pulses indicates the
amount of product measured by the flowmeter during a delivery.
An optional temperature compensation kit can be added to the
Figure 3-2. E4000 Register Head
base unit.

An operator communicates with the register via an LCD screen and a 4 button control panel. Internally
mounted relays operate electrical solenoid valves to control the flow of product. Delivery ticket information
is transmitted through the power/data cable from the rear of the register to a cab mounted junction box,
then to the ticket printer or hand-held computer.

Power and data connections are made to terminal strips inside the register and junction box. Configura-
tion parameters are programmed into the register manually by the buttons or from an external computer
using the E4000 configuration program.

An internal calibration switch is positioned inside the register to allow access to the Weights and Measures
configuration menu, and is mechanically sealed on the outside of the register.

16
3.3. Display
The 2x20 character LCD display is primarily intended to
show the volume of product being delivered. The two-line
display configuration also allows two parameters to be shown
simultaneously, such as delivered volume and price during
delivery or net and gross volume during calibration. The
display is also the method by which the E4000 communicates
instructions to operators as they navigate through the
software menus. Figure 3-3. LCD Display

3.4. Keypad
The 4 button keypad is the method used to enter configuration data and select function options for the
E4000 register.

Figure 3-4. E4000 Keypad

START/ENTER Confirms/accepts selected option on display

^ Increments the displayed character through the available character set

> Moves cursor to the right .
STOP/CANCEL Terminates delivery or exits current selection.

Pressing the up arrow on the control panel will scroll the selected character through a complete ASCI
character set (upper and lower case letters, all numerals and symbols). A space character is also included
in the character set. It is the fifth character after the lowercase z and is located between the right facing
arrow and the exclamation point:

→, [space], !
Access the Weights and Measures functions by depressing the internal switch beneath the seal screw on
the side of the register and pressing the > button simultaneously.

3.5. Electronic Temperature Compensation (Optional)

A temperature probe is available as an option for electronic temperature correction of the delivered volume
of product. This correction is mandatory for some products under Weights and Measures legislation in
certain states and countries. The probe is a 100 ohm RTD. The E4000 measures the product temperature
during delivery and uses the approved API volume correction table for the product at that temperature.
The resulting calculation when applied to the gross volume gives a net volume corrected to 60 OF or 15 OC
depending on the chosen units or product (505 LPG/510 LPG).

The use of electronic temperature correction has been shown to reduce the amount of unmeasured
product by approximately 1% versus mechanical ATC. For fluids without a recognized correction table,
approved formulas or expansion factors are used to calculate net volume. The RTD probe can be installed
in a Neptune meter, replacing the mechanical ATC bellows, or in the strainer cover.

17
3.6. Valve control
Red Seal provides an optional single stage solenoid valve (figure 3-4) to control the opening and closing
of the differential valve on LPG meters. The valve is opened only when the E4000 is powered and the
start button has been pressed to commence a delivery. The valve will close whenever the stop button is
pressed during a delivery or power is lost to the register.

Dual stage valves are also available for making preset deliveries of LPG. The E4000 has 2 relays which
control the two-stage shut off either by volume or monetary amount. The first stage reduces flow by 90%
to slowly bring delivered volume up to the preset amount. The second stage shuts off flow when the preset
amount is reached without hydraulic shock to the delivery system.

Figure 3-5. Single Stage LPG Valve

Figure 3-6. Dual Stage LPG Valve

Caution: All valves supplied with the E4000 (security valves and dual-stage preset) are wired with
an in-line TVS (transient voltage suppressor) to protect the E4000 from harmful voltage spikes. If
an E4000 is installed on another manufacturer’s meter with a different solenoid valve (or a Neptune
meter using another manufacturer’s valve), an appropriate TVS must be installed. Contact custom-
er service for details.

