MonoBlock II+ Part 4418104 - Rev0

MonoBlock II+ Additive Injector
Installation & Operation Manual

Installation & Operation manual MonoBlock II+ Page 1 of 19

Installation & Operation Manual

MONOBLOCK
TM
II+

Additive Injector

Honeywell Enraf Americas Inc. .
2000 Northfield Court
Roswell, GA 30076, USA
Phone: +1 770 475 1900
Email: enraf-us@honeywell.com


CONTENTS

1. MBII+ Functional Description Page 3

1.1 MBII+ Mounting Page 3
1.2 Control Solenoid Page 4
1.3 Meter Sensor Page 4
1.4 3-Way Diverter Valve, Inlet Valve and Needle Valve Page 5

2. MBII+ Wiring Page 6

2.2 Meter Sensor - General Page 6
2.3 Meter Sensor Pulse Signal Output Page 7
2.4 Customer Equipment for Meter Sensor Input Page 7

3. MBII+ Fluid Connections Page 8

3.1 Fluid Inlet Piping Page 8
3.2 Fluid Outlet Piping Page 8
3.3 Thermal Expansion Relief Page 9
3.4 Equipment connections Page 10

4. Specifications Page 11

4.2 Meter & Sensor Page 11

5. Parts Assembly Drawing Page 12

5.1 Parts List (UL) Page 13
5.2 General Arrangement Drawing Page 14

6. Electrical Connection Drawings Page 15

6.1 MBII+ Sensor Lead Identification Page 15
6.2 Sourced Inputs Page 16
6.3 Un-sourced Inputs Page 16

7. MBII+ Standard Features Page 17

7.1 Options & Accessories Page 17

8. SERVICE CHEAT SHEET Page 18

8.1 MBII+ PHOTOGRAPH WITH INDEXED COMPONENTS Page 18
8.2 Service Tools Page 19

1. MONOBLOCK II+ FUNCTIONAL DESCRIPTION

The MonoBlock II+ is a cost effective solution to chemical additive injection in the petroleum terminal industry.
This manifold design meets the entire standard requirements for metering and control of a cyclical injection
chemical stream. The MonoBlock II+ provides an electrically operated solenoid valve and a precision fluid
meter in a common manifold. In addition, the manifold includes an inlet strainer, inlet valve, a calibration
security diverter valve with integral flow control and an outlet check valve. Combining this functionality into a
single manifold block reduces the size of the instrumentation. This is critical in the limited spaces available on
loading racks. Additionally, combining the solenoid, meter, and test port into a single manifold eliminates most
potential leak points common to component built injectors assembled in the field by system integrators.

This manifold block provides the physical instrument needed to allow a Terminal Automation System (TAS),
Preset (Load Computer, BCU), or PLC System to directly control chemical additive injection. This manifold does
not include the control electronics necessary to pace the chemical injected into a fuel stream, nor does it contain
the logic necessary to accumulate additive volume passing through it.

AC line voltage is typically used to energize the solenoid valve and allow flow. The controlling device (e.g.
Fusion4 MiniPak, MP 3000, MP6, BlendPak 3000+) then accumulates flow volume in the form of pulses
transmitted from the meter sensor. When sufficient volume of additive chemical has moved through the
manifold, the controlling device then turns off the solenoid valve in order to stop flow. It is the task of the
controlling device, Terminal Automation System, Preset, or PLC System, to execute the ratio control algorithms
necessary for precise dosage of chemicals into the fuel stream. Functionality for recipe, injection interval,
tolerance, alarm annunciation, shutdown, etc. are all the responsibility of the controlling system. If the
controlling system is not capable of this level of function, manifold blocks alone are not the solution. The user
should consult our factory for information on complete injection panels that include microprocessor based
SMART controllers having the capability of complete injection control.

