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Chemtec ProPAC5M Additive Injector v1.

CHAPTER 2
SYSTEM DESCRIPTION

System Hardware "snubber" network or MOV should be used across


inductive loads. Similarly, if the DC switches are used to
The MicroPAC controller is completely self-contained and drive inductive loads, “snubber” networks or diodes to the
is normally mounted inside an explosion proof housing. power supply should be used to inhibit large voltage
The unit provides (4) optically isolated high current spikes on turn off.
switches (AC or DC), (2) low current DC switches, (2)
high-speed input channels connected to hardware The two low current DC outputs are optically isolated
counters, and (6) digital status inputs. Controller power is Darlington transistor outputs with open collectors. Each
115VAC/60 hZ. or 230VAC/50hZ. As an option, controller output is rated for an open circuit voltage of 50 volts and
power includes both 12 vDC or 24 vDC power supply will maintain an output voltage of less than 0.8 volts with a
options for truck-mount or other DC powered applications. current of 30mA.

The controller design is based on a CMOS Z80 8 bit


microprocessor operating at 9.8304 MhZ. A Z80 KIO chip System Firmware
all input and output to the processor. The unit provides a
serial communications 2-wire link operating at RS485 As the Controller is required to perform a number of
signal levels on a party line communications circuit. functions concurrently with, but independently of each
other, the system firmware is structured as a number of
System firmware is stored in a 27C128 type of EPROM. independent tasks operating under the control of a simple
This chip is socket mounted to allow for easy firmware but fast multitask executive. The executive schedules all
modifications. The controller uses a battery backup RAM of the defined tasks on an equal priority "round robin"
with a built-in calendar clock. This ram is used for normal basis. A task is given control of the processor and that
processor functions and is also used to store the system task is then expected to relinquish control back to the
parameters, totalizing counters, and a transaction log. executive whenever it is unable to continue execution due
This chip is also socket mounted so that in event of a to the unavailability of data or a peripheral device. All
board failure, this chip can be transferred to the new tasks are completely resident in the EPROM memory and
board, thereby maintaining all system statistics and are always active.
parameters.
To minimize the overhead of the executive/task scheduler,
All digital inputs are intended to be operated with a dry all tasks are considered to be of equal priority. When a
contact closure signal source. All inputs are buffered by a task is scheduled, the executive sets up the stack pointer
RC network to provide noise and over-voltage protection. equal to the current tasks stack pointer and then turns
Although intended to operate at 0 and + 5 volt logic levels, over the central processing unit to the task at the
all of the inputs can be connected to + or - 15 volts without instruction immediately following where the task last
damage. The receiving circuit is a 74HC series chip and suspended itself. When a task suspends itself, only the
so the logic threshold voltage is + 2.5 volts. The two task's current instruction pointer and task's stack pointer
inputs that drive the high-speed counters are buffered by are preserved, no other registers or flags are preserved. If
"Schmidt trigger" gates to provide further noise immunity data or registers must be preserved across a task
and so prevent false counting. Although the unit provides suspension, then it is the responsibility of the task to save
for 6 digital status inputs, four of these status inputs are this data on the stack before suspending itself and
commonly connected to the external push button switches restoring this data when the task is rescheduled. At each
used for data entry (when used with optional explosion cycle of the task scheduler, the system "watchdog timer" is
proof enclosure with explosion proof external kicked or restarted. Should any of the tasks keep control
pushbuttons). Four (4) local push button switches are of the processing unit for too long a period of time, this
incorporated into the MicroPAC display board. watchdog timer will time out, clear all outputs and
generate a non-masking interrupt to the processor unit to
Each of the 4 heavier current outputs uses optically force a complete restart of the system.
isolated solid-state switches. For AC use, these switches
are TRIAC units rated at 2.5 amps continuous and up to All system timing is derived from the system clock. The
230 VAC. For DC use, the switches are Darlington output 9.8304 MhZ clock frequency is scaled down by one of the
transistor switches rated at 3 amps and up to 60 VDC. counter timer chips, which cause it to generate a "real time
Although RC filtering is used across each AC output, a clock" interrupt every 0.5 mS or 2000 times a second. This
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Chemtec ProPAC5M Additive Injector v1.2

time period is further scaled down in the firmware to supervisory computer; it always waits to
operate most timers to a resolution of 0.1 seconds. be polled and then responds to a poll.

