Chemtec
CHAPTER 2
SYSTEM DESCRIPTION
System Hardware
The MicroPAC controller is completely self-contained and
is normally mounted inside an explosion proof housing.
The unit provides (4) optically isolated high current
switches (AC or DC), (2) low current DC switches, (2)
high-speed input channels connected to hardware
counters, and (6) digital status inputs. Controller power is
115VAC/60 hZ. or 230VAC/50hZ. As an option, controller
power includes both 12 vDC or 24 vDC power supply
options for truck-mount or other DC powered applications.
The controller design is based on a CMOS Z80 8 bit
microprocessor operating at 9.8304 MhZ. A Z80 KIO chip
all input and output to the processor. The unit provides a
serial communications 2-wire link operating at RS485
signal levels on a party line communications circuit.
System firmware is stored in a 27C128 type of EPROM.
This chip is socket mounted to allow for easy firmware
modifications. The controller uses a battery backup RAM
with a built-in calendar clock. This ram is used for normal
processor functions and is also used to store the system
parameters, totalizing counters, and a transaction log.
This chip is also socket mounted so that in event of a
board failure, this chip can be transferred to the new
board, thereby maintaining all system statistics and
parameters.
All digital inputs are intended to be operated with a dry
contact closure signal source. All inputs are buffered by a
RC network to provide noise and over-voltage protection.
Although intended to operate at 0 and + 5 volt logic levels,
all of the inputs can be connected to + or - 15 volts without
damage. The receiving circuit is a 74HC series chip and
so the logic threshold voltage is + 2.5 volts. The two
inputs that drive the high-speed counters are buffered by
"Schmidt trigger" gates to provide further noise immunity
and so prevent false counting. Although the unit provides
for 6 digital status inputs, four of these status inputs are
commonly connected to the external push button switches
used for data entry (when used with optional explosion
proof enclosure with explosion proof external
pushbuttons). Four (4) local push button switches are
incorporated into the MicroPAC display board.
Each of the 4 heavier current outputs uses optically
isolated solid-state switches. For AC use, these switches
are TRIAC units rated at 2.5 amps continuous and up to
230 VAC. For DC use, the switches are Darlington output
transistor switches rated at 3 amps and up to 60 VDC.
Although RC filtering is used across each AC output, a
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ProPAC5M Additive Injector v1.
"snubber" network or MOV should be used across
inductive loads. Similarly, if the DC switches are used to
drive inductive loads, “snubber” networks or diodes to the
power supply should be used to inhibit large voltage
spikes on turn off.
The two low current DC outputs are optically isolated
Darlington transistor outputs with open collectors. Each
output is rated for an open circuit voltage of 50 volts and
will maintain an output voltage of less than 0.8 volts with a
current of 30mA.
System Firmware
As the Controller is required to perform a number of
functions concurrently with, but independently of each
other, the system firmware is structured as a number of
independent tasks operating under the control of a simple
but fast multitask executive. The executive schedules all
of the defined tasks on an equal priority "round robin"
basis. A task is given control of the processor and that
task is then expected to relinquish control back to the
executive whenever it is unable to continue execution due
to the unavailability of data or a peripheral device. All
tasks are completely resident in the EPROM memory and
are always active.
To minimize the overhead of the executive/task scheduler,
all tasks are considered to be of equal priority. When a
task is scheduled, the executive sets up the stack pointer
equal to the current tasks stack pointer and then turns
over the central processing unit to the task at the
instruction immediately following where the task last
suspended itself. When a task suspends itself, only the
task's current instruction pointer and task's stack pointer
are preserved, no other registers or flags are preserved. If
data or registers must be preserved across a task
suspension, then it is the responsibility of the task to save
this data on the stack before suspending itself and
restoring this data when the task is rescheduled. At each
cycle of the task scheduler, the system "watchdog timer" is
kicked or restarted. Should any of the tasks keep control
of the processing unit for too long a period of time, this
watchdog timer will time out, clear all outputs and
generate a non-masking interrupt to the processor unit to
force a complete restart of the system.
All system timing is derived from the system clock. The
9.8304 MhZ clock frequency is scaled down by one of the
counter timer chips, which cause it to generate a "real time
clock" interrupt every 0.5 mS or 2000 times a second. This
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.