1.1 MONOBLOCK II+ MOUNTING

The MonoBlock II+ manifold may be mounted in any orientation provided the gear axles remain horizontal.
The inlet and outlet ports can be up, down, left, or right. The arrowed line in the sketch below depicts the
horizontal axis of the gear axles in the block. When choosing a mounting position, make certain that the
arrowed line remains orientated horizontally.

OUTLET
GEA R AX LES
3/8" FNPT
INLET
3/8" FNPT
HORIZONTAL MOUNTING AX IS
TOP VIEW
END VIEW
GEA R AX LES

1.2 MONOBLOCK II+ SOLENOID INPUT

The MonoBlock II+ manifold has a single control input. That input is the electrical connections to the actuator
coil of the solenoid valve. The coil is typically operated from AC line voltage (110V-240V) and frequency
(50/60Hz) common to the area of the world where the block is used. Optionally, DC coils in 12V and 24V
models are available. Coil voltage is model dependent and should be specified when placing the equipment
order.

The solenoid valve is normally closed. This means that when the coil is de-energized (no voltage applied) the
valve is closed. Applying the rated voltage to the coil opens the fluid flow path through the MonoBlock II+.

1.3 MONOBLOCK II+ SENSOR OUTPUT

The MonoBlock II+ meters the fluid flowing through it. Two high precision oval gears are mounted in a
measuring chamber machined into the block. As fluid passes through the measuring chamber, the fluid force
rotates the gears. Imbedded into the gears are four high field strength rare earth magnets. As the gears rotate,
these magnets pass beneath a Hall-Effect pickup mounted in the sensor housing. The magnetic field from the
gear magnets causes the Hall-Effect pickup to change state (off-on-off) as each magnet passes. Approximately
5000 pulses (Nominal K-factor) are generated for each gallon of fluid passing through the meter (or1320
pulses/liter; nominal resolution).

The customers equipment is responsible for providing a means of calibration of the meter. That is, a method of
determining the exact number of pulses per gallon, liter, etc. of fluid. This calibration factor is normally referred
to as the K-Factor for the meter. The K-factor is then used by the customers equipment for conversion of
pulses received to volume dispensed.

1.4 MONOBLOCK II+ 3-WAY DIVERTER VALVE

Mounted on the discharge side of the MonoBlock II+ is the Allen Wrench adjustable 3-Way Diverter Valve with
position indicators. The valve can be positioned to OUTLET or TEST positions. OUTLET directs flow to the
discharge port of the MonoBlock and on to the point of injection, whilst positively isolating the TEST port.
Conversely TEST directs flow to the calibration port whilst positively isolating the discharge port. This operation
ensures that additive flow can only ever be in one direction.

Mounted on the inlet side of MBII+ is an Allen Wrench adjustable inlet isolation valve to positively isolate the
block during maintenance. The inlet isolation valve and outlet & calibration port isolation valve can be
operated only after removing the security plates.

Located on outlet side (as shown below) of the MBII+ is an Allen Wrench adjustable integral needle valve for
flow control adjustments (fine tuning of the flow-rate). The factory default position being fully open, the
adjustment is most commonly made to reduce the flow-rate of the additive at very low injection rates, there-by
elongating the injection period and enhancing flow control.

The integral needle valve is made tamper-proof with an Allen head screw as shown below. This screw needs to
be completely removed to access the needle valve.

2. MONOBLOCK II+ WIRING

2.1 CONTROL SOLENOID

The solenoid wiring should be a minimum of #16 AWG/1.5mm and a maximum of #14 AWG/2.5mm, type
THHN or THWN wire. Good practice dictates AC and DC wiring should be run in separate conduits or multi-
core cables for extended distances. Follow local, state, and federal codes and practices applicable to your area.

WARNING: The solenoid coil presents an inductive load to the switching device controlling it. High counter
EMF voltages may be produced when removing the voltage source from such loads. Steps should be taken to
ensure these high surge voltages are properly dissipated, or damage to the controlling device may occur.
Consult with the manufacturer of the controlling equipment for guidance regarding the control of inductive loads.
Triac switching is recommended.

