Chemtec ProPAC5M Additive Injector v1.

CHAPTER 3

SYSTEM INSTALLATION & START-UP GUIDE

The Chemtec ProPAC5M injector should be installed in accordance with standard practices applicable to the environment
where the unit is to be located. The standard system is designed for use in hazardous area locations classified as Class 1,
Div. 1, Group D. ATEX European approval is pending.

Important Reference Documents - System Start-Up

Operation Manual
Chapter 1, Page 6 General Specifications
Chapter 2, Page 5-6 ERRORS/ALARMS Defined
Chapter 2, Page 6-8 Manual & Auto-Calibration
Chapter 2, Page 8 Entering MicroPAC Program To Change Parameters
Chapter 2, Page 13 Use of Load Permissive Output Signal
Chapter 4, Page 1-5 Signal Definitions & Connections
Chapter 5, Page 1-18 System Parameters Defined

Applicable CAD Drawings

Electrical Wiring Schematic Generated For Each Injector Application
Mechanical Drawing Optional, not included in base price
P&ID Drawing Optional, not included in base price

Appendix
Appendix 3A Auto-Calibration & Manual Calibration Routine
Appendix 3B Troubleshooting Guide For Injecting
Appendix 3C Viewing Parameters, Changing Parameters & System Reboot
Appendix 5 Parameter Values

Other Documents
As Required

Important Tools & Hardware - System Start-Up

Hand Tools General hand tools
‘ Electrical Standard equipment
Calibration Graduated cylinder 1000 ML or larger

Electrical & Mechanical Considerations

Electrical Considerations
Starter / Breaker
• Verify power and operability
• Verify pump sequencing
• Verify pump pressure (125-175 typical)

MicroPAC
• Wire terminations, general
• Main Meter Pulse wiring verification, J1
• Load Permissive Output Wiring verification, J4 AC
• Line, Neutral & Ground wire verification, J4 AC
• J4 (Pin 1-11, top to bottom) wiring verification, AC side
• J1 (Pin 11-1, top to bottom) wiring verification, DC side
• ARM wiring verification, J1

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• Verify 5vDC LED powers on power-up, see Appendix 3B

• Verify 15vDC LED powers on power-up, see Appendix 3B
• Fuse alignment verification for additive injector, see Appendix 3B

MicroPAC Firmware Considerations

EPROM Chip
• Verify the current EPROM for the application is installed properly
• Verify power-up and operability of EPROM
• Version INJ604 should display when cycling power to the unit (Latest 2006 revision)
• INJ604 provides Main Product units to read in Barrels, Gallons, Liters, Pounds or Cubic
Meters
• INJ604 provides Additive units to read in CC, ML, Fluid Ounces, Liters, or Grams

CALIBRATION PARAMETERS

MAIN PRODUCT

Main Meter K- Factor – Parameter 101

Primary means used to adjust Main Meter Factor

Main Meter K-Factor is a value that specifies the number of pulses generated by the Main Product flow meter for a
given volume of fluid

Note An accurate Meter K-Factor ensures the volume of Main Product actually dispensed (measured volume)
equals the volume of Main Product as indicated on the MicroPAC display (display volume)

Parameter 101 “Main Product Flow Meter K-Factor”

• Value entered represents 1000 times the meter factor for the Main Product flow meter
• 1000 used to accommodate meters that generate < 1 pulse per internal unit of volume
• Example: 1 pulse per 10 gallons or non-integer value such as 12.5 pulses per gallon
• The design restricts the value of the meter factor Parameters to numeric values less than 65,000. If the
computed value of the meter factor is greater than this value, then a different volume unit must be
selected or additional correction made using the CALIBRATION factor
• Parameter is kept in the battery backed up memory, therefore, value maintained when power lost

Example 1 – User provides 1 pulse per gallon Example 6 – User provides 1 pulse per 40 gallons
Parameter 101 = 1 X 1000 = 1000 Parameter 101 = 1/40 X 1000 = 25

Example 2 - User provides 1 pulse per 2 gallons Example 7 – User provides 1 pulse per 50 gallons
Parameter 101 = ½ X 1000 = 500 Parameter 101 = 1/50 X 1000 = 20

Example 3 – User provides 12.5 pulses per gallon Example 8 – User provides 1 pulse per 100 gallons
Parameter 101 = 12.5 X 1000 = 12500 Parameter 101 = 1/100 X 1000 = 10

Example 4 – User provides 1 pulse per 10 gallons *Note: All of these examples require
Parameter 101 = 1/10 X 1000 = 100 Parameter 102 = 10,000

Example 5 – User provides 1 pulse per 20 gallons

Parameter 101 = 1/20 X 1000 = 50

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Main Meter Calibration Factor – Parameter 102

