Smith Meter®

AccuLoad IV
Installation & Maintenance Manual
Bulletin MN06201 Issue/Rev. 0.3 (9/22)
September 2022
AccuLoad IV Installation & Maintenance Manual

Important
All information and technical specifications in this document have been carefully checked and compiled by
the author; however, we cannot completely exclude the possibility of errors. TechnipFMC is always grateful
to be informed of any errors; contact us at TechnipFMC.com.

Caution
The default or operating values used in this document and in the configuration parameters of the
AccuLoad IV are for factory testing only and should not be construed as default or operating values for
your metering system. Each metering system is unique and each configuration parameter must be
reviewed and programmed for that specific metering system application.

Disclaimer
TechnipFMC hereby disclaims all responsibility for damages, including but not limited to consequential
damages arising out of or related to the inputting of incorrect or improper program or default values
entered in connection with the AccuLoad IV.

Technical Support
Field Service Response Center
24/7 Technical Support/Schedule a Technician: +1 844.798.3819

System installation supervision, startup, and commissioning services are available.

Customer Support
Customer Service
TechnipFMC
Measurement and Production Solutions
1602 Wagner Avenue
Erie, PA 16510 USA
+1 814.898.5000
[email protected]
TechnipFMC.com

Literature Library
http://info.smithmeter.com/literature/

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AccuLoad IV Installation & Maintenance Manual

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 AccuLoad IV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1.1 AccuLoad IV ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1.2 AccuLoad IV QT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1.3 AccuLoad IV N4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1.4 AccuLoad IV SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.2 Electronic Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Warnings and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.1 Hazardous Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.2 Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.3 Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.3.1 Electrostatic Discharge Precautions in Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.4 RF Radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.5 Site-Specific Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.6 Weights and Measures Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 Pre-Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 ST and QT Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 N4 and SA Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Mechanical Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Electrical Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 General Electrical Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 ATEX- and IECEx-Approved Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.2 Hazard Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.3 Special Conditions for Safe Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.4 Cable Entries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.5 Cover Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.6 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 UL Brazil INMETRO-Approved Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.1 Hazard Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Contents ii
AccuLoad IV Installation & Maintenance Manual

3.3.2 Special Conditions for Safe Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3.3 Cable Entries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.4 Cover Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.5 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 ALIV SA Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Electronic Layouts and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.1 FCM Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.2 MMI Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5.3 THMI Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.4 A4M Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.4.1 A4M I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.4.2 A4M I/O Index Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.4.3 A4M Special I/O Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5.4.4 A4M S1 DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5.4.5 A4M SW2 DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5.5 A4B Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5.5.1 A4B I/O Index Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5.5.2 A4B DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5.6 A4I Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.5.6.1 A4I I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5.6.2 A4I I/O Index Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5.6.3 A4I DIP Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6 General Wiring Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.6.1 AC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.6.2 DC Instrument Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.6.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6.4 I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6.5 Meter Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6.6 Analog I/O Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6.7 Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Communications Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.1 Ethernet Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.1.1 ST and N4 Model Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.7.1.2 QT Model Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.7.1.3 SA Model Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.7.1.4 SA Board Set IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.8 Serial Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.9 Pulse Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4 Meter I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.1 I/O Index Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2 Meter Connection Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.1 PRIME 4 Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Contents iii
AccuLoad IV Installation & Maintenance Manual

4.2.2 Genesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.3 Universal Pulse Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2.4 PPS Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2.5 PA-6 Preamplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2.6 Promass 80, 83, and 84 Coriolis Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2.7 Promass 83 and 84 Coriolis Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3 Meter Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3.1 Meter Inputs for ST and N4 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3.2 Meter Inputs for QT and SA Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4 Additive Meters and Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.5 A4I Kit Retrofit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5 Closing and Sealing the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.1 Closing the Explosion-Proof Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2 Sealing the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.2.1 Sealing ST and QT Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.2.2 Sealing N4 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1 Explosion-Proof Enclosure Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1.1 ST and QT Models in Special Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1.2 N4 and SA Models in Special Environments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Touch-Screen Screen-Protector Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Replacing the Clock Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4 Diagnostic Troubleshooting on A4M, A4B, and A4I Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.5 Returning a Circuit Board Using a Return Merchandise Authorization (RMA) . . . . . . . . . . . . . . . . . . . . . 66
6.5.1 A4M Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.5.2 THMI Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

7 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Contents iv
AccuLoad IV Installation & Maintenance Manual

1 Introduction
This manual provides guidance for the electrical installation and general maintenance of the Smith Meter
AccuLoad IV. When installed following the guidelines contained in this manual, the AccuLoad should
provide many years of safe, accurate, and reliable use.

This manual addresses the requirements specific to the AccuLoad IV and it is assumed that the installation
designers and fabricators are familiar with the applicable industrial facility construction standards specific to
the particular facility. The ST and QT models are designed for use in Class 1, Division 1 and Zone 1
hazardous locations, while the N4 and SA models are designed for North American Class 1, Division 2
environments only. If questions arise, please contact our Field Service Response Center or Customer
Support.

1.1 Product Description

The AccuLoad provides accurate, reliable control and measurement of liquid petroleum blending and
transfer operations. While primarily intended for use in refined petroleum distribution terminals, it can be
easily configured for a wide variety of liquid transfer applications.

Operators can select an amount of product to transfer and the AccuLoad monitors and controls the
configured pumps, valves, and additive injectors to safely and efficiently transfer the precise recipe and
amount. During the transfer, all processing parameters are monitored to provide operators with an
accurate amount of each component of the recipe delivered.

In addition to real-time control of the loading process, the AccuLoad also calculates averages and live
quantities of all products and additives delivered. This information is stored in a runtime database that can
be monitored by a supervisory host system. Whenever a transaction is completed, the AccuLoad stores a
detailed record in an internal transaction log for subsequent retrieval or printing.

1.1.1 AccuLoad IV Models

The AccuLoad IV is available in several hardware configurations and with multiple standard and optional
modules.

1.1.1.1 AccuLoad IV ST

The Single Touch Screen (ST) model has the following specifications:
• Explosion-proof enclosure

• Two-arm operation

• Up to four single- or dual-pulse product meter inputs

• Up to four additive meter inputs or, with the optional A4I module, up to 24 additive meter inputs

• AccuLoad III to IV upgrade kit (UG3)

Introduction 1
AccuLoad IV Installation & Maintenance Manual

Figure 1: AccuLoad IV ST

Introduction 2
AccuLoad IV Installation & Maintenance Manual

Figure 2: AccuLoad IV ST Dimensions

1.1.1.2 AccuLoad IV QT
The Quad Touch Screen (QT) model has the following specifications:

• Explosion-proof enclosure

• Up to six-arm operation

• Up to six single- or dual-pulse product meter inputs

• Up to four additive meter inputs or, with the optional A4I module, up to 24 additive meter inputs

• AccuLoad III to IV upgrade kit (UG3)

Introduction 3
AccuLoad IV Installation & Maintenance Manual

Figure 3: AccuLoad IV QT

Introduction 4
AccuLoad IV Installation & Maintenance Manual

Figure 4: AccuLoad IV QT Dimensions

1.1.1.3 AccuLoad IV N4
The NEMA 4 (N4) model has the following specifications:

• 304 stainless steel, NEMA 4X-rated enclosure

• One-or two-arm operation

• Up to four single- or dual-pulse product meter inputs

• Up to four additive meter inputs with local input/output (I/O)

• Optional integrated card reader, indicator lights, and stop button

Introduction 5
AccuLoad IV Installation & Maintenance Manual

Figure 5: AccuLoad IV N4

Introduction 6
AccuLoad IV Installation & Maintenance Manual

Figure 6: AccuLoad IV N4 and MMI Dimensions

1.1.1.4 AccuLoad IV SA
The Split Architecture (SA) model is comprised of one field control module (FCM) and one or two man-
machine interfaces (MMI). The FCM contains the I/O control electronics that are connected to meters,
valves, permissives, and other hardware; it can be located for convenient access by service personnel.
The MMI components are the operator control panels and can be located for convenient access by drivers.

The SA model has the following specifications:

• 304 stainless steel, NEMA 4X-rated enclosure

• Up to 18-arm operation

Introduction 7
AccuLoad IV Installation & Maintenance Manual

• Up to 24 single- or dual-pulse product meter inputs

• Up to 56 additive meter inputs with the A4I I/O module or, with the remote A4I module, up to 96
additive meter inputs

The MMI has an optional integrated card reader, indicator lights, and stop button.

Figure 7: AccuLoad IV SA

DC WIRING TRAY

AC WIRING TRAY
DC WIRING TRAY

DC WIRING TRAY
'A' 'B' 'C' 'D'

Introduction 8
AccuLoad IV Installation & Maintenance Manual

Figure 8: AccuLoad IV SA FCM

Introduction 9
AccuLoad IV Installation & Maintenance Manual

1.1.2 Electronic Modules

The AccuLoad IV has the following standard and optional electronic modules. Table 1: Electronic Modules
by Model explains which modules are standard or optional for each AccuLoad model; Table 2: Model
Functions and Capacities provides details about each module.
Table 1: Electronic Modules by Model
Model Standard Modules Optional Modules
ST THMI A4I (up to two; only one may be
A4M installed internally)
QT THMI A4I (up to two external or internal)
A4M
A4B
N4 THMI Card reader
A4M
SA MMI component THMI Card reader
SA FCM component A4M A4I (up to one per board set)
A4B A4M and A4B (up to three board sets)

Table 2: Model Functions and Capacities

Module Description Interfaces Power Model & Location
THMI Touch-screen user interface; Ethernet 24 volts direct ST (front cover)
connects to the A4M via Serial current (VDC) QT (front cover)
Ethernet N4
SA MMI
A4M Main I/O board that provides up
Meter pulse input 93 to 230 volts ST
to six dual-channel product Pulse outputs alternating QT
meter pulse inputs; pulse inputs
Digital I/O alternating current (VAC) N4
not used for product meters can
current/direct current (AC/ SA FCM
be used for up to four meteredDC)
injector pulse inputs Analog I/O
Ethernet
A4B I/O expansion for the QT and Meter pulse input 24 VDC QT
SA models Digital I/O AC/DC SA FCM
Ethernet
A4I Optional I/O expansion module Additive meter pulse input 24 VDC ST
generally used for metered Digital input DC QT
injector interfaces Digital output AC SA FCM
(may be mounted
internally or in
separate enclosure)
Card Proximity card reader for Serial communication 24 VDC N4
reader access control SA MMI
(may be mounted in
front cover or in
separate enclosure)

Introduction 10
AccuLoad IV Installation & Maintenance Manual

1.2 Warnings and Precautions

Before you begin installing the AccuLoad, please read all of the following warnings and cautions to the
reduce the risk of injury, equipment damage, or malfunction.

WARNING: The AccuLoad should never be relied upon to act as the primary safety system control for
the flow valve and pump controls (such as emergency stop, overfill, and ground protection). These
should always be handled by separate systems specifically designed for that application; for example,
safety systems specifically to meet safety integrity level (SIL) requirements. Any power control circuits
from these external systems should be wired in series ahead of the AccuLoad to remove power to
ancillary devices.

1.2.1 Hazardous Voltages

Hazardous voltages are involved in the installation and maintenance of the AccuLoad. Only qualified
individuals should perform this installation.

1.2.2 Hazardous Locations

The ST and QT models are approved for use in an explosive environment (Class I, Division 1, Groups C
and D and Zone 1 Ex d ia, IIB Gb), but specific installation methods are required to produce a
comprehensive explosion-proof system. This manual only provides guidance for the installation of the
AccuLoad. In general, keeping the front cover bolted closed in accordance with the instructions in Section
5: Closing and Sealing the Enclosure is the key to maintaining explosion protection.

Any modification to the housing invalidates the hazardous location rating of the AccuLoad. For example:
• Do not replace the bolts in the front cover except with those supplied by the manufacturer. Using
unapproved bolts invalidates the explosion-proof rating of the enclosure.
• Do not drill or machine the housing.
• Do not attempt to replace the touch screen or glass except as part of a factory-supplied assembly.

1.2.3 Electrostatic Discharge Precautions

The electronic components in the AccuLoad are susceptible to damage by electrostatic discharge (ESD).
To minimize the risk of damage, the following precautions should be followed:

• Before touching a circuit board with hands or tools, personnel and tools should be grounded using
a wrist strap.

• Avoid touching components or traces on the circuit boards and handle by the edges or mounting holes.