2.2 METER SENSOR (GENERAL)

The sensor wiring can be three conductor #18-22 AWG/0.5-1mm shielded instrument cable, with a foil or
braided wire shield. Use Belden
number 9363 or similar. Drain or screen wires should be terminated on a DC

COMMON or on a specifically assigned shield termination at the controller end only. Do not terminate shields to
AC earth ground. Tape off and isolate the shield at the sensor end. Refer to wiring diagrams in this document
for specific connection details.

2. MONOBLOCK II+ WIRING

2.3 METER SENSOR PULSE SIGNAL OUTPUT

The MonoBlock II+ meter sensor output is an un-sourced, open collector, NPN transistor output. The blue
sensor wire is connected to the transistor collector. The emitter of the transistor is connected to the black wire,
or DC COMMON connection. The term un-sourced means that no voltage is applied to the output from within
the sensor. It must be pulled to a high or on or true state by voltage supplied from an external source. The
sensor electronics then drives the collector low or off or false with each pulse transmitted. The output is NOT
driven high internally within the sensor. This industry common scheme allows the sensor to drive external
equipment supplied by its own internal transmitter power. There must be a common connection between the
DC negative of the sensor supply and the DC COMMON of the signal accumulating device. Refer to the wiring
diagrams at the end of this manual for specific connection details.

2.4 CUSTOMER EQUIPMENT FOR METER SENSOR INPUT

The controlling equipment used for capturing pulses from the MonoBlock II+ may be of two general
categories; Un-sourced Inputs, having no voltage present normally on the input connection; Sourced Inputs,
having a DC pull-up voltage supplied to the input connection. Two different wiring methods are used for the two
types of pulse inputs. Wiring diagrams are provided at the end of this document for each type of input. Refer to
the documentation for the controlling equipment for a description of the inputs to determine the type. If the
documentation still does not resolve the issue, the following test can be performed.

A digital Volt-Ohm meter is used to test the equipment input for the presence of voltage. Use the setup in the
sketch below. Place the meter in the DC Voltage mode. Disconnect any wires on the DC Pulse Input. Power
the controller. Measure the voltage from the DC COMMON terminal (black voltmeter lead) to the DC Pulse
Input (red voltmeter lead). If the voltage reading is greater than +5.0 volts, the input is considered a sourced
input. If the voltage reading is less than +5.0 volts, the input is considered an un-sourced input. Refer to the
corresponding wiring diagram for connections.

Test setup for determining customer equipment input type.
> +5.0 Volts = Sourced Input
< +5.0 Volts = Un-sourced Input

3. MONOBLOCK II+ FLUID CONNECTIONS

The fluid inlet and outlet of the MonoBlock II+ manifold is marked with engraved text on the block. The inlet
pressure should always be higher than the outlet pressure to ensure proper operation.
Note: differential pressure vs. solenoid rating needs to be taken into account for optimal performance.
Note: manifold block maximum working pressure is 400 PSI (27 Bar)

3.1 FLUID INLET PIPING

Attention should be given to flow dynamics when sizing the tubing, isolation valve and strainer components
feeding the injector inlet. The minimum tubing size for flows approaching the 2.5 Gal/min (9.5 Liters/min)
maximum flow rate through the MonoBlock II+ is . The isolation valve, feed pipe and strainer size must be
increased to handle the flow required for the number of blocks being fed.

3.2 FLUID OUTLET PIPING

Stainless steel tubing is also used for piping the outlet of the MonoBlock II+ manifold to the point of injection.

WARNING: A check valve and an isolation valve MUST be installed between the manifold and the point
of injection! Failure to install an isolation valve will require complete fuel delivery system shutdown in
the event of a need for service on the injector manifold. Failure to install a check valve in the line may
result in fuel backing up into the additive chemical delivery system and may cause contamination or
spill.

Good design practice dictates that an isolation valve, usually a quarter turn ball valve, be installed at the point of
chemical injection into the fuel piping. This valve should meet the needs of local policies and practices
regarding piping system valves.