Chapter 2_Page 2 of 10
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MicroPAC Operational States
IDLE STATE WITH PIPES NOT FLUSHED
IDLE STATE
OPERATE STATE
CALIBRATE STATE
EMERGENCY STATE
STATISTICS / PARAMETER STATE
OPERATE STATE WITH ERRORS
DATA ENTRY STATE
SIMULATING A LOAD / TEST STATE
WAITING FOR AUTHORIZATION
TEMPORARY STOP STATE
FREEZE STATE – ENABLED WAITING FOR
MAIN PRODUCT FLOW
Idle State
When power is first applied to the unit, the controller
performs a number of initializations and then enters the
IDLE state. On entering the IDLE STATE, the controller
will set up an additive pump turn off timer. When this timer
times-out, the controller removes or forces to the OFF
state all additive pump power.
In the IDLE STATE the controller will monitor the status of
all digital inputs. If the CALIBRATION signal is true, then
the unit will enter the CALIBRATION STATE. If the
PARAMETER pushbutton is engaged, the unit will enter
the STATS/PARAMETER STATE, therein allowing
programmed parameters to be viewed.
While in the IDLE STATE the controller tests for a number
of ERROR conditions and monitors the Main Product and
the Additive flow meter pulse signals. If flow is detected
when flow is “not authorized”, the controller will enter the
EMERGENCY STATE (ERROR STATE) and indicate the
proper ERROR for the unauthorized flow. The controller
also monitors the ARM INPUT signal and on the false-to-
true transition of the ARM SIGNAL, the unit will enter the
OPERATE STATE. If under control of a remote computer
the unit will enter the OPERATE STATE upon receipt of
an "AUTHORIZE" serial command.
In the IDLE STATE pulses from the Main Product and the
Additive flow meters are still processed however the
volumes are allocated to unknown product totalizing
counters when the unit is NOT ARMED. Only when the
unit is ARMED will it inject additive as programmed.
Operate State
If the unit is under the control of a supervisory control
computer, then the "AUTHORIZE" serial commands are
used to set up the conditions for the injection of additive.
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ProPAC5M Additive Injector v1.2
These commands may be used to set up the main product
to additive blend ratio (injection rate) and the final volume
of the product transfer in terms of Main Product.
In manual or contingency mode of operation the controller
will enter the OPERATING STATE on the false-to-true
transition of the ARM INPUT SIGNAL. On receipt of the
ARM signal, the controller and first read the PRD1, PRD2
and PRD3 inputs to determine the product that is to be
generated and will turn on the additive pump motor(s), as
required by the product definition.
On entering the operate state, the display will be set to an
"888888" display to allow verification of all display
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
condition on the ARM signal or it can be delayed for 2
seconds to ensure Main Product pressure is adequate. At
this time the unit will initialize a flow present rundown
timer. If no Main Product flow pulses are received in this
period of time the unit will assume there is a failure in the
Main Product pulse input signal and will terminate the
transfer operation by removing the LOAD PERMISSIVE
output signal. The timer is reset every time a pulse is
received from the Main Product pulse transmitter.
In the manual mode of operation the controller will
continuously monitor the ARM INPUT signal. Whenever
the signal becomes false (loss of signal) the controller will
immediately terminate the injection of additive, wait for a
short period of time to ensure all valves are closed, and
then enter the IDLE STATE. This describes the normal
ending for additive injection operation in the manual mode.
Under remote computer control the end of a load will be
signaled on MicroPAC receipt of the "END OF LOAD"
serial command.
During the OPERATE STATE the Main Product pulses
received (MPLS input, Connector J1 Pin 7/8) are
converted to a true volume using the Main Product flow
meter prescale K-Factor and Main Product flow meter
Calibration Factor. The true volume is used to update the
totalizing counter associated with the product, as selected
by input signals PRD1, PRD2 and PRD3. Similarly,
pulses received on the APLS (Additive A pulse) and BPLS
(Additive B pulse) signals from the additive flow meters
are converted to a true volume using the respective
prescale K-Factors and Calibration Factors for each
additive meter. The true additive volumes are then used
to adjust the flow rate of the additive being injected.
MicroPAC may be programmed such that on detection of
an ERROR condition the unit will enter the EMERGENCY
STATE (ERROR STATE), terminate further injection
Chemtec
attempts, and terminating product loading by removing the
LOAD PERMISSIVE OUTPUT signal. MicroPAC’s
response to an error condition may be altered by means of
system parameters. When under remote computer
control, the unit normally continues operation in case of
ERROR but signals the controlling computer that an
ERROR has been detected. The decision to terminate
load operations is made by the controlling computer.