3.7. Junction Box

The junction box, located in the vehicle cab, houses a
PC board and serves as the connection point for the
E4000 peripherals mounted in the cab. The power to
the E4000 and printer is distributed from here. Data
passes through the junction box on its way to the printer.
The RS232 data link from the E4000 to any peripheral-
computing device such as a Hand held or Laptop is
made here. The same RS232 connector is used for
downloading the E4000 configuration parameters from a
laptop using the E4000 Configuration Program.
Figure 3-7. Junction Box

18
3.7. Printer
The E4000 printer is an Epson TM-U295 single feed style dot-
matrix printer which uses a standard 4-1/8” wide truck meter
delivery ticket , Neptune or Veeder Root. The printer is intended
for internal use only and should be mounted in the cab of the
truck. A data cable is supplied with the printer kit. The printer
power cable comes with the Junction Box. The junction box steps
up truck voltage from 12V to 24V to power the printer. The E4000
can also be used with a Blaster printer or an EPSON TM-U220D
roll printer.

3.8 Mobile Computer Figure 3-8. Printer

The E4000 has been specifically designed to operate with a mobile
computer such as a laptop, hand-held or PDA. The computer plugs
directly into the 9-pin RS-232 serial connector on the junction box that is
not occupied by the printer.

There are two modes of operation with an external computer:

1. The computer is running the E4000 Configuration Program and is temporarily connected to the junction
box to change non metrological parameters and update stand alone pricing.

2. The computer has fuel delivery application software running and carries customer account information
required by the driver during a shift. The computer interacts digitally with the E4000, extracts volume data
and uses this to calculate the customer invoice and update the account records. The mobile computer
updates the company database when returned to the office at the end of the shift.

19
4. INSTALLATION
4.1. Introduction
Before attempting to install an RML2000/E4000 system, read this manual! To simplify installation and
reduce the time required, follow the directions provided in this document. Each installation will vary
depending on the layout and overall condition of the truck, the fluid being measured, and the installer’s
experience with electronic registers and flowmeters.

WARNING: LPG systems should be installed in accordance with national standards ref: NFPA
58. Power, input and output (I/O) wiring must be in accordance with Class I, Division 2 wiring
methods Article 501-4(b) of the National Electrical Code, NFPA 70 for installations in the U.S., or as

accordance with the authority having jurisdiction.

4.2. Check Parts

Before commencing installation, unpack the entire contents of the E4000 packaging. Lay out the parts as
they would be installed on the truck. This will highlight any missing or incorrectly ordered/supplied parts.
Verifying that all the necessary parts are available in advance will reduce the truck downtime and avoid
any wasted truck preparation work.

4.3. Truck Preparation

Before commencing the installation:
Check that the condition of the truck battery is within the E4000 specifications.
Disconnect the battery.
Close the manual supply valves and bleed down the meter.
Disconnect the pressure line from the top of the differential valve.
Warning: Pressure must be completely relieved before proceeding.

4.4. Installing the RML2000 Mass Flowmeter

The unit must be mounted using the approved bracket available from Red Seal (or a similarly fabricated
bracket that will hold the unit securely, place no stress on the meter, and transmit minimal vibration). The
four bolts securing the clamps which hold the meter should be torqued to 55-65 ft-lbs. The bolts attaching
the top plate (for mounting the register) should be torqued to 15-17 ft-lbs.

The unit should be mounted horizontally so that the electronics module faces outward (figure 4-1).

Figure 4-1. RML2000 in Bracket

20
The meter may be mounted for either left or right handed flow; however, the flow of liquid through the
meter must always be in the direction indicated by the arrow on the meter housing. (Left to right flow when
the unit is viewed with the nameplate on the right.)

Isolate the meter with valves upstream, downstream, and in the vapor return line, as close to the meter as
practicable. The valves are required to ensure the meter remains filled with propane during the “zeroing”
procedure. (see section 5).

Use flexible hose (min. length 8”) for connections to both the inlet and outlet of the meter to eliminate
stress on the meter due to misalignment of piping. (See Figure 4-2, tank to meter inlet, and Figure 4-3,
differential valve to hose reel.).