An injection point check valve is required. This check valve should be a positive shut-off, spring closed check
such as a plug or ball type. A small opening or cracking pressure is acceptable, generally limited to a maximum
of 15 PSI/1Bar. Cracking pressures of 1 PSI to 10 PSI/0.06 to 0.6 Bar are common in the industry. Ensure the
flow characteristic (Cv) of the check valve is adequate to handle the maximum flow rate expected through the
injector manifold. Although the location is not critical, it is common practice to place the check valve near the
isolation valve at the point of injection.

Remember, pressure differentials across the isolation valve, check valve, tubing, manifold, strainer, etc. all
accumulate and ultimately dictate the required supply pump pressure. Minimizing the individual pressure drops
allow the lowering of the supply pump pressure and effectively reduces the load and wear on the system.

WARNING: Care should be exercised when connecting multiple injector manifold blocks to one
common point of injection. Each manifold line MUST have its own check valve to prevent cross
contamination. The length of common piping should be minimized to ensure all additive chemical being
injected reaches the fuel line. Not all chemicals are compatible. If multiple additives are used
simultaneously, be certain to size common piping for the combined flow.

3. MONOBLOCK II+ FLUID CONNECTIONS (continued)

3.3 THERMAL EXPANSION RELIEF

Thermal relief bypass kits may be required with the MonoBlock II+ manifold when installed with a point-of-
injection actuated valve. This includes a solenoid valve or electric or pneumatic actuated ball valve.

The MonoBlock II+ manifold will stop flow in the reverse direction when the solenoid is de-energized. The
check valve in the block prevents reverse flow. When the additive chemical injection system is idle, any fluid
expansion that occurs between the block and the point of injection MUST be relieved, usually back to additive
storage. When designing the pumping system, provision should be made to allow this thermal expansion
volume to return to the additive chemical storage tank.

FILTER
SOLENOID
FLOW
TES T PORT
INLET
OUTLET
DIVERTER
VA LVE
VA LVE
CONTROL
METER
CHECK
VA LVE
QUICK CONNECT
DIVERTER
VA LVE
3/8" NPT 3/8" NPT
THERMAL
RELIEF

MonoBlock II+ Process and Instrumentation Diagram (P&ID)

3.4 EQUIPMENT CONNECTIONS

Solenoid

Two Red Wires - Actuator Coil
Green Wire w/ Yellow Stripe - Earth Ground

Meter Pickup Sensor

(3-wire, Hall-Effect pickup, Open Collector Output)
Red Wire - Sensor Power
Black Wire - Power & Signal Common
Blue Wire - Pulse Signal

Fluid

Inlet - 3/8 Female NPT
Outlet - 3/8 Female NPT

4. SPECIFICATIONS

4.1 CONTROL SOLENOID

General Data:
Orifice Sizes: 5/32 (Consult Factory for non-standard orifice sizes)
Max Differential Pressure: 100 PSI, 10Bar (with standard solenoid & standard orifice;
Consult Factory for higher pressure differentials)
Certifications: UL/CSA

Coil Data:
Parker 22.0 Watts @ 120 VAC, 11 Watts @ 240VAC
ASCO 17.1 Watts @ 120 VAC, 8.6 Watts @ 240VAC

4.2 METER & PICKUP SENSOR

Manifold Block Physical:
Fluid Port Sizes: 3/8 FNPT
Material (Body): 303 Stainless Steel
Material (Elastomers): Teflon/ FEP Encapsulated VITON/FF500-75
Max Working Pressure: 400 PSI, 27Bar

Fluid Metering Gears:
Nominal Pulse Resolution: 5000 pulses/gallon (1320 pulses/liter) in water (Half Height Gear)
Material (Gears): Ryton (Phillips Petroleum Co.)

