KNAPPCO-CIVACON
COVER SHEET FOR
PRODUCT LITERATURE
PART #: H52530PAE
TITLE: MANUAL ROM II PLUS EURO VERSION 3204E
REVISION: F
REVISION DATE: December 2005
Revision History
Revision ESR Number Drawn By Changes
F
N/A
JKH
Initial iDOC Release
INSTRUCTIONS FOR PRODUCTION HOUSE
(INSERT ‘X’FOR ALL THAT APPLY)
X
X
X
Paper Size 8.5” X 11”
Paper Size 11” X 17”
Paper Size 8.5” X 5.5”
Two-Sided
Stapled
Folded – Tri-folded
Folded – Bi-folded
Booklet Form (11 X 17 sheets folded into 8.5 X 11 pages)
Black and White
Black and White – First Page Color
Color
Notes:
1) Do not duplicate this cover sheet
2) Paper to be used is white, 20 lbs. unless otherwise noted
3) Document must have hand signature before being reproduced.
ROM II PlusTM
RETAINED –OVERFILL MONITORING SYSTEM
INSTALLATION AND WIRING INSTRUCTIONS
PART NUMBER
H52530PAE
CIVACON – A DOVER RESOURCES CO.
4304 MATTOX ROAD
KANSAS CITY, MO 64150
OPW FLUID TRANSFER GROUP EUROPE, B.V.
BOEWEITSTRAAT 1
P.O. BOX 32, 2150 AA NIEUW-VENNEP
THE NETHERLANDS
TABLE OF CONTENTS
1 PRODUCT DESCRIPTION ........................................................ 5
2 THE ROM II Plus SYSTEM OPERATION.............................................. 7
2.1 THE OPTIC SENSORS..................................................................................................................7
2.2 THE ROM II Plus ONBOARD MONITOR (OBM)..........................................................................8
2.3 THE TOP ONLY ROM II Plus ONBOARD MONITOR ..................................................................9
2.4 THE 5-WIRE TOP ONLY ROM II Plus ONBOARD MONITOR.....................................................9
3 OBM MOUNTING INSTRUCTIONS .................................................. 9
4 WIRING INSTRUCTIONS - THE WIRE .............................................. 10
5 WIRING INSTRUCTIONS – POWER INPUT TERMINALS ................................ 11
5.1 NON-I.S. RELAY OUTPUT WIRING............................................................................................12
6 TOP SENSORS INSTALLATION .................................................. 13
6.1 THREADED HOUSING SENSOR INSTALLATION ...................................................................13
6.2 FLANGED HOUSING SENSOR INSTALLATION.......................................................................13
6.3 SENSING POINT ADJUSTMENT................................................................................................13
6.4 2-WIRE SENSOR WIRING CONNECTIONS...............................................................................15
7 BOTTOM SENSORS INSTALLATION [If so equipped] .................................. 15
7.1 THREADED HOUSING RETAINED PRODUCT SENSOR INSTALLATION..............................15
7.2 WIRING CONNECTIONS.............................................................................................................16
8 WIRING INSTRUCTIONS - 2-WIRE SENSORS & ROM II Plus ............................. 17
9 WIRING DIAGRAMS - 2-WIRE SENSORS & ROM II Plus ................................ 20
10 WIRING DIAGRAMS - 5-WIRE SENSORS & ROM II Plus ............................... 24
11 WIRING INSTRUCTIONS - AUXILIARY INPUTS ...................................... 28
12 WIRING INSTRUCTIONS - SOCKETS.............................................. 28
13 PROGRAMMING OF THE INSTALLED SENSORS .................................... 32
14 POWER ON TEST ............................................................ 35
14.1 STATUS LIGHTS [LEDs] ..........................................................................................................35
14.2 TESTING THE SENSORS .........................................................................................................36
14.3 SOCKET TEST...........................................................................................................................36
15 TROUBLESHOOTING GUIDE.................................................... 37
15.1 TOOLS REQUIRED ...................................................................................................................37
15.2 SYSTEM OVERVIEW.................................................................................................................37
15.3 PROBLEM SYMPTOMS ............................................................................................................37
15.3.1 No GREEN Permit LED or dimly lit; No YELLOW Power LED or dimly lit; other
LEDs are also out or dimly lit. .................................... 37
15.3.3 A RED Compartment LED is on solid. .............................. 38
15.3.2 One or more RED Compartment LEDs are flashing. ................... 38
15.3.4 Trailer will not load at loading rack; appropriate YELLOW and GREEN LEDs
are lit. ...................................................... 39
15.3.6 Side Pushbutton Reset Switch will not cause monitor to switch permissive
when tank contains retained product. (A Bottom / Retained Product RED LED
ON) ........................................................ 40
15.3.7 Auxiliary Input Switches will not cause monitor to switch to Permissive. ... 40
15.3.8 All Display Indicators are Flashing................................. 41
16 REPLACEMENT MODULES ..................................................... 41
17 WARRANTY ................................................................ 42
17.1 TECHNICAL ASSISTANCE.......................................................................................................42
CIVACON
Copyright 2003
3
H52530PAE Rev F
December
2005
TABLE OF FIGURES & DIAGRAMS
FIGURE 1 – PULSED SIGNAL GENERATION................................................................... 6
FIGURE 2 – MONITOR HOUSING MOUNTING DETAILS ................................................. 9
FIGURE 3 – POWER & CONTROL WIRING .................................................................... 11
FIGURE 4 - TOP SENSOR DIMENSIONS........................................................................ 13
FIGURE 5 - RETAIN PRODUCT SENSOR DIMENSIONS ............................................... 15
FIGURE 6A - POWER AND INTRINSICALLY SAFE WIRING – SHEET 1 OF 2 .............. 16
FIGURE 6B - POWER AND INTRINSICALLY SAFE WIRING – SHEET 2 OF 2 .............. 17
FIGURE 7 – TERMINAL DESIGNATIONS & CONNECTION DETAILS ........................... 19
DIAGRAM 8A – 2-WIRE TOP & BOTTOM SENSOR WIRING / 8 COMPARTMENTS ..... 20
DIAGRAM 8B – 2-WIRE TOP SENSOR WIRING TO ROM / 8 COMPARTMENTS. ........ 21
DIAGRAM 8C – 2-WIRE BOTTOM SENSOR WIRING TO ROM / 8 COMPARTMENTS . 22
DIAGRAM 9A – 5-WIRE TOP SENSOR WIRING / 12 COMPARTMENTS....................... 24
DIAGRAM 9B – 5-WIRE TOP SENSOR WIRING TO ROM.............................................. 25
DIAGRAM 10 – 5-WIRE TOP & BOTTOM SENSOR WIRING / 8 COMPARTMENTS ..... 26
DIAGRAM 11 – THERMISTOR / 2-WIRE OPTIC SOCKET WIRING TO ROM ................ 29
DIAGRAM 12 – 5-WIRE OPTIC SOCKET WIRING TO ROM ........................................... 30
DIAGRAM 13 – PROGRAMMING JUMPER LOCATION DETAIL .................................... 31
ROM®, ROM IITM & ROM II Plus are Registered Trademarks and Trademarks of
CIVACON.
This product uses Patent # 5,349,994, assigned to CIVACON and other Patents Pending.
This document and all the information therein is the property of CIVACON; it is
proprietary and shall not be copied, and is not to be used directly or indirectly in any
way detrimental to the interest of CIVACON. All copyright and intellectual property
rights are reserved.
© 2003 CIVACON
A DOVER Resources Company
CIVACON
Copyright 2003
4
H52530PAE Rev F
December
2005
1 PRODUCT DESCRIPTION
This manual describes the operation, installation, and troubleshooting of the CIVACON
ROM II Plus (Retain Overfill Monitor) System. It is intended to help operators,
maintenance men, and specifiers understand the operation and features of the ROM II
Plus system. Some of the information in this manual has come from the field experience of
our sales representatives and customers. It is recommended reading this manual
completely before installation of any equipment.
The ROM II Plus is a tank truck / trailer mounted On Board Monitoring (OBM) system with
sensors mounted in the top and bottom of each tank compartment. The ROM II Plus
monitor detects and communicates a pending overfill condition to a loading rack control
monitor, and signals which tank compartment is overfilled. The ROM II Plus monitor also
detects and communicates a retain condition to a loading rack control monitor, and signals
which tank compartment has retained product. This control system will enable a tank
trailer truck to load at API optic, thermistor or float petroleum loading rack monitors while
using only two wire optic sensors. If all of the optic sensors do not detect any liquids, the
monitor provides the necessary signal information to the appropriate API sockets to enable
loading of the tank trailer truck.
The ROM II Plus on board monitor includes some additional new features and benefits
when compared to it’s predecessor the ROM II. These include:
A. Support for tanks with up to 8 compartments using 2-wire overfill and retained
sensors.
B. Support for tanks with up to 12 compartments using 5-wire overfill sensors (up to 8
compartments of 5-wire overfill sensors and 2-wire retained sensors are also
supported)
C. Number of sensor installed is automatically configured at installation.
terminators are used or needed.
No
D. Includes 4 separate Aux. Inputs.
E. Retained timer expires on loading rack plug disconnect (thermistor or optic outputs)
F. Supports and makes full use of Civacon Pressure –Vacuum Overfill Sensors (PVO
Sensors).
The ROM II Plus onboard monitor has been designed for use with the following Civacon
Sensors:
Models 1050 & 1051 2-Wire ROM Top (Overfill) Sensors with Holders
Models 1350 & 1351 2-Wire ROM Top (Overfill) Replacement Sensors
Models 1000, 1001, 1000R, 1001R, 1000Q & 1001Q Bottom (Retain Sensors)
Model 1111 5-Wire Top (Overfill) Sensor with Holder
Model 1301 5-Wire Top (overfill) Replacement Sensor
CIVACON
Copyright 2003
5
H52530PAE Rev F
December
2005
The typical Civacon On Board Monitoring System consists of a ROM II Plus onboard
control monitor (Model 3204 Series), a top 2 wire ROM optic sensor (Model 1050 or 1051),
a bottom 2 wire ROM optic sensor (Model 1000, 1001, 1000R or 1001R), seven (7)
conductor cable (Model 2300), strain relief fittings (Model EL05117), and optional sockets
for loading rack connections. The ROM II Plus onboard control monitor can be configured
for use with top and bottom sensors, or top only sensors by way of how the monitor is
programmed at installation time. Float, Thermistor and Optic socket outputs from the
onboard control monitor allow compatibility with different types of rack control monitors
commonly used. The ROM II Plus onboard control monitor and sensors are designed to
provide many years of trouble free service, although should a problem occur, an advanced
patented internal diagnostic feature can pin point the problem with minimal testing or
troubleshooting.
CAUTION!: DO NOT apply power to this monitor without thoroughly reading this manual
and checking all connections. DO NOT connect a battery charger or other pulsed power
supply to this monitor as this may permanently damage the monitor.
CAUTION!: DO NOT perform any welding on the tanker when power is applied to this
monitor, as welding on the tanker with the monitor power on may permanently damage the
monitor.
SAFETY NOTE: Since power for the monitor comes from the truck battery, and it
must be fused externally from the monitor's enclosure. The monitor's mounting
location is classified for use in a Zone 1 (EEx 2G [ia] IIB T4 Tamb= -40C to +60C)
location, or a safe area.
CIVACON
Copyright 2003
6
H52530PAE Rev F
December
2005
2 THE ROM II Plus SYSTEM OPERATION
The ROM II Plus system uses self-checking principles to provide a continuous check on all
system components. This is accomplished by the exchange of digital pulses between
sensor and monitor. These digital pulses must pass through all active components in the
sensor, sensor wiring, and the control monitor to test all the components in the entire
sensing circuit.
2.1 THE OPTIC SENSORS
The (2-wire) optic sensors require only two wires for connection to the ROM II Plus
monitor. Each sensor has an internal electrical pulse generator. This pulse is
converted to a pulse of light (infrared) and directed through a prism, and is detected
on the other side of the prism. If the prism is dry the light pulse is reflected through;
if the prism is wetted by a liquid, the light pulse is diverted into the liquid and does
reflect back through the prism to the detector. In the case of a dry sensor, the light
pulse is detected by a photo diode and converted back into a digital pulse. This
pulse is sent back to the control monitor over 100 times a second on the same two
wires. See Figure 1 for a simple diagram of these pulsed signals. Both top and
bottom sensors operate the same, and are approved for use in Zone 0 hazardous
locations. Refer to Figures 5A & 5B for approval details.