Figure 4-2. Flexible Hose at Inlet Figure 4-3. Flexible Hose at Outlet

4.5. Installing a Retrofit RML2000 Mass Flowmeter

The installation procedure for a retrofit RML2000 is essentially the same as for a new installation. The
vapor release and differential valve from a previous Neptune 2” 4D-MT meter can be reused. If the prior
installation used mechanical temperature compensation, the installer will be required to replace the strain-
er cover with one that accommodates the E4000 thermowell. (See section 4.7, Installing the RTD). The 80
mesh strainer can be replaced with 16 mesh. (80 mesh is acceptable but will result in reduced flow and
more frequent cleaning,)

4.6. Positioning the E4000 Register Head

The RML2000 bracket supplied by Red Seal
provides a mounting plate with pre-drilled holes
for the E4000 (figure 4-4). If this bracket is not
used, the installer will be required to manu-
facture a custom fixture to secure the register.
When considering a position for the bracket,
ensure that the register controls will be easily
and safely accessible by a driver. Also, the RTD
probe cable must reach to the vapor release
strainer cover as discussed in Section 4.8, Wir-
ing the RTD.
Figure 4-4. E4000 Mounted on Bracket

21
4.7 Installing the RTD
E4000 registers equipped with an RTD (figure 4-5) are supplied with a ½” NPT male threaded
thermowell. The RTD can be installed in the available dual-port strainer cover (figure 4-6). To ensure
good conductivity to the RTD, fill the thermowell with anti-freeze or mineral oil before inserting the probe.

Note: If replacing the strainer cover, this is a good time to check the strainer and clean if necessary.

Figure 4-5. RTD Figure 4-6. Dual-Port Strainer

4.8 Wiring the RTD

The RTD is a 4 wire shielded probe. There is a cable entry port specifically for the RTD on the side of
the E4000. Run the cable through this port and connect the wires to the RTD terminals 6, 7, 8 and 12 as
shown in figure 4-13. If mounting the RTD in the strainer cover ensure enough slack to allow the strainer
cover to be removed for servicing. Secure the RTD cable with the cable gland supplied.

The lock washer supplied with the RTD cable gland can be discarded.

Figure 4-7. RTD Wiring

22
4.9 Installing the Single Stage LPG Solenoid Valve
Mount the solenoid valve to the E4000 mounting plate using the bracket provided. Mount the valve with
the ports configured as shown in figure 4-8. Connect the COM port of the solenoid valve to the top of
the differential valve. Pipe the NO or Normally Open port to pump pressure at the drain plug on either the
vapor eliminator or the meter connector. Pipe the NC or Normally Closed port to the vent line check valve
on top of the vapor eliminator. Figure 4-9 shows the completed plumbing.

Figure 4-8. Solenoid Valve Figure 4-9. Valve Wiring and Plumbing

4.10 Wiring the Single Stage LPG Solenoid Valve

Install a straight conduit nipple, supplied with the valve kit, in the threaded electrical opening of the LPG
solenoid valve. Teflon tape should be used on the threads of the conduit nipple to make a watertight seal.
Run the two black wires from the solenoid valve through the factory supplied conduit, into the register
using the conduit hub at the left side of the rear of the register. The green ground wire is not required and
can be cut off. Teflon tape should be applied to the threads of the 90 degree conduit nipple before it is
inserted in the conduit hub.

Figure 4-10. Conduit Fittings

23
Connect the white wire to terminal 23 and the black wire to terminal 24 on the register’s POWER 12 VDC
terminal strip (figure 4-13).

Connect the orange wire to terminal 18 (PRESET), and the blue/black wire from the twisted pair to either
black wire from the solenoid valve (there is no required polarity for the solenoid valve) and secured with
the supplied wire nut. The other black wire from the solenoid valve should be connected to terminal 19
(PRESET).