• Keep circuit boards in static-control packaging (such as static-shielding bags) when not installed.

• Protect against ESD in workspaces when handling circuit boards.

1.2.3.1 Electrostatic Discharge Precautions in Hazardous Locations

Note the following additional precautions when operating the AccuLoad in hazardous locations:

• The touch screen features a plastic screen protector (installed at the factory) with a surface area
exceeding the area specified in IEC/EN 60079-0, and as such requires the following statement:

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AccuLoad IV Installation & Maintenance Manual

“Warning: Clean display with a damp cloth only.” This is to ensure that stray static charges are not built
up on the surface that could lead to a static discharge.

• Special care must be taken with shielding termination to ensure signal integrity. See Section 3.1: General
Electrical Installation Requirements for more information.

• The AC and DC wiring should be physically separated (do not use the same conduit or entry) to avoid
induced noise.

ATEX- and IEC-approved installations have special requirements; see Section 3.2: ATEX- and IECEx-
Approved Installations for details.

To ensure the correct operation, Section 3.6.7: Typical Wiring Diagrams for wiring diagrams.

1.2.4 RF Radiation
The AccuLoad generates, uses, and can radiate radio frequency (RF) energy and, if not installed and used
in accordance with this manual, may cause interference to radio communications. It has not been tested to
comply with the limits pursuant to Federal Communications Commission’s FCC Code of Federal
Regulations, Title 47, Part 15 (CFR 47), as electronic control equipment used by an industrial complex is
exempt from the rules.

Operation of this equipment in a residential area may cause interference, in which case the user, at their
own expense, will be required to take whatever measures that may be necessary to correct the
interference. The explosion-proof version of the AccuLoad has been evaluated against international
standard IEC 61326-1: Electrical Equipment for Measurement, Control and Laboratory Use and has been
found to comply with European Community Electromagnetic Compatibility (EMC) Directive 2014/30/EU.

1.2.5 Site-Specific Configuration

The AccuLoad is shipped from the factory in a completely initialized state and must be properly configured
for the specific installation prior to operation. The unit will not operate due to alarm conditions until the
configuration is completed. Using a personal computer (PC) running the AccuMate application is the best
method to set the initial configuration, but if AccuMate is not available, all configuration parameters are
accessible using the AccuLoad’s touch screen. See the AccuLoad IV Operator Reference Manual
(MN06200) for information about parameter settings.

1.2.6 Weights and Measures Requirements

The AccuLoad is used by a global market. Requirements regarding weights and measures may vary
depending on the region. Users are required to verify that the AccuLoad is configured and operated in a
manner consistent with local codes and that proper notification (permit for use) or registration has been filed
with the local authority or jurisdiction.

Weights and measures authorities rely on either physical sealing or electronic sealing with password
protection to secure metrological parameters for use in legal trade. See Section 5.2: Sealing the Enclosure
in this manual for information about physically sealing the AccuLoad or the AccuLoad IV Operator
Reference Manual (MN06200) for instructions on setting a password.

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AccuLoad IV Installation & Maintenance Manual

2 Pre-Installation
Considerations
2.1 Environmental Considerations
In areas where the ambient temperature is very high, it is recommended that the AccuLoad be installed
under a canopy or sun shield to limit direct sunlight radiation.

In areas of high humidity (tropical) or with varying temperature swings, it is recommended to place
desiccant packs (TechnipFMC part number 647001443) inside of the enclosures, and to maintain these
while in service.

2.2 ST and QT Models

The enclosures of the ST and QT explosion- and flame-proof models are manufactured from aluminum
alloy and are designed to be operated in normal environmental conditions free of corrosive agents.

In areas including but not limited to environmentally corrosive atmospheres, special considerations for
additional environmental protection shall be made if installing into near shore areas that are subject to
wind-borne seawater spray and subject to possible continuous accumulations of saltwater on the
equipment. The recommended protection is exclusion of the environment by placing the equipment into a
secondary protected environment, such as a kiosk or a control room. If exclusion of the environment is not
possible, then extra means must be taken to maintain the equipment’s integrity, including frequent cleaning
and inspection intervals. See Section 6: Maintenance for additional information.

2.3 N4 and SA Models

The enclosures of the N4 and SA models, as well as the MMI and FCM modules, are manufactured from
304 stainless steel (which offers a higher resistance to corrosive environmental atmospheres) and are
designed to be operated in normal environmental conditions free of corrosive agents.

In areas with environmentally corrosive atmospheres—such as near shore areas that are subject to wind-
borne saltwater spray and possible accumulation of saltwater on AccuLoad equipment—special
considerations for additional environmental protections should be made. We recommend placing the
AccuLoad equipment in a secondary, protected environment, such as a kiosk or control room; if this is not
possible, extra means must be taken to maintain the equipment’s integrity, including frequent cleaning and
inspections. See Section 6: Maintenance for additional information.

2.4 Mechanical Installation Considerations

In addition to all previous warnings and cautions, the following installation recommendations should be
reviewed before installation:

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AccuLoad IV Installation & Maintenance Manual

• A solid bracket (rear- or bottom-mount) should be used to support the AccuLoad. Refer to the
AccuLoad IV specifications (SS06200) for the weight and mounting dimensions.

• The location and the height of the AccuLoad should easily permit operation of the front touch screen
and allow for a near-perpendicular viewing angle to minimize parallax effects.

• Leave room for the front panel of the AccuLoad to open at least 90 degrees to provide access for
servicing the AccuLoad. Note that the covers are hinged on the left.

• See the following table regarding cable access for each AccuLoad IV model. Refer to the AccuLoad IV
specifications (SS06200) for additional details about the location and size of the wiring access
openings in the enclosures.
Table 3: Cable Access
Model Top Cable Access Bottom Cable Access
ST Two 1-inch 11.5 NPT Three 1.25-inch 11.5 NPT
QT One 1-inch 11.5 NPT Two 1.25-inch 11.5 NPT
Five 1-inch 11.5 NPT
N4 Three 1.75 inch
SA MMI Three 1.75 inch
SA FCM Ten 2 inch

2.5 Electrical Installation Considerations

Although the AccuLoad is rated to operate in ambient temperatures up to 60 °Celsius (C), it is advisable to
keep all electronics as cool as possible to reduce thermal stress on the electronic components. In hot, sunny
areas, the AccuLoad should be mounted in shade to prevent the housing from exceeding the rated
temperature.

In addition to this manual’s installation instructions, the following electrical warnings and precautions
should be reviewed before installation.

The following recommendations are based on our knowledge of electrical codes. The local electrical
codes should be reviewed to ensure that these recommendations follow the local code. Additionally,
installation manuals of all the equipment being wired into the AccuLoad should be reviewed for transmission
distances and wire recommendations.

• All wiring must be routed into AccuLoad through the cable entries. Do not route DC and AC wiring
through the same conduit entry.

• The DC signal wires must be shielded multi-conductor cable of 18 to 24 American Wire Gauge (AWG)
minimum stranded copper.

• For Ethernet connections, a minimum of Cat 5-rated cable should be used and the Ethernet wiring
practices described in the ISO/IEC 11801 should be followed for cable lengths, etc.

• Connectors are sized for a maximum of 14-gauge wire. Consult your local electrical codes for the
minimum wire size required for your application.

• All AC wiring should be stranded copper and must comply with federal, state, and local codes and
specifications.

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AccuLoad IV Installation & Maintenance Manual

• Two separate AC circuits must be provided from the breaker panel. One circuit should supply isolated
power to the AccuLoad’s electronics (instrument power). The second circuit should supply power to
external devices (Section 3.6.1: AC Input Power).

• For proper operation, the AccuLoad must be earth grounded. The grounding point should be as close
to the unit as possible.

• To ensure proper earth grounding, the resistance between the ground lug in the AccuLoad and the
grounding point must not exceed 2 Ω. The proper grounding point is a ½- to ¾-inch diameter copper
stake that extends into the water table. Where this is not practical, a ground plane may be used.

Electrical conduit, piping, and structural steel are not considered proper grounding points for
equipment using electronics.

2.5.1 Typical Wire Sizes and Cable Lengths

See the following tables for typical wire sizes, cable lengths, and baud rates.
Table 4: Typical Wire Sizes
Number and Gauge Belden Number or
Equipment
of Wire Equivalent
Transmitters 4/18 gauge 9418
4/20 gauge 8404
Temperature probes 4/22 gauge 8729 or 9940
Density and pressure transmitters
EIA-232 3/24 gauge 9533
EIA-485 Communications 4/24 gauge 9842
Ethernet Cat 5 or Cat 6 1584A or 2412

Table 5: Serial Communications (EIA-232) Maximum Cable Length and Baud Rate
Baud Rate Feet Meters
115,200 62.5 18.25
57,600 125 37.5
38,400 250 75
19,200 500 150
9,600 1,000 305

Table 6: Serial Communications (EIA-485) Maximum Cable Length and Baud Rate
Baud Rate Feet Meters
9,600 to 115,200 4,000 1,220

Pre-Installation Considerations 15
AccuLoad IV Installation & Maintenance Manual

3 Installation
The general steps in the installation process are to physically mount the AccuLoad, electronically connect it
to work with associated equipment, and then configure it to suit its specific operational and measurement
environment. This manual provides information about the electrical installation of the AccuLoad IV.

For dimensional drawings and basic requirements for mounting the AccuLoad IV, see the AccuLoad IV
specifications (SS06200). For information about configuring the AccuLoad IV, refer to the AccuLoad IV
Operator Reference Manual (MN06200).

3.1 General Electrical Installation Requirements

It is imperative that the electrical installation be performed by a qualified individual who is familiar with
associated risks involved with the installation, operation, and maintenance of electrical equipment in
hazardous (classified) locations. This individual must possess knowledge of local and national electrical
codes, in addition to ordinances concerned with hazardous location safety requirements. It is
recommended (may be required in some jurisdictions) that the final installation be verified and inspected
by the authority having jurisdiction before placing the equipment into service.

Electrical installations in hazardous areas have features specifically designed to make them suitable for
use in such locations and it is the operator’s responsibility to maintain the integrity of those special
features.

The operator must ensure that electrical equipment is:

• Installed and operated correctly

• Monitored on a regular basis

• Maintained with due regard to safety

Additionally, the following guidelines should be followed:

• AC Circuits must be isolated from DC circuits and brought into the unit through their respective
conduit openings.

• Be sure all connections on the terminal blocks are tight.

• All shields must be connected to terminals 3, 13, 14, or 15 on terminal block TBE4 on the A4M Board or
terminals 9 and 10 on TB14 on the A4B Board.

• All exposed shields must be properly insulated to prevent short circuits to other terminals or to the
chassis. The shield at the device (such as a temperature device or transmitter) must be cut back to the
insulation and taped off. All shields should be continuous. If splices are required, they must be soldered
and properly insulated. If other communicating devices are used with the AccuLoad, refer to the
manual for that unit for shielding information. Shields for other communicating equipment should not
be terminated in the AccuLoad.

Shields must not be terminated at the ground lugs.

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AccuLoad IV Installation & Maintenance Manual

• Sufficient slack should be provided for the wiring in the AccuLoad to permit easy removal of the
boards. With sufficient slack, the terminal blocks can be removed and laid out of the way so that the
boards can be replaced without removing individual wires.

• A ground lug is provided in the unit; the wire from the lug should be connected to the proper grounding
point (see Section 2.5: Electrical Installation Considerations for more information).

• Typical installation diagrams are provided in the following sections to show the electronic connections
between the AccuLoad and compatible electronic modules. Before wiring any ancillary equipment,
refer to its product-specific installation manual.

3.2 ATEX- and IECEx-Approved Installations

The following sections contain information about installing models ST and QT, which have explosion-proof
enclosures.

3.2.1 Installation
General Installation should be in accordance with IEC 60079-14; the wiring system should be in
accordance with Section 9 of IEC 60079-14.

3.2.2 Hazard Warnings

To prevent the ignition of hazardous atmospheres, disconnect from the power supply before opening the
enclosure. Keep the enclosure tightly closed when circuits are alive.

The AccuLoad contains internal battery-powered circuits; to prevent the ignition of hazardous
atmospheres, do not open its enclosure unless the area is known to be non-hazardous. To reduce the risk
of ignition of hazardous atmospheres, conduit runs must have a sealing fitting connected within 18 inches of
the enclosure. Substitution of components may impair intrinsic safety.