Communications with outside equipment is carried out TASK2 This task is responsible for processing
over a serial communications circuit operating over a two all of the data received from the flow
meter pulse device in accordance with
wire polled party line network at RS485 voltage and
the conditions set up by TASK0. This
current levels. Serialization and de-serialization of the task is also responsible for
data is performed by a UART chip, which interrupts the preprocessing all of the digital status
processor whenever a character has been received. One inputs and generating all of the required
of the KIO’s counter timers divides the system clock by DC and AC output signals. This task is
values required so as to allow the communications baud also responsible for kicking the
"watchdog timer" and the periodic
rate to be software selectable to one of the standard baud
updating of the data shown on the two
rates. lines of 16 characters each vacuum
fluorescent display.
To allow the additive injector unit to process very high-
speed pulse rates from two high-resolution flow meters, TASK3 This task is responsible for processing
two of KIO counter timers are used to count and all of the data received from the IRda
accumulate flow meter pulses until the processor is able to transceiver located on the front of the
controller unit. The communications
schedule the appropriate task to process this pulse data.
over this link follows standard ASCII
In those instances where a flow meter is connected to one protocol similar to that used for the
of the slow speed digital status inputs, then that input is RS485 serial communications link.
sampled by the real time clock interrupt service routine at
a rate of 2000 times per second allowing for a maximum
count frequency of approximately 800 pulses per second. Note IRda transceiver not implemented in
Version 1.0 and Version 1.1 of software
System firmware is structured so that it can operate in a
number of different configurations of input and output
Operation Description
signals. The selection of the configuration that is to be
used is made by a parameter stored in the systems non-
MicroPAC controls the simultaneous injection of up to two
volatile memory.
(2) additives into a single main product stream. Normally,
control of the operation of the additive injector is exercised
The following are the tasks that form the controller
by means of two electrical "handshake" signals.
firmware:

TASK0 This task monitors all DC status inputs


ARM INPUT SIGNAL Input signal from external device is
and front panel push button switches
used to signal the start of a new
and causes the system to react as
load
required. This task also monitors for
some of the error conditions and if an
LOAD PERMISSIVE Output signal from the MicroPAC is
error is detected, the task terminates the
OUTPUT SIGNAL typically used to terminate main
transfer operation. This task is also
product loading in the event of one
responsible for forming the data that is
of the following two (2) conditions
shown on the vacuum fluorescent
exist:
display.

ƒ Loss of POWER
TASK1 This task monitors the serial
ƒ ERROR (Alarm condition)
communications channel for any
message sent to the controller address.
MicroPAC may be controlled using the serial
If a message with an address
communication circuit. Control is typically provided by a
corresponding to the address set up for
remote “master” computer such as the TAS or PLC using
controller is received without ERROR,
the RS485 serial port. A wide variety of standard industry
then this task responds back with the
protocols may be utilized however the standard protocol
required data. MicroPAC never initiates
loaded in the unit is the ProPAC3 protocol. Other
a transmission of data to the “master”
protocols are available as an option.

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Chemtec ProPAC5M Additive Injector v1.2