Secondary means used to adjust Main Meter Factor
Typical Value 10,000

Parameter 102 “Secondary Product Meter Calibration Factor”

• CALIBRATE factor is stored in the non-volatile memory
• Numeric value equal to the CALIBRATE factor times 10,000 (ten thousand)
• Factor used to get around the problem of entering a decimal point and allows calibrating a flow meter to
an accuracy of about 0.01%
• Maximum value 30,000

Ratio of Main Product Volume to Additive Volume – Parameter 108

Value to define Main verses Additive Volume – Typical Value =3785
(3785 CC/ML in 1 U.S. Gallon)

Ratio of Additive to Main Product Multiplication Factor – Parameter 109

Value to Multiply Additive Volumes – Typical Value = 1

ADDITIVE

Additive A Meter K- Factor – Parameter 110

Meter factor (K-Factor) is a value that specifies the number of pulses generated by the additive flow meter for a
given volume of additive dispensed.

Nominal K-Factor for ProPAC5M standard additive meters:

Model 7738 = 2600 pulses per US gallon – Parameter 110 Value = 260

Model 7718 = 6000 pulses per US gallon – Parameter 110 Value = 600

Note When using Auto-Calibration, the MicroPAC automatically calculates and changes a new Calibration
Factor “Parameter 106”. Parameter 110 “Meter K-Factor” remains a constant, as programmed.

Note If DISPLAY VOLUME < MEASURED VOLUME then K-Factor is too LOW and should be INCREASED
If DISPLAY VOLUME > MEASURED VOLUME then K-Factor is too HIGH and should be LOWERED

Additive B Meter K- Factor – Parameter 111

Meter factor (K-Factor) is a value that specifies the number of pulses generated by the additive flow meter for a
given volume of additive dispensed.

Nominal K-Factor for ProPAC5M standard additive meters:

Model 7738 = 2600 pulses per US gallon – Parameter 110 Value = 260

Model 7718 = 6000 pulses per US gallon – Parameter 110 Value = 600

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Calibration Mode Speed of Injection – Parameter 114

Defines Speed of Injection During Automatic Calibration Routine – Typical Value = 1000

Maximum Volume of Additive During Calibration Routine – Parameter 116

Defines the maximum volume of additive dispensed during the Automatic Calibration Routine
Typical value = 500 (500 CC/ML when using a 1000 CC/ML graduated cylinder)
Typical value = 250 (250 CC/ML when using a 500 CC/ML graduated cylinder)

Additive A Meter Calibration Factor – Parameter 121

Used to adjust accuracy of the Additive Meter

An accurate Calibration Factor ensures the volume of additive actually dispensed (measured volume) equals the
volume of additive as indicated on the MicroPAC display (display volume).

Parameter 121 “Additive Meter Calibration Factor”

• Numeric value equal to the CALIBRATE factor times 10,000 (ten thousand)
• Factor used to get around the problem of entering a decimal point and allows calibrating a flow meter to
an accuracy of about 0.01%
• Maximum value 32,000
• Nominal value 10,000
• Value automatically changed during Auto-Calibration run

Additive B Meter Calibration Factor – Parameter 122

Used to adjust accuracy of the Additive Meter

An accurate Calibration Factor ensures the volume of additive actually dispensed (measured volume) equals the
volume of additive as indicated on the MicroPAC display (display volume).

Parameter 122 “Additive Meter Calibration Factor”

• Numeric value equal to the CALIBRATE factor times 10,000 (ten thousand)
• Factor used to get around the problem of entering a decimal point and allows calibrating a flow meter to
an accuracy of about 0.01%
• Maximum value 32,000
• Nominal value 10,000
• Value automatically changed during Auto-Calibration run

Method of Calibration – Parameter 140

Specifies the method in which an additive flow meter calibration is to be performed.
Value of 1=Do not allow manual calibration
Value of 2=Use manual or old style calibration
Value of 3=Use Automatic Calibration (Typical)

Unit of Measure Main Product – Parameter 141

Specifies the unit of measure for Main Product Volumes

Value 0=Gallons (GL)

Value 1=Liters (Lt)
Value 2=Barrels (BL)
Value 3=Cubic Meters (M3)
Value 4=Pounds (lb)

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Unit of Measure Additive A & B – Parameter 142

Specifies the unit of measure for Additive A&B Volumes

Value 0=Cubic Centimeters (cc)

Value 1=Milliliters (ml)
Value 2=Fluid Ounces (oz)
Value 3=Liters (Lt)
Value 4=Grams (gr)

Useful Conversions

US Gallon = 3785.41 CC’s

Meter factor in pulses per liter = 0.26417 X meter factor in pulses per US gallon
Meter factor in pulses per liter = 0.21997 X meter factor in pulses per Imp gallon

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