The maximum ambient temperature for the enclosure is 60 °C for ATEX and IECEx applications and
55 °C for North American Zone applications.

3.2.3 Special Conditions for Safe Use

Special conditions for safe use include:

• Wiring and cable glands should be suitable for operation at 81 °C.

• Flame path dimensions for flanged joint widths must be a minimum of 19.05 mm. The clearance
between flat joint surfaces must be less than 0.05 mm (0.002 inch) or such that a (0.002 inch) feeler
gauge cannot enter the joint more than 3.2 mm (0.125 inch) at any point. Flame-proof joints should be
maintained as outlined in Section 10.4 of IEC 60079-14.

3.2.4 Cable Entries

Cable entries must be in accordance with IEC 60079-1 section 13, as follows:

Installation 17
AccuLoad IV Installation & Maintenance Manual

• For wiring systems using cable glands, the gland or thread adaptor must be Ex d certified. The cable
ends must be securely installed and, depending on the cable type, be properly protected from
mechanical damage. Requirements outlined in Section 10.4 of IEC 60079-14 should be followed.

• For wiring systems using conduit, an Ex d certified sealing device must be immediately at the entrance of
the enclosure. Any unused entry must be suitably blocked with an Ex d IIB IP 65 certified plug for ATEX
and IECEx applications. For North American Zone applications, the plug must be listed close up type.
Requirements outlined in Section 10.5 of IEC 60079-14 shall be followed.

3.2.5 Cover Fasteners

Cover bolts are required to be M8 x 1.25-6g, DIN 912, steel grade 12.9.

3.2.6 Grounding
The touch-screen user interface (if provided) is protected by an intrinsic safety barrier; the enclosure must
be grounded in accordance with national electrical code regulations; for example National Electrical Code
(NEC) or Canadian Electrical Code (CEC).

Equipment bonding should be provided at the external grounding facility terminal; an external connection is
not required when using metallic conduit or armored cable.

The external grounding facility terminal wire range is 10 to 12 AWG (5.26 mm2 to 3.31 mm2 wire).

3.3 UL Brazil INMETRO-Approved Installations

The following information is specific to AccuLoad models ST and QT to be installed in Brazil, which
requires INMETRO standards to be followed.

3.3.1 Hazard Warnings

To prevent the ignition of explosive atmospheres and to avoid electric shock, disconnect the power circuits
before opening the Ex d enclosure. Keep the enclosure tightly closed when circuits are alive.

The AccuLoad contains internal battery-powered internal circuits; to prevent the ignition of an explosive
atmosphere, do not open the enclosure unless the area is known to be non-hazardous. Substitution of
components may impair intrinsic safety.

The maximum ambient temperature for the enclosure is 60 °C for INMETRO-approved applications.

3.3.2 Special Conditions for Safe Use

Special conditions for safe use include:

• Cables and cable glands should be suitable for operation at 81 °C.

• For information about the dimensions of flame-proof joints, contact TechnipFMC at the address provided
on the back page this manual.

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3.3.3 Cable Entries

All cable entries must meet the requirements of ABNT NBR IEC 60079-1, summarized as follows:

• Any installation accessories used in the cable entries (such as cable glands, adapters, or bushings) must
be Ex d certified. The cable ends must be properly installed and adequately protected against
mechanical damage.

• For wiring systems using conduits, a certified sealing unit must be used immediately at the entrance of the
enclosure. Any unused input must be correctly closed with a certified device that guarantees the type
and degree of protection (IP65).

3.3.4 Cover Fasteners

The EX d enclosure requires cover mounting bolts to be M8 x 1.25-6g, DIN 912, steel grade 12.9.

3.3.5 Grounding
The touch-screen user interface (if provided) is protected by an intrinsic safety barrier, the Ex d enclosure
must be grounded in accordance with national electrical code regulations.

The ground connection must be made through the external ground terminal of the Ex d enclosure. An
external connection is not necessary when using metal conduits or shielded cables.

The cross section of the external ground wiring must be 10 to 12 AWG (5.26 mm2 to 3.31 mm2 wire).

3.4 ALIV SA Installations

North American Division 2 and Zone 2 installation requirements must be followed for the installation of
the AccuLoad IV N4 and SA equipment; substitution of components may void safety certifications.
Compliance with local codes is mandatory.

The AccuLoad IV SA model is comprised of the following units:

• One FCM unit that contains all of the I/O control electronics connected to peripheral hardware, such as
meters, valves, and permissives

• One or two MMI units that act as the operator control panels

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Each MMI is connected to its MMIs by Ethernet or serial cables.

Figure 9: AccuLoad IV Split Architecture Units

Optional
Ethernet

MMI
MMI

FCM

The FCM unit can be installed at a location that is convenient to service personnel. The MMI units can be
installed for convenient access by drivers. Typical installation approaches are shown below.
Figure 10: Typical Installations for AccuLoad IV SA
MMI FCM

Lane Two

FCM MMI FCM

Lane One
MMI FCM

Lane One

3.5 Electronic Layouts and Connections

This section provides wiring information and drawings for the SA model’s units, as well as all of the
AccuLoad’s electronic modules.

3.5.1 FCM Unit

The FCM unit contains between one and four board sets to provide control of up to 24 loading arms. Each
board set consists of an A4M module, an A4B module, and an optional A4I module. These board sets are
mounted in the FCM enclosure, as shown below in Figure 11: SA Model FCM components.

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AccuLoad IV Installation & Maintenance Manual

Additionally, a factory-wired DC distribution block is located on the bottom left corner of the FCM. One
distribution terminal block is provided for each A4M board in the FCM. The input to this terminal block is
factory wired to its associated board set and provides 12 separate slots to supply 24 VDC to external
equipment, such as MMI units, external meter transmitters, and DC digital inputs.
Figure 11: SA Model FCM components

+ 24 VDC GND

P1 P1 P2 P2 Factory Wired

+24 VDC
P1 1 2 3 4 5 6 7 8 9 10 11 12

Ground
P2 1 2 3 4 5 6 7 8 9 10 11 12

3.5.2 MMI Units

The basic MMI unit contains a THMI module and, optionally, any of the following items:

• Proximity card reader

• One or two indicator lights

• Pushbutton switch

• 24-VDC power supply

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The MMI requires power and Ethernet communications from the FCM. The power connections can be made
with AC or DC supplies when made to the appropriate terminals. The Ethernet connection is made between
the THMI module and the configured board set in the FCM enclosure.
Figure 12: Model SA MMI components

+ 24 VDC GND

P1 P1 P2 P2 Factory Wired

+24 VDC
P1 1 2 3 4 5 6 7 8 9 10 11 12

Ground
P2 1 2 3 4 5 6 7 8 9 10 11 12

3.5.3 THMI Module

The THMI module’s touch-screen user interface is standard on the ST, N4, and QT models of the
AccuLoad IV. It connects to the A4M board using an Ethernet cable.

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The following figure identifies the wiring connections on the THMI electronic module.

Figure 13: THMI Module Connections

CN4
1 V+ 12/24 V
2 GND
3 GND

ETH1

CN6

3.5.4 A4M Board

The main input/output board for the AccuLoad IV is an A4M board available for the ST, QT, and N4 models,
as well as the SA model’s MMI component. This board provides up to six dual-channel product meter pulse
inputs; any pulse inputs that are not used for product meters can be used for up to four metered injector
pulse inputs.

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AccuLoad IV Installation & Maintenance Manual

The replaceable parts on the A4M board are the power fuse, AC digital output relays, and the analog I/O
modules. Refer to the AccuLoad IV parts list (PO06200) for details.
Figure 14: A4M Board Layout
Analog I/O Modules

ETH3 ETH2
ACIM1

1
ACIM2
AM1 AM2 AM3 AM4 AM5 AM6 1
ETH4 ETH1
ACIM3

TBE2
ACIM4
TBE5

CN7
1 1
Ethernet Connections 6
ACIM5
PT2

CN6 S2 U22
PT1

U41
LMOD1 AC Digital
Output Relays
18 U29 U38 P4

1 SSR1 1
S1 P3
12
SSR2
1
CN1
TBE6

U28

TBE3
SW2 SSR3
TBK1

CN9
SSR4

10
DIP Switches CN4 U1 U8
U7 U4 P1
L1 SSR5
U10
1 10 12
U11 SSR6
1 P2
U3
U9
CN5 U5 SSR7 1
U17 SW1 U2
TBK4

1 SSR8
TBE4

TBE7
CN8
TBK2

SSR9
10
C119
SSR10
1
8
10
C94 D11
SSR11
TBK5

1 T1
16 HS1
TBK3

Supply Fuse 1
TBE1
3
C95
8 5

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AccuLoad IV Installation & Maintenance Manual

3.5.4.1 A4M I/O Connections

The following drawing details the A4M board’s I/O connections.
Figure 15: A4M Board Connections
TBE5
1 RTD + A4M
2 SIG +
AM1 PT1
3 SIG -
1 +
4 RTD - Pulse In 1 Enet Enet
2 -
5 RTD + 3 2
3 + TBE2
6 SIG + Pulse In 2 AC in Com 1
AM2 4 -
7 SIG - Enet Enet In 7 AC 2
5 + 4 1
8 RTD - Pulse In 3 In 8 AC 3
6 -
9 RTD + In 9 AC 4
7 +
10 SIG + Pulse In 4 PT2 In 10 AC 5
AM3 8 -
11 SIG - 1 + In 11 AC 6
9 + Pulse In 7
12 RTD - Pulse In 5 2 -
10 - TBE3
13 SIG + 3 +
AM4 11 + Pulse In 8 1
14 SIG - Pulse In 6 4 - Out 4 AC
12 - 2
15 SIG +
AM5 TBK1 3
16 SIG - S1 Out 5 AC
1 TX 4
17 SIG + OFF 1 ON
AM6 2 RX 5
18 SIG - Out 6 AC
Com 1 6
3 RTS
TBE6 232
7
4 CTS 8 Out 7 AC
1 HS Prv +
5 COM 8
2 HS Prv - OFF 1 ON
6 TX + 9
3 RTD + Out 8 AC
AM6 7 TX - 10
4 RTD - 4
8 RX + 485 11
5 RTD + S2 Out 9 AC
AM5 9 RX - 12
6 RTD -
10 COM
7 RTD +
AM4 TBK2 TBE7
8 RTD - TBK4 1 TX 1
1 + Com 2 Out 10 AC
9 Gnd 2 RX 2
In 1 DC 232
10 Gnd 2 - 3 COM 3
3 + Out 11 AC
TBE4 4 TX + 4
In 2 DC
1 TX 4 - 5 TX - 5
Com 4 5 + Out 12 AC
2 RX 6 RX + 485 6
232 In 3 DC
3 Com 6 - 7 RX - 7
7 + Out 13 AC
4 - Pulse 8 COM 8
In 4 DC 8 - Out 1 9
5 + TBK3
9 N.C. Out 14 AC
6 - 10
In 5 DC 1 TX +
7 + 10 N.C.
2 TX - Out 9 AC
8 - TBK5 Com 3 microSD
In 6 DC 3 RX +
9 + 1 + 485 Card
Out 1 DC 4 RX -
10 2 - 5 COM
+24 VDC CN4
11 3 +
Out Out 2 DC
12 4 -
13 5 + L1 L2 Gnd
Out 3 DC
14 DC Gnd F2 6 - F1
• • •
15 7 + Pulse
16 +24 VDC In 24 V 8 - Out 2 TBE1

3.5.4.2 A4M I/O Index Numbering

The following table provides details about configuring the A4M board’s I/Os.
Table 7: A4M I/O Index Numbering
AccuLoad Configuration Index
Terminals Type of I/O
Number
TBK1 Serial communication port RS232/485 Comm 1
TBK2 Serial communication port RS232/485 Comm 2
TBK3 Serial communication port RS485 Comm 3

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Table 7: A4M I/O Index Numbering

AccuLoad Configuration Index
Terminals Type of I/O
Number
TBK4 DC digital input Digital inputs 1 through 3
TBK4 Pulse output Pulse output 1
TBK5 DC digital output Digital outputs 1 through 3
or pulse outputs 3 through 5
TBK5 Pulse output Pulse output 2
TBE1 AC power input (115 to 230) Not applicable
TBE2 AC digital input Digital inputs 7 through 11
TBE3 AC digital output Digital Outputs 4 through 9
TBE4 Serial communication port RS232 Comm 4
TBE4 DC digital input Digital inputs 4 through 6
TBE4 24 VDC power - 1 amp maximum Not applicable
TBE4 DC electronic ground Not applicable
TBE5 Analog I/O Analog I/O 1 through 6
TBE6 High-speed prover pulse output Not applicable

TBE6 Analog I/O Analog I/O 4 through 6

TBE7 AC digital input Digital outputs 10 through 14
PT 1 Meter pulse inputs Pulse inputs 1 through 6
PT 2 Meter pulse inputs Pulse Inputs 7 through 8

3.5.4.3 A4M Special I/O Considerations

The DC digital output terminals on TBK5 can be configured as low-speed pulse outputs, as follows:
Table 8: Low-Speed Pulse Outputs
Terminals Outputs
Terminals 1 and 2 Digital output 1 or pulse output 3
Terminals 3 and 4 Digital output 2 or pulse output 4
Terminals 5 and 6 Digital output 3 or pulse output 5

If digital valve control is used for any product- or flow-controlled additive meters connected to pulse
inputs located on the A4M or A4B board, the digital outputs controlling the flow control valve must also
be located on the A4M or A4B, respectively.