MicroPAC Operational States These commands may be used to set up the main product
to additive blend ratio (injection rate) and the final volume
IDLE STATE WITH PIPES NOT FLUSHED of the product transfer in terms of Main Product.
IDLE STATE
OPERATE STATE In manual or contingency mode of operation the controller
CALIBRATE STATE will enter the OPERATING STATE on the false-to-true
EMERGENCY STATE transition of the ARM INPUT SIGNAL. On receipt of the
STATISTICS / PARAMETER STATE ARM signal, the controller and first read the PRD1, PRD2
OPERATE STATE WITH ERRORS and PRD3 inputs to determine the product that is to be
DATA ENTRY STATE generated and will turn on the additive pump motor(s), as
SIMULATING A LOAD / TEST STATE required by the product definition.
WAITING FOR AUTHORIZATION
TEMPORARY STOP STATE On entering the operate state, the display will be set to an
FREEZE STATE – ENABLED WAITING FOR "888888" display to allow verification of all display
MAIN PRODUCT FLOW segments. The unit will then make true the Load
Permissive (PRMSV) output signal. The Load Permissive
signal can be made true immediately on seeing a true
Idle State condition on the ARM signal or it can be delayed for 2
seconds to ensure Main Product pressure is adequate. At
When power is first applied to the unit, the controller this time the unit will initialize a flow present rundown
performs a number of initializations and then enters the timer. If no Main Product flow pulses are received in this
IDLE state. On entering the IDLE STATE, the controller period of time the unit will assume there is a failure in the
will set up an additive pump turn off timer. When this timer Main Product pulse input signal and will terminate the
times-out, the controller removes or forces to the OFF transfer operation by removing the LOAD PERMISSIVE
state all additive pump power. output signal. The timer is reset every time a pulse is
received from the Main Product pulse transmitter.
In the IDLE STATE the controller will monitor the status of
all digital inputs. If the CALIBRATION signal is true, then In the manual mode of operation the controller will
the unit will enter the CALIBRATION STATE. If the continuously monitor the ARM INPUT signal. Whenever
PARAMETER pushbutton is engaged, the unit will enter the signal becomes false (loss of signal) the controller will
the STATS/PARAMETER STATE, therein allowing immediately terminate the injection of additive, wait for a
programmed parameters to be viewed. short period of time to ensure all valves are closed, and
then enter the IDLE STATE. This describes the normal
While in the IDLE STATE the controller tests for a number ending for additive injection operation in the manual mode.
of ERROR conditions and monitors the Main Product and Under remote computer control the end of a load will be
the Additive flow meter pulse signals. If flow is detected signaled on MicroPAC receipt of the "END OF LOAD"
when flow is “not authorized”, the controller will enter the serial command.
EMERGENCY STATE (ERROR STATE) and indicate the
proper ERROR for the unauthorized flow. The controller During the OPERATE STATE the Main Product pulses
also monitors the ARM INPUT signal and on the false-to- received (MPLS input, Connector J1 Pin 7/8) are
true transition of the ARM SIGNAL, the unit will enter the converted to a true volume using the Main Product flow
OPERATE STATE. If under control of a remote computer meter prescale K-Factor and Main Product flow meter
the unit will enter the OPERATE STATE upon receipt of Calibration Factor. The true volume is used to update the
an "AUTHORIZE" serial command. totalizing counter associated with the product, as selected
by input signals PRD1, PRD2 and PRD3. Similarly,
In the IDLE STATE pulses from the Main Product and the pulses received on the APLS (Additive A pulse) and BPLS
Additive flow meters are still processed however the (Additive B pulse) signals from the additive flow meters
volumes are allocated to unknown product totalizing are converted to a true volume using the respective
counters when the unit is NOT ARMED. Only when the prescale K-Factors and Calibration Factors for each
unit is ARMED will it inject additive as programmed. additive meter. The true additive volumes are then used
to adjust the flow rate of the additive being injected.
Operate State
If the unit is under the control of a supervisory control MicroPAC may be programmed such that on detection of
computer, then the "AUTHORIZE" serial commands are an ERROR condition the unit will enter the EMERGENCY
used to set up the conditions for the injection of additive. STATE (ERROR STATE), terminate further injection

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Chemtec ProPAC5M Additive Injector v1.2

attempts, and terminating product loading by removing the ERROR-4 Unauthorized Additive B flow - only
LOAD PERMISSIVE OUTPUT signal. MicroPAC’s used when two additive injection is
response to an error condition may be altered by means of utilized
system parameters. When under remote computer If there is Additive B product flow when
control, the unit normally continues operation in case of the flow is not expected then the
ERROR but signals the controlling computer that an additive injector controller will remove
ERROR has been detected. The decision to terminate the permissive signal, shut off all
load operations is made by the controlling computer. pumps and valves and terminate the
transaction and display this error.