No wires will be connected to terminals 20, 21, and 22 (PRE-WARN). NOTE: The solenoid valve used
must feature a transient voltage suppressor. Check for the TVS to have been previously installed, by Red
Seal, under a section of heat shrink tubing where the two black wires enter the solenoid valve. If the TVS
is not present, contact the factory for additional wiring instructions.

4.11 Installing the Dual-Stage LPG Valve

Install the LPG solenoid valve (first stage) per section 4.10.

Remove the drain plugs from the dual-stage LPG differential valve (figure 4-11). Verify that the threads on
the valve body are clean and undamaged.

Apply a pipe sealer (approved for LPG service) to the NPT threads on the 90 degree elbows. Caution:
Make sure that sealant does not enter tubing as this may damage the solenoid valve. Install the two
90 degree elbows in the differential valve body. Install the tubing/solenoid valve assembly, aligning the
elbows as shown. Securely tighten the tube fittings.

Figure 4-11. LPG Dual-Stage Valve Assembly

4.12 Wiring the Dual Stage LPG Valve

Install two straight conduit nipples, supplied with the valve kit, in the threaded electrical opening of each
solenoid valve. Teflon tape should be used on the threads of the conduit nipples to make a watertight seal.
Run the two black wires from the main valve through the factory supplied conduit, into the register using
the conduit hub at the left side of the rear of the register. Teflon tape should be applied to the threads of
the 90 degree conduit nipple before it is inserted in the conduit hub.
Remove the center hole plug from the E4000 register base and install the supplied 90 degree conduit
nipple in the center port at the rear of the register. A supplied rubber gasket should be installed over the

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 Figure 4-12. Dual Stage Valve Wiring Conduits

threads of the 90 degree conduit nipple before it is inserted in the port of the register. Run the two orange
wires from the shutdown valve through the factory supplied conduit and into the register through the
center port (figure 4-12).

Connect the white wire to terminal 23 and the black wire to terminal 24 on the register’s POWER 12 VDC
terminal strip (figure 4-15).

Connect the orange wire to terminal 21 (PRE-WARN), and the blue/black wire to one of the orange wires
from the shutoff valve and one of the black wires from the main valve. Secure all three wires with the
supplied wire nut.

The remaining orange wire from the LPG shutdown solenoid valve should be connected to terminal 19
(PRESET), and the remaining black wire from the main valve should be connected to terminal 22 (PRE-
WARN).

Connect a jumper wire from terminal 18 (PRESET) to terminal 20 (PRE-WARN).

CAUTION: Both the main solenoid valve and the shutdown valve must feature a transient voltage
suppressor. Valves supplied by Red Seal have a TVS installed under a section of heat shrink tubing where
the two wires enter. If using a valve from another manufacturer, the appropriate TVS must be installed.
Operating without a TVS could result in damage to the E4000.

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4.13 Installing the Junction Box and
Printer
Select a suitable location in the cab to
position the junction box so that the two
RS-232 ports are easily accessible and
the junction box cover can be removed for
service (figure 4-13). Route the 40 ft. power/
data cable from the E4000 register head
at the rear of the truck before permanently
fixing the junction box. Route the cable away
from sharp edges, drive train components,
hot exhaust components, or other sources
of potential damage. It is recommended that
the cable be run through liquid-tight conduit
for protection.

The junction box dimensions are 10.5” x 7”.

Select a suitable location, orient the box, and
Figure 4-13. Junction Box Installation
mark and drill the bolt holes in the mounting
surface. The mounting holes are accessible
from inside the box. Route the power and data cables to the junction box. Secure excess cable to prevent
damage.

4.14 Wiring the E4000 Register Head

The supplied 40 ft. power/data cable connects the E4000 and the cab mounted junction box.

Run the power/data cable the length of the truck from the flowmeter to the cab and into the area selected
for the junction box. Automotive conduit is recommended to protect the cable from the environment.
Secure the cable to the truck frame or existing truck wiring using cable ties. Route to avoid moving body
parts, (drive shaft, etc) and sources of high temparature.