3.5.4.4 A4M S1 DIP Switch Settings

The following table provides information about S1 dual in-line package (DIP) switch settings on the A4M
board.
Table 9: A4M S1 DIP Switch Settings
Switch Setting
S1-1 Factory use
S1-2 Factory use
S1-3 Reserved
S1-4 Reserved
S1-5 Reserved

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Table 9: A4M S1 DIP Switch Settings

Switch Setting
S1-6 Clear pairing information
S1-7 Off for ST, QT, and N4 models
Board set selector for SA model board set (see Section 3.7.1.4: SA Board
Set IP Addresses)
S1-8 Off for ST, QT, and N4 models
Board set selector for SA model board set

3.5.4.5 A4M SW2 DIP Switch Settings

For the ST, QT, and N4 models, all four DIP switches in SW2 should be in the OFF position during normal
operation.

For the SA model, DIP switches SW2-3 and SW2-4 should be used to select the board set with which the
A4M module is associated.

Special functions can be activated on all of the AccuLoad models when switch SW2-1 is set to ON. To
activate the special functions, first disconnect the power supply from the AccuLoad and then set the
switches to the special function. When finished, re-connect the power supply to the AccuLoad. After the
special function is complete, you should re-set the DIP switches as follows:

• For the ST, QT, and N4 models, all switches should be set to OFF.

• For the SA model, switches SW2-1 and SW2-2 should be set to OFF and switches SW2-3 and SW2-4
should be set according to the board set.
Table 10: A4M Board SW2 DIP Switch Settings
SW2-1 SW2-2 SW2-3 SW2-4 Setting Action
0 0 0 0 Normal operation for models ST, QT, N4, and SA board set A
0 0 0 1 Normal operation for model SA board set B
0 0 1 0 Normal operation for model SA board set C
0 0 1 1 Normal operation for model SA board set D
0 1 0 0 Reserved
0 1 0 1 Reserved
0 1 1 0 Reserved
0 1 1 1 Reserved
1 0 0 0 Forces default IP address of 192.168.0.1
1 0 0 1 Erases configuration database
1 0 1 0 Erases all databases (configuration, transaction, event, and driver)
1 0 1 1 Clears security passcodes
1 1 0 0 Forces touch screen recalibration
1 1 0 1 Reserved
1 1 1 0 Reserved
1 1 1 1 Reserved

3.5.5 A4B Board

The A4B board is a standard electronic module that provides I/O expansion for the QT model and the SA
model’s FCM component.

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The replaceable parts on the A4B board are the power fuse and the AC digital output relays. Refer to the
AccuLoad IV parts list (PO06200) for details.
Figure 16: A4B Board Layout

LMOD1 U7
1 12
PT1

1
SSR1 U15 U13 U12 U11 U10 U9

SSR2

TB14
CN1
TB10

SSR3
P2
U14
SSR4

10
SSR5

SSR6

ETH2
1

SSR7
U3 Ethernet
U20
SSR8 Connections

ETH1
TB9

S1 S1
SSR9
DIP Switches
SSR10

1
SSR11 CN2
12

U24
SSR12 U4
1

S2 CN3

TB12
SSR13 U28

SSR14
TB8

U30 U33
SSR15

12
SSR16 U37
10

Analog Digital
Output Relays
U25
1

ACIM1
TB13

U29
TB11

ACIM2
U34
5

ACIM3
12

U38
TB2
1 2
ACIM4
C14

Power Fuse

If digital valve control is used for any product- or flow-controlled additive meters connected to pulse inputs
located on the A4M or A4B board, the digital outputs controlling the flow control valve must also be
located on the A4M or A4B board, respectively.

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Figure 17: A4B Board Connections

A4B
TB10 PT1 TB14

12
11
10
1 HS PRV + 1

9
8
7
6
5
4
3
2
1
Out #15 AC
2 HS PRV - 2

-
+
-
+
-
+
-
+
-
+
-
+
3 NC 3
Out #16 AC
4 NC 4

Pulse In #12

Pulse In #10
Pulse In #11

Pulse In #9

Pulse In #8

Pulse In #7
5 NC 5
Out #17 AC
6 NC 6
7 NC 7
Out #18 AC
8 NC 8
9 Gnd 9
Out #19 AC
10 Gnd 10

TB9 Enet
1 2
Out #20 AC
2
3 Enet
Out #21 AC 1
4
5
6
Out #22 AC ON TB12
BIO In #1 1
7 S1 1 8
Out #23 AC Com #1 2
8
OFF BIO Out #1 3
9
Out #24 AC BIO In #2 4
10
Com #2 5
11
Out #25 AC BIO Out #2 6
12
BIO In #3 7
Com #3 8
TB8
BIO Out #3 9
1
Out #26 AC BIO In #4 10
2
Com #4 11
3
Out #27 AC BIO Out #4 12
4
5 TB13
Out #28 AC
6 BIO In #5 1
7 Com #5 2
Out #29 AC
8 BIO Out #5 3
9 TB2 BIO In #6 4
Out #30 AC
10 Com #6 5
BIO Out #6 6
+24 VDC

TB11 BIO In #7 7
Ground

1 In #12 AC Com #7 8
2 In #13 AC BIO Out #7 9
3 In #14 AC BIO In #8 10
4 In #15 AC F1 Com #8 11
1
2

5 AC in Com BIO Out #8 12

Refer to the installation manual for wiring details

3.5.5.1 A4B I/O Index Numbering

The following table provides details about configuring the A4B board’s I/Os.
Table 11: A4B I/O Index Numbering
Terminals Type of I/O AccuLoad Configuration Index Number
TB8 AC digital output Digital outputs 26 through 30
TB9 AC digital output Digital outputs 20 through 25
TB10 AC digital output Digital outputs 15 through 19
TB11 AC digital input Digital inputs 12 through 15
TB12 DC digital input or output Digital Inputs 16 through 19
or digital outputs 31 through 34
TB13 DC digital input or output Digital inputs 20 through 23
or digital outputs 35 through 38
PT1 Meter pulse inputs Meter pulse inputs 9 through 14

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3.5.5.2 A4B DIP Switch Settings

The following table provides information about S1 DIP switch settings on the A4B board.
Table 12: A4B DIP Switch Settings
Switch Setting
S1-1 Factory use
S1-2 Reserved
S1-3 Reserved
S1-4 Reserved
S1-5 Reserved
S1-6 Clear pairing information
S1-7 Off for ST, QT, and N4 models
Board set selector for SA model
S1-8 Off for ST, QT, and N4 models
Board set selector for SA model

3.5.6 A4I Board

The A4I board is an optional electronic module for the ST, QT, and N4 models, as well as the SA model’s
FCM component. It provides 20 AC digital outputs and 10 inputs that can be used in the following ways:

• Additive meter pulse inputs

• General purpose DC digital inputs
• Interface with up to 10 metered injectors
You can use multiple A4I boards on the AccuLoad, as follows:
Table 13: Maximum Number of A4I Boards
Model A4I Boards
ST Up to two externally
QT Up to two externally or internally
N4 Up to two, but only one may be
installed internally
SA (FCM component) Up to four externally or internally

Up to two A4I modules can be connected to an A4M board and can either be mounted inside the AccuLoad
enclosure or in a separate external enclosure.

For any additive meters connected to pulse inputs located on the A4I, the digital outputs controlling the
associated pump and solenoid valve must be located on the same A4I module.

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The replaceable parts on the A4I board are the power fuse and the AC digital output relays.
Figure 18: A4I Board Layout
Ethernet Connections

CN1 LMOD1

ETH2 ETH1

TB9
CN3

TB5
U10 U11 U9 CN2
AC Digital
Output Relays
SSR1
U22

SSR2

P1
S1 SSR3
DIP
U5
Switches

TB8
SSR4
TB4

SSR5
U4

SSR6

P8 SSR7
S2

SSR8
U27
SSR9

SSR10
TB3

SSR11

SSR12

SSR13
TB7

SSR14

SSR15
TB2

SSR16
12V
24V
5V

Power
SSR17
Fuse
TB6

SSR18
F1
TB1

C5
C14 SSR19

D3 SSR20

3.5.6.1 A4I I/O Connections

The A4I board requires 24 VDC power and either serial or Ethernet communications connections to the
A4M board to operate. Ethernet communications should be used whenever possible, but the serial
communication option is provided to facilitate upgrades and maintain backward compatibility.

Firmware updates are not available over serial connections in the A4I.

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The following drawing shows the A4I board’s I/O connections.

Figure 20: A4I Connections

A4I
TB5 TB9
1 +V Out
Enet Enet
2 Inj Pulse/DC In 1 Out 1-Out 10
2 1
3 Common
4 +V Out
5 Inj Pulse/DC In 2
6 Common
7 +V Out
8 Inj Pulse/DC In 3

TB4 TB8
1 Common N/C 12
2 +V Out N/C 11
S1
3 Inj Pulse/DC In 4 Out 1 10
OFF 1 ON
4 Common Out 2 9
5 +V Out Out 3 8
6 Inj Pulse/DC In 5 Out 4 7
7 Common Out 5 6
8 +V Out Out 6 5
8
9 Inj Pulse/DC In 6 Out 7 4
10 Common Out 8 3
Out 9 2
TB3 Out 10 1
1 +V Out
2 Inj Pulse/DC In 7 TB7
3 Common Out 11 10
4 +V Out Out 12 9
5 Inj Pulse/DC In 8 Out 13 8
6 Common Out 14 7
7 +V Out Out 15 6
8 Inj Pulse/DC In 9 Out 16 5
9 Common Out 17 4
10 +V Out Out 18 3
11 Inj Pulse/DC In 10 Out 19 2
12 Common Out 20 1

TB2
1 RS485 (Rx -) CN5 Injector +V Out Selection
5 3 1
2 RS485 (Rx +)/RS232 (Rx) 1-2 24V
3 RS485 (Tx -) • • • 3-4 12V
• • •
4 RS485 (Tx +)/RS232 (Tx) 6 4 2 5-6 5V

J1
TB1 TB6
1 +24 VDC
•
F1
DC Input •
2 Gnd/RS232 Com Out 11-Out 20
Earth Ground
to Circuit Ground

The A4I board has jumpers that allow customization. If the A4I board is connected to additive meters for
which the transmitters require DC power, the voltage select jumpers (see Table 14: A4I Jumper Settings)
are used to set the meter power supply voltage to 5, 12, or 24 VDC.
Table 14: A4I Jumper Settings
Designation Jumpers Description
5V 1 and 2 24 V – +V Out
12V 3 and 4 12 V – +V Out
24V 5 and 6 5 V – +V Out

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Table 15: A4I Switch Settings

Switch Setting
S1-1 Factory Use
S1-2 OFF = Address 100
ON = Address 200
S1-3 OFF = Band 9600
ON = Band 38,400
S1-4 OFF = RS 232
ON = RS 485
S1-5 OFF = Address 100
ON = Address 200
S1-6 Reserved
S1-7 Model SA Board Set Selector - see section 6, Off for all other models
S1-8 Model SA Board Set Selector - see section 6, Off for all other models