Emergency State (ERROR STATE) ERROR-5 Additive A overall blend ratio error
If the overall blend ratio for additive A
If so enabled by means of a system parameter, the is outside of acceptable limits for a
MicroPAC will enter the EMERGENCY STATE from both number of time slots, the additive
the IDLE STATE and the OPERATING STATE whenever injector controller unit will remove the
it detects an ERROR condition. permissive signal, shut off all pumps
and valves and terminate the
Based on parameter programming, the MicroPAC on transaction and display this error.
entering the EMERGENCY STATE will remove the Load
Permissive output signal, terminate injections, remove ERROR-6 Additive B overall blend ratio error -
power to the additive pumps and display the specific only used when two additive
ERROR on the 2 line X 16 character display, as follows: injection is utilized
If the overall blend ratio for additive B
is outside of acceptable limits for a
number of time slots, the additive
injector controller unit will remove the
permissive signal, shut off all pumps
and valves and terminate the
transaction and display this error.

ERROR LISTING & DEFINITIONS ERROR-7 Additive A Time Slot blend ratio
error
ERROR-1 No Main Product flow when If the instantaneous or time slot blend
expected ratio for additive A is outside of
If main product flow is expected and acceptable limits for a number of time
there are no pulses from the main slots, the additive injector unit will
product flow meter within a time frame remove the permissive signal, shut off
specified by a system parameter, then all pumps and valves and terminate the
the additive injector unit will remove the transaction and display this error.
permissive signal and display this
error. ERROR-8 Additive B Time Slot blend ratio
error - only used when two additive
ERROR-2 Unauthorized Main Product flow injection is utilized
If there is main product flow when the If the instantaneous or time slot blend
flow is not expected the additive ratio for additive B is outside of
injector controller will remove the acceptable limits for a number of time
permissive signal, terminate the slots, the additive injector unit will
transaction and display this error. remove the permissive signal, shut off
all pumps and valves and terminate the
ERROR-3 Unauthorized Additive A flow transaction and display this error.
If there is Additive A product flow when
the flow is not expected then the
additive injector controller will remove
the permissive signal, shut off all
pumps and valves and terminate the
transaction and display this error.

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Chemtec ProPAC5M Additive Injector v1.2

ERROR-9 No Additive A flow or under treat ERROR-15 Communication timeout


with Additive A If there is loss of communications with
If there has been insufficient or no the supervisory computer and the
additive flow when required, the product transfer has been authorized
additive injection unit will remove the by the computer, then the injector unit
permissive signal, terminate the will remove the permissive signal,
transaction and display this error. terminate the transaction and display
this error.

ERROR-10 No Additive B flow or under treat


with additive B - only used when two ERROR-16 Parameter check-sum error
additives are injected The additive injection controller
If there has been insufficient or no detected an error in the check sum for
additive flow when required, the the parameters stored in the battery
additive injection unit will remove the backed up memory. This check is done
permissive signal, terminate the at the start and end of each product
transaction and display this error. transfer. The additive injector controller
will remove the permissive signal, shut
ERROR-11 Over treat with Additive A off all pumps and valves and terminate
If there has been too much additive A the transaction and display this error.
blended into the main product, the
additive blending controller will remove ERROR-17 Loss of ARM SIGNAL during load
the permissive signal, terminate the operation
transaction and display this error If there was an unexpected loss of the
message. ARM enable condition, additive injector
controller will remove the permissive
ERROR-12 Over treat with Additive B - only used signal, shut off all pumps and valves
when two additives are injected and terminate the transaction and
If there has been too much Additive B display this error.
blended into the main product, the
additive blending controller will remove
the permissive signal, terminate the ERROR-18 Controller timed out waiting for
transaction and display this error authorization by supervisory
message. computer
The additive injection controller did not
ERROR-13 Unable to load because Additive A receive authorization to proceed with a
in Main Product pipe load within a specified time period. The
If a product without Additive A is additive injector controller will remove
selected and there is still Additive A in the permissive signal, shut off all
the system pipes, the controller will pumps and valves and terminate the
display this error message and remove transaction and display this error.
the permissive signal.
ERROR-19 Timeout while in temporary stop
ERROR-14 Unable to load because Additive B If the unit remains in the temporary
in Main Product pipe - only used stop state for too long a period of time,
when two additive injection is the load will terminated, the permissive
utilized removed and this error displayed.
If a product without Additive B is
selected and there is still Additive B in ERROR-20 Too many errors - system lockup
the system pipes, the controller will If there have been too many errors
display this error message and remove detected by the additive injector unit,
the permissive signal. then the unit will remove the
permissive signal and remain in this
state until power is removed and
restored or the condition is reset via
the serial communications link.

