Chemtec ProPAC5M Additive Injector v1.

APPENDIX 3B

TROUBLESHOOTING GUIDE

NO DISPLAY FOLLOWING POWER-UP

Provided the display is functioning properly and provided

system power is wired correctly, on Power-Up the
MicroPAC should display the Version Number and the
Version Date, as shown in Figure 1.

Note This screen message is followed by a second message

screen that identifies the unit as an Injector

If the unit powers-up and does correctly display the

messages as mentioned above, then the display and the
microprocessor controlling the display is functioning
correctly and the +5 volt DC power is available. If the
power-up messages DO NOT appear, check the +5VDC Normal Display
power by checking the RED LED on the power supply Figure 1
board (AC side) positioned above the output modules.

The +5 VDC LED is located forward of the +15 VDC LED,

as per Figure 2.

Note If the +5VDC LED is lit, then +5VDC power is available

The LED for +15VDC power indicates power is

available for Secondary Product (additive) flow meter
Hall-Effect sensor

Under normal circumstances, both the +5 VDC LED

and +15 VDC LED should be lit

Action 1
If neither LED is lit – check supply POWER +5 vdc LED
Note: +15 vdc LED to rear of +5 vdc LED
AC powered units
Figure 2
• Check J4 Pin 9 - should indicate 115/230 VAC/60hZ.

DC powered units (optional, special order)

• Check J4 Pin 9 - should indicate +12 Volts or
+24 Volts, as powered
Action 2
If the change from the initial display message does NOT
occur but the +5VDC LED is lit, this indicates that the main
processor has not taken over control of the display.
Reasons include the possibility that the memory may be
corrupted.
To correct this problem the user will have to perform a
SYSTEM REBOOT in accordance with procedures
outlined in APPENDIX 3C. A system REBOOT will cause
the default parameters to be reloaded into the memory. If
this action fails to cause the unit’s display to operate
properly, the unit should be replaced.
Note If a SYSTEM REBOOT is performed, ensure that all
modified parameters are re-entered into the program
parameters prior to entering the unit into service

Appendix 3B_Page 1 of 3
Chemtec
Action 3
If the problem with the main processor appears
immediately after a U2 EPROM memory chip has been
changed, then make sure no pins on the integrated circuit
have been bent and ensure that the U2 EPROM circuit
chip is correctly mounted using the alignment “notch”.
Note The controller unit has two replaceable socket mounted
microchips – the U2 is for the system firmware EPROM
and the U3 is for system RAM
Action 4
If the display is not powered but the wiring indicates the
proper voltage exists on J4 Pin 9 (i.e. 115 VAC), then
check the MAIN FUSE, which is located at the BOTTOM
of the fuse rack assembly.
Fuse identification and mounting orientation is note on
Figure 3 below.
Note Access to the fuse rack is accomplished by removing
the FUSE RACK cover
Fuse Orientation & Definitions (Typical)
Figure 3
Note
Fuse Position – “Λ” SHAPE when MicroPAC provides output
power as showm for solenoids for Additive A and Additive B
above
Fuse Position – HORIZONTAL FOR Spare, Main Power and any
output used as a DRY CONTACT.
PUMP START and ALARM/ERROR outputs commonly used as
DRY CONTACTS
OUTPUT RELATED PROBLEMS
If the unit appears to be functioning but there appears to
be a problem associated with one of the four output relay
signals, then each replaceable output power module (AC
or DC) may be tested independently.
Located in the center of the power supply board near the
top edge of the board is a 5-pin connector. Connecting
any one of the first 4 pins (L-R) to the rightmost pin will
cause the respective power switch to be Positioned-ON.
Appendix 3B_Page 2 of 3
ProPAC5M Additive Injector v1.2
The ON state of a power switch is indicated by the 4 LEDs
just to the right of the connector. The left most pin and left
most LED correspond to the top power switch (Output 1)
and the right most pin and the right most LED correspond
to the bottom power switch (Output 4).
Output Modules 1-4
1= Sol.A, 2 = Sol.B, 3 = Pump Start, 4 = Alarm/Error
Figure 4
FUSE RELATED PROBLEMS
Fuse location and purpose is described below. A SPARE
fuse is provided with each MicroPAC. Orientation of each
fuse defines whether POWER for the fuse is POWERED
directly from the MicroPAC, or supplied from a source
external to the unit
Example
User supplies power from a PLC to power the LOAD
PERMISSIVE OUTPUT signal. Based on this example the
MicroPAC is not providing the power for the switch, but merely
making a contact closure, therefore install as a DRY CONTACT.
NO ADDITIVE FLOW OR UNDER-TREAT ERROR 9
• Ensure all system shut-off valves are OPEN
• Check additive pump pressure
• Check all strainers and filters for obstruction
• Ensure additive solenoid is opening on receipt of
ARM signal
• Check additive meter to ensure gears are “free” and
turning uninhibited
• Check additive meter Hall-Effect sensor for failure
UNAUTHORIZED ADDITIVE FLOW ERROR 3
“Additive flow when not expected”
With additive pump positioned ON, close outlet to process
and open test port to determine if additive flows when
solenoid is closed. If additive flows when the solenoid is
closed, then check the following:
ƒ open solenoid on MiniBLOCK and ensure no
trash is under seat
ƒ inspect solenoid plunger seat for damage
ƒ remove fitting with through-hole in bottom of
solenoid cavity and re-tape using Teflon tape.
Reinstall fitting and reassemble solenoid to
MiniBLOCK
Chemtec ProPAC5M Additive Injector v1.2

NO MAIN PRODUCT FLOW

ERROR 1

• Check Main Product meter pulse signal INPUT

wiring located on MicroPAC connector J1 Pins 7 & 8.
• Check program parameters relating to Main Product
K-Factors and Calibration Parameters

INJECTOR OVERALL BLEND RATIO ERROR

ERROR 5

• Check system dynamics for pressure and flow of

Main Product & Additive
• Check Parameters relating to blend ratios

EXCESSIVE ERRORS - SYSTEM LOCKUP

ERROR 20

• Check Parameters relating to ERRORS

• Reference ERROR DESCRIPTION for cause
determination

Note If ERROR 20 is activated, the ERROR can only

be reset by cycling POWER to the MicroPAC or
by serial COM command

All other ERRORS can be reset by new ARM input

signal, power cycle or serial command

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