Emergency State (ERROR STATE)
If so enabled by means of a system parameter, the
MicroPAC will enter the EMERGENCY STATE from both
the IDLE STATE and the OPERATING STATE whenever
it detects an ERROR condition.
Based on parameter programming, the MicroPAC on
entering the EMERGENCY STATE will remove the Load
Permissive output signal, terminate injections, remove
power to the additive pumps and display the specific
ERROR on the 2 line X 16 character display, as follows:
ERROR LISTING & DEFINITIONS
ERROR-1 No Main Product flow when
expected
If main product flow is expected and
there are no pulses from the main
product flow meter within a time frame
specified by a system parameter, then
the additive injector unit will remove the
permissive signal and display this
error.
ERROR-2 Unauthorized Main Product flow
If there is main product flow when the
flow is not expected the additive
injector controller will remove the
permissive signal, terminate the
transaction and display this error.
ERROR-3 Unauthorized Additive A flow
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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ProPAC5M Additive Injector v1.2
ERROR-4 Unauthorized Additive B flow - only
used when two additive injection is
utilized
If there is Additive B 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.
ERROR-5 Additive A overall blend ratio error
If the overall blend ratio for additive A
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-6 Additive B overall blend ratio error -
only used when two additive
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-7 Additive A Time Slot blend ratio
error
If the instantaneous or time slot blend
ratio for additive A is outside of
acceptable limits for a number of time
slots, the additive injector unit will
remove the permissive signal, shut off
all pumps and valves and terminate the
transaction and display this error.
ERROR-8 Additive B Time Slot blend ratio
error - only used when two additive
injection is utilized
If the instantaneous or time slot blend
ratio for additive B is outside of
acceptable limits for a number of time
slots, the additive injector unit will
remove the permissive signal, shut off
all pumps and valves and terminate the
transaction and display this error.
Chemtec
ERROR-9 No Additive A flow or under treat
with Additive A
If there has been insufficient or no
additive flow when required, the
additive injection unit will remove the
permissive signal, terminate the
transaction and display this error.
ERROR-10 No Additive B flow or under treat
with additive B - only used when two
additives are injected
If there has been insufficient or no
additive flow when required, the
additive injection unit will remove the
permissive signal, terminate the
transaction and display this error.
ERROR-11 Over treat with Additive A
If there has been too much additive A
blended into the main product, the
additive blending controller will remove
the permissive signal, terminate the
transaction and display this error
message.
ERROR-12 Over treat with Additive B - only used
when two additives are injected
If there has been too much Additive B
blended into the main product, the
additive blending controller will remove
the permissive signal, terminate the
transaction and display this error
message.
ERROR-13 Unable to load because Additive A
in Main Product pipe
If a product without Additive A is
selected and there is still Additive A in
the system pipes, the controller will
display this error message and remove
the permissive signal.
ERROR-14 Unable to load because Additive B
in Main Product pipe - only used
when two additive injection is
utilized
If a product without Additive B is
selected and there is still Additive B in
the system pipes, the controller will
display this error message and remove
the permissive signal.
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ProPAC5M Additive Injector v1.2
ERROR-15 Communication timeout
If there is loss of communications with
the supervisory computer and the
product transfer has been authorized
by the computer, then the injector unit
will remove the permissive signal,
terminate the transaction and display
this error.
ERROR-16 Parameter check-sum error
The additive injection controller
detected an error in the check sum for
the parameters stored in the battery
backed up memory. This check is done
at the start and end of each product
transfer. The additive injector controller
will remove the permissive signal, shut
off all pumps and valves and terminate
the transaction and display this error.
ERROR-17 Loss of ARM SIGNAL during load
operation
If there was an unexpected loss of the
ARM enable condition, additive injector
controller will remove the permissive
signal, shut off all pumps and valves
and terminate the transaction and
display this error.
ERROR-18 Controller timed out waiting for
authorization by supervisory
computer
The additive injection controller did not
receive authorization to proceed with a
load within a specified time period. The
additive injector controller will remove
the permissive signal, shut off all
pumps and valves and terminate the
transaction and display this error.