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Chemtec ProPAC5M Additive Injector v1.2

The number of successive errors that If at the instant that the CALIBRATION pushbutton is
will be accepted before the system engaged, the INCREMENT (^) pushbutton is also
locks up is specified by a system engaged, then the system will force the use of Additive B
parameter. This error counter is reset at the normal inject volume and at the primary inject
back to its starting point if there is a interval.
successful transaction that is
terminated by removal of the ARM MicroPAC will exit the CALIBRATE STATE and return to
signal and not by an error condition. the IDLE STATE when the CALIBRATION pushbutton is
no longer engaged. In all cases, on returning to the IDLE
Note ERROR 20 is the only ERROR that MUST be state, the system will restore the ADDITIVE A IN PIPES
reset by cycling POWER to the MicroPAC and ADDITIVE B IN PIPES condition to the state it was in
on entering the CALIBRATE STATE.

MicroPAC will remain in the EMERGENCY STATE Note It is always assumed by the MicroPAC that during
(ERROR STATE) until: calibration the additive dispensed was directed into
a graduated cylinder and not into the Main Product
i. There is a true to false transition of the ARM
input signal except for ERROR-20
Statistics / Parameter State
ii. There is a power down and power up sequence
(power to the unit is removed and then restored) The controller will enter the STATISTICS / PARAMETER
state from the IDLE STATE when the PARAMETER
iii. A reset or an ARM transaction command is pushbutton is engaged. The unit will remain in the
received from the supervisory computer system STATISTICS / PARAMETER state for as long as there is
activity in PAR, CAL, SHIFT (<) or INCREMENT (^) front
panel pushbutton switches.
Calibration State
Note If there is a period of 15 seconds of inactivity on
The MicroPAC will enter the CALIBRATE STATE from the these signals, then the injector unit will return to
IDLE STATE when a true condition is detected on the the IDLE STATE
CALIBRATION input signal (Calibration pushbutton
engaged). The unit will simulate the input of a true When the PAR front panel pushbutton switch engaged,
condition on the ARM INPUT SIGNAL (or authorization the display will show the current parameter name on the
from the supervisory computer if COM used) and will top line of the display and the parameter number as 3
simulate the receipt of pulses from the Main Product flow digits and the parameter’s numeric value as 5 digits on the
meter. Actual Main Product flow is NOT required. While bottom line of the display. If the parameter represented a
in the Calibrate mode the unit will display the amount of totalizer, then the totals value would be shown as 8 digits.
additive that the injector “believes” was delivered based on If the PARAMETER pushbutton is engaged the current
existing parameters. By comparing the volume that the parameter number will be decremented and each time the
MicroPAC “believes” it delivered with the actual or CALIBRATION pushbutton is engaged the current
measured volume, a “new” Calibration Factor for the meter parameter number is incremented. The numeric value of
being calibrated is automatically computed when utilizing the parameter is continuously updated.
the Auto-Calibration feature.

Data Entry State


Note Reference Appendix 3A Auto-Calibration Routine
The controller will enter the DATA ENTRY STATE when
the user enters the program.
If at the instant that the CALIBRATION pushbutton is
engaged, the SHIFT (<) pushbutton is engaged, then the Note Data Entry can NOT occur when ARM INPUT
system will force the use of Additive A at the normal inject signal is ON
volume and at the primary injection interval.

Example 28 CC every 40 gallons of Main Product

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Chemtec ProPAC5M Additive Injector v1.2

Data is typically entered using the four front panel of the button, the additive pumps will be turned off and the
pushbuttons. While in this state, the operator is prompted system will wait until the START/ENTER push button
for the required data and some “reasonable” tests are switch is engaged, at which time the system will resume
made on the entered data. When all the required data has product loading and additive injection. If the
been obtained the controller will immediately enter the STOP/CLEAR pushbutton is pressed while the system is
OPERATE STATE if remote computer authorization is not already in TEMP STOP STATE, the system will terminate
required or the DATA AVAILABLE STATE is required. If the load and return to the IDLE state. If the system
there is a period of 15 seconds of inactivity and no new remains in the state for too long a period of time, the unit
data is entered through the push button data entry will timeout, terminate the load, and return to the IDLE
switches, then the additive injector controller unit will state.
return to the IDLE STATE.