3.5.6.2 A4I I/O Index Numbering

The following tables provide details about configuring the A41 board’s I/Os.
Table 16: First Optional A4I I/O Index Numbering
Terminal
Type of I/O AccuLoad Configuration Index Number
Block
TB3 Injector pulse Inj 11 in or DC In 30 – Pin 2 Inj 12 in or DC In 31 – Pin
or digital input 5 Inj 13 in or DC In 32 – Pin 8 Inj 14 in or DC In 33 –
Pin 11
TB4 Serial communication port Inj 8 in or DC In 27 – Pin 3 Inj 9 in or DC In 28 – Pin 6
RS232/485 Inj 10 in or DC In 29 – Pin 9

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Table 16: First Optional A4I I/O Index Numbering

Terminal
Type of I/O AccuLoad Configuration Index Number
Block
TB5 Serial communication port Inj 5 in or DC In 24 – Pin 2 Inj 6 in or DC In 25 – Pin 5
RS485 Inj 7 in or DC In 26 – Pin 8

TB7 AC digital output AC Out 49 – Pin 10

AC Out 50 – Pin 9
AC Out 51 – Pin 8
AC Out 52 – Pin 7
AC Out 53 – Pin 6
AC Out 54 – Pin 5
AC Out 55 – Pin 4
AC Out 56 – Pin 3
AC Out 57 – Pin 2
AC Out 58 – Pin 1
TB8 AC digital output AC Out 39 – Pin 10
AC Out 40 – Pin 9
AC Out 41 – Pin 8
AC Out 42 – Pin 7
AC Out 43 – Pin 6
AC Out 44 – Pin 5
AC Out 45 – Pin 4
AC Out 46 – Pin 3
AC Out 47 – Pin 2
AC Out 48 – Pin 1

Table 17: Second Optional A4I I/O Index Numbering

Terminal
Type of I/O AccuLoad Configuration Index Number
Block
TB3 Injector pulse Inj 21 in or DC In 40 – Pin 2 Inj 22 in or DC In 41 – Pin 5 Inj 23
or digital input in or DC In 42 – Pin 8 Inj 24 in or DC In 43 – Pin 11

TB4 Serial communication port Inj 18 in or DC In 37 – Pin 3 Inj 19 in or DC In 38 – Pin 6 Inj 20

RS232/485 in or DC In 39 – Pin 9

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Table 17: Second Optional A4I I/O Index Numbering

Terminal
Type of I/O AccuLoad Configuration Index Number
Block
TB5 Serial communication port Inj 15 in or DC In 34 – Pin 2 Inj 16 in or DC In 35 – Pin 5 Inj 17
RS485 in or DC In 36 – Pin 8

TB7 AC digital outputs AC Out 69 – Pin 10

AC Out 70 – Pin 9
AC Out 71 – Pin 8
AC Out 72 – Pin 7
AC Out 73 – Pin 6
AC Out 74 – Pin 5
AC Out 75 – Pin 4
AC Out 76 – Pin 3
AC Out 77 – Pin 2
AC Out 78 – Pin 1
TB8 AC digital outputs AC Out 59 – Pin 10
AC Out 60 – Pin 9
AC Out 61 – Pin 8
AC Out 62 – Pin 7
AC Out 63 – Pin 6
AC Out 64 – Pin 5
AC Out 65 – Pin 4
AC Out 66 – Pin 3
AC Out 67 – Pin 2
AC Out 68 – Pin 1

3.5.6.3 A4I DIP Switch Settings

The following table provides information about S1 DIP switch settings on the A4I board.
Table 18: A4I Switch Settings
Switch Setting
S1-1 Factory use (always OFF)
S1-2 Module address (OFF = 100, ON = 200)
S1-3 Serial baud rate (OFF = 9600, ON = 38400)
S1-4 Serial mode (OFF = RS232, ON = RS485)
S1-5 Serial termination resistors (OFF = disable, ON = enable)
S1-6 Clear pairing information
S1-7 Off for ST, QT, and N4 models
Board set selector for SA model (see Section 3.7.1.4: SA Board Set IP
Addresses)
S1-8 Off for ST, QT, and N4 models
Board set selector for SA model

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3.6 General Wiring Information

During initial installation of the AccuLoad and anytime an electronic module is installed, the two
calibration numbers (Cal 1 and Cal 2) written on the top of the module should be configured in
AccuMate for AccuLoad IV to ensure optimum accuracy.

3.6.1 AC Input Power

The AccuLoad A4M board has two AC power inputs, as follows:

• The first AC power input is for instrument power, which powers the AccuLoad’s electronics and is
connected to the A4M board at TB1 (see Figure 22: AC Power Inputs to AccuLoad A4M Board). The
instrument power should be clean and must meet the requirements listed in the AccuLoad IV
specifications (SS06200).

• The second AC power input is used to drive external AC equipment (such as solenoids) and should be
supplied to the AccuLoad by a separate circuit from the power panel.

Figure 22: AC Power Inputs to AccuLoad A4M Board

Field I/O
Power Power
Distribution AccuLoad
Panel
Instrument
Power TB1

Separate
Circuits

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Figure 23: Example of AC Wiring for a Typical AccuLoad

Terminal Board Key

3.6.2 DC Instrument Power

The AC instrument power is connected to the A4M module, which produces 24 VDC power for the standard
modules in the AccuLoad (THMI and A4B). The A4M board’s DC power supply is also capable of supplying
up to a maximum of 1 amp of regulated DC power, which can be used to power optional A4I modules, card
readers, meter pulse transmitters, and other external DC circuits.

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Figure 24: DC Power Wiring on ST, QT, and N4 Models

A4M Module

TBE4
Factory wired to
AccuLoad internal
9 modules
10
+24 VDC 11
12 To meter transmitters,
13 remote A4I etc.
DC GND 14
15
16 Factory wired to
AccuLoad internal
modules

3.6.3 Grounding
The AccuLoad must be properly grounded to ensure safe and reliable operation.

The AccuLoad requires a single-point earth ground dedicated to the AccuLoad provided by a grounding
rod. Less than 2 ohms must be measured between the ground lug of the AccuLoad’s enclosure and the
grounding rod.

Any ground wires or shields in the cables connected to devices external to the AccuLoad (such as printers
or analog sensors) should only be connected to TBE4 terminals 13, 14, or 15 at the AccuLoad end of the
cable. It is very important to ensure this is the only grounding point.

3.6.4 I/O Connections

From the factory, none of the AccuLoad’s I/O connections or functions are defined. You must configure
your AccuLoad’s I/O points based on the equipment at your facility and the operations you want to be
performed. For example, if a digital flow control valve should to be interfaced with the AccuLoad as part of
a loading rack installation, you must configure the AccuLoad with digital outputs for the upstream and
downstream solenoids. You also must assign the upstream solenoid function to a digital output to be used
for the solenoid’s control and then do the same for the downstream solenoids.

The only I/O points that are automatically assigned by the AccuLoad are meter pulse inputs (both product
meters and additive meters). The AccuLoad assigns the pulse inputs based on the number of meters and
injectors defined in your configuration. Any pulse input which is not automatically assigned a function by
the AccuLoad is available for user-selectable functions.The pulse input assignments for various meter
configurations are provided in Section 4.3: Meter Input Wiring.

3.6.5 Meter Pulses

The AccuLoad counts pulses from the meters to determine the volume or mass that has flowed through the
meter. The AccuLoad can be configured to receive pulses in one of three modes:

• Single Channel—One pulse input receives a single stream of pulses from the meter.

• Dual Channel—Two pulse inputs receive two separate pulse streams from the meter. This enables the
AccuLoad to detect the direction of flow and meter connection problems with one of the channels so
an alarm can be raised. This also enables the AccuLoad to determine the direction of flow through the
meter.

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• Dual Channel with Integrity—Four pulse inputs receive two pulses streams and two inverted pulse
streams from the meter. This enables the AccuLoad to detect the direction of flow and meter connection
problems, including when both pulse streams are inactive.

For each of the above meter pulse modes, the signal on the input to the AccuLoad must be less than 1 volt
for a minimum of 80 microseconds and then transition to greater than 5 volts and remain above 5 volts for
a minimum of 80 microseconds to qualify as a valid pulse (as shown in the following graph).
Figure 25: Meter Pulse Requirements

3.6.6 Analog I/O Modules

The A4M board has six slots into which modules can be inserted to interface to analog sensors or actuators
(such as a pressure sensor or valve). Typically, these modules are installed at the factory, but changes and
replacements of these modules may be done in the field. The analog I/O points are fully configurable and can
be inputs (such as temperature or pressure) or outputs (such as analog valve control). Five types of analog
interface modules are available, which are inserted into a socket on the A4M board as described in the
following table.
Table 19: Types of Analog I/O Modules
Analog Module Type Electrical Connection Functions
Resistive temperature Four-wire, 100-ohm RTD Temperature input
device (RTD)
CRI 4-20 mA input Temperature, pressure, and density
General purpose input

CRO 4 to 20 mA output Analog valve control

Flow rate output
General purpose output
VTI 1 to 5 VDC input Temperature, pressure, and density
General purpose input

VTO 1 to 5 VDC output Analog valve control

Flow rate output
General purpose output

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Figure 27: Analog I/O Modules

Sockets Analog Module

AM 1
Set Cal 1 and Cal 2
parameters to these
Alignment Pins Mounting Screw
values in AccuLoad
Side View Top View analog configuration

CAUTION: Before inserting or removing any analog module, first ensure that all associated circuits are
de-energized. Use proper ESD practices.To remove a module, loosen the captive retaining screw and
then gently pull the module out of the socket while slightly rocking the module.

To insert a module, line up the pins with the socket holes, push the module in until it is seated against the
circuit board, and then tightening the retaining screw.

3.6.7 Typical Wiring Diagrams

The following diagrams provide details for wiring the AccuLoad IV.
Figure 29: AC Digital Input

AccuLoad External AC Wiring

AC
TBE2
(L2) AC IN
AC Common
L2
AC
In #7 (AC) AC supply

In #8 (AC) L1
AC

AC In #9 (AC)

In #10 (AC)
AC

AC In #11 (AC)

AC

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Figure 30: AC Digital Output

AccuLoad L

AC Power Supply

Alarm,
Valve,
etc.

Receiving Device

Figure 31: DC Digital Input

AccuLoad External DC Wiring

+24 VDC from A4M

TBE4 10, 11, or 12

IN X+
3K

IN X-
3K

DC Ground from A4M

TBE4 13, 14, or 15

Figure 32: DC Digital Output

AccuLoad
External DC Wiring
+24 VDC from A4M
TBE4 – 10, 11 or 12

DC Output +

External DC Actuated
Device (i.e. Valve)
DC Output -

DC Ground from A4M

TBE4 – 13, 14 or 15

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Figure 33: RTD Temperature Probe Analog Inputs

AccuLoad Resistance Temperature
Terminal Block TBE5 Probe
Red
RTD + 1
SIG + Red
2
Black
SIG - 3
RTD - Black
4

A4M TBE6
9 or 10

Figure 34: Active 4-20 mA Analog Inputs

AccuLoad IV A4M
Terminal Block TB5

RTD +

SIG X +
Vin
SIG X -

RTD - GND
4-20 mA
Ground (TB4)
Transmitting Device

Figure 35: Passive 4-20 mA Analog Inputs

AccuLoad IV A4M
Terminal Block TB5

RTD + External Power

SIG X +
Vin
SIG X -

RTD - GND
4-20 mA
Ground (TB4)
Transmitting Device

Figure 36: Analog Outputs

AccuLoad IV A4M
Terminal Block TBE5 Receiving Device
RTD +
SIG X +
4-20 mA
SIG X -
RTD -
Ground (TBE4)
GND

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Figure 37: External Counter Wiring

AccuLoad External Meter
A4M +24V
Pulse Wiring
TBE4 10, 11, or 12

IN X+
3K

IN X-
3K Open Collector
Meter Output

A4M GND
TBE4 13, 14, or 15

For pulse transmitters requiring 12 VDC (such as GPST), install the P2412 converter. See the AccuLoad
Preset Accessory P2412 Converter Installation manual (MN06117) for details.