ERROR-19 Timeout while in temporary stop
If the unit remains in the temporary
stop state for too long a period of time,
the load will terminated, the permissive
removed and this error displayed.
ERROR-20 Too many errors - system lockup
If there have been too many errors
detected by the additive injector unit,
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.
Chemtec
The number of successive errors that
will be accepted before the system
locks up is specified by a system
parameter. This error counter is reset
back to its starting point if there is a
successful transaction that
terminated by removal of the ARM
signal and not by an error condition.
Note ERROR 20 is the only ERROR that MUST be
reset by cycling POWER to the MicroPAC
MicroPAC will remain in the EMERGENCY STATE
(ERROR STATE) until:
i. There is a true to false transition of the ARM
input signal except for ERROR-20
ii. There is a power down and power up sequence
(power to the unit is removed and then restored)
iii. A reset or an ARM transaction command is
received from the supervisory computer system
Calibration State
The MicroPAC will enter the CALIBRATE STATE from the
IDLE STATE when a true condition is detected on the
CALIBRATION input signal (Calibration pushbutton
engaged). The unit will simulate the input of a true
condition on the ARM INPUT SIGNAL (or authorization
from the supervisory computer if COM used) and will
simulate the receipt of pulses from the Main Product flow
meter. Actual Main Product flow is NOT required. While
in the Calibrate mode the unit will display the amount of
additive that the injector “believes” was delivered based on
existing parameters. By comparing the volume that the
MicroPAC “believes” it delivered with the actual or
measured volume, a “new” Calibration Factor for the meter
being calibrated is automatically computed when utilizing
the Auto-Calibration feature.
Note Reference Appendix 3A Auto-Calibration Routine
If at the instant that the CALIBRATION pushbutton is
engaged, the SHIFT (<) pushbutton is engaged, then the
system will force the use of Additive A at the normal inject
volume and at the primary injection interval.
Example 28 CC every 40 gallons of Main Product
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ProPAC5M Additive Injector v1.2
If at the instant that the CALIBRATION pushbutton is
engaged, the INCREMENT (^) pushbutton is also
engaged, then the system will force the use of Additive B
at the normal inject volume and at the primary inject
interval.
is
MicroPAC will exit the CALIBRATE STATE and return to
the IDLE STATE when the CALIBRATION pushbutton is
no longer engaged. In all cases, on returning to the IDLE
state, the system will restore the ADDITIVE A IN PIPES
and ADDITIVE B IN PIPES condition to the state it was in
on entering the CALIBRATE STATE.
Note It is always assumed by the MicroPAC that during
calibration the additive dispensed was directed into
a graduated cylinder and not into the Main Product
Statistics / Parameter State
The controller will enter the STATISTICS / PARAMETER
state from the IDLE STATE when the PARAMETER
pushbutton is engaged. The unit will remain in the
STATISTICS / PARAMETER state for as long as there is
activity in PAR, CAL, SHIFT (<) or INCREMENT (^) front
panel pushbutton switches.
Note If there is a period of 15 seconds of inactivity on
these signals, then the injector unit will return to
the IDLE STATE
When the PAR front panel pushbutton switch engaged,
the display will show the current parameter name on the
top line of the display and the parameter number as 3
digits and the parameter’s numeric value as 5 digits on the
bottom line of the display. If the parameter represented a
totalizer, then the totals value would be shown as 8 digits.
If the PARAMETER pushbutton is engaged the current
parameter number will be decremented and each time the
CALIBRATION pushbutton is engaged the current
parameter number is incremented. The numeric value of
the parameter is continuously updated.
Data Entry State
The controller will enter the DATA ENTRY STATE when
the user enters the program.
Note Data Entry can NOT occur when ARM INPUT
signal is ON
Chemtec
Data is typically entered using the four front panel
pushbuttons. While in this state, the operator is prompted
for the required data and some “reasonable” tests are
made on the entered data. When all the required data has
been obtained the controller will immediately enter the
OPERATE STATE if remote computer authorization is not
required or the DATA AVAILABLE STATE is required. If
there is a period of 15 seconds of inactivity and no new
data is entered through the push button data entry
switches, then the additive injector controller unit will
return to the IDLE STATE.
Data Available State, Waiting for Authorization
The controller will enter the DATA AVAILABLE STATE
when the controller unit has obtained all required data
from the operator via the pushbutton data entry keys. The
remote controlling computer, upon seeing the controller
enter this state, asks for the data that has been entered.