Unique System Features


Data Available State, Waiting for Authorization
The following describes the various functions or features
The controller will enter the DATA AVAILABLE STATE provided by the MicroPAC controller under control of the
when the controller unit has obtained all required data firmware, as described herein.
from the operator via the pushbutton data entry keys. The
remote controlling computer, upon seeing the controller Multi-Roll Capability – The MicroPAC controller may be
enter this state, asks for the data that has been entered. used for several different functions including electronic
Upon receiving this data, the remote computer will either injector, batch controller, or wild-stream blender with a
authorize the load or reject the authorization request change of a single microchip.
based on the validity of the entered data. If the controller
is enabled, it will immediately enter the OPERATE STATE 2-Additive Injector – MicroPAC current firmware may be
and proceed with the product transfer. If the authorization used to control up to two (2) separate additive injectors
request is rejected, the controller will display the reason during simultaneous operation.
for the rejection as sent by the control computer and return
to the IDLE STATE. Multiple Protocols – MicroPAC may be programmed to
use one of several industry standard protocols including
ProPAC3, Lubrizol, Smith Meter, Daniels, Modbus and
Freeze State, Waiting for Main Product Flow others.

The controller will enter the freeze state when there is no Main Product Flow Simulation - If the controller is
Main Product flow but the ARM signal is ON. programmed to simulate Main Product flow then the unit
may be used as an additive dispenser, therein dispensing
Example: driver changing compartments when only one the volume of additive as programmed and based on
ARM signal used simulated Main Product flow.

Following a time-out, the unit may be programmed to shut Flushing of Main Product Line - The system is capable of
down the additive pumps and enter the FREEZE STATE. flushing or purging the pipes and main product flow meter
The system will remain in this state indefinitely or until at the end of the load so that subsequent loads are not
Main Product flow is again detected or the ARM signal contaminated with any additive that may still be left in the
removed. The additive system will be restarted and will pipes after the point of additive addition. This flushing can
continue until the target volume of Main Product is be initiated by the loss of the high flow signal near the end
attained or when the ARM signal is removed. of the load or by the system itself when the delivered
volume approaches the final preset volume. MicroPAC will
terminate additive flow such that the pipes after the point
Temporary Stop State - Used With External Mounted of additive injection are flushed with clear product. When
Pushbuttons Only this feature is used, the controller will slightly over-treat the
product during the main part of the product transfer so that
When the unit is wired to use external data entry push when the lines are flushed and the correct preset volume
buttons the unit will enter the TEMP STOP STATE when reached, the overall blend ratio will as required.
the STOP/CLEAR pushbutton switched is engaged while
the system is in the OPERATE STATE. On engagement

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Chemtec ProPAC5M Additive Injector v1.2

Default System Parameters Inhibiting Transfer of Product

System firmware contains a set of default parameters that The conditions under which the transfer of a product is
can be used to overwrite any values already existing in the inhibited are governed by a parameter. A product transfer
battery backed-up memory. The system default values can be inhibited if:
are reloaded when the SYSTEM REBOOT ROUTINE is
performed.
i. A product without Additive A is selected
Note SYSTEM REBOOT procedure is described in and there is "Additive A in pipes" i.e. an
detail in Appendix 3C herein insufficient volume of main product has
been transferred after an additive A has
The ability to reload a known set of parameters quickly been added to ensure that there is no
allows the system to be restarted quickly in the event of a Additive A left in the loading arm and
catastrophic failure of the battery backed up system main product flow meter.
memory or if the user corrupts parameters. The
parameters that are actually reloaded are parameters in ii. A product without Additive B is selected
the range from #100 through to #899. Parameters #1 and there is "Additive B in pipes" i.e. an
through #99 are the system totalizing counters and are not insufficient volume of main product has
reset. Parameters #900 through #999 are read only been transferred after an Additive B has
parameters or special variables that are calculated or been added to ensure that there is no
modified by the system and made available for viewing as Additive B left in the loading arm and
if they were a parameter. main product flow meter.