Sensor Physical:
Sensor Thread: 1/2 FNPT per Electrical Standards
Material: Aluminum

Sensor Electrical:
Type: Solid-state, bi-polar magnetic gated, open collector output
Sensor Power: 5vdc to 25vdc, 20 mA maximum
Open Collector Output: 5vdc to 25dc, 100 mA maximum (un-sourced)
3-wire Connection -
Red Wire Function: Sensor power
Black Wire Function: Sensor power common & emitter (signal common)
Blue Wire Function: Sensor signal, open collector output (un-sourced)

Environmental:
Ambient Operating Range: -4F to 150F, -20C to 66C


5. MONOBLOCK II+ PARTS ASSEMBLY

1
2
7
6 4
18
20
19
2 8
30
31
25
26
27
9
12
11
17
16
23
22
21
10
3 2
3 3
3
15
16
17
11
13
2 4
29
12
5
27
30
14
10
11
13
11
34
8
8
31
8
8
29

Refer to the next page for the parts Identification table.

5.1 PARTS LIST (UL)

Component Number Object Description
1 10-31700 MBII+, Block Half Height 303SS
2 10-31411 Gear Set Ryton Oval Half Height
3 10-31444 PIN 3/16 x 7/818-8SS DOWEL (set or each)
4 10-31701 MBII+, Meter Cover
5 10-31616 O-Ring, Meter Cover, MBII+ TEF-032
6 10-31460 (M) Bolt Socket Cap, #8-32 x 3/8SS (set or each)
7 10-31556 Sensor Assembly For MB II+
8 10-31717 Screw, 6-32 x 3/8 Socket head (set or each)
9 10-50000 Test Port For MBII+ Male NS
10 10-31702 MBII+, Diverter body
11 10-31623 O-Ring, Port TEF-012 (set or each)
12 10-31624 O-Ring, Bottom TEF #205
13 10-31625 O-Ring, Top TEF-016
14 10-31703 MBII+, Valve Retainer, Open/Closed
15 10-31704 MBII+, Valve Retainer, Outlet/Test
16 10-31705 MBII+, Security plate
17 10-31718 Screw, 6-32 x Socket head, Security wire hl (set or each)
18 10-30011 Filter 80 Mesh
19 10-31706 MBII+, Filter cap
20 10-31711 O-Ring, filter cap, encapsulated, (017)
21 10-31712 Check ball, SS, 5/16
22 10-31633 Check Valve Spring
23 10-31707 MBII+, Check Valve Cap
24 10-31713 O-Ring, Check Valve Cap, encapsulated, (014)
25 10-31708 MBII+, Expansion plug
26 10-31714 Expansion spring
27 10-31719 NINV O ring, exp plug flow stem Zalac (007) (set or each)
28 10-31709 MBII+, Flow stem
29 ## Screw, Mounting, 5/16-18 x 1-3/4 Socket Cap
30 10-31710 MBII+, Flow stem cap
31 10-31716 O-Ring, Flow stem cap, encapsulated (012)
32 10-20172 SOL VLV MB2 120V KAL OR CHEM (PKR)
33 10-20172-1 SOL VLV MB2 120V KAL OR CHEM (ASCO)
34 10-31455 Screw, Meter Cover, #10-32 x 3/8 Socket Cap

5.2 MONOBLOCK II+ GENERAL ARRANGEMENT

E
L
E
T
L
F
R
T
E
L
T
U
O
T
E
T
HONEYWELL ENRAF
MONOBLOCK II +
2.50
S
T
N
I
E
T
L
I
F
R
OUTLET
TES T
N
E
P
O
C
L
O
S
E
D
O
C
L
S
E
D
E
P
N
O
10.00
(2) MGT. HOLES
3.50
Flow
Adjustmen t
3/ 8" FNPT
IN LET 3/ 8" FN PT
OUT LET
Check
Valve
Flow Meter &
Test Port
Quick Connect
Fil ter
Diverter Valve
Inlet / Closed
Outlet / Test
Pick-Up Sensor
5/16 " SOCKE T CAP SCR EW
Soleno id
Valve
Diverter Valve
1.50
Cap
1.50
3/8" FNPT
OUTLET

6. ELECTRICAL CONNECTION DRAWINGS

+ VDC Supply Voltage
(5 - 25 Volts )

Signal

DC Common

6.1 MONOBLOCK II+ SENSOR LEAD IDENTIFICATION

NOTES:
The power supply pictured above may be a separate supply or part of the controller / additive pulse
accumulator electronics.