Upon receiving this data, the remote computer will either
authorize the load or reject the authorization request
based on the validity of the entered data. If the controller
is enabled, it will immediately enter the OPERATE STATE
and proceed with the product transfer. If the authorization
request is rejected, the controller will display the reason
for the rejection as sent by the control computer and return
to the IDLE STATE.
Freeze State, Waiting for Main Product Flow
The controller will enter the freeze state when there is no
Main Product flow but the ARM signal is ON.
Example: driver changing compartments when only one
ARM signal used
Following a time-out, the unit may be programmed to shut
down the additive pumps and enter the FREEZE STATE.
The system will remain in this state indefinitely or until
Main Product flow is again detected or the ARM signal
removed. The additive system will be restarted and will
continue until the target volume of Main Product is
attained or when the ARM signal is removed.
Temporary Stop State - Used With External Mounted
Pushbuttons Only
When the unit is wired to use external data entry push
buttons the unit will enter the TEMP STOP STATE when
the STOP/CLEAR pushbutton switched is engaged while
the system is in the OPERATE STATE. On engagement
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ProPAC5M Additive Injector v1.2
of the button, the additive pumps will be turned off and the
system will wait until the START/ENTER push button
switch is engaged, at which time the system will resume
product loading and additive injection. If the
STOP/CLEAR pushbutton is pressed while the system is
already in TEMP STOP STATE, the system will terminate
the load and return to the IDLE state. If the system
remains in the state for too long a period of time, the unit
will timeout, terminate the load, and return to the IDLE
state.
Unique System Features
The following describes the various functions or features
provided by the MicroPAC controller under control of the
firmware, as described herein.
Multi-Roll Capability – The MicroPAC controller may be
used for several different functions including electronic
injector, batch controller, or wild-stream blender with a
change of a single microchip.
2-Additive Injector – MicroPAC current firmware may be
used to control up to two (2) separate additive injectors
during simultaneous operation.
Multiple Protocols – MicroPAC may be programmed to
use one of several industry standard protocols including
ProPAC3, Lubrizol, Smith Meter, Daniels, Modbus and
others.
Main Product Flow Simulation - If the controller is
programmed to simulate Main Product flow then the unit
may be used as an additive dispenser, therein dispensing
the volume of additive as programmed and based on
simulated Main Product flow.
Flushing of Main Product Line - The system is capable of
flushing or purging the pipes and main product flow meter
at the end of the load so that subsequent loads are not
contaminated with any additive that may still be left in the
pipes after the point of additive addition. This flushing can
be initiated by the loss of the high flow signal near the end
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
of additive injection are flushed with clear product. When
this feature is used, the controller will slightly over-treat the
product during the main part of the product transfer so that
when the lines are flushed and the correct preset volume
reached, the overall blend ratio will as required.
Chemtec
Default System Parameters
System firmware contains a set of default parameters that
can be used to overwrite any values already existing in the
battery backed-up memory. The system default values
are reloaded when the SYSTEM REBOOT ROUTINE is
performed.
Note SYSTEM REBOOT procedure is described in
detail in Appendix 3C herein
The ability to reload a known set of parameters quickly
allows the system to be restarted quickly in the event of a
catastrophic failure of the battery backed up system
memory or if the user corrupts parameters. The
parameters that are actually reloaded are parameters in
the range from #100 through to #899. Parameters #1
through #99 are the system totalizing counters and are not
reset. Parameters #900 through #999 are read only
parameters or special variables that are calculated or
modified by the system and made available for viewing as
if they were a parameter.
Resetting Totalizing Counters
The system maintains a number of totalizing counters that
describe the throughput of Main Product and Additive
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
changed in the same way as all the other system
parameters. The value of the totalizing counters is always
displayed as 8 digits.
Product Definition
In manual mode of operation, the system allows for the
selection of one of eight products by means of three
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
blend ratio to be used. Under remote computer control,
the selection of blend ratio is specified in the
“Authorization Command”. The command may also be
used to specify which of the eight products available is to
be used.