The above test must be satisfied before the system will


allow transfer of a clear product. The only way to clear this
Resetting Totalizing Counters "additized product only" condition is to transfer an
additized load sufficiently large that the additive injector
The system maintains a number of totalizing counters that controller unit performs an orderly shutdown, purging the
describe the throughput of Main Product and Additive main flow meter and pipes with clear product.
dispensed using the system. Included is the total
throughput for each of the 8 possible products that can be
selected by external inputs. All of these totals are treated
as parameters numbered 1 through 99 and they can be First Injection of Additive
changed in the same way as all the other system
parameters. The value of the totalizing counters is always The Main Product volume at which the first injection of
displayed as 8 digits. additive is accomplished may be specified by a system
parameter. This allows for very small amounts of product
to be transferred, such as would occur during a "top up"
operation, without an additive addition. These small
Product Definition transfers are insufficient to flush the pipes if any additive
had been blended. After the start of additive addition, the
In manual mode of operation, the system allows for the flow rate of additive will be controlled at such a rate so as
selection of one of eight products by means of three to maintain the target blend ratio.
contact closure inputs, operator selection by means of the
data entry push button switches or by the remote control
computer. Each product definition can specify if injection
is to be performed, the additive used for injection, and the Additive Over treat
blend ratio to be used. Under remote computer control,
the selection of blend ratio is specified in the The controller can be set up to over treat (i.e. treat at a
“Authorization Command”. The command may also be slightly higher rate than would normally be used) to
used to specify which of the eight products available is to account for the Main Product flow during the slow flow
be used. stage at the end of a load when additive injections are
inhibited. This is done to allow for the purging (flushing) of
the main product flow meter chamber and the lines from
the flow meter to the truck connection.

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Chemtec ProPAC5M Additive Injector v1.2

Restart of a Loading Operation – Under Remote controller monitors the volume of Main Product
Computer Control transferred. When the volume equals the total volume as
authorized (downloaded) by the computer MINUS the
When under control of the remote computer system the volume required to effectuate the flush, MicroPAC makes
additive injector can be instructed to restart a loading a final injection of additive (if necessary) and then
operation without resetting the displayed and reported terminates all flow of additive until the authorized Main
additive and Main Product volumes. By simply sending a Product volume is achieved.
new Main Product end target volume, the unit will restart
the loading operation without resetting any of the totalizing As an alternative, the remote computer can remove the
counters. This allows the injector unit to properly end the ARM input signal to the MicroPAC at a specific volume of
loading of each compartment, make any final additive Main Product still to be loaded (i.e. 200 gallons
volume corrections as may be required, yet displaying remaining), therein effectuating the Main Product line
cumulative volumes. This allows for ease of checking of flush.
volumes with a "bill of lading".

Flush Operations – Using High Flow Signal


Measurement of Main Product Volume - During Slow A wired input signal may be used to indicate High Flow /
Flow Slow Flow for Main Product.

During each product transfer, the unit will measure the Note The START of High Flow (leaving low flow for high flow)
volume of Main Product between the time that the system and the START of Low Flow (leaving High Flow going to
enters slow flow (as indicated by the HIFL signal Slow Flow) is the same reference point
becoming false) and when the transfer operation is
completed as indicated by the ARM SIGNAL becoming When MicroPAC is providing “local” control over flush
false and the end of the load "dribble" time elapsing. This operations and the High Flow signal is used (MicroPAC
value of Main Product flow is stored in battery backed up connector J-1, Pin 5), then additive injections will be
memory as a "read only" parameter value (Parameter terminated when the HIGH-FLOW signal is removed.
number 904) that can be displayed to allow an easy way
of checking that the main product volume during slow flow If the system is under local MicroPAC control and the High
phase is sufficient to purge the main product flow meter Flow signal is not available, then additive injections shall
and pipes of any additive. be terminated when the ARM OUTPUT signal is removed.
The flow of Main Product will continue, thereby achieving
the Main Product line flush.