Figure 38: High-Speed Prover Output Wiring

AccuLoad
High Speed
Prover Output

TBE6-1

External Prover
TBE6-2

3.7 Communications Wiring

3.7.1 Ethernet Communications
The recommended networking strategy is to place the AccuLoad on a segmented network, which isolates
the industrial control network traffic from the broader general purpose network traffic associated with
corporate LANs and the Internet. This strategy enhances the security and throughput on the critical control
portion of the network. The following figure illustrates this networking strategy.

If the AccuLoad IV must be directly installed on a Class A network, the AccuLoad’s internal IP addressing
scheme must be changed to avoid address conflicts. For instructions on configuring internal IP
addresses for the ST, QT, and N4 models using the AccuLoad’s touch screen, refer to the AccuLoad IV
Operator Reference Manual (MN06200). For details about changing internal IP addresses for the SA
model using DIP switches, see Section 3.7.1.4: SA Board Set IP Addresses.

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AccuLoad IV Installation & Maintenance Manual

Figure 39: Recommended Network Strategy

AccuLoad

Process Database Data Historian AccuLoad

Firewall Firewall

Automation Server
Corporate
LAN

PLC

Internet Industrial Control

Network

3.7.1.1 ST and N4 Model Ethernet Connections

Ethernet connections for the ST and N4 models are shown in the following diagram.
Figure 40: Ethernet Connections in AccuLoad ST and N4 Models

A4M

ETH 1 (reserved)

THMI ETH 2
A4I (optional)
ETH 3
External
Ethernet ETH 4

A4I (optional)

3.7.1.2 QT Model Ethernet Connections

Ethernet connections for the QT model are shown in the following diagram.
Figure 41: Ethernet Connections in AccuLoad QT Model

A4M

ETH 1 (reserved)

THMI ETH 2
A4I (optional)
ETH 3 A4B
External
ETH 4
Ethernet

A4I (optional)

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AccuLoad IV Installation & Maintenance Manual

3.7.1.3 SA Model Ethernet Connections

Ethernet is used for communication between the SA model’s FCM and MMI units, as shown in the
following diagram. On each MMI’s THMI board, the Ethernet cable connects the ETH1 RJ45 jack to a
board set in the FCM.
Figure 42: Ethernet Connections for SA Model

A4M
MMI A
Primary CPU Board Set SAA
ETH1
THMI ETH2
ETH3 A4I (optional) A4B
External
Network ETH4
Connection

A4M
Primary CPU Board Set SAB
ETH1
ETH2
ETH3 A4I (optional) A4B
External
Network ETH4
Connection

A4M
Primary CPU Board Set SAC
ETH1
ETH2
ETH3 A4I (optional) A4B
External
Network ETH4
Connection

MMI B A4M
(optional) Primary CPU Board Set SAD
ETH1
THMI ETH2
ETH3 A4I (optional) A4B
External
Network ETH4
Connection

3.7.1.4 SA Board Set IP Addresses

The addresses of the MMI’s board sets are assigned using DIP switches on each board in the set. The DIP
switches must be set based on the board set (A, B, C, or D) with which the board is associated, as detailed
in the table below. The A4M module has two DIP switches (SW1 and SW2) and the A4B and A4I boards
each have a single DIP switch (SW1). (See section x to find these DIP switches on each board’s layout).

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AccuLoad IV Installation & Maintenance Manual

For new equipment, these DIP switches are set at the factory and should not need adjustment during
installation. However, any time a module is moved or replaced, the IP address must be reset according to
the table below.
Table 20: MMI IP Address DIP Switch Settings
SW-1 on A4M, A4B, and
Board Set SW-2 on A4M Board
A4I Boards
A Switch 7: OFF Switch 3: OFF
Switch 8: OFF Switch 4: OFF
B (optional) Switch 7: OFF Switch 3: OFF
Switch 8: ON Switch 4: ON
C (optional) Switch 7: ON Switch 3: ON
Switch 8: OFF Switch 4: OFF
D (optional) Switch 7: ON Switch 3: ON
Switch 8: ON Switch 4: ON

3.8 Serial Communications

The AccuLoad provides four serial ports, as described in the following table and diagrams:
Table 21: Serial Communication Ports
Communication Port Name Terminal Locations Description
Comm 1 A4M-TBK1 RS-232 or RS-485 with flow control
Comm 2 A4M-TBK2 RS-232 or RS-485
Comm 3 A4M-TBK3 RS-485
Comm 4 A4M-TBE4 RS-232

Figure 43: Four-Wire RS-485 Serial Wiring

AccuLoad External Device
TX+ RX+
RX+ TX+
TX- RX-
RX- TX-

AccuLoad
TX+
RX+
TX-
RX-

Figure 44: Two-Wire RS-485 Serial Wiring

AccuLoad Com 1, 2, or 3 AccuLoad A4I or External
Device

TX+ RX+

RX+ TX+

TX- RX-

RX- TX-

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AccuLoad IV Installation & Maintenance Manual

Figure 45: RS-232 Serial Wiring

TX RX

RX TX

GND GND

Figure 46: Multi-Drop RS-232 Serial Wiring

RX TX GND RX TX GND

TX

RX

GND

3.9 Pulse Outputs

The AccuLoad can be configured to provide up to five pulse outputs, as detailed in the following table.
Table 22: Pulse Output Configurations
Pulse Outputs Configurations
1 and 2 Frequency range of 0 to 3,000 Hz
Open-collector connection
A4M terminals: TBK4 7 and 8; TBK5 7 and 8 (dedicated)
3, 4, and 5 Frequency range of 0 to 125 Hz
Digital-output connection
A4M terminals: TBK5 1 through 6 (shared with DC outputs 1 through 3)

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AccuLoad IV Installation & Maintenance Manual

4 Meter I/O Connections

4.1 I/O Index Numbering
When configuring the AccuLoad, I/O points are referred to by their index number.

4.2 Meter Connection Details

4.2.1 PRIME 4 Meter
The AccuLoad uses the I/O connection points in the following table to connect to Smith Meter PRIME 4
meters.
Table 23: Prime 4 Connections
AccuLoad Connections Prime 4 Connections
Pulse input A plus White (signal A output)
Pulse input B plus (dual-pulse only) Yellow (signal B output); no connection for single-
channel meters
Pulse input A and B minus connect to DC
ground
+ 24 VDC Red (input power)
DC ground Black (common)

4.2.2 Genesis
The AccuLoad uses the I/O connection points in the following table to connect to Smith Meter Genesis
meters.
Table 24: Genesis Connections
AccuLoad Connections Genesis Connections
Pulse input A plus Terminal 2 (signal A output)
Pulse input B plus (dual-pulse only) Terminal 3 (signal B output); not used for single-channel
connection

Pulse input A and B minus connect

to DC ground
+ 24 VDC Terminal 1 (input power)
DC ground Terminal 4 (electronics ground)
Terminals 5 through 8 are not used

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AccuLoad IV Installation & Maintenance Manual

4.2.3 Universal Pulse Transmitter

The AccuLoad uses the I/O connection points in the following table to connect to the Smith Meter Universal
Pulse Transmitter (UPT).
Table 25: UPT Connections
AccuLoad Connections UPT Connections
Pulse input A plus Terminal 5 (signal A output)
Pulse input B plus (dual-pulse only) Terminal 3 (signal B output); not used for single-channel
connection
Pulse input A and B minus connect
to DC ground
+ 24 VDC Terminal 2 (input power)
DC ground Terminal 1 (electronics ground)
Pulse input A integrityplus Terminals 6 (signal A integrity output); not used for non-
integrity connection
Pulse input B integrity plus Terminals 4 (signal A integrity output); not used for non-
integrity connection
Terminal 7 (shield); no connection
Terminal 8 (verification pulse output); connect to optional
verification device
Terminal 9 (inverted verification pulse output); connect to
optional verification device
Terminal 10; no connection

4.2.4 PPS Transmitter

The AccuLoad uses the I/O connection points in the following table to connect to the Smith Meter
Photoelectric Pulse Security (PPS) Transmitter.
Table 26: PPS Transmitter Connections
AccuLoad Connections PPS Transmitter Connections
Pulse input A plus Terminal 5 (signal A output)
Pulse input B plus (dual-pulse only) Terminal 3 (signal B output); not used for single-channel
connection

Pulse input A and B minus connect

to DC Ground
+ 24 VDC Terminal 2 (input power)
DC ground Terminal 1 (common)
Pulse input A integrity plus Terminals 6 (signal A integrity output); not used for non-
integrity connection
Pulse input B integrity plus Terminals 4 (signal A integrity output); not used for non-
integrity connection

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AccuLoad IV Installation & Maintenance Manual

4.2.5 PA-6 Preamplifier

The AccuLoad uses the I/O connection points in the following table to connect to the Smith Meter PA-6
Preamplifier.
Table 27: PA-6 Preamplifier Connections
AccuLoad Connections PA-6 Connections
Pulse input A plus Terminal 3 (signal A output)
Pulse input minus – DC ground

+ 24 VDC Red (input power)

DC ground White (common)

For dual-pulse turbine meter connections, one PA-6 Preamp on Boss #1 and a second PA-6 Preamp on
Boss #2 are available. In this case, the wiring to the B pulse input of the AccuLoad is done the same as the
wiring to the A pulse input as shown above.

4.2.6 Promass 80, 83, and 84 Coriolis Meters

The AccuLoad uses the I/O connection points in the following table to connect to the Promass 80, 83, and
84 Coriolis meters.
Table 28: Promass 80, 83, and 84 Coriolis Meter Single-Channel Connections
AccuLoad Connections Promass 80, 83, and 84 Connections
Pulse Input A Plus +24 VDC
Pulse Input A Minus Terminal 24 (Signal A output) for Promass output options Model 80: A,
D, S, and T
Model 83: A, B, S, T, C, D, 2, 4, and 5
Model 84: S, T, D and 2
Terminal 22 (Signal A output) for Promass output options Model 80: 8
Model 83: N and P Model 84: N

DC Ground Terminal 25 (Signal A Negative) for Promass output options Model 80: A,
D, S, and T
Model 83: A, B, S, T, C, D, 2, 4, and 5
Model 84: S, T, D, and 2
Terminal 23 (Signal A ground) for Promass output options Model 80: 8
Model 83: N and P Model 84: N

The Promass output option is defined by the last character of the Promass model code.

4.2.7 Promass 83 and 84 Coriolis Meters

The AccuLoad uses the I/O connection points in the following table to connect to the Promass 83 and 84
Coriolis meters.

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AccuLoad IV Installation & Maintenance Manual

Because the pulse input circuitry of the AccuLoad requires the input pulse OFF voltage to be less than 1
volt (and the ON voltage to be more than 5 volts), it is important that the Line Monitoring function on the
Promass 84 be disabled when connecting the Promass 84 to the AccuLoad. If the Line Monitoring
function on the Promass 84 is enabled, the OFF voltage of the pulses will be more than 1 volt and thus
will not be counted by the AccuLoad. Three jumpers on each frequency output submodule on the I/O
board enable and disable the Line Monitoring function. The factory default is to enable line monitoring.
See the Proline Promass 84 Operating Instructions (MN0M032) to enable and disable this functionality.

Table 29: Promass 83 and 84 Coriolis Meter Dual-Channel Connections

AccuLoad Connections Promass 83 and 84 Connections
Pulse Input A Plus +24 VDC
Pulse Input A Minus Promass Terminal 24 (Signal A output) for Promass output options
Model 83: M
Model 84: M and 1

AccuLoad DC Ground Promass Terminal 25 (Signal A negative) for Promass output options
Model 83: M
Model 84: M and 1
Pulse Input B Plus +24 VDC
Pulse Input B Minus Promass Terminal 22 (Signal B Output) for Promass output options
Model 83: M
Model 84: M and 1

DC Ground Promass Terminal 23 (Signal A Negative) for Promass output options

Model 83: M
Model 84: M and 1

The Promass output option is defined by the last character of the Promass model code.

4.3 Meter Input Wiring

The AccuLoad totals volume or mass in response to pulses received at the pulse input terminals of the
A4M, A4B, or A4I modules. The pulse input connections to use for each meter is dependent on the
configuration of the AccuLoad. For product meters, the AccuLoad automatically assigns the pulse inputs
based on the products defined in the configuration database. The number of pulse inputs required for each
meter varies based on the type of meter specified in the configuration database, as follows:
Table 30: Meter Pulse Input Connections
Meter Type Required Pulse Inputs
Single-channel One pulse input per meter
Dual-channel Two pulse inputs per meter
Dual-channel with integrity Four pulse inputs per meter

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AccuLoad IV Installation & Maintenance Manual

The tables in the following sections detail the pulse input assignments made by the AccuLoad for each of
the possible number of product meters. Any pulse inputs not required for connection of the product meters
are available to be configured for use as an additive meter or pulse densitometer.