SENSOR CIRCUITRY
PULSE
GENERATOR
SIGNAL WIRE
GND. WIRE
EMITTER
DIGITAL PULSE
OUTPUT SIGNAL
DETECTOR
DRY PRISM
SENSOR CIRCUITRY
PULSE
GENERATOR
SIGNAL WIRE
GND. WIRE
EMITTER
NO
OUTPUT SIGNAL
DETECTOR
WET PRISM
FIGURE 1 – PULSED SIGNAL GENERATION
CIVACON
Copyright 2003
7
H52530PAE Rev F
December
2005
2.2 THE ROM II Plus ONBOARD MONITOR (OBM)
The ROM II Plus Onboard Monitor provides connections for 8 overfill (top) channels,
8 retain (bottom) channels, a red diagnostic LED for each channel (compartment), a
green permit LED, a yellow power LED, a Retain Reset Switch LED for the built-in
timer (which is activated via a momentary pushbutton switch on the side of the
housing), the 12~24 Volt power connection, and compatible industry standard
Thermistor, Optic and Float Switch rack control monitor outputs. In addition, the
ROM II Plus OBM contains input connections for four auxiliary inputs, and one
auxiliary output. These auxiliary inputs are NOT fail-safe since they connect to
simple normally-open (N.O.) switches for activation. The unit also contains
additional LEDs to indicate auxiliary input status, timer status, and socket power /
signal status.
The ROM II Plus monitor contains patented advance diagnostics that can
distinguish between sensor failures and wiring problems. Each sensor channel is
wired to only one sensor, and the status for that channel is indicated by a
corresponding LED. The LED will signal the type of failure with a different (unique)
flashing light pattern for an open, shorted to ground, or sensor-to-sensor short wire
connection, and a solid light for a wetted or faulty sensor. The ROM II Plus parallel
wiring (when 2-wire sensors are used) and advanced diagnostics does not require a
special tester to troubleshoot a field problem.
If at any time an overfill (top) sensor becomes wetted, the ROM II Plus monitor will
switch the API Float, Thermistor and Optic loading rack outputs immediately to
non-permissive. When a returning tank truck contains retained product, it will light
the corresponding retain (bottom) red LED solid using the same advanced
diagnostics. The tank must be completely drained before the ROM II Plus monitor
will switch the loading rack outputs to permissive. If loading over (on top of) the
retained product is desired, then activating the retained reset switch will force the
ROM II Plus monitor to a permissive state for approximately forty (40) minutes,
allowing the load to proceed for this amount of time, or until the loading rack plug is
disconnected from the socket. At NO time are the overfill (top) sensors effected by
the reset switch. After the forty minute cycle is complete, or the loading rack plug
disconnected, and product remains in the tank compartments, the ROM II Plus
monitor will again switch non-permissive. This feature is beneficial when multiple
loads are taken for in-tank blending but extra attention must be given to prevent an
overfilled tank. Please note that the reset switch may be activated again to start or
re-start another 40 minute timing cycle as long as a loading rack plug is attached to
either the thermistor or optic socket.
When used with Civacon PVO Sensors, the ROM II Plus will work identical as with
other Civacon overfill detection sensors as an overfill detection monitor, but will new
include the ability to also sense pressure and vacuum conditions within a tank
compartment, and signal for rack or truck compartment shutdown when the
overpressure or over vacuum condition occurs. When one of these conditions
occur, as they are generally quick occurrences that disappear quickly, the ROM II
Plus monitor will capture and remember this event, requiring manual confirmation
and acknowledgement of it happening by the operator in order to again get a
permissive to load signal (permit LED). This is done via the pushbutton reset switch
on the side of the housing. Pressing this pushbutton will clear the stored / captured
CIVACON
Copyright 2003
8
H52530PAE Rev F
December
2005
high pressure or high vacuum condition and allow the ROM II Plus to again permit
(if everything else if O.K.).
Top prevent repetitive nuisance shutdowns and allow a troublesome truck to finish
loading or unloading under supervision, once a PVO sensor detects a pressure or
vacuum condition twice in any one compartment, the next occurance in the same
compartment will be ignored. This feature is cancelled if the power is removed
and re-applied to the ROM II Plus monitor (causing the troublesome compartment to
again cause shutdown).
2.3 THE "TOP ONLY" ROM II Plus ONBOARD MONITOR
The ROM II Plus monitor can be configured for (2-wire sensor) top only (overfill)
operation. Simply not connecting any retained sensors during setup / programming
will disable the retain (bottom) circuitry. Top only ROM II Plus configuration will
provide the advantages of 2 wire sensors and advanced diagnostics with the ability
to install retain sensors at a later date.
2.4 THE “5-WIRE TOP ONLY” ROM II Plus ONBOARD MONITOR
The ROM II Plus monitor can be configured for use with the industry standard 5wire sensor top only (overfill) operation. Simply connecting the the 5-wire overfill
sensors to the monitor instead of the standard 2-wire sensors during setup /
programming will configure the ROM II Plus monitor for 5-wire top only (overfill)
operation. Top only ROM II Plus 5-wire configuration will provide the advantages of
up to twelve (12) compartment operation, loading rack compatibility with the ability
to install standard 2-wire retain sensors (up to 8 maximum) at a later date.
3 OBM MOUNTING INSTRUCTIONS
The ROM II Plus Onboard Monitor has four (4) mounting feet with holes, at the base of its cast
aluminum housing, used for mounting the enclosure. These are provided so that it may be
securely bolted to a grounded metal portion of the trailer that will provide an excellent physical
support to the monitor. Locate the monitor in an area that is visible to the operator near the
sockets and bottom loading adapters. The holes through the mounting feet are for 5/16 inch (8
mm) diameter bolts. Refer to Figure 2 for mounting dimension information for the housing.
Mounting dimensions are given in millimeters (with inches in parenthesis).
To protect the electronics inside the housing, keep the monitor’s cover on the housing until you are
ready to wire the monitor. The housing provides seven (7) 20 x 1.5 mm conduit holes (½" NPT on
some U.S. models). Refer to Figure 2 for location and use of these holes. These holes provide
for easy wiring access to the various electrical terminals on the monitor. The three (3) holes on the
right side of the housing are used for wiring to the sockets. The two (2) located on the left side of
the housing are used for wiring the 12 ~ 24 Volt DC power and the Auxiliary Inputs. The two (2)
holes along the bottom of the housing are used for the overfill (top) and retain (bottom) sensors.
Any holes that are not used should be properly sealed with the plugs provided with the monitor.
Once the housing is installed, you are ready to remove the cover frame, gasket, and window; and
begin the wiring procedure.
CIVACON
Copyright 2003
9
H52530PAE Rev F
December
2005
WARNING: There is only one conduit hole provided at the left top side of the
monitor to bring the NON-intrinsically safe power wiring into the housing. The
remaining six (6) NPT holes are used for intrinsically safe signals and wiring. This
convention MUST be complied with in order to maintain the system approvals!
10.00 [254.0]
ROM II Plus
8
7
TOP SENSORS
6
5
4
3
TO THERMISTOR
SOCKET OR
AUX. OUTPUT
FLT
2
1
AUX
POWER INPUT &
NON - I.S. RELAY
OUTPUT
LISTED
9VX9
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
COMPARTMENT INDICATORS
SOLID RED=WET OR FAULTY SNSR
FLASHING CODE=
1 EVERY 5 SEC.=OP EN CIRCUIT
2 EVERY 5 SEC.= SHORT TO GND
3 EVERY 5 SEC.= SHORTED SNSRS
AUX 1
AUX 2
AUXILIARY
INPUTS
AUX 3
AUX 4
HIGH PRESS.
HIGH VAC.
TO OPTIC
SOCKET
5W
PERMIT
PRG
TIMER
TOUCH HERE FOR
RETAINED RESET
5.38 [136.7]
ERR
COM
R
LISTED
9VX9
0539
II(1) G [EEx ia] IIB
RETAINED RESET
SWITCH
DEMKO 04 ATEX 0318938
TO OVERFILL AND
RETAINED SENSORS
Ø0.31 [Ø8.0]
FIGURE 2 - MONITOR HOUSING – MOUNTING DETAILS
4 WIRING INSTRUCTIONS - THE WIRE
All wiring entering the housing must enter through the appropriate conduit openings shown in
Figure 2. Use weather-tight cable strain reliefs or liquid-tight (IP 65 minimum) conduit fittings to
keep out external moisture. The use of weather-tight cable strain reliefs with the sensor and
socket housings as well is also imperative for a moisture resistant system. We require the use of a
high quality stranded and tinned copper wire with a minimum thickness of 1.0 mm2 (20 gauge
AWG) for all electrical connections to the monitor. Trim about 6 mm (¼") of the insulation off the
end of each wire that will be connected to the terminal blocks of the monitor. Insert the trimmed
wire into its appropriate slot on the terminal block and tighten the screw on top of that slot securely.
Ensure that NO stray strands of wire have separated from the connection that could cause a
potential short with an adjacent terminal. It is recommended if possible to use wire ferrules or
wire pin connectors on each of the stripped wire ends before inserting the wires into the
terminals. These will provide superior connections and prevent the possibility of stray
strands of wire causing potential shorts between terminals. Due to the vibrations that can
occur on a trailer, it is extremely important to double-check all wiring connections for good
mechanical integrity. The proper color code of the wires will save time and money on the
installation and on any technical help or troubleshooting which may be required in the future.
CIVACON Model 2300 cable is a seven (7) conductor color coded cable which is highly
recommended for use with the installation of CIVACON ROM IITM overfill prevention equipment.
This cable is usable for up to a 6-compartment installation. For installations 7 & 8 compartment
installations, we recommend CIVACON Model 7215 cable. CIVACON also makes a Model 2100
cable that is a five (5) conductor color coded cable which may be used for 5-Wire top only (overfill)
sensor installations, and for installation of the loading rack socket(s). For European EN 13922
compliant wiring installations for 5-Wire top only (overfill) sensor installations, Civacon Model
2100E (5) conductor color coded cable is available that meets the color codes of this standard.
CIVACON
Copyright 2003
10
H52530PAE Rev F
December
2005
5 WIRING INSTRUCTIONS – POWER INPUT TERMINALS
SAFETY FIRST!! POWER MUST BE OFF WHEN INSTALLING OR REMOVING POWER
LEADS TO THE MONITOR. THE WIRES FOR THE POWER FROM THE BATTERY
MUST BE KEPT SEPARATE FROM THE SENSOR AND SOCKET WIRING! THEY
CANNOT BE RUN TOGETHER IN THE SAME CONDUIT! This is important to maintain
safe current levels in the intrinsically safe sensors, auxiliary switches, and socket wiring.
Do not apply power to the monitor without reading this manual and thoroughly checking all
connections. Measure the truck / trailer system voltage. The monitor is designed to operate from
on truck systems with nominal power of either 12 or 24 Volts DC (9 VDC min. to 32 VDC max.),
negative ground systems, supplied by a battery (or batteries). If your voltage measurement is not
within this range, contact CIVACON before installing the monitor. Power from battery chargers
or other pulsed power supplies may permanently damage the monitor. If the power wires
pass through a Zone 1 hazardous area, the conduit and wire type must be suitable for this use.
The monitor's power supply circuit should contain a switch and an inline fuse with a maximum
current rating of ½ Amp. This fuse should be located in the trailer’s nose box or in the truck cab,
and an inline switch located in the truck cab so that the overfill system can be turn off when the
truck is out of service. This may also be accomplished with an appropriate cabinet door, guard bar
or other safety / power interlock switch on the trailer or truck. It is recommended that the power to
the monitor be switched off when not in use (i.e.- When servicing the electrical system or when
driving the vehicle). The wires from the power source must only enter the ROM II Plus monitor’s
housing via the proper conduit opening, which is the upper left hand opening (refer to Figure 2 &
3). Bringing this power into the housing will void the system’s safety approvals! See
cautions about this earlier in the manual.
An external junction box, fuse holder, and fuse that can be installed directly into the housing’s
upper left hand conduit port (for in-line fuse placement) may be purchased from CIVACON as a kit
product if one is not available locally. Please contact the factory for further information on this
product. This product comes with its' own instruction sheet.