Purging of Main Product Pipe (Flushing)

The unit has the capabilities to ensure that the product Additive Exists Main Product Line
delivery lines are purged or flushed or any additives at the
end of a product transfer. Flushing is accomplished when If additive flushing is desired and additive is the Main
the MicroPAC controller terminates additive injections at Product line following the end of a product load, then the
slow flow and counts sufficient Main Product flow to MicroPAC will display the appropriate ERROR message
ensure an adequate flush. This purging of the lines is provided that the ERROR is enabled.
performed in a number of different ways depending of the
type of control of the system.

ERROR (Alarm) Outputs

Flush Operations – Under Control of Remote MicroPAC provides an AC ERROR output signal that may
Computer be utilized to notify local personnel in the event of an
When the MicroPAC is under the control of a remote ERROR condition. The output is normally wired to
“master” control computer, the computer may be used to CLOSE whenever the MicroPAC detects an ERROR
download the volume of Main Product to be loaded via a condition. The signal may be used to sound a horn, light
serial command. During Main Product loading, the an alarm light or be used for another purpose.

Chapter 2_Page 9 of 10
Chemtec ProPAC5M Additive Injector v1.2

Note The Load Permissive output is typically used to terminate System Phase Log
product loading instead of the alarm output signal
MicroPAC maintains in a 16 entry push down stack the
The ERROR signal is normally OPEN and CLOSES on last 16 phases or operational steps of the system.
ERROR however this may be reversed so that the signal
Note The phase push down stack can be accessed only
is normally closed and opens on ERROR. This would be
using the RS485 communications circuit
the operating mode if the error output were used as a
permissive signal for another system. The push down stack will show in detail the last 16 steps
in the processing of a load. This log is not required for
The ERROR condition may be cleared (reset) when one of normal operation of the unit but is beneficial in analyzing
the following three conditions exist: any malfunction of the system. The possible phases that
the system can be in are detailed in Chapter 6, ProPAC5M
Protocol Manual.
ƒ MicroPAC power is cycled
ƒ receipt of a new ARM signal
ƒ receipt of serial communication reset command
Display of Messages Sent by Control Computer

The MicroPAC provides for the display of messages that


may be generated by the control computer. The remote
Allocation of Volumes to Totalizing Counters
control computer can over-ride either the top or bottom
line or both lines of the unit’s display. The remote
Flow as measured by the various flow meters is allocated computer can also cause the displays to revert back to the
to totalizing counters. These counters are set up in terms normal displays as are generated by the unit itself. This
of end products (in accordance with each one of the 8 feature allows for a very convenient method of advising
possible product select codes) and in terms of individual the operator of a problem or special condition. For
example, if a load rack was out of service for some reason
base products (Main Product and Additive A or Additive
an appropriate message could be sent down by the
B). When the unit is under control of a remote computer remote control computer.
and authorization is made specifying the desired blend
ratio, then the Main Product volume is always allocated to
Totalizer #021.
Flow Simulation

To assist in testing and maintenance, MicroPAC may be


programmed to simulate Main Product flow as well as
Initial ERROR Inhibit Additive flow. Parameter #896 provides for the flow
simulation of Main Product, Additive A, and Additive B to
The controller may be configured to ignore additive blend be enabled independently.
ratio ERRORS for a certain number of time slots at load
start. This feature is useful in very low temperatures If simulation of Main Product is enabled, then the Main
Product flow meter pulses will be simulated whenever the
where the additive is not preheated and may have
LOAD PERMISSIVE output is ON. The speed at which
congealed within the additive injection system. these pulses are simulated is determined by Parameter
#897.

If simulation of an Additive is enabled, then that additive


Transaction Log (optional) flow meter pulses will be simulated whenever the additive
solenoid valve is ENERGIZED. The speed at which these
MicroPAC maintains a transaction log of all significant additive flow meter pulses are simulated is determined by
events. Events include ERROR conditions, power Parameter #899.
restoration events, changes to parameters, and load
completions. This transaction log is maintained as a push
down stack containing the last 200 transactions. Each
time a new transaction log entry is written, the oldest
transaction entry is discarded and so the last 200 entries
are always available. The transaction log can only be
read by means of the communications circuit.

The format of the transaction log record is described in


detail in Chapter 6 “ProPAC5M Protocol Manual”.

Chapter 2_Page 10 of 10