Some drilling may be required to pass through plating at the back of the truck and through bulkheads into
the cab. Placing grommets or watertight fittings on any holes to prevent cable damage is required.

The power/data cable should pass through the right side port of the E4000 register as viewed from the
rear (figure 4-17).

Make the connections as shown in the wiring diagrams for the E4000 register (figure 4-14, single-stage
valve or figure 4-15, dual-stage valve). The colors of the wires are shown in the diagram for identification
purposes. The numbers correspond to the E4000 terminal strip position to which the wire is connected.
See figure 4-16 for an example of proper wire routing and connection.

Caution: The drain (shield) wire should be cut off on the register end to prevent interference with power or
data lines. The drain wire is connected at the junction box end only.

Caution: Factory supplied plastic cable glands and metal liquid tight connectors prevent moisture
from entering the E4000 Register. Rubber gaskets should be installed over the threads of the
conduit hubs so that they are on the outside of the register base. Teflon tape should be used
to seal the plastic cable gland and metal conduit nipple where they are inserted into the conduit

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Figure 4-14. Register Wiring for LPG, RML2000 Mass Flow Meter, Single Stage Valve

Figure 4-15. Register Wiring for LPG, RML2000 Mass Flow Meter, Dual Stage Valve

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hubs. Also, the factory supplied hole plug
should be installed in the center port at the
rear of the E4000, and must be installed with
the step on the inside washer facing the hole
in the register base. This will center the hole
plug correctly and ensure it will not leak.

If the E4000 is equipped with a heated display,

the leads from the display heater will be
preinstalled at the 12 volt terminals. If the wires
are disconnected during the installation process,
reinstall the red display wire to terminal 24 and
white to terminal 23. The ferrule containing both
white and red wires attaches to terminal 16
(figure 4-18).

Figure 4-16. Register Terminals

Figure 4-17. E4000 Wiring Ports

Figure 4-18. Heated Display Connections

(other wires omitted for clarity)

4.15 Wiring the Junction Box

The data/power cable should pass through the center port in the junction box. The printer power cable
should pass through the left port, and the truck power cable should pass through the right port. Factory
supplied cable strain relievers are required to prevent damage to cables as they enter the junction box.
Make the connections as shown in the wiring diagram (figure 4-19) for the junction box.

Terminal block J8 is specifically for powering the RML2000. The red wire should be connected to the +19
VDC terminal of this block, and the red/black wire to common.

Always complete the HHC DATA wiring, even if you are not using a hand-held computer, because this
is also required to communicate with the register when using the E4000 configuration program.

Connect the drain (shield) wire to the SHIELD terminal of the PRINTER DATA terminal block. The length
of the shield wire should be such that it cannot contact the metal junction box or lid.

Do not replace the E4000 cover or the junction box lid at this point.

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 Figure 4-19. E4000 Junction Box Wiring Diagram, LPG, RML2000 Mass Flow Meter

29
4.15 Wiring the RML2000 Meter to the E4000 Register
Caution: The RML2000 transmitter electronics are susceptible to damage from electro-
static discharge. Make sure you are grounded to the truck frame before making the fol-
lowing connections.
Using the RML2000 cable kit, insert the leads from the 4-conductor power/encoder cable into the
RML2000 transmitter housing and connect to the terminals as follows:

Red wire: Positive terminal (+)

Black wires: Negative terminal (-)
White wire: Terminal B

Using the conduit and conduit connectors provided, run the cable from the transmitter housing to the reg-
ister via the center hole at the rear of the E4000. The straight connector screws into the meter transmitter
housing and the 90-degree elbow to the rear of the E4000. Take care to ensure water-tight seals between
the conduit and the enclosures by repeating the method described in “Wiring the E4000 and Junction
Box” above

Inside the E4000, connect the 4-conductor cable as shown in figure 4-14 or 4-15:

White wire: Encoder terminal 2

One black: Encoder terminal 4
Red wire: Connect to red wire from junction box with wire nut
Other black: Connect to red/black wire from junction box with wire nut

Figure 4-20. Transmitter Connections

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4.16 Installing the Printer
The Epson TM-U295 printer is available with the E4000.
Find a suitable location in the cab for the printer. End
user requirements may vary but a commercially available
stand is recommended to secure the printer. Bolt the
printer stand to a sturdy section of the cab floor and
attach the printer with Velcro strips (figure 4-21). Remove
the printer’s rubber feet to get maximum holding force
from the Velcro.