Wire the power into the power input terminal block as shown in Figure 3. Be careful to observe the
correct polarity. The topmost terminal is the positive (+) terminal, and the one just below it is the
negative (-) terminal. Applying the power with the incorrect polarity will not damage the monitor,
but will prevent it from working properly.
CIVACON
Copyright 2003
11
H52530PAE Rev F
December
2005
5.1 NON-I.S. RELAY OUTPUT WIRING
Included on the Power Input Terminal Block are two terminals that serve as a non
intrinsically safe (non I.S.) dry relay contact output. This output provides a switched output
that corresponds with the permissive & non permissive status of the ROM II Plus monitor.
This dry relay contact output may be used to provide a relay closure / opening signal to any
device on the vehicle within the rating of the relay contact. The relay contact is rated at
30 VDC, 1 Amp resistive (max.). When using this relay contact, provide the
appropriate external fuse for the load being operated to assure that the relay contact
is not over-loaded and damaged. Also assure that the load (device being driven) is
located in a safe area on the vehicle, or is suitable rated for the intended area of
installation.
RED
ROM II Plus
BLACK
RELAY
8
7
RELAY
LISTED
9VX9
ROM II Plus
0539
DEMKO 04
ATEX 0318938
8
COMPARTMENT
SOLID RED=
FLASHING
1 EVERY
2 EVE
3E
7
TOP SENSORS
6
5
4
3
2
1
FLT
AUX
LISTED
9VX9
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
COMPARTMENT INDICAT ORS
SOLID RED=WET OR FAULT Y SNSR
FLASHING CODE=
1 EVERY 5 SEC.=OPEN CIRCUIT
2 EVERY 5 SEC.=SHORT TO GND
3 EVERY 5 SEC.=SHORTED SNSRS
POWER AND CONTROL WIRING
AUX 1
AUX 2
AUX 3
AUX 4
POWER AND CONTROL WIRING WIRE COLOR / FUNCTION DETAILS
HIGH PRESS.
HIGH VAC.
5W
PERMIT
PRG
TIMER
TOUCH HERE FOR
RETAINED RESET
ERR
COM
RED - POS. 12/24 VDC INPUT POWER
BLACK - NEG. VDC INPUT POWER
RELAY - NON-I.S. RELAY CONTACT (N.O.)
RELAY - NON-I.S. RELAY CONTACT (N.O.)
RELAY CONTACT RATING 30 VDC, 1 AMP.
MAXIMUM, RESISTIVE LOAD
FIGURE 3 – POWER & CONTROL WIRING
CIVACON
Copyright 2003
12
H52530PAE Rev F
December
2005
6 TOP SENSORS INSTALLATION
Install the TOP (Overfill) Sensors in the appropriate locations in the top of the tank or trailer using
the following information. Then install lengths of multi-conductor cable (CIVACON Model 2300 or
7215) between each sensor housing leaving sufficient lengths for making the connections inside
each sensor housing, and to tie the cable neatly to the rollover rail. A longer length of wire is
required from the sensor in the rear most compartment to run down the tank head to the ROM II
Plus onboard monitor located near the bottom loading adapters. If this is a front wired trailer, then
the longer length is used on the sensor in the front of the trailer to run down the front head. It is
recommended that you use CIVACON premium cable because the color coding will help wiring
and troubleshooting in later steps.
See Figure 4 for additional technical mounting and dimensional information on these sensors.
6.1 THREADED HOUSING SENSOR INSTALLATION
A threaded housing sensor is equipped with a 2 inch BSPP housing with two M-20 conduit
openings. See Figure 4 for mounting dimensions. This sensor can be mounted two ways.
First, the sensor can be mounted though a 60 mm (2-3/8 inch) diameter hole in the
manhole cover, and secured using the gasket and lock nut provided. The gasket should be
installed between the cover and base of the sensor housing. Second, the sensor can be
mounted into a 2 inch BSPP female half-coupling welded into the top skin of the tank, or the
manhole. In this case the locknut and gasket are not used.
6.2 FLANGED HOUSING SENSOR INSTALLATION
A flange mounted sensor is equipped with flanged housing with two M-20 conduit openings.
See Figure 4 for mounting dimensions. The flanged sensor is designed to be mounted
against a 133.35 mm (5-¼ inch) flange welded into the skin of the trailer, or the manhole.
Use a 133.35 mm (5-¼ inch) O.D. flange with four (4), 7 mm (9/32 inch) bolt holes equally
spaced around a 114.30 mm (4-½ inch) bolt circle. This flange is a Tank Trailer
Manufacturer’s Association (TTMA) standard 2-1/2 inch flange pattern. Install the sensor
with the gasket between sensor base and flange.
6.3 SENSING POINT ADJUSTMENT
The actual sensing point can be adjusted by loosening the set screw on the side of the
sensor housing. See Figure 4 for locations. Generally the sensor is adjusted with its
sensing point typically 6 – 12 mm (¼ - ½ inch) above the normal high level point with
enough empty space (outage) above the sensing point to allow for sufficient response time
to shut off the loading process and prevent an overflow condition. Many European
countries require a minimum of 150 liters (33 gallons) of outage in each compartment. The
American Petroleum Institute’s (API) latest recommendation is for a minimum of 275 liters
(60 gallons) outage in each compartment, regardless of actual compartment volume. The
ROM II Plus system and rack monitor will have a maximum response time of about onehalf (½) second. Keep in mind that the loading terminal’s metering system shut off valve
will also have a longer response time. Once the sensor is adjusted to proper height, tighten
the set screw. Even if the sensor is not adjusted, insure that the set screw is tight.
The standard sensors supplied with the system provide for a typical adjustment range
between 127 mm (5 inches) minimum to a maximum of 178 mm (7 inches). If a longer
CIVACON
Copyright 2003
13
H52530PAE Rev F
December
2005
sensor is required, please contact the factory for additional information. Special sensors
can be made up to 3.66 meters (144 inches) long.
101.60
(4.00")
4 HOLES 7.11 (0.28") DIA.
EQUAL SPACED ON 114.30
(4.50") DIA. BOLT CIRCLE.
133.35
(5.25")
82.55
(3.25")
EARTHING
SCREW
M20 x 1.5
EACH SIDE
(180 DEG.)
M20 x 1.5
2 PLCS.
96.77
(3.81")
84.07
(3.31")
GASKET
GASKET
TANK SHELL OR
MANHOLE COVER
TANK SHELL OR
MANHOLE COVER
2" BSPP
HEIGHT ADJ.
SET SCREW
LOCKNUT
50.80
(2.00")
DIA.
127.0 (5")MIN.
127.0 (5")MIN.
177.8 (7")MAX.
177.8 (7")MAX.
SENSING POINT
SENSING POINT
FIGURE 4 - TOP SENSOR DIMENSIONS
CIVACON
Copyright 2003
14
H52530PAE Rev F
December
2005
6.4 2-WIRE SENSOR WIRING CONNECTIONS
Make all 2-wire wiring connections as defined in Figure 6 using Wiring Diagrams 8A, 8B
and 8C, 9A, 9B and 8C and 10 as appropriate to the installation. Refer to the following
table for the correct diagrams to use.
Maximum No. of
Compartments
Type of Sensors
Use Diagrams
Eight (8)
2-Wire ROM
8A, 8B & 8C
Twelve (12) Top Sensor 5-Wire Optic Sensors
Only
Eight (8)
9A & 9B
5-Wire Optic Top with Bottom Sensors 10, 9B & 8C
Be sure to double check that your wiring connections are correct. Also, we have found that
a small amount of non-corrosive sealant or electrical grease in each crimp connection will
prevent corrosion and provide very reliable wire connections. See the SEALED WIRE
CONNECTIONS addendum at the rear of the manual.
7 BOTTOM SENSORS INSTALLATION [If so equipped]
Install the BOTTOM (Retained Product) Sensors, if so equipped, in the appropriate locations in the
bottom of the tank or trailer using the following information. Then install lengths of multi-conductor
cable (CIVACON Model 2300 or 7215 between each sensor housing leaving sufficient lengths for
making the connections inside the sensor housings, and to tie the cable neatly to any conduit run
from the rear to the front of the trailer. Do not let this cable sag beneath the bottom of the trailer,
as it may catch on something. A longer length of wire is required from the sensor in rear most
compartment to run to the ROM II Plus onboard monitor located near the bottom loading
adapters. If this is a front wired trailer, then the longer length is used on the sensor in the front of
the trailer. It is recommended that you use the CIVACON premium cable because the color coding
will help wiring and troubleshooting in later steps.
7.1 THREADED HOUSING RETAINED PRODUCT SENSOR INSTALLATION
A threaded housing retained product sensor is designed to fit into a ½ inch NPT halfcoupling style weld bushing, welded into the bottom of each compartment at the lowest
point. See Figure 5 for additional mounting dimension technical information on these
sensors and weld bushing. The collar should not protrude more than 19 mm (¾ inch)
beyond the outside shell of the tank, and flush with the inside of the tank when possible.
CIVACON supplies a special half coupling collar with each retain sensor purchased. This
half-coupling requires an opening of 28.6 mm (1-1/8 inch) diameter be cut into the bottom of
the compartments. Weld it appropriately so the mechanical strength of this coupling is
maintained with the compartment wall. Thread the sensor into the half coupling using pipe
sealant or Teflon® tape to lubricate and seal the threads. Always use the hex fitting to
tighten the unit. Do NOT use the body of the sensor to tighten it.
CIVACON
Copyright 2003
15
H52530PAE Rev F
December
2005
NOTE: Check to see that the sensor housings will not interfere with the emergency valves.
It is also a good idea to check for compartment leaks BEFORE wiring the retain sensors.
7.2 WIRING CONNECTIONS
Make all wiring connections, as shown in Figure 5 with Diagrams shown in Figures 6
through 10, that show the 1 through 8 compartment configurations. Be sure to double check
that your wiring connections are correct. Also, we have found that a small amount of noncorrosive sealant or electrical grease in each crimp connection will prevent corrosion and
provide very reliable wire connections.
See the SEALED WIRE CONNECTIONS
addendum at the rear of the manual.
28.8 (1.13")
DIA.
TANK WALL
FULL WELD
5 MM (0.2")
TYPICAL
TANK WALL
THICHNESS
23.1 (0.91")
BUSHING
HEIGHT
1/2 IN. NPT THREAD
WELD BUSHING (COLLAR)
SENSE POINT
2.54 (0.1") TYP.
40.6 (1.6") TYP.
SENSE POINT
TANK BOTTOM
20.3 (0.8")
1/2 IN. NPT THREAD
82.6 (3.25")
MODEL 1001
MODEL 1000
127 (5.00")
31.75
(1.25")
1/2 IN. NPT HOLE
ONE EACH END.
FIGURE 5 – RETAINED PRODUCT SENSOR MOUNTING DIMENSIONS
CIVACON
Copyright 2003
16
H52530PAE Rev F
December
2005
8 WIRING INSTRUCTIONS – 2-WIRE SENSORS & ROM II Plus
The sensors must be wired according to Figure 6, as mentioned previously. The wires
from the sensors should enter the ROM II Plus housing via the proper conduit opening
(refer to Figure 2). The CIVACON ROM sensors follow the two wire ROM signal format.
See the Figure 6 diagrams for a complete sensor system wiring diagram.
CIVACON has full color wall charts that is available for the ROM II Plus system. Please
contact the factory for a copy.
NON- I.S.
WIRING
2. A SSOCIAT ED AP PARATUS must be installed in accordance with
NEC ANSI/NFPA 504 and ANSI/ ISA RP12.6 for the United States. In Canada,
the installation must be in accordanc e with the Canadian Elec trical Code.
CEC Part 1. In Europe, the ins tallation may be in acc ordance with EN6007914 or according to national ins tallation requirements.
CLASS I , DIV . 2, GROUPS C & D
ZONE 0, GROUP II B
HAZARDOUS LOCATIONS
8-30 VDC
TRUCK
POWER
3. Where multiple circuits extend from the same piece of intrins ically
s afe equipment, they mus t be installed in separate cables or in one c able
having suitable insulation. Refer to the standards described in Note 2 for
information regardin g the installation of intrinsically safe equip ment.
MODEL 3203/3204 OBM UNIT
ROM II Plus
8
4. Capacitance and inductance of the field wiring from the intrinsically
safe equipment to the barrier should be c alc ulated and should be inc luded
in the sys tem calcula tions as shown in Table 1. Cable capacitance (Cc)
plus intrinsically safe equip ment capacitanc e (Ci) must be less than the
mark ed capac itance (Ca or Co) shown on any barrier used. The s ame
applies for induc tanc e (Lc, Li and La or Lo, respec tiv ely ). Where the cable
capacitance and inductance per foot are not k nown, the following values
s hall be used: Cc = 60 pF/ft. , Lc = 0.2 µH/ ft .
>
Voc (or Vt)
I max
P max
>
>
Isc (or It)
Po
Ci + Cc
Li + Lc
<
<
Ca
La
1
FLT
API SOCKET
CIVACON
BOTTOM SENSORS
053904
DEMKO
ATEX 0318938
COMPARTMENT INDICATORS
HIGH
PRESS.
SOLID
RED=WET OR
FAULTY
SNSR
FLASHING
1
EVERY 5 CODE=
SEC.=OPHIGH
EN CIRCUIT 5W
2 EVERY
EVERY 5
5 SEC.=
SEC.= SHORTED
SHORT VAC.
TOSNSRS
GND
3
AUX 1
PERMIT
PRG
AUX 2
TIMER
AUX 3
ERR
TOUCH HERE FOR
AUX 4
RETAINED RESET COM
ASSOCIAT ED AP PARATUS - MODEL 3203/3204
V max
TOP SENSORS
6 5 4 3 2
2W
TABLE 3:
I.S . EQUIP MENT
7
AUX
LISTED
9VX9
CIVACON
API SOCKET
If Po of the barrier is not known, it may be calculated us ing the formula Po = (Voc *
Is c)/4 = (Uo * Io)/4.
5. Vehicle Equipment must not use or generate more than 30 V rms or
DC with respect to earth.
6. Power to the unit is supplied from a resistive limited supply of
Ui = 30 VDC and Ii = 500 mA .
RETAIN SENSORS
DATE DATE
CODE
CODE
ENTITY PARAMET ERS FOR TERM INAL BLOCK TB2
TERMINALS
Uo / Voc Io / Isc
TOP SENSORS 1,2,3,4,5,6 ,7 OR 8 TO COM(GND) 18.6 V 28 mA
BOT SENSORS 1,2,3,4,5,6 ,7 OR 8 TO COM(GND) 18.6 V 28 mA
TOP SENSORS 1,2,3,4,5,6 ,7,8 OR IN P AR TO COM(GND) 18.6 V 224 mA
BOT SENSORS 1,2,3,4,5,6 ,7,8 OR IN P AR TO COM(GND) 18.6 V 224 mA
5-WIRE RED,YEL,ORN OR GRN TO COM(GND) 18.6 V 48 mA
5-WIRE RED,YEL,ORN OR GRN IN PAR TO COM(GND) 18.6 V 128 mA
ENTITY PARAMET ERS FOR TERM INAL BLOCK TB3
TERMINALS
Ui
Ii
FLOAT 1 OR FLOAT 2 TO GND 15.0 V 1 A
FLOAT 1, FLOAT 2 IN P ARALLEL TO GND 15.0 V 15 mA
THERM ORN OR THERM RED TO GND 15.0 V 15 mA
OPTIC - PULSE OUT, PULSE IN OR PWR TO GND 15.0 V 190 mA
Co / Ca
--------------1,66 uF
1,66 uF
---------------
Lo / La
--------------2.83 mH
2.83 mH
---------------
Pi
15 W
220 mW
220 mW
2.85 W
Ci
---------------------10,0 uF
DATE DATE
CODE
CODE
CLASS I, DIV. 1, GROUPS C & D
OR CLASS I, ZONE 0, GROUP IIB
HAZARDOUS LOCATIONS
Li
320 uH
--------------8,86 mH
FIGURE 6A – POWER AND INTRINSICALLY SAFE WIRING
APPROVAL AGENCY CONTROL DIAGRAM – SHEET 1 of 2
CIVACON
Copyright 2003
17
H52530PAE Rev F
December
2005
NON- I.S.
WIRING
MODEL 3203/3204 OBM UNIT
OVERFILL 5-WIRE (TOP) SENSORS
8-30 VDC
TRUCK
POWER
CONNECT ONLY ONE OF THE FOLLOWING TO THE RACK
ROM II Plus
8
7
TOP SENSORS
6 5 4 3 2
1
FLT
OR
OR
OR
AUX
LISTED
9VX9
SWITCHES, ETC.
BOTTOM SENSORS
053904
DEMKO
ATEX 0318938
COMPARTMENT
2W
INDICATORS
PRESS.
HIGH
SOLID
RED=WET
FAULTY
SNSR
FLASHING
CODE=OR
5W
1
HIGH
EN CIRCUIT
VAC.
2 EVERY
EVERY 5
5 SEC.=OP
SEC.= SHORT
TO GND
3 EVERY 5 SEC.= SHORTED SNSRS
PERMIT
AUX 1
PRG
AUX 2
TIMER
AUX 3
ERR
TOUCH HERE FOR
AUX 4
RETAINED RESET COM
PROGRAM USE ONLY WITH SUP PLIED JUMPER
SENSOR NO. 8
RED
CONNECT EITHER 2-WIRE OR 5-WIRE PROBES BUT NOT BOTH
OVERFILL 2-WIRE (TOP) SENSORS
SENSOR HOUSING
SENSOR HOUSING
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
BROWN (TO NO. 1)
RED (TO NO. 2)
ORANGE (TO NO. 3)
YELLOW (TO NO. 4)
GREEN (TO NO. 5)
BLUE (TO NO. 6)
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
GRAY
WHITE
WHITE
WHITE
RED
BLACK
SENSOR NO. 7
RED
SENSOR NO. 7
BLACK
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
GRAY
WHITE
RED
BLACK
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
BROWN (TO NO. 1)
RED (TO NO. 2)
ORANGE (TO NO. 3)
YELLOW (TO NO. 4)
GREEN (TO NO. 5)
BLUE (TO NO. 6)
WHITE
SENSOR HOUSING
WHITE
SENSOR HOUSING
RETAIN (BOTTOM) 2-WIRE SENSORS
BLACK
SENSOR NO. 8
FIGURE 6B – POWER AND INTRINSICALLY SAFE WIRING
APPROVAL AGENCY CONTROL DIAGRAM – SHEET 2 of 2
Additions Notes:
1. Maximum ambient temperature is 70o C (160o F)
2. Intrinsically Safe Device Parameters: (See TABLES 2 & 3 & 4 )
3. ASSOCIATED APPARATUS must be installed in accordance with NEC ANSI/NFPA 504 and
ANSI/ISA RP12.6 for the United States. In Canada, the installation must be in accordance with
the Canadian Electrical Code. CEC Part 1. In Europe, the installation may be in accordance
with EN60079-14 or according to national installation requirements.
4. Where multiple circuits extend from the same piece of intrinsically safe equipment, they must
be installed in separate cables or in one cable having suitable insulation. Refer to the
standards described in Note 2 for information regarding the installation of intrinsically safe
equipment.
5. Capacitance and inductance of the field wiring from the intrinsically safe equipment to the
barrier should be calculated and should be included in the system calculations as shown in
Table 1. Cable capacitance (Cc) plus intrinsically safe equipment capacitance (Ci) must be
less than the marked capacitance (Ca or Co) shown. The same applies for inductance (Lc, Li
and La or Lo, respectively). Where the cable capacitance and inductance per foot are not
CIVACON
Copyright 2003
18
H52530PAE Rev F
December
2005
known, the following values shall be used: Cc = 60 pF/ft (200 pF/M), Lc = 0.2 µH/ft (0.66
µH/M).
I.S. EQUIPMENT ASSOCIATED APPARATUS – MODEL 3203/3204
V max
≥
Voc
(or Vt)
I max
≥
Isc
(or It)
P max
≥
Po
Ci + Cc
≤
Ca
Li + Lc
≤
La
If Po of the barrier is not known, it may be calculated using the formula Po = (Voc * Isc)/4 = (Uo
* Io)/4.
6. Vehicle Equipment must not use or generate more than 30 V rms or DC with respect to earth.
7. Power to the unit is supplied from a resistive limited supply of Ui = 30 VDC and Ii = 500 mA.
8. TB4 inputs are for simple switch mechanisms with NO inductance or capacitance. They
provide Intrinsically Safe circuits for passive switches or jumpers with NO energy storing or
discharging capability.
9. CIVACON devices connected to TB2 are sensor Models 1111, 1051, 1000, 1001, 1000R,
1001R, and replacement sensors Models 1301, 1351, plus special length versions of the same
models with an "S" suffix.
10. Auxiliary Output terminal (Aux Out of TB3-3/4) can be connected to Auxiliary Input (Aux In. of
TB3-11/12 of secondary OBM module. Do not cross connect.
11. CIVACON devices connected to TB3 are Intrinsically Safe outputs from rack monitor Models
8000 series, 8100 series, 8300 series, 8400 series, and 8500 series. The connections are less
than 50 feet.
CIVACON
Copyright 2003
19
H52530PAE Rev F
December
2005
9 WIRING DIAGRAMS – 2-WIRE SENSORS & ROM II Plus
The following wiring diagrams are associated with wiring 2-wire ROM sensors to the ROM
II Plus onboard monitor. The first group of three diagrams (Diagrams 7A, 7B & 7C) are for
wiring sensors on trailers of up to 6 compartments maximum using Civacon 7-conductor
cable (Model 2300). The second group of three diagrams (8A, 8B & 8C) are for wiring
sensors on trailers of up to 8 compartments maximum using Civacon 10-conductor cable
(Model 7215).
NOTE: The wiring diagrams show sensor wire color codes for Civacon ROM sensors
(RED & BLACK).
SEE MANUAL FOR COMPLETE W IRING DETAILS
* 5-W IRE COLORS IN ( ) ARE PER EN 13922
(+)12/24 VDC
(-)VDC
BRN
FLOAT
BRN
+
_ AUX
ROM II Plus
N.O. RLY
8
7
TOP SENSORS
6
5
4
3
2
1
N.O. RLY
FLT
AUX
ORN
LISTED
9VX9
2W
DEMKO 04
ATEX 0318938
BLK (WHT)
YEL
COMPARTMENT INDICATORS
SOLID RED=WET OR FAULTY SNSR
FLASHING CODE=
1 EVERY 5 SEC.=OPEN CIRCUIT
2 EVERY 5 SEC.=SHORT TO GND
3 EVERY 5 SEC.=SHORTED SNSRS
COM
AUX1
AUX2
AUX 2
AUX3
AUX 3
AUX4
AUX 4
C 8
O
M
7
HIGH PRESS.
HIGH VAC.
ORG (BLU)
5W
RED (GRY)
PRG
TIMER
TOUCH HERE FOR
RETAINED RESET
5
GND
RESET SW.
ERR
PROGRAM
COM
4 3 2 1 C 8 7 6 5 4 3 2
O
2-WIRE
M BOTTOM SENSORS
TOP SENSORS
6
OPTIC*
GRN
PERMIT
AUX 1
THERM.
RED
BOTTOM SENSORS
0539
1
5-WIRE SENSORS*
RED(GRAY)
YELLOW
BLK(WHT)
ORN(BLU)
GREEN
FIGURE 7 – TERMINAL DESIGNATIONS & CONNECTION DETAILS
CIVACON
Copyright 2003
20
H52530PAE Rev F
December
2005
OVERFILL (TOP) SENSORS
OVERFILL (TOP) SENSORS
SENSOR HOUSING
SENSOR HOUSING
SENSOR HOUSING
VIOLET
GRAY
WHITE
GRAY
WHITE
SENSOR HOUSING
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
GRAY
WHITE
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
GRAY
WHITE
ORANGE (TO NO. 3)
YELLOW (TO NO. 4)
GREEN (TO NO. 5)
BLUE (TO NO. 6)
WHITE
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
WIRING NOTES:
1. WIRING SPLICES IN HOUSINGS ARE
INDICATED BY BLACK DOTS.
2. UNUSED / UNCONNECTED WIRES IN CABLE
NOT SHOWN INSIDE / OR IN BETWEEN
JUNCTION BOXES. TRIM THESE BACK
TO CABLE JACKET AT EACH LOCATION.
SENSOR NO. 8
SENSOR NO. 7
SENSOR NO. 2
SENSOR NO. 1
SENSOR NO. 8
SENSOR NO. 7
SENSOR NO. 2
SENSOR NO. 1
3. WIRING SHOWN REFLECTS COMPARTMENT
NO. 1 AT FRONT OF TANK, WITH CABLE
RUNNING DOWN REAR HEAD OF TANK.
4. SENSOR WIRE COLORS SHOWN ARE FOR
CIVACON ROM SENSORS. FOR CIVACON
'QUICK-START" SENSORS SUBSTITUTE WHITE
SENSOR WIRE FOR RED SENSOR WIRE
IN DIAGRAM.
5. CABLE WIRE COLORS SHOWN ARE FOR
CIVACON 10-CONDUCTOR CABLE.
6. IF RETAINED (BOTTOM) SENSORS ARE NOT
USED, IGNORE WIRING SHOWN.
BLACK
RED
BLACK
RED
WHITE
GRAY
BLACK
WHITE
GRAY
VIOLET
RED
WHITE
SENSOR HOUSING
RETAIN (BOTTOM) SENSORS
RED
WHITE
GRAY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
BLUE (TO NO. 6)
GREEN (TO NO. 5)
YELLOW (TO NO. 4)
ORANGE (TO NO. 3)
SENSOR HOUSING
BLACK
SENSOR HOUSING
WHITE
GRAY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
BROWN
SENSOR HOUSING
RETAIN (BOTTOM) SENSORS
FIGURE 8A – 2-WIRE TOP (OVERFILL) & BOTTOM (RETAINED) SENSOR WIRING
UP TO 8 COMPARTMENTS - Using CIVACON 10-Conductor Cable
CIVACON
Copyright 2003
21
H52530PAE Rev F
December
2005
2-WIRE TOP (OVERFILL) SENSOR WIRING
COLOR DETAILS - USING 10 CONDUCTOR
CIVACON CABLE
BROWN - TO SENSOR NO. 1 RED WIRE
RED - TO SENSOR NO. 2 RED WIRE
ORANGE - TO SENSOR NO. 3 RED WIRE
YELLOW - TO SENSOR NO. 4 RED WIRE
GREEN - TO SENSOR NO. 5 RED WIRE
BLUE - TO SENSOR NO. 6 RED WIRE
VIOLET - TO SENSOR NO. 7 RED WIRE
GRAY - TO SENSOR NO. 8 RED WIRE
WHITE - TO ALL SENSOR BLACK WIRES
ROM II Plus
8
7
TOP SENSORS
6
5
4
3
FLT
2
1
AUX
LISTED
9VX9
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
AUX 1
COMPARTMENT INDICATORS
SOLID RED=WET OR FAULTY SNSR
FLASHING CODE=
1 EVERY 5 SEC.=OPEN CIRCUIT
2 EVERY 5 SEC.=SHORT TO GND
3 EVERY 5 SEC.=SHORTED SNSRS
AUX 2
AUX 3
AUX 1
AUX 2
AUX 4
AUX 3
AUX 4
HIGH PRESS.
HIGH VAC.
5W
PERMIT
PRG
TIMER
TOUCH HERE FOR
RETAINED RESET
ERR
COM
WHITE
GRAY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
BROWN
TO TOP (OVERFILL) SENSORS
FIGURE 8B – 2-WIRE TOP (OVERFILL) SENSORS TO ROM WIRING CONNECTIONS
UP TO 8 COMPARTMENTS - Using CIVACON 10-Conductor Cable
CIVACON
Copyright 2003
22
H52530PAE Rev F
December
2005
2-WIRE TOP (OVERFILL) SENSOR WIRING
COLOR DETAILS - USING 10 CONDUCTOR
CIVACON CABLE
BROWN - TO SENSOR NO. 1 RED WIRE
RED - TO SENSOR NO. 2 RED WIRE
ORANGE - TO SENSOR NO. 3 RED WIRE
YELLOW - TO SENSOR NO. 4 RED WIRE
GREEN - TO SENSOR NO. 5 RED WIRE
BLUE - TO SENSOR NO. 6 RED WIRE
VIOLET - TO SENSOR NO. 7 RED WIRE
GRAY - TO SENSOR NO. 8 RED WIRE
WHITE - TO ALL SENSOR BLACK WIRES
ROM II Plus
8
TOP SENSORS
6
5
4
3
7
FLT
2
1
AUX
LISTED
9VX9
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
COMPARTMENT INDICATORS
SOLID RED=WET OR FAULTY SNSR
HIGH PRESS.
FLASHING CODE=
1 EVERY 5 SEC.=OP EN CIRCUIT
2 EVERY 5 SEC.= SHORT TO GND
HIGH VAC.
PERMIT
5W
PRG
3 EVERY 5 SEC.= SHORTED SNSRS
AUX 1
AUX 2
AUX 3
AUX 4
PERMIT
PRG
TIMER
TIMER
TOUCH HERE FOR
RETAINED RESET
ERR
COM
ERR
COM
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET
GRAY
WHITE
TO BOTTOM (RETAINED) SENSORS
FIGURE 8C – 2-WIRE BOTTOM (RETAINED) SENSORS TO ROM WIRING CONNECTIONS
UP TO 8 COMPARTMENTS - Using CIVACON 10-Conductor Cable
CIVACON
Copyright 2003
23
H52530PAE Rev F
December
2005
10 WIRING DIAGRAMS – 5-WIRE SENSORS & ROM II Plus
The following wiring diagrams are associated with wiring 5-wire optic sensors to the ROM
II Plus onboard monitor. The first group of two diagrams (Figures 9A & 9B) are for wiring
just top (overfill) sensors on trailers of up to 12 compartments maximum using Civacon 5conductor cable (Model 2100 or 2100E). The next diagram in this group (Figure 10 is for
wiring 5-wire top (overfill) sensors AND 2-wire bottom (retained) sensors on trailers of up
to either 8 compartments maximum using Civacon 5-wire and 10-wire cables (Models
2100 & 7215).
NOTE: Please refer back to Figure 7 for terminal designations and connection details of
each terminal on the ROM II Plus module.
CIVACON
Copyright 2003
24
H52530PAE Rev F
December
2005
5-WIRE
OVERFILL (TOP) SENSORS
SENSOR HOUSING
BLUE
SENSOR HOUSING
SENSOR HOUSING
BLUE
BLUE
WHITE
GREEN
GRAY
BLUE
WHITE
GREEN
GRAY
YELLOW
YELLOW
YELLOW
GREEN
WHITE
5-WIRE
OVERFILL (TOP) SENSORS
YELLOW
WHITE
BLUE
BLUE
WHITE
GREEN
GRAY
YELLOW
YELLOW
GREEN
GREEN
GRAY
SENSOR HOUSING
BLUE
GRAY
YELLOW
WHITE
BLUE
GREEN
GRAY
YELLOW
WHITE
GRAY
YELLOW
BLUE
WIRING NOTES:
1. WIRING SPLICES IN HOUSINGS ARE
INDICATED BY BLACK DOTS.
2. WIRING SHOWN REFLECTS COMPARTMENT
NO. 1 AT FRONT OF TANK, WITH CABLE
RUNNING DOWN REAR HEAD OF TANK.
3. TOP (OVERFILL) SENSOR CABLE WIRE COLORS
SHOWN ARE FOR CIVACON 5-CONDUCTOR
CABLE.
SENSOR NO. 12
SENSOR NO. 2
SENSOR NO. 11
SENSOR NO. 1
FIGURE 9A – 5-WIRE TOP (OVERFILL) SENSOR WIRING UP TO 12 COMPARTMENTS
Using CIVACON 5-Conductor Cable
CIVACON
Copyright 2003
25
H52530PAE Rev F
December
2005
5-WIRE TOP (OVERFILL) SENSOR
WIRE COLOR / FUNCTION DETAILS
GRAY - POS. VDC SENSOR POWER
YELLOW - SIGNAL TO SENSOR
WHITE - NEG. VDC SENSOR POWER
BLUE - SIGNAL FROM SENSOR
GREEN - DIAGNOSTIC SIGNAL
ROM II Plus
8
TOP SENSORS
6
5
4
3
7
FLT
2
1
AUX
LISTED
9VX9
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
AUX 1
COMPARTMENT INDICATORS
AUX 2
AUX 3
SOLID RED=WET OR FAULTY SNSR
HIGH PRESS.
FLASHING CODE=
1 EVERY 5 SEC.=OP EN CIRCUIT
2 EVERY 5 SEC.= SHORT TO GND
3 EVERY 5 SEC.= SHORTED SNSRS
HIGH VAC.
AUX 1
PERMIT
AUX 2
AUX 4
AUX 3
AUX 4
5W
PRG
TIMER
TOUCH HERE FOR
RETAINED RESET
ERR
COM
GRAY
YELLOW
WHITE
BLUE
GREEN
TO TOP (OVERFILL) SENSORS
FIGURE 9B – 5-WIRE TOP (OVERFILL) SENSORS TO ROM WIRING CONNECTIONS
UP TO 12 COMPARTMENTS - Using CIVACON 5-Conductor Cable
CIVACON
Copyright 2003
26
H52530PAE Rev F
December
2005
5-WIRE
OVERFILL (TOP) SENSORS
SENSOR HOUSING
SENSOR HOUSING
BLUE
SENSOR HOUSING
BLUE
BLUE
WHITE
GREEN
GRAY
BLUE
WHITE
GREEN
GRAY
YELLOW
YELLOW
YELLOW
GREEN
WHITE
5-WIRE
OVERFILL (TOP) SENSORS
WHITE
YELLOW
GREEN
GRAY
WHITE
YELLOW
BLUE
YELLOW
BLUE
WHITE
GREEN
GRAY
YELLOW
GREEN
GRAY
SENSOR HOUSING
BLUE
GREEN
GRAY
WHITE
YELLOW
BLUE
BLUE
GRAY
YELLOW
WIRING NOTES:
1. WIRING SPLICES IN HOUSINGS ARE
INDICATED BY BLACK DOTS (
).
2. UNUSED / UNCONNECTED W IRES IN CABLE
NOT SHOWN INSIDE / OR IN BETWEEN
JUNCTION BOXES. TRIM THESE BACK
TO CABLE JACKET AT EACH LOCATION.
SENSOR NO. 8
SENSOR NO. 8
SENSOR NO. 7
SENSOR NO. 2
SENSOR NO. 1
SENSOR NO. 7
SENSOR NO. 2
SENSOR NO. 1
3. WIRING SHOWN REFLECTS COMPARTMENT
NO. 1 AT FRONT OF TANK, WITH CABLE
RUNNING DOWN REAR HEAD OF TANK.
4. SENSOR WIRE COLORS SHOWN ARE FOR
CIVACON ROM SENSORS. FOR CIVACON
'QUICK-START" SENSORS SUBSTITUTE WHITE
SENSOR WIRE FOR RED SENSOR WIRE
IN DIAGRAM.
5. TOP (OVERFILL) SENSOR CABLE W IRE COLORS
SHOWN ARE FOR CIVACON 5-CONDUCTOR
CABLE.
6. BOTTOM (RETAINED) SENSOR CABLE WIRE
COLORS SHOWN ARE FOR CIVACON
10-CONDUCTOR CABLE.
7. IF RETAINED (BOTTOM) SENSORS ARE NOT
USED, IGNORE WIRING SHOWN.
BLACK
RED
BLACK
RED
WHITE
GRAY
BLACK
WHITE
GRAY
VIOLET
RED
BLACK
WHITE
WHITE
GRAY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
BLUE (TO NO. 6)
GREEN (TO NO. 5)
YELLOW (TO NO. 4)
ORANGE (TO NO. 3)
SENSOR HOUSING
SENSOR HOUSING
RETAIN (BOTTOM) SENSORS
RED
SENSOR HOUSING
WHITE
GRAY
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
BROWN
SENSOR HOUSING
RETAIN (BOTTOM) SENSORS
FIGURE 10 – 5-WIRE TOP (OVERFILL) & 2-WIRE BOTTOM (RETAINED) SENSOR WIRING
UP TO 8 COMPARTMENTS - Using CIVACON 5 & 10-Conductor Cables
CIVACON
Copyright 2003
27
H52530PAE Rev F
December
2005
11 WIRING INSTRUCTIONS - AUXILIARY INPUTS
The AUXILIARY INPUTS are four (4) independent intrinsically safe signal sources
connected to monitoring circuits. These inputs provide a voltage source that when
connected to the COM common terminals, will enable the auxiliary permissive circuit.
This, in addition to the normal overfill sensor permissive circuit, controls the overall
"PERMISSIVE" state of the monitor. You must have BOTH circuits permissive before any
overall external “PERMISSIVE” output is given to the loading rack sockets. The
CONTROL DIAGRAMS of Figure 6 and detail diagram in Figure 7 shows the connections
to TB4 which is to the left of TB2, the sensor connections. This figure also shows the
auxiliary devices as simple switches. Unused inputs MUST be connected to the
Auxiliary Inputs COM common terminal on TB3.
CIVACON 5 or 7 conductor cable may be used to connect these auxiliary devices to the
ROM II Plus. Please remember that these signals are intrinsically safe and CANNOT be
run with any other wires in a cable. Only the auxiliary wires and their commons can be run
together in a cable.
Any type of simple switch may be used as the switching device. These can be pressure
switches which connect to the air lines to indicate a pressurized line, or an un-pressurized
condition. The switch could also be a micro-switch to indicate the position of something
that moves. In all cases, this switching mechanism MUST NOT be accidentally
connected to a NON-intrinsically safe voltage source. Because of this low switching
current requirement for intrinsically safe circuits, the contact material on the switching
mechanism should be GOLD plated. If contact materials that can corrode are used, then
the integrity of the switched signal could be compromised, and not work reliably all the
time. If GOLD contact plating is not available, then the best possible material available for
low voltage circuits should be used, with every effort made to keep the corrosive
atmospheres out of the switching chamber of the device.
This leads us to the next problem of corrosion, keeping the connections to the wires free
from corrosion. Boots, sealant, junction boxes, or any means must be used to maintain
the integrity of the connection to the switching device. The cables' integrity to moisture
must also be maintained with any exposed internal wires. Sealing the ends of the cable
jacket are suggested, unless the cable enters a liquid-tight junction box that has strain
relief fittings on it to keep the moisture outside of the junction boxes.
12 WIRING INSTRUCTIONS - SOCKETS
Locate and mount the socket housing(s) in the vicinity of the bottom loading adapters
using the bolt holes provided inside each housing. Taking into account the plug and cable
that will be coming from the loading rack monitoring equipment so that it does not interfere
with the bottom loading adapters when connected.
Conduit openings are provided at the OBM so that each type of socket used may have its
own conduit connection. Cross reference the CIVACON part number of the socket to its
proper wiring diagram and connect accordingly (refer to Diagrams 11 and 12). Please use
CIVACON
Copyright 2003
28
H52530PAE Rev F
December
2005
the CIVACON Instruction Sheet H50200PA, which is packaged with each socket, for
additional reference information on the sockets.
Liquid-tight strain relief fittings or conduit fittings are required for all cable entry locations.
Note that pipe plugs are required to be installed in all of the openings which are not used
for cable entry. A thread sealant is also recommended to be used with each strain relief
fitting or pipe plug.
Suitable for connection to the Intrinsically Safe outputs from CIVACON
Rack Monitors, Models 8000 Series 8100 Series, 8300 Series, 8400
Series & 8500 Series.
PLEASE NOTE: A new feature allows the ROM II Plus Onboard Monitor to pass wet
sensor status information along to the rack / gantry monitor. A new
Figure 12 – 5-Wire Optic Socket Wiring is included in this revision of the
manual that shows a new No. 5 Green Wire connection from the ROM II
Plus to the socket. On rack / gantry monitor’s so capable, the wet top,
overfill sensor displayed on the ROM II Plus display will also be
displayed properly on the rack / gantry monitor.
CIVACON
Copyright 2003
29
H52530PAE Rev F
December
2005
CIVACON THERMISTOR SOCKETS
Match your socket model number with the model numbers below.
Connect the wires shown below to the THERM section of terminal block (TB7) on the ROM
II Plus monitor.
CAUTION: The THERMISTOR RED and ORN wires are NOT the same wires as the
OPTIC RED and ORN wires.
(VIEWED FROM WIRE CONNECTION SIDE)
ORANGE
EARTH CONNECTION
INSIDE SOCKET'S
METALLIC HOUSING
VAPOR RECOVERY HOSE
INTERLOCK SWITCH
EYELETS
1
GRAY
2
8
9
VIOLET
E1
WHITE (GROUND)
FACTORY INSTALLED
10
7
WHITE
(TO TRUCK
3
10 cm
min.
CHASSIS)
BLUE
6
4
E2
WHITE
5
GREEN
YELLOW
WHITE
BROWN
RED
(TO TRUCK CHASSIS
VIA MOUNTING BOLT
OF SOCKET)
10 cm
min.
WHITE
E3
CONNECT TO CHASSIS
AT LEAST 10 cm AWAY
FROM E1 & E2 GROUND
CONNECTIONS
WIRING SHOWN USES MODEL 1920-6
DUMMY IN A MODEL 4401xx SOCKET
TO THERMISTOR / 2-WIRE OPTIC SOCKET
ROM TO THERM ISTOR / 2-WIRE OPTIC
SOCKET WIRING C OLOR D ETAILS - USING
5-CONDUCTOR CIVACON CABLE
ORANGE - T O SOCKET PIN N O. 1
RED - TO SOCKET PIN NO. 2
ROM II Plus
TOP SENSORS
8
7
6
5
4
WHITE - TO CHASSIS EARTH CONNECTION
FLT
3
2
1
AUX
LISTED
9VX9
ORANGE
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
AUX 1
RED
WHITE
COMPARTMENT INDICATORS
SOLID RED=WET OR FAULTY SNSRHIGH PRESS.
FLASHING CODE=
1 EVERY 5 SEC.=OP EN CIRCUIT HIGH VAC.
2 EVERY 5 SEC.= SHORT TO GND
3 EVERY 5 SEC.= SHORTED SNSRS
FLT
2
1
5W
AUX
PERMIT
PRG
AUX 2
BROWN
TIMER
AUX 3
AUX 4
ERR
TOUCH HERE FOR
RETAINED RESET
COM
2W
RED
WHITE
HIGH PRESS.
HIGH VAC.
5W
PRG
ERR
COM
FIGURE 11 – THERMISTOR /2-WIRE OPTIC SOCKET WIRING
CIVACON
Copyright 2003
30
H52530PAE Rev F
December
2005
CIVACON OPTIC SOCKETS
Match your socket model number with the model numbers below.
Connect the wires shown below to the OPTIC section of the terminal block (TB7) on the
ROM II Plus monitor.
CAUTION: The OPTIC RED and ORN wires are NOT the same wires as the
THERMISTOR RED & ORN wires.
(VIEWED FROM WIRE CONNECTION SIDE)
EARTH CONNECTION INSIDE
SOCKET'S METALLIC HOUSING
EYELET
E1
E3
10 cm
min.
8
GRAY (POWER)
10 cm
min.
9
EYELET
E2
CONNECT TO CHASSIS
AT LEAST 10 cm AWAY
FROM E1 & E2 GROUND
CONNECTIONS
WHITE (GROUND)
FACTORY INSTALLED
WHITE
(TO TRUCK CHASSIS)
WHITE (TO TRUCK CHASSIS VIA
VAPOR RECOVERY
MOUNTING BOLT OF SOCKET)
HOSE INTERLOCK SWITCH
10
6
BLUE (SIGNAL FROM OBM)
4
5
GREEN (DIAGNOSTIC SIGNAL)
YELLOW (SIGNAL TO OBM)
WHITE (GROUND FROM OBM)
TO 5-WIRE OPTIC SOCKET
ROM TO 5-WIRE OPTIC SOCKET WIRING
COLOR DETAILS - USING 5-CONDUCTOR
CIVACON CABLE
WHITE - TO CHASSIS EARTH CONNECTION
YELLOW - TO SOCKET PIN NO. 4
GREEN - TO SOCKET PIN NO. 5
BLUE - TO SOCKET PIN NO. 6
GRAY - TO SOCKET PIN NO. 8
ROM II Plus
8
7
TOP SENSORS
6 5 4 3 2
FLT
1
AUX
LISTED
9VX9
BOTTOM SENSORS
2W
0539
DEMKO 04
ATEX 0318938
COMPARTMENT INDICATORS
SOLID RED=WET OR FAULTY SNSR
FLASHING CODE=
1 EVERY 5 SEC.=OP EN CIRCUIT
2 EVERY 5 SEC.= SHORT TO GND
3 EVERY 5 SEC.= SHORTED SNSRS
AUX 1
HIGH PRESS. 5W
HIGH VAC.
PERMIT
WHITE
YELLOW
BLUE
GRAY
GREEN
2
1
FLT
AUX
PRG
AUX 2
AUX 3
AUX 4
TIMER
TOUCH HERE FOR
RET AINED RESET
ERR
COM
HIGH PRESS.
HIGH VAC.
2W
WHITE
YELLOW
BLUE
5W
GRAY
GREEN
PRG
ERR
COM
FIGURE 12 – 5-WIRE OPTIC SOCKET WIRING
CIVACON
Copyright 2003
31
H52530PAE Rev F
December
2005
13 PROGRAMMING OF THE INSTALLED SENSORS
NOTE: The ROM II Plus Onboard Monitor ships from the factory with the sensor
programming jumper installed at the bottom of TB3 (see Figure 13 for location).
DO NOT remove this jumper until after the installed sensors are programmed for
use.
When Truck battery voltage (>9 V) is connected to the PROGRAM connector, the unit will
begin looking at active DRY SENSOR input signals. After 5 seconds of stable input
signals, the appropriate number of wired/active sensors is shown by the flashing RED
Compartment LEDs. These flashing LEDs are the number of compartments that will be
programmed for use. The correct number of flashing LEDs for each type of programming
varies and is described in detail in the programming sections below
To program the installed and wired optic sensors for use with the ROM II Plus monitor,
follow the instructions in the programming section below for the type of sensors being
installed.
2W
RESS.
VAC.
5W
RMIT
PRG
PROGRAMMING
JUMPER
ERR
COM
FIGURE 13 – PROGRAMMING JUMPER LOCATION - DETAIL
2-WIRE SENSOR PROGRAMMING INSTRUCTIONS
The ROM II Plus system can use either just CIVACON ROM 2-wire sensors on Top, up to
eight (8) total, or up to eight (8) 2-wire Top and eight (8) 2-wire Bottom (retained) sensors.
1. With the power off, verify that the factory installed “Programming Jumper” is
connected to the PROGRAM connector
2. Turn the power on to the unit. (Voltage must be above 9 VDC).
3. The unit will begin looking for DRY SENSOR input signals. After 5 seconds of
stable input signals, the Compartment LEDs for all of the compartments that have
dry sensors attached (overfill and/or retained) will indicate by flashing ON and OFF
indicating they are ready for programming as active sensors.
4. If retained sensors are installed, the number of dry retained sensors MUST match
the number of dry overfill sensors seen.
CIVACON
H52530PAE Rev F
32
Copyright 2003
December
2005
5. The installer must now either:
A.) Wet each overfill sensor, starting at Compartment No. 1. When wetted, the
Compartment Overfill LED will light SOLID RED, as well as the Retained
LED (if present) changing to SOLID RED also. This compartment is now
programmed for use. Note: The installer must check that the proper (and
equal number of) Retained LED matching the overfill sensor changes from
FLASHING to SOLID RED to verify proper Retained Sensor wiring (to the
right compartment connector). Wet testing MUST be done in sequence from
Compartment No. 1 and proceeding to the last compartment.
B.) Proceed to step No. 6 below without wet testing, if wet testing is
inconvenient to do. It is strongly recommended that the wet test of each
compartment’s sensor be done to assure that the proper number of
sensors has been programmed.
6. To have the programming accepted, the installer MUST now remove the
programming jumper while power is still applied to the unit. This saves the
programming to memory.
7. Turn the power to the ROM II Plus onboard monitor OFF AFTER removing the
program jumper.
5-WIRE SENSOR PROGRAMMING INSTRUCTIONS
The ROM II Plus system can use either just CIVACON 5-wire sensors on Top, up to twelve
(12) total, or up to eight (8) 5-wire Top sensors and eight (8) 2-wire Bottom (retained)
sensors. NOTE: If over eight (8) top sensors are connected, two LEDs will flash to
indicate the total number of installed 5-wire sensors. These two flashing LEDs
MUST be added together to equal the total number of installed 5-wire sensors (for
example 8 & 3 flashing means 11 installed sensors).
NOTE: This section applies to CIVACON 5-Wire Optic Sensors. NOTE: If 5-Wire Optic
Sensors are to be used as overfill sensors, 2-wire retained sensors may or may
not be used.
1. With the power off, verify that the factory installed “Programming Jumper” is
connected to the PROGRAM connector
2. Turn the power on to the unit. (Voltage must be above 9 VDC).
3. The unit will begin looking for DRY SENSOR input signals. After 5 seconds of
stable input signals, the last active RED Compartment LED will flash indicating the
total number of wired/active 5-wire sensors to be programmed. This flashing LED is
the total number of compartments that will be programmed for use. If over eight
(8) top sensors are connected, two LEDs will flash to indicate the total
number of installed 5-wire sensors. The flashing Compartment LED(s) indicate
the total number of dry sensors attached (overfill and/or retained) that are ready for
programming as active sensors.
CIVACON
Copyright 2003
33
H52530PAE Rev F
December
2005
4. If Bottom (retained) sensors are installed, the number of dry retained sensors MUST
match the number of dry overfill sensors seen. THIS ONLY APPLIES UP TO
EIGHT (8) MAXIMUM. No more than eight (8) 5-wire Top sensors may be wired
to the ROM II Plus when Bottom (retained) sensors are used.
5. The installer must now either:
A.) Wet the Last (flashing) Compartment overfill sensor. When wetted, the
Last Compartment Overfill LED will light SOLID RED, as well as ALL
connected Retained LEDs (if present).
This compartment is now
programmed for use. Note: The installer must check that the proper (and
equal number of) Retained LEDs matching the overfill sensors changes from
FLASHING to SOLID RED to verify proper Retained Sensor wiring (to the
right compartment connector).
B.) Proceed to step No. 6 below without wet testing, if wet testing inconvenient
to do.
It is strongly recommended that the wet test of each
compartment’s sensor be done to assure that the proper number of
sensors has been programmed.
6. To have the programming accepted, the installer MUST remove the
programming jumper while power is still applied to the unit. This saves the
programming to memory.
7. Turn the power to the ROM II Plus onboard monitor OFF AFTER removing the
program jumper.
PROGRAMMING ERROR MESSAGES / CODES
The ROM II Plus monitor will display an error message via the the ERROR LED if the
programming attempt is not correct. These codes are as follows:
One flash of the ERROR LED every 5 Seconds = Program / Setup Failure (please
repeat the above steps again).
Two flashes of the ERROR LED every 5 Seconds = Program Jumper attached to
the Program Terminal after successful programming completed. Remove jumper to
clear condition.
CIVACON
Copyright 2003
34
H52530PAE Rev F
December
2005
14 POWER ON TEST
Make one last check of all wiring to ensure proper connections. Check closely the sensor wiring
and wire crimp connections. Wiring errors are the most common mistakes made during
installation. Turn power ON to the ROM IITM onboard monitor. Be sure to use a well charged
battery or filtered 12VDC power supply. Battery chargers alone will not work unless properly filtered
by a 12VDC battery.
14.2 STATUS LIGHTS [LEDs]
Check for the following conditions.
On power up, the ROM II Plus onboard monitor first displays its internal software revision
by flashing one of the RED LEDs on the top row of compartment indicators and one of the
RED LEDs on the bottom row of compartment indicators, indicating major (top row) and
minor (bottom row) software revision of the unit. This information may be helpful if calling
for troubleshooting assistance. Once done, the unit will continue to power up as described
below.
The POWER light is the YELLOW LED at the upper left-hand side of the monitor. When
this light is ON, it is indicating that power is being applied to the power terminals of the
monitor (refer to Figure 2), and that the internal fuse is intact. The NORMAL indication of
the POWER LED is an ON state.
The PERMIT light is the GREEN LED at approximately the center of the monitor (below the
High Pressure & High Vacuum LEDs). When this light is ON, it is indicating that the
sensors are operating, and NOT detecting an overfill situation. This is a "PERMISSIVE"
condition. Any RED LED ON should cause this GREEN LED to be turned OFF. The
NORMAL indication of the PERMIT LED is an ON state.
The COMPARTMENT DIAGNOSTIC lights are the RED LEDs located horizontally at the
upper center of the monitor. The functions of these RED LEDs are to indicate which
compartment is in an overfill condition or a retained product condition, and to assist in the
troubleshooting of the ROM II Plus overfill system in case of a mechanical or electrical
problems. The NORMAL indication of the COMPARTMENT DIAGNOSTIC LEDs is an OFF
state.
If a sensor “wetted”, or is causing a problem, it should light its' corresponding RED LED.
The LED to the right of the row is designated as NUMBER ONE and is for the sensor
nearest the front (cab) of the tank. For example, if the Number Two (2) LED is lit, this
means the second sensor from front the tank (cab) is either wet or faulty. This condition
must be troubleshot before testing may continue. Corrective actions include repairing the
faulty wiring, or replacing the defective sensor if required.
The TIMER STATUS YELLOW LED is located to the right of the GREEN Permit LED. This
LED flashes when the retain reset timer is counting (running). There are two conditions that
enable the retain reset timer.
1-
CIVACON
Copyright 2003
When there is NO retained product, and all the RED LEDs are OFF. The
first instance that a compartment is loaded with product, and a retain
(bottom) compartment diagnostic LED comes ON, this will start the timer
counting.
35
H52530PAE Rev F
December
2005
2-
The other instance is when there is retained product on board, and at least
one of the lower RED LEDs is ON. Pressing or activating the RESET switch
will start the timer counting also.
When the timer finishes counting after about 40 minutes, this LED will go out. Resetting the
power will also reset the timer back to zero. The NORMAL indication for this LED in a static
condition is an OFF state.
The AUX INPUTS GREEN LEDs are at the lower left side of the monitor, below the Power
LED. They are organized in a 1, 2, 3, 4 pattern, vertically, and correspond to the same
order as the terminals of TB4. These LEDs must be ON to have the monitor be in a
"PERMISSIVE" state when the sensors are NOT wetted.
The SOCKET STATUS YELLOW LEDs are located at the right side of the monitor. These
LEDs and are NOT normally ON unless an appropriate testing device is connected to the
socket output terminals of TB3 (with the exception of the FLOAT Output LED which follows
the status of the Permissive LED). The top most LED (Float Output) corresponds to the
status of the float output relay, lighting when the relay is closed (Permissive monitor state).
The next “Socket Status” LED is the THERMISTOR output LED, and lights when there is
sufficient voltage present between the RED or ORN terminal, and BLK terminal of the
THERM output of TB3, AND there is a permissive status present in the monitor. This LED
may flutter in brightness. The last “Socket Status” LED is the OPTIC Output LED of the
monitor, and lights when there is sufficient voltage present between the RED and BLK
terminals of the OPTIC output of TB3.
If the above conditions do not exist, refer to the Troubleshooting section of this manual.
14.3 TESTING THE SENSORS
Wet each top (overfill) sensor and watch for the corresponding red diagnostic LED to light
SOLID. If the LED does not light, or the wrong LED lights, check the wiring of that sensor
to the correct terminal block input.
Testing the bottom (retain) sensors can be accomplished by filling each compartment with
water until the sensors sensing point is wetted, and watch for the red diagnostic LED to light
SOLID. If the LED does not light, or the wrong LED lights, check the wiring of that sensor
to the correct terminal block input. Then drain the compartment and check that the
previously lit diagnostic LEDs have turned off. Sensors, with LEDs remaining lit because of
fluid remaining in the tank, must be threaded deeper into the tank compartment. It is
recommended to remove the sensor and tap the half coupling deeper into the tank using a
½-14 NPT tap.
If the above condition does not exist, refer to the Troubleshooting section of this manual.
14.4 SOCKET TEST
The socket output connections can be tested using a Model 1391 Optic System Tester, and a
volt-ohm meter. Test the Thermistor and Optic outputs using the instructions that come with the
Model 1391, or the Model 1391 instructions in the Troubleshooting section of this manual. Float
output can be tested by checking for continuity (zero ohms) when permissive (green LED is on).
CIVACON
Copyright 2003
36
H52530PAE Rev F
December
2005
15 TROUBLESHOOTING GUIDE
Good troubleshooting practices are defined procedures that when followed will give fast results to
help isolate problem areas. This troubleshooting section is arranged in a flow chart outline, and the
steps should be followed in the order as they appear.
NOTE: All tests are assumed to be being done on a unit that is already programmed correctly for
use with sensors.
15.1 TOOLS REQUIRED
12345-
CIVACON Screw driver, small flat blade (packaged with ROM IITM monitor).
Screw drivers, #1 or #2 Phillips, and 5mm (3/16") flat blade.
Wrench, 11 mm (7/16”).
Multi-Meter (Volts, Ohm, Etc.)
Model 1391 Optic System Tester, with H50325 Thermistor test leads.
15.2 SYSTEM OVERVIEW
The monitor electronics are internally fused, and this fuse is not replaceable. The average
power consumption of the electronics in the monitor is less than ¼ Amp. It is
recommended that a ¼ Amp external fuse be installed in the power supply line. The
voltage being run to the TB1 power terminals is NOT intrinsically safe. The wiring to the
power terminals (TB1) MUST NOT be run with intrinsically safe wiring. All power input
connections are made at TB1. Check to make sure that all of the above testing procedures
have been followed, and that all of the wiring is correct.
15.3 PROBLEM SYMPTOMS
First look for the symptom that best resembles the condition of your ROM IITM system. Start
by removing the cover, gasket, and window of the OBM, and saving the hardware.
Symptom sub-sections are shown below in bold type and underlined.
15.3.1
No GREEN Permit LED or dimly lit; No YELLOW Power
LED or dimly lit; other LEDs are also out or dimly lit.
ACTION:
Measure voltage at TB1 with volt meter (set on DC volt scale).
Voltage on TB1 should be between 11.0 V and 28.0 V. and be the
correct polarity.
RESULTS:
Is Voltage below 11.0V ?
Check battery voltage;
Check inline fuse or switch, and for corroded contacts;
Check for corroded wire connections or defective 7 way connector in
nose box;
Non-filtered power supply used to power trailer (do not use battery
charger alone);
1234-
CIVACON
Copyright 2003
37
H52530PAE Rev F
December
2005
5-
RESULTS:
12-
RESULTS:
1-
Other accessories on the same power circuit, like marker lights or
brake lights; thereby sagging the voltage down.
Is Voltage OK (11.0V to 28.0V) ?
Check for sensor wires shorted to ground;
If voltage on TB1 is OK, and all the LEDs are out, the internal fuse is
blown.
Replace the monitor.
Is Voltage over 30.0V ?
Check voltage source immediately ! You may overheat the monitor
and blow the fuse if not corrected immediately.
15.3.2
A RED Compartment LED is on solid.
ACTION:
Check tank compartment for a wetted sensor first. If sensor is wet,
then "Un-wet" the sensor. Does this correct the problem ?
Otherwise continue below.
ACTION:
Remove the sensor wire corresponding with the solid lighted LED.
(Example: If #4 top LED is lit solid, then remove sensor wire in the
monitor at TB2 "COMP4" of "TOP SENSORS"; and switch the wire
connection with a wire from the next nearest working sensor
connection. e.g.- "COMP3").
RESULTS:
If the same LED continues to light solid, replace the monitor.
15.3.3
One or more RED Compartment LEDs are flashing.
ACTION:
Count number of LED flashes in each 5-Second
period.
RESULTS:
12-
3-
CIVACON
Copyright 2003
Refer below for Action to take depending upon number of flashes
every 5-Seconds.
One Flash every 5 - Seconds. ACTION: Correct OPEN sensor wire
condition. Inspect the sensor cable for damage / broken wire.
Two Flashes every 5 – Seconds. ACTION: Correct SHORTED to
GROUND sensor wire condition. Look for wires pinched in all sensor
housing lids, or cable hold down tabs on the roll-over rail.
Three Flashes every 5 – Seconds. ACTION: Inspect the sensor
cable for damage / shorted wires. Inspect wiring at TB2 of onboard
monitor for stray strands of wire shorting together.
38
H52530PAE Rev F
December
2005
15.3.4
Trailer will not load at loading rack; appropriate YELLOW
and GREEN LEDs are lit.
ACTION:
Check that the sockets are wired properly. See the section on
sockets in this manual for socket wiring information. Correct any
wiring mistakes if found. Does this correct the problem ?
Otherwise continue below.
ACTION:
Determine which socket output section you are having problems with.
Use the following appropriate section for troubleshooting. The TB3
output sections may be tested a two locations. At the rear of the
socket with the faceplate removed, but the wires still connected to it.
Or at TB3 on the monitor. To be able to test the outputs at this TB3
location, it is usually a good idea to disconnect the wires from the
appropriate cable, and add short wires to the terminals so the test
leads from the tester may be clipped onto the wires exposed
conductors. This method will be indicated below, if required.
FLOAT OUTPUT: Using an Ohm meter, check for continuity (zero ohms) across TB3 BRN to BRN.
1High resistance ( >100 ohms), replace the monitor.
2Low resistance (0 to 100 ohms), re-check wiring and wire
connections, because this is a correct reading.
NOTE:
THERMISTOR
OUTPUT:
THE THERMISTOR AND OPTIC OUTPUTS OF THE MONITOR
REQUIRE THE MODEL 1391 TESTER TO TEST THEM. THESE
OUTPUTS REQUIRE AN EXTERNAL VOLTAGE TO POWER THEM
UP.
Using the Model 1391 and H50325 Thermistor output test lead set,
test the thermistor output section of the monitor. Follow the
instructions packaged with Model 1391 Optic System Tester, or
follow these instructions with H50325 Thermistor output test leads.
NOTE: The BLK Terminal on TB3 (mentioned below) between the Therm. &
Optic sections is a shared ground terminal for wiring both sockets.
1234567-
8CIVACON
Copyright 2003
Remove cable wire connections from TB3 "THERM" - ORN, RED,
and BLK.
Connect small pieces of wire, stripped on both ends, into TB3
"THERM" - ORN, RED, and BLK.
Connect red boot clip leads to TB3 "THERM" - ORN and RED.
Connect black boot clip lead to TB3 "THERM" - BLK.
Plug the H50325 Thermistor test lead set to Model 1391 tester, and
turn ON the tester.
Does the THERM SOCKET STATUS LED (YELLOW) light on the
monitor ? Continue if lit, otherwise replace the monitor.
Touch red test sensor to TB3 "THERM" - RED, and then ORN. A
solid tone should be heard on both RED and ORN connections. If
the tone is missing, replace the monitor.
If the above conditions are met, then you may have an intermittent
THERMISTOR output problem, or the RACK system may be at fault.
39
H52530PAE Rev F
December
2005
OPTIC
OUTPUT:
Follow the instructions packaged with Model 1391 Optic System
Tester, or follow these instructions. Use the OPTIC test lead set that
has four wires with four alligator clips and rubber boots.
NOTE: The BLK Terminal on TB3 (mentioned below) between the Therm. &
Optic sections is a shared ground terminal for wiring both sockets.
123-
45678-
CIVACON
Copyright 2003
Remove cable wire connections from TB3 "OPTIC" - ORN, YEL,
RED, and BLK.
Connect small pieces of wire, stripped on both ends, into TB3
"THERM" - ORN, YEL, RED, and BLK.
Connect red boot clip leads to TB3 "THERM" - ORN, YEL, and RED
matching the color code of the wires. (Example: TB3 "OPTIC" RED to red test lead wire ).
Connect black boot clip lead to TB3 "THERM" - BLK.
Plug the OPTIC test lead set to Model 1391 tester, and turn ON the
tester.
Does the OPTIC SOCKET STATUS LED (YELLOW) light on the
monitor ? Continue if lit, otherwise replace the monitor.
A beeping tone should be heard. If the tone is missing, replace the
monitor.
If the above conditions are met, then you may have an intermittent
OPTIC output problem, or the RACK system may be at fault.
15.3.5
Side Pushbutton Reset Switch will not cause monitor to
switch to Permissive when tank contains retained product.
(A Bottom / Retained Product RED LED is ON)
ACTION:
Turn the power to the monitor off and then back on again, then press
side mounted mechanical Reset Push Button again. Does this
correct the problem? Otherwise continue below.
ACTION:
Remove cover and window of monitor and place a jumper wire
between the Reset and GND terminals at the bottom of TB3. Does
this cause the monitor to go Permissive and the Retained LED to
start flashing? If yes, ACTION: Remove the wires to the side
mounted pushbutton Retained Reset Switch and check the function
of the switch with an Ohm meter. The switch should close when the
pushbutton is depressed. If it does not, ACTION: The pushbutton
switch is defective. Replace the switch.
15.3.7
Auxiliary Input Switches will not cause monitor to switch
to Permissive.
ACTION:
Are the four GREEN AUX INPUT LEDs lit ? If they are, and all the
other problem possibilities have been checked and passed, then
replace the monitor. If not, continue below.
40
H52530PAE Rev F
December
2005
ACTION:
If they are not all lit, check wire connections at TB4 – Terminals 1, 2,
3, 4 and COM. Correct any wiring mistakes if found. Does this
correct the problem? Otherwise continue below.
ACTION:
If they are not all lit, test the input terminal corresponding to the LED
that is NOT lit. Check the terminal by taking a small piece of wire
and shorting the COM terminal to the corresponding input terminal at
TB4 – Terminal 1, 2, 3, or 4 that is NOT lit. Does the LED light, and
does this correct the problem? If it does, find and correct any
wiring mistakes between the monitor and the external switch.
OR, replace the defective external switch device.
15.3.8
All Display Indicators are Flashing.
ACTION:
All of the display indicators flashing at the same time indicates of loss
of internal communications between the unit’s display circuit board
and the main circuit board. This will also be accompanied by the
BLUE LED in the lower right corner of the display NOT flashing, also
indicating loss of internal communications. ACTION: Replace the
monitor.
16 REPLACEMENT MODULES
SAFETY FIRST!! POWER MUST BE OFF WHEN INSTALLING OR REMOVING POWER
LEADS TO THE MONITOR. THE WIRES FOR THE POWER FROM THE BATTERY MUST
BE KEPT SEPARATE FROM THE SENSOR AND SOCKET WIRING! USE CAUTION
WHEN REPLACING THE MODULE. ENSURE ALL WIRING IS PROPERLY
RECONNECTED TO THE CORRECT TERMINALS ON THE MODULE.
The monitor electronics are replaced as a module. There are NO replaceable or repairable parts
inside the module. The replacement module is a slightly different part number that the original unit
because you normally don't need to replace the aluminum enclosure that the module is mounted
in.
The standard version replacement module is a Model C52323P. This is a universal voltage (12/24
Volt DC, 8 channel (compartment), top and bottom version module; with four auxiliary inputs.
It is imperative that the four mounting screws (with lockwashers) be re-installed on the
module to secure it to the enclosure. Every replacement module comes with new screws in
the event you have lost the original screws. NEW REPLACEMENT MODULES MUST BE
REPROGRAMMED FOR THE NUMBER OF COMPARTMENTS (SENSORS) IN USE ON THE
TANK.
If the monitor is operating as described in the above POWER ON TEST section, you may securely
replace the cover frame, window, and the gasket using the saved hardware.
CIVACON
Copyright 2003
41
H52530PAE Rev F
December
2005
17 WARRANTY
All parts and products are thoroughly inspected and tested from the time raw material is received
at our plant, until the product is completed. We guarantee that all products are free from defects in
materials and workmanship for a period of one year from the date of shipment. Any product that
may prove defective within said one year period will, at our option, be promptly repaired, or
replaced, or credit given for future orders. This warranty shall not apply to any product that has
been altered in any way, which has been repaired by any party other than an authorized service
representative, or when such a failure is due to misuse or conditions of use. We shall have no
liability for labor costs, freight costs, or any other cost or charges in excess of the amount of invoice
for the products.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND
SPECIFICALLY THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.
WARNING:
CIVACON products should be used in compliance with applicable federal, state, and local
laws and regulations. Product selection should be based on physical specifications and
limitations, compatibility with the environment, and the material to be handled.
CIVACON MAKES NO WARRANTY OF FITNESS
FOR A PARTICULAR USE.
17.1 TECHNICAL ASSISTANCE
If at any time during the installation a question arises that is not covered in this Installation
Instruction, or with any other applicable documents referenced, feel free to call the
CIVACON TECHNICAL ASSISTANCE LINE:
In Europe, Call +31(0)252 660 300.
In the U.S.A., Call 1-800-5 CIVACON.
For the CUSTOMER SERVICE DEPARTMENT:
In the Europe, Call +31(0)252 660 300; E-Mail: [email protected]
In other countries, call your local agent.
OPW FLUID TRANSFER GROUP EUROPE, B.V.
BOEWEITSTRAAT 1
P.O. BOX 32, 2150 AA NIEUW-VENNEP
THE NETHERLANDS
+31(0)252 660 300
CIVACON
Copyright 2003
42
H52530PAE Rev F
December
2005
SEALED WIRE CONNECTIONS
1-
IT IS IMPERATIVE THAT ALL WIRE CONNECTIONS BE CORROSION FREE
FOR PROPER SYSTEM PERFORMANCE.
2-
ALL CIVACON SUPPLIED WIRE IS TIN COATED TO RESIST CORROSION.
3-
ALWAYS DOUBLE CHECK THAT YOUR WIRING CONNECTIONS ARE
ELECTRICALLY CORRECT BEFORE CRIMPING.
4-
WHEN POSSIBLE, ENSURE NO MOISTURE ENTERS THE WIRE JUNCTION
AREA OF THE ENCLOSURE.
5-
AS A SECONDARY PRECAUTION AGAINST MOISTURE AND CORROSION, WE
HAVE FOUND THAT A SMALL AMOUNT OF SILICONE RUBBER SEALANT IN
EACH CRIMP CONNECTION WILL DETER CORROSION.
6-
WE SUGGEST USING THE PERMATEX® BRAND OF SILICONE SEALANT
CALLED ULTRA BLUE, PART # 77B. THIS IS A NON-CORROSIVE TYPE OF
SILICONE SEALANT. DO NOT USE GENERIC SILICONE (BATHTUB TYPE)
SEALANT BECAUSE IT IS USUALLY CORROSIVE ON COPPER AND TIN.
7-
TAKE THE SEALANT NOZZLE AND PLACE IT IN THE BOTTOM OF THE END
SPLICE TERMINAL. (IT USUALLY HAS A WHITE NYLON HOUSING)
8-
SQUEEZE A BEAD OF SEALANT INTO THE BOTTOM OF THE END SPLICE
TERMINAL, AND CONTINUE SQUEEZING AS YOU REMOVE THE NOZZLE.
ENSURE THAT THERE IS NO LARGE AIR BUBBLE IN THE END OF THE
SPLICE.
9-
STOP WHEN THE BEAD REACHES THE END OF THE TERMINAL HOUSING.
10 -
STRIP THE WIRES TO THE PROPER LENGTH, AND TWIST THEM TOGETHER.
11 -
INSERT THE TWISTED WIRES INTO THE FILLED END SPLICE TERMINAL, AND
CRIMP THE CONNECTION. REMOVE ANY EXCESS SEALANT FROM THE
CONNECTION.
12 -
PULL ON THE CRIMP TO ENSURE A GOOD CONNECTION IS MADE, AND
THEN LEAVE IT ALONE TO CURE.
13 -
ANYBODY'S SEALED TYPE SPLICES MAY USUALLY BE USED IN PLACE OF
THE SPLICES SUPPLIED BY CIVACON.
TEST THEM FOR YOUR
COMPATIBILITY.
14 -
IF YOU WANT TO USE A GREASE INSTEAD OF A SEALANT, USE
TRUCK-LITE® BRAND NYK-77 CORROSION PREVENTIVE COMPOUND.
CIVACON
Copyright 2003
43
H52530PAE Rev F
December
2005