In the AccuLoad IV, the valve control solenoid outputs or metered injector solenoid outputs must be
configured or landed on the same board as the associated meter pulse input.

The following conventions are used in the tables below:

• Bold, italicized text is used to indicate a different between AccuLoad III and AccuLoad IV
connections.

• The product meter naming convention used is:

• M = meter
• Number = meter number
• Letter = channel

For example, M2A.

• “Pgm” means that the pulse output is programmable so it can function as a metered injector or a
densitometer pulse input.

• “n/a” means that the pulse input is not applicable.

4.3.1 Meter Inputs for ST and N4 Models

Refer to the following tables regarding meter inputs for the ST and N4 models.
Table 31: Six-Product Meters (AccuLoad IV Models ST and N4)
In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8
Single pulse M1A M2A M3A M4A M5A M6A Pgm Pgm
Dual pulse n/a n/a n/a n/a n/a n/a n/a n/a
Dual pulse with integrity n/a n/a n/a n/a n/a n/a n/a n/a

Table 32: Five-Product Meters (AccuLoad Models ST and N4)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8
Single Pulse M1A M2A M3A M4A M5A Pgm Pgm Pgm
Dual Pulse n/a n/a n/a n/a n/a n/a n/a n/a
Dual pulse with integrity n/a n/a n/a n/a n/a n/a n/a n/a

Table 33: Four-Product Meters (AccuLoad Models ST and N4)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8
Single Pulse M1A M2A M3A M4A Pgm Pgm Pgm Pgm
Dual Pulse M1A M1B M2A M2B M3A M3B M4A M4B
Dual pulse with integrity n/a n/a n/a n/a n/a n/a n/a n/a

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AccuLoad IV Installation & Maintenance Manual

Table 34: Three-Product Meters (AccuLoad Models ST and N4)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8
Single Pulse M1A M2A M3A Pgm Pgm Pgm Pgm Pgm
Dual Pulse M1A M1B M2A M2B M3A M3B Pgm Pgm
Dual pulse with integrity n/a n/a n/a n/a n/a n/a n/a n/a

Table 35: Two-Product Meters (AccuLoad Models ST and N4)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8
Single Pulse M1A M2A Pgm M4A Pgm Pgm Pgm Pgm
Dual Pulse M1A M1B M2A M2B Pgm Pgm Pgm Pgm
Dual pulse with integrity M1A M1B M1A M1B M2B M2B M2A M2B

Table 36: One-Product Meters (AccuLoad Models ST and N4)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8
Single Pulse M1A Pgm Pgm Pgm Pgm Pgm Pgm Pgm
Dual Pulse M1A M1B Pgm Pgm Pgm Pgm Pgm Pgm
Dual pulse with integrity M1A M1B M1A M1B Pgm Pgm Pgm Pgm

4.3.2 Meter Inputs for QT and SA Models

Refer to the following tables regarding meter inputs for the QT and SA models.
Table 37: Six-Product Meters (AccuLoad IV QT and SA Models)
In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8 In #9 In #10 In #11 In #12 In #13 In #14
Single M1A M2A M3A Pgm Pgm Pgm Pgm Pgm M4A M5A M6A Pgm Pgm Pgm
pulse
Dual M1A M1B M2A M2B M3A M3B Pgm Pgm M4A M4B M5A M5B M6A M6B
pulse
Dual/ n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a
integrity

Table 38: Five-Product Meters (AccuLoad IV QT and SA Models)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8 In #9 In #10 In #11 In #12 In #13 In #14
Single M1A M2A M3A Pgm Pgm Pgm Pgm Pgm M4A M5A M6A Pgm Pgm Pgm
pulse
Dual M1A M1B M2A M2B M3A M3B Pgm Pgm M4A M4B M5A M5B Pgm Pgm
pulse
Dual/ n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a
integrity

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AccuLoad IV Installation & Maintenance Manual

Table 39: Four-Product Meters (AccuLoad IV QT and SA Models)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8 In #9 In #10 In #11 In #12 In #13 In #14
Single M1A M2A Pgm Pgm Pgm Pgm Pgm Pgm M3A M4A Pgm Pgm Pgm Pgm
pulse
Dual M1A M1B M2A M2B Pgm Pgm Pgm Pgm M3A M3B M4A M4B Pgm Pgm
pulse
Dual/ n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a
integrity

Table 40: Three-Product Meters (AccuLoad IV QT and SA Models)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8 In #9 In #10 In #11 In #12 In #13 In #14
Single M1A M2A Pgm Pgm Pgm Pgm Pgm Pgm M3A Pgm Pgm Pgm Pgm Pgm
pulse
Dual M1A M1B M2A M2B Pgm Pgm Pgm Pgm M3A M3B Pgm Pgm Pgm Pgm
pulse
Dual/ M1A M1B M1A M1B M2A M2B M2A M2B M3A M3B M3A M3B Pgm Pgm
integrity

Table 41: Two-Product Meters (AccuLoad IV QT and SA Models)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8 In #9 In #10 In #11 In #12 In #13 In #14
Single M1A M2A Pgm Pgm Pgm Pgm Pgm Pgm M3A Pgm Pgm Pgm Pgm Pgm
pulse
Dual M1A M1B M2A M2B Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm
pulse
Dual/ M1A M1B M1A M1B M2A M2B M2A M2B Pgm Pgm Pgm Pgm Pgm Pgm
integrity

Table 42: One-Product Meters (AccuLoad IV QT and SA Models)

In #1 In #2 In #3 In #4 In #5 In #6 In #7 In #8 In #9 In #10 In #11 In #12 In #13 In #14
Single M1A Pgm Pgm Pgm Pgm Pgm Pgm Pgm M3A Pgm Pgm Pgm Pgm Pgm
pulse
Dual M1A M1B Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm
pulse
Dual/ M1A M1B M1A M1B Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm Pgm
integrity

4.4 Additive Meters and Digital Inputs

The A4I module provides 10 inputs that can be used for either additive meter pulse inputs or as DC digital
inputs and 20 AC digital outputs. The AC digital outputs are wired using the same method shown for the
A4M and A4B modules. However, the meter pulse and DC digital inputs are wired differently on the A4I
module, as illustrated in the following diagrams.

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AccuLoad IV Installation & Maintenance Manual

The A4I module provides outputs to supply power to the additive meter. The voltage supplied is
selectable (5, 12, or 24 VDC) using jumpers on the module.

Figure 47: A4I Additive Meter Wiring

AccuLoad
A4M +24V
TBE4 10, 11, or 12
External Prover
Pulse Counter

TBE6-1

TBE6-2
Power Counter

A4M GND
TBE4 13, 14, or 15

Figure 48: A4I Digital Input Wiring

AccuLoad
A4M +24V
External Meter Pulse
TBE4 10, 11, or 12 Wiring

Monoblock Transmitter
Internal Pull Up
12 VDC

3K
V+ Supply
TBE6-2
Signal
3K
Common Common

4.5 A4I Kit Retrofit Installation

Use the following process to retrofit an A4I board onto an A4M board assembly using the Single A4I
Retrofit Kit (part number P8000018993) or Dual A4I Retrofit kit (P8000018994).

The following process does not include steps needed to authorize entry into the housing in an Ex
environment or closing the housing. For instructions on securing the housing, see Section 5.1: Closing
the Explosion-Proof Housing.

The tools needed for this installation include a #2 Phillips-head screwdriver, a 5/16-inch wrench, and a 1/4-
inch wrench. The necessary installation hardware is included in the retrofit kits.

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AccuLoad IV Installation & Maintenance Manual

The following drawing shows the installation of the dual A4I board kit.
Figure 49: Dual A4I Boards on A4M Board

Complete the following steps to install one or two A4I boards onto the AccuLoad IV’s A4M board:

1. Remove the power supply from the AccuLoad IV.

2. On the ST and QT models, remove the cover bolts. On the N4 or SA models, loosen the latches to
open the door.

3. Remove the four captive screws from the A4M board’s polycarbonate shield using a Phillips head
screwdriver.

4. Remove the captive mounting fastener from the A4M board that is closest to AC input terminal block
TBE1.

Due to the risk of cross-threading standoff, remove the captive mounting fastener by hand.

5. Install the kit’s four 0.25-inch hex standoffs and nylon insert locknuts onto the A4Ms board’s polycar-
bonate shield.

6. Re-install the A4M board’s shield on the A4M board.

7. Align the 0.25-inch standoffs on the A4M board with the first A4I board (A4I #1). The Ethernet jacks on
the A4I board should be near the Ethernet jacks on the A4M board.

8. On the first A4I board, ensure that DIP switch S1-2 is OFF to designate it as A4I #1.

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AccuLoad IV Installation & Maintenance Manual

9. Connect an Ethernet cable as follows:

• On QT models, connect an Ethernet cable from ETH2 on the A4I #1 board to ETH2 on the A4B
board.

• On ST and N4 models, connect an Ethernet cable from ETH2 on the A4I board to ETH3 on the
A4M board.

• On SA models, complete the following steps:

a. Disconnect the Ethernet cable between ETH3 on the A4M board and ETH1 on the A4B board.

b. Connect the Ethernet cable from ETH2 on the A4I board to ETH3 on the A4M board.

c. Reconnect the Ethernet cable from ETH1 on the A4B board to ETH1 on the A4I board.

10. If your kit includes a second A4I board, complete the following steps:

a. Install four 1.5-inch hex standoffs to secure the A4I #1 board to the A4M board and provide space
between the two A4I boards.

b. On the A4I #1 board, connect of the second Ethernet cable to ETH1. (You’ll connect the other end
later.)

c. On the second A4I board, ensure that DIP switch S1-2 is ON to designate it as A4I #2.

d. Align the 1.5-inch standoffs with the A4I #2 board. The Ethernet jacks on the A4I #2 board should
be near the Ethernet jacks on the A4M board.

11. Attach the A4I board polycarbonate shield using the supplied screws to secure the A4I #2 board to the
assembly and protect it.

12. If you installed an A4I #2 board, connect the Ethernet cable from ETH2 on the A4I #2 board to ETH1
on the A4I #1 board.

13. Install ground wires for the installed A4I boards using the captive mounting fastener nearest to TBE1
on the A4M board.

Due to the risk of cross-threading standoff, remove the captive mounting fastener by hand.

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AccuLoad IV Installation & Maintenance Manual

14. Connect the DC power supply wiring (red and black twisted pair) as shown below in Figure 50: A4M to
A4I Wiring:
Figure 50: A4M to A4I Wiring

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AccuLoad IV Installation & Maintenance Manual

5 Closing and Sealing the

Enclosure
5.1 Closing the Explosion-Proof Housing
When securing the front cover of the AccuLoad models ST or QT, complete the following steps to ensure
the unit is properly sealed and is safe to operate in a Division 1, Zone 1 environment:

1. Inspect the door seal O-ring for damage and replace if damaged. The O-ring is not required to maintain
the explosion-proof rating; however, it is required to maintain the IP 65 ingress protection rating.

2. Grease cover flange with petroleum jelly or TechnipFMC grease (part number 644886401) before
attaching the cover to the housing.

3. Verify that the mating areas between the front cover and the main housing are not scratched, corroded, or
otherwise damaged such that the surface contact between them would be compromised.

4. Close the cover and tighten the cap screws around the perimeter of the front cover using the sequence
shown below. The final torque should be 20 ft∙lb/240 in∙lb (27.1 N∙m/276.4 Kg.cm). Be sure to note the
locations for the two longer bolts used for the security seal wire.

5. Check that the enclosure is properly sealed by verifying the cover-to-enclosure joint gap with a 0.0015-
inch (0.0381-mm) feeler gauge. The feeler gauge must not enter the joint more than a ¼ inch (6 mm)
at any point around the perimeter of the cover to the housing joint (see Figure 53: Flame Path Verifica-
tion for an example).
Figure 51: Cover Bolt Torque Pattern for AccuLoad IV Model ST
7 3 2 6 10
11
18

12 17
13 16

14 15

8 4 1 5 9

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AccuLoad IV Installation & Maintenance Manual

Figure 52: Cover Bolt Torque Pattern for AccuLoad IV Model QT

15 11 7 3 2 6 10 14 18

19
28

20 27

21 26

22 25

23 24

16 12 8 4 1 5 9 13 17

Figure 53: Flame Path Verification

5.2 Sealing the Enclosure

All AccuLoad enclosures can be sealed using standard seal wires.