Data and power cables are supplied with the printer kit
and junction box. The printer power cable is prewired to
the printer power terminal of the junction box as shown
in figure 18. Plug the power connector into the round
DC24V port as marked on the rear of the printer. The
9-pin connector on the printer data cable plugs into the
Figure 4-21. Printer Installation
printer data socket provided on the junction box. Attach the
25-pin end of the data cable to the RS-232 socket
on the rear of the printer. (Note: To ensure proper
operation, use only the cable supplied with the printer.)

In the E4000 software under Supervisor>Com

Ports>Printer>Handshaking, set Handshaking to
“Hardware”. All of the DIP switches on the bottom of the
printer should be off (figure 4-22). (This is for software
EA.01.05.E and later versions.) Figure 4-22. Printer DIP Switches

4.17 Connecting Power to the Junction Box

The junction box for the E4000 Electronic Register includes a voltage regulator to ensure that the unit
receives clean power within the appropriate voltage range. The box comes prewired for printer power and
truck power connections, and has an in-line 5A fuse on the power input (figure 4-24).The E4000 junction
box includes three wires for connecting to truck power (figure 4-25).

Figure 4-23. Junction Box (Voltage Regulator on Figure 4-24. In-line 5A Fuse Holder
Right)

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RED (TRUCK POWER +12 VDC): Attach to a switched accessory circuit on the truck fuse panel or use
the supplied self-stripping power tap to connect to a switched accessory line (below).

BLACK (TRUCK POWER COMMON): Attach to the negative terminal of the battery, and verify that the re-
sistance from the terminal connection to the negative terminal of the battery is less than 1 ohm (measured
with power to the E4000 system switched off).

GREEN (TRUCK FRAME): Attach to the negative terminal of the battery, and verify that the resistance
from the terminal connection to the negative terminal of the battery is less than 1 ohm (measured with
power to the E4000 system switched off).

Caution: The E4000 system will not function reliably unless two separate grounds of less than 1
ohm are used.

Figure 4-25. Junction Box Cables - Printer on Figure 4-26. Crimp Lugs and
Left, Truck Power on Right Power Tap

Provided with the kit are crimp lugs that can be attached to the ends of the black and green junction box
power wires, and a self-stripping tap connector that can be used to tap the red wire into an existing truck
power wire (figure 4-26). Make sure that the wire being tapped is a switched accessory line. To use
the tap connector, place the unstripped end of the junction box power wire into the side with the closed
end, then slip the power wire from the truck into the other side. Use pliers to drive the metal tap through
the wires and flush with the surface, then close the hinged cover until it snaps into place (figure 4-27).

With all connections completed turn the ignition switch to the ON position. The E4000 will power up as
indicated by the LCD back light illuminating. Replace the E4000 register cover taking care to position the
cover gasket correctly.

Check that the printer power light is illuminated. Replace the junction box cover. To configure and calibrate
the E4000 before it enters service refer to Section 5 of this manual.

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 1 2

3 4
Figure 4-27. Using the Self-Stripping Power Tap.

4.15 Connecting a Mobile Computer

To operate with the E4000, a mobile computer plugs into a 9 pin serial connector on the junction box. Red
Seal has prepared a communications protocol document specifying how a computer can interface directly
to the register. The protocol allows the external computer to extract data and control the operation of the
register from a position in the cab. Application developers wishing to interface their product to the E4000
should contact Red Seal directly.

33