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ProPAC5M Additive Injector v1.2
Inhibiting Transfer of Product
The conditions under which the transfer of a product is
inhibited are governed by a parameter. A product transfer
can be inhibited if:
i. A product without Additive A is selected
and there is "Additive A in pipes" i.e. an
insufficient volume of main product has
been transferred after an additive A has
been added to ensure that there is no
Additive A left in the loading arm and
main product flow meter.
ii. A product without Additive B is selected
and there is "Additive B in pipes" i.e. an
insufficient volume of main product has
been transferred after an Additive B has
been added to ensure that there is no
Additive B left in the loading arm and
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
"additized product only" condition is to transfer an
additized load sufficiently large that the additive injector
controller unit performs an orderly shutdown, purging the
main flow meter and pipes with clear product.
First Injection of Additive
The Main Product volume at which the first injection of
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
transfers are insufficient to flush the pipes if any additive
had been blended. After the start of additive addition, the
flow rate of additive will be controlled at such a rate so as
to maintain the target blend ratio.
Additive Over treat
The controller can be set up to over treat (i.e. treat at a
slightly higher rate than would normally be used) to
account for the Main Product flow during the slow flow
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.
Chemtec
Restart of a Loading Operation – Under Remote
Computer Control
When under control of the remote computer system the
additive injector can be instructed to restart a loading
operation without resetting the displayed and reported
additive and Main Product volumes. By simply sending a
new Main Product end target volume, the unit will restart
the loading operation without resetting any of the totalizing
counters. This allows the injector unit to properly end the
loading of each compartment, make any final additive
volume corrections as may be required, yet displaying
cumulative volumes. This allows for ease of checking of
volumes with a "bill of lading".
Measurement of Main Product Volume - During Slow
Flow
During each product transfer, the unit will measure the
volume of Main Product between the time that the system
enters slow flow (as indicated by the HIFL signal
becoming false) and when the transfer operation is
completed as indicated by the ARM SIGNAL becoming
false and the end of the load "dribble" time elapsing. This
value of Main Product flow is stored in battery backed up
memory as a "read only" parameter value (Parameter
number 904) that can be displayed to allow an easy way
of checking that the main product volume during slow flow
phase is sufficient to purge the main product flow meter
and pipes of any additive.
Purging of Main Product Pipe (Flushing)
The unit has the capabilities to ensure that the product
delivery lines are purged or flushed or any additives at the
end of a product transfer. Flushing is accomplished when
the MicroPAC controller terminates additive injections at
slow flow and counts sufficient Main Product flow to
ensure an adequate flush. This purging of the lines is
performed in a number of different ways depending of the
type of control of the system.
Flush Operations – Under Control of Remote
Computer
When the MicroPAC is under the control of a remote
“master” control computer, the computer may be used to
download the volume of Main Product to be loaded via a
serial command. During Main Product loading, the
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ProPAC5M Additive Injector v1.2
controller monitors the volume of Main Product
transferred. When the volume equals the total volume as
authorized (downloaded) by the computer MINUS the
volume required to effectuate the flush, MicroPAC makes
a final injection of additive (if necessary) and then
terminates all flow of additive until the authorized Main
Product volume is achieved.
As an alternative, the remote computer can remove the
ARM input signal to the MicroPAC at a specific volume of
Main Product still to be loaded (i.e. 200 gallons
remaining), therein effectuating the Main Product line
flush.
Flush Operations – Using High Flow Signal
A wired input signal may be used to indicate High Flow /
Slow Flow for Main Product.
Note The START of High Flow (leaving low flow for high flow)
and the START of Low Flow (leaving High Flow going to
Slow Flow) is the same reference point
When MicroPAC is providing “local” control over flush
operations and the High Flow signal is used (MicroPAC
connector J-1, Pin 5), then additive injections will be
terminated when the HIGH-FLOW signal is removed.
If the system is under local MicroPAC control and the High
Flow signal is not available, then additive injections shall
be terminated when the ARM OUTPUT signal is removed.
The flow of Main Product will continue, thereby achieving
the Main Product line flush.
Additive Exists Main Product Line
If additive flushing is desired and additive is the Main
Product line following the end of a product load, then the
MicroPAC will display the appropriate ERROR message
provided that the ERROR is enabled.
ERROR (Alarm) Outputs
MicroPAC provides an AC ERROR output signal that may
be utilized to notify local personnel in the event of an
ERROR condition. The output is normally wired to
CLOSE whenever the MicroPAC detects an ERROR
condition. The signal may be used to sound a horn, light
an alarm light or be used for another purpose.
Chemtec
Note The Load Permissive output is typically used to