MonoBlock Sensor
Equivalent Circuit
MonoBlock Sensor
Equivalent Circuit
MonoBlock Sensor
Equivalent Circuit

6. ELECTRICAL CONNECTION DRAWINGS

6.2 WIRING DIAGRAM FOR SOURCED INPUTS

6.3 WIRING DIAGRAM FOR UN-SOURCED INPUTS

NOTES:
The power supply pictured above may be a separate supply or part of the controller / additive pulse
accumulator electronics.

Resistor R1 value varies with the Power Supply voltage.
For 5 - 12 volts use 1500 ohms.
For 12.1 - 18 volts use 2200 ohms.
For 18.1 - 25 volts use 2700 ohms.
For all voltages, watt, 10% or better precision resistors are satisfactory.

7. MONOBLOCK II+ STANDARD FEATURES

303 Stainless steel block.
3/8 FNPT inlet and outlet ports
Inlet and outlet tapered plug style isolation valves with 180operation
Allen wrench access bolts to provide tamper resistance
Valve cover plates with seal wire screws for added security
Patent pending thermal relief device
Allen adjustable integral needle for precise flow throttling
Oval gear meter cavity machined into block
Strainer basket positioned perpendicular to flow in face of block
SS ball check valve, machined and polished to achieve optimum sealing
Meter, solenoid, mounting holes and component heights are identical to legacy MBII ensuring
seamless integration
New Male Test P/N Port 10-50000 (Parker)
New Calibration Kit P/N 10-31565-PKR
Explosion proof solenoid machined into block
Explosion proof Hall-Effect meter sensor
High resolution gears 5000 pulses/gallon (1320 Pulses/Liter) output
Meter accuracy of 0.5%
Meter repeatability 0.25%
Max. flow rate 2.5 Gal/min (9.5 Liters/min)
Min. flow rate 0.1 Gal/min (0.38 Liters/min)
Oval Gear material 538 Ryton
Sensor is 3-wire type with power (12VDC), common, and pulse signal connections
Sensor carries UL listing for Class1, Div1, Group C & D
UL solenoid, machined into manifold block
Solenoid 120 VAC, 240 VAC, 24 VDC or 12 VDC powered
Weight 11lbs (5kgs) approx. unmounted

7.1 OPTIONS & ACCESSORIES

New Calibration Kit P/N 10-31565-PKR
Thermal Relief Kit
P/N 10-31572
P/N 10-31572-MP (for MP6 Multi-pack)

8. SERVICE CHEAT SHEET

8.1 MBII+ PHOTOGRAPH WITH INDEXED COMPONENTS

22
21
24
23
1
31
27
30
27
28
25
11
12
13
15
17
16
10
11
32 , 33
19
20
18
8 (pet screws)
2
3
34
6
4
5
7
17
14
8
(pet screws)
16
10
11 11
12

Please refer to page 13 for parts identification table

8.2 SERVICE TOOLS

Allen Wrench sizes to consider when servicing MBII+:

Honeywell Enraf Americas Inc.
2000 Northfeld Court
Roswell, GA 30076, USA
Phone: +1 770 475 1900
GTS hot line +1 880 423 9883
Email: enraf-us@honeywell.com
www.honeywellenraf.com
4418104_ENG
October 2010
2010 Honeywell International Inc.

MonoBlock II+ Part 4418104 - Rev0

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MonoBlock II+ Additive Injector

Installation & Operation Manual

number 9363 or similar. Drain or screen wires should be terminated on a DC

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