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AccuLoad IV Installation & Maintenance Manual

5.2.1 Sealing ST and QT Models

On the ST and QT models, the sealing wire is threaded through holes in two cover bolts, as shown in the
following drawings.
Figure 54: AccuLoad Model ST Sealing

Seal Wire

Cross
drilled
bolts

Standard
bolts

Figure 55: AccuLoad Model QT Sealing

Seal wire

Cross drilled bolts

Standard Bolts

5.2.2 Sealing N4 Models

To seal NEMA 4 enclosures, thread the sealing wire through any of the cover-locking clamps opposite the
hinge.

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AccuLoad IV Installation & Maintenance Manual

6 Maintenance
The following sections provide information about maintaining your AccuLoad IV to ensure optimal
functionality.

6.1 Explosion-Proof Enclosure Maintenance

AccuLoad ST and QT models with explosion-proof enclosures (with XP in the model code) should be
maintained using the following flame-path inspection criteria.

WARNING: To prevent the ignition of hazardous atmospheres, disconnect the AccuLoad from its main
power supply before opening the cover.

• Installation, inspections, maintenance. repairs, overhauls, and reclamation of AccuLoads in the

European Union (EU) must be performed by qualified personnel in accordance with the applicable
requirements of EN 60079-14, EN 60079-17, and EN 60079-19, in addition to all local codes and
regulations.

• Installation, inspections, maintenance, repairs, overhauls, and reclamation of AccuLoads relying on

IECEx certification must be performed by qualified personnel in accordance with the applicable
requirements of IEC 60079-14, IEC 60079-17, and IEC 60079-19, as required by local codes and
regulations.

• Guidance for equipment inspection and maintenance is provided by EN/IEC 60079-17: Electrical Apparatus
for Explosive Gas Atmospheres, Inspection and Maintenance of Electrical Installations in Hazardous
Areas, and should be used for the inspection and maintenance process.

• When performing maintenance that requires opening the enclosure cover, all flame paths (defined as
the machined-flanged surface between the housing and the cover), should be inspected to ensure that
they are clean, undamaged, and have no scratches, nicks, corrosion, or other defects that could affect
the integrity of the flame path. If defects are detected, the equipment should not be placed back into
service until the issues are resolved.

• Verify that all tapped cover bolt threaded locations in the enclosure are clean and intact with no missing
or stripped threads.

• Verify that the cover bolts are the required M8 x 1.25-6g, DIN 912, steel grade 12.9. Prior to
reassembly, apply a light coating of nickel-based anti-seize lubricant, such as Loctite Anti-Seize
Lubricant (TechnipFMC part number 646002-401) to all bolt threads.

• Verify that any blind-threaded cover bolt holes do not have excessive grease or anti-seize lubricant
packed into them, as this could cause hydraulic fractures of the enclosure when the bolts are tightened.

• Inspect to ensure that the environmental O-ring is correctly installed (seated into the groove) and in
good condition (no cracks, etc.). If the O-ring is defective, replace it to maintain environmental
protection. Grease the cover flange with petroleum jelly or Super Lube Multi-Purpose Synthetic Grease
with Syncolon (TechnipFMC part number 644886-401) before reattaching the cover to the housing.

• Follow the cover bolt torquing procedure as outlined in Section 5.1: Closing the Explosion-Proof
Housing. When complete, verify the flame path gaps according to the procedure.

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6.1.1 ST and QT Models in Special Environments

The ST and QT models have aluminum, explosion-proof enclosures. In corrosive environments, such as
near salt water, it is the user’s responsibility to increase the inspection intervals for verification of the flame-
path integrity. Inspection intervals vary with local conditions, and it is the user’s responsibility to determine
appropriate intervals. The most effective preventive maintenance is periodic washing of the enclosure to
remove any salt buildup on exterior surfaces. It is recommended to wash using a mild soap applied with a
sponge or cloth, followed by a low-pressure, non-saline water rinse.

It also is very important to maintain the painted exterior finish of the equipment. If exterior corrosion is
detected, the following steps should be taken on the exterior surface:

1. The finish should be cleaned.

2. Any corrosion should be removed by mechanical means.

3. Prepare the exterior for painting.

4. The affected area should be repainted with a corrosion-inhibiting paint. The factory paint is two-
component, polyurethane-acrylic enamel Polane T manufactured by Sherwin Williams in Precision Tan
and Carbon Black.

Enclosures located in corrosive environments are required to have a coating of petroleum jelly or
TechnipFMC grease (part number 644886401) to flanged metal surfaces (including the flame path
between the window and cover and the keypad cover) to offer a protective barrier and reduce the effects of
exposure to wet, salty air. The surface should be cleaned and new grease applied each time the enclosure
cover is opened for inspections or maintenance.

6.1.2 N4 and SA Models in Special Environments

The N4 and SA models have 304 stainless steel enclosures. In corrosive environments, such as near salt
water, it is the user’s responsibility to prevent degradation of the stainless steel finish. The most effective
preventive maintenance is periodic washing of the enclosure to remove any salt buildup on exterior
surfaces. It is recommended to wash using a mild soap applied with a sponge or cloth, followed by a low-
pressure, non-saline water rinse.

In severe conditions, segregation from the environment or an application of a protective coating is

recommended.

6.2 Touch-Screen Screen-Protector Maintenance

The touch screen for the AccuLoad IV is a resistive element that uses a thin layer of glass as the top-most
layer to enable the sensor to work when wet, when you are wearing gloves, and to avoid damage from
exposure to hydrocarbons and other chemicals. To protect this thin layer of glass, a plastic screen protector
is applied to it.

The touch screen and screen protector should only be cleaned with a clean, damp cloth.

Over time, the screen protector may become scratched, marred, clouded, or otherwise damaged and
should be replaced. To do so, complete the following steps:

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AccuLoad IV Installation & Maintenance Manual

1. Carefully remove the existing screen protector by finding the edge of the plastic and, using a nylon
screwdriver or similar tool, peeling back a corner of the screen protector until you can grasp and remove
it.

Avoid using metal screwdrivers, knife blades, or sharp tools that could scratch or crack the
underlying glass.

2. Clean the glass using a clean, damp cloth and allow to dry.

3. Peel the backing off the replacement screen protector and apply it to the screen, working from one
edge to the other, taking care to avoid trapping air bubbles.
Figure 56: Touch-Screen Screen Protector
Touch Screen/Display Glass

Replacement Screen Protector

6.3 Replacing the Clock Battery

The AccuLoad IV’s backup clock battery should be replaced every five years. Use the following steps to
replace the clock battery:

WARNING: Do not replace the clock battery in a hazardous area.

1. Disconnect the AccuLoad from its main power supply before opening the cover.

2. On the A4M and A4I boards, remove wiring connections and Ethernet cables.

3. Remove the A4M board from the AccuLoad’s enclosure using the four captive fasteners on the corners
of the board.

4. Locate the hole in the A4M board’s mounting tray that enables access to the real-time clock (RTC) bat-
tery.

5. Remove the battery using the following steps:

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AccuLoad IV Installation & Maintenance Manual

a. Position the A4M board so the gold tab on the RTC Figure 57: Removing the Battery
battery socket is pointing toward you.

b. Using the flathead screwdriver supplied with your

AccuLoad, press down on the battery on the right
side of the gold tab and then gently pull it toward
you.

c. After the battery is unseated, use ESD-safe

technical tweezers or needle-nose pliers to
remove the battery from the board.

6. Install new replacement battery using the following steps:

a. Position the A4M board so the gold tab on the RTC Figure 58: Replacing the Battery
battery socket faces away from you.

b. Place the new RTC battery under the edge of the

gold tab and in the hole.

c. Using the flathead screwdriver, guide the RTC bat-

tery into the socket.

7. Re-install the A4M board into the AccuLoad’s housing

using the four captive fasteners on the corners of the
board and then restore all necessary connections.

8. Close the AccuLoad’s housing according to the information in Section 5: Closing and Sealing the
Enclosure.

6.4 Diagnostic Troubleshooting on A4M, A4B, and

A4I Boards
The A4M, A4B, and A4I circuit boards for the AccuLoad IV contain a seven-segment light-emitting diode
(LED) display capable of providing information about the status of the board. See the following table for
diagnostic codes.
Table 43: A4M, A4B, and A4I Diagnostic Codes
Diagnostic
Function Description
Code
Bootloader Status Bb The Bootloader has an active error
UU The processor’s firmware is currently updating
FF A hardware failure has occurred and the processor is unable to
read memory; the board must be replaced
E1 A TCP timeout has occurred; check the connection between
BBB and the Ethernet port and replace the hardware

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AccuLoad IV Installation & Maintenance Manual

Table 43: A4M, A4B, and A4I Diagnostic Codes

Diagnostic
Function Description
Code
Bootloader Errors E2 A hardware failure has occurred in the Bootloader; the board
must be replaced
E3 An upgrade error has occurred; retry the firmware update
E4 A firmware error has occurred; retry the firmware update
E5 A firmware cyclic redundancy check (CRC) error has occurred;
retry the firmware update
E6 A hardware failure involving a Bootloader CRC error has
occurred; the board must be replaced
E7 A hardware failure involving an unprogrammed media access
control (MAC) address has occurred; the board must be
replaced

6.5 Returning a Circuit Board Using a Return

Merchandise Authorization (RMA)
If you need to return a circuit board, use the guidelines in the following sections.

All electronic materials must be returned using proper ESD protective packaging; for example, in a
static-shielding bag.

6.5.1 A4M Boards

Use the following guidelines when returning an A4M board:

• Remove and retain the license key (dongle); these are not included with replacement A4M boards and
will be needed.

• Retain any functioning analog modules. Return non-working modules that need to be replaced.

Do not hot-swap analog modules when diagnosing problems—they require initialization that is
performed during the power-up process to work properly.

• Disconnect and retain the long Ethernet patch cable. Leave the short Ethernet cable connected to the
COM module in place.

• All terminal blocks (connectors) should be removed and retained; they are not included with
replacement boards.

6.5.2 THMI Module

If your AccuLoad has a display-related issue and the problem cannot be narrowed down to a specific
component (such as the touch sensor or LCD), it is recommended that you return the THMI display module
and touch screen assembly as a unit.

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AccuLoad IV Installation & Maintenance Manual

7 Related Publications
The following literature can be obtained from TechnipFMC Measurement Solutions Literature Fulfillment at
[email protected] or online at info.smithmeter.com/literature/online_index.html.

When requesting literature, please reference the appropriate title and document number, as follows:

• AccuLoad IV Operator Reference Manual (MN06200)

• AccuLoad IV parts list (PO06200)

• AccuLoad IV specifications (SS06200)

• AccuLoad Calculations technical paper (TP06004)

Related Publications 67
Notice
All procedures, data, information, drawings, specifications or other material, whether accompanying this document or separately
supplied in furtherance of this document, contain confidential and proprietary information which (i) is the property of TechnipFMC plc,
(ii) is disclosed by TechnipFMC only in confidence, and (iii) except as TechnipFMC may otherwise permit in writing, is to be used,
disclosed or copied only to the extent necessary for the evaluation and use thereof by the recipient.

The foregoing shall not apply to any such material to the extent that the contents (i) are now or subsequently become available to the
public without payment, (ii) were previously known to the recipient, or (iii) subsequently become otherwise known to the recipient
without restriction.

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the
information contained herein does not purport to cover all details or variations in hardware and software, nor to provide for every
possible contingency in connection with installation, operation and maintenance.

TechnipFMC makes no representation or warranty, either expressed or implied, with respect to, and assumes no responsibility for, the
accuracy, completeness, or sufficiency of the information contained herein. No warranties of merchantability or fitness for a particular
purpose shall apply.

Smith Meter is a registered trademark. The TechnipFMC logo is a trademark.

This document takes precedence over and supersedes in their entirety all previous versions or revisions.

Bulletin MN06201 Issue/Rev 0.3 (9/22)

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