Chemtec ProPAC5M Additive Injector Version 1.

Table of Contents

Chapter 1 ProPAC5 Additive Injector – Series 2A2M

Introduction – Product Overview ....................................................................................................... 1 - 1
MicroPac Control Module .................................................................................................................. 1 - 1
Miniblock Overview............................................................................................................................ 1 - 2
Dual Additive Injector Overview…………………………………………………………………………….1 - 2
System Operation Overview.............................................................................................................. 1 - 2
System Configuration & Parameters ................................................................................................. 1 - 2
Front Panel Display & Controls ......................................................................................................... 1 - 3
Operation – Control by Remote Computer Supervisory System………………………………………. 1 - 3
Operation – Manual Control or Contingency Mode ........................................................................... 1 - 3
Additive Flush……………………………………………………………………………………………….. 1 - 3
Error Checking (Alarm Features)…………………………………………………………………………..1 - 4
Special Features ................................................................................................................................ 1 - 4
Display Language ............................................................................................................................. 1 - 5
Communications Facilities................................................................................................................. 1 - 5
Safety Approvals................................................................................................................................ 1 - 5
Specifications..................................................................................................................................... 1 - 6

Chapter 2 System Description

System Hardware .............................................................................................................................. 2 - 1
System Firmware............................................................................................................................... 2 - 1
Operating Description........................................................................................................................ 2 - 2
Idle state...................................................................................................................................... 2 - 3
Operate State.............................................................................................................................. 2 - 3
Emergency State......................................................................................................................... 2 - 4
Error Listings and Definitions ...................................................................................................... 2 - 4
Calibration State……………………………………………………………………………………….. 2 - 6
Statistics/Parameter State........................................................................................................... 2 - 6
Data Entry State.......................................................................................................................... 2 - 6
System Features................................................................................................................................ 2 - 7
Default System Parameters ........................................................................................................ 2 - 8
Resetting of System Totalizers ................................................................................................... 2 - 8
Product Definition........................................................................................................................ 2 - 8
Inhibiting Transfer of Product...................................................................................................... 2 - 8
First Injection of Additive ............................................................................................................. 2 - 8
Additive Overtreat ....................................................................................................................... 2 - 8
Restart of a Loading Operation - Under Remote Computer ....................................................... 2 - 9
Measurement of Main Product Volume During Low Flow Stage ................................................ 2 - 9
Main Product Flushing ................................................................................................................ 2 - 9
Flush Operations - Under Remote Computer .............................................................................2 - 9
Flush Operations - Using High Flow Signal…………………………………………………………. 2 - 9
Additive Exists Main Product Line …………………………………………………………………… 2 - 9
Alarm Outputs……………………………………………………………………………………………2 - 9
Allocation of Volumes to Totalizing Counters ………………………………………………………. 2 -10
Initial Error/Alarm Inhibit ………………………………………………………………………………. 2 -10
Transaction Log …………………………………………………………………………………………2 -10
System Phase Log …………………………………………………………………………………….. 2- 10
Display of Messages Sent by Control Computer …………………………………………………….2 -10
Flow Simulation ………………………………………………………………………………………….2 -10

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Chemtec ProPAC5M Additive Injector Version 1.2

Chapter 3 System Installation & Startup Guide

Important Reference Documents - System Startup...........................................................................3 - 1
Important Tools and Hardware - System Startup .............................................................................. 3 - 1
Electrical & Mechanical Considerations ............................................................................................ 3 - 1
MicroPac Firmware Considerations................................................................................................... 3 - 2
Calibration Parameters - Main Product ............................................................................................. 3 - 2
Calibration Parameters - Additive...................................................................................................... 3 - 3

Appendix 3A Auto Calibration Routine ............................................................................................. 3A- 1

Appendix 3B Troubleshooting Guide ............................................................................................... 3B- 1

No Display Following Power Up ...................................................................................................... 3B- 1
Output Related Problems ………………………………………………………………………………….3B- 2
Fuse Related Problems ……………………………………………………………………………………3B- 2
No Additive Flow or Under-Treat ………………………………………………………………………...3B- 2
Unauthorized Additive Flow ……………………………………………………………………………….3B- 2
No Main Product Flow ……………………………………………………………………………………..3B- 3
Injector Overall Blend Ratio Error ………………………………………………………………………...3B- 3
Excessive Errors - System Lockup ……………………………………………………………………….3B- 3

Appendix 3C Viewing Parameter, Changing Parameters & System Reboot ................................. 3C- 1

Chapter 4 Signal Definitions and Connections

Dry Contact Closure DC Input Signals .............................................................................................. 4 - 1
Product Select Signals ................................................................................................................ 4 - 2
Power Output Switch Signals ............................................................................................................ 4 - 3
DC Output Signals ............................................................................................................................. 4 - 4
Serial Communications Signals......................................................................................................... 4 - 4
DC Pulse Power ................................................................................................................................ 4 - 5
System Power.................................................................................................................................... 4 - 5

Chapter 5 System Totals and Parameters

Overview............................................................................................................................................ 5 - 1
System Totalizers .............................................................................................................................. 5 - 2
Product Totals ............................................................................................................................. 5 - 2
Main Product Totals .................................................................................................................... 5 - 2
Additive Totals............................................................................................................................. 5 - 3
Meter and Calibration Factors ........................................................................................................... 5 - 4
Product Definition .............................................................................................................................. 5 - 6
Additive Treat Rate Parameters ........................................................................................................ 5 - 7
General Parameters ......................................................................................................................... 5 - 8
System and Control Features ...................................................................................................... 5 -8
Slow Flow and Flushing .............................................................................................................. 5 - 9
Timeouts and Delays .................................................................................................................5 -11
Error Related..............................................................................................................................5 -12
System Hardware and Signal Definition Parameters .......................................................................5 -14
System Configuration.................................................................................................................5 -14
Signal Definitions .......................................................................................................................5 -14
RS-485 Serial Communications.................................................................................................5 -15
System Display Features..................................................................................................................5 -16
Simulation Mode Features ………………………………………………………………………………..5 -16
Read Only Parameters .....................................................................................................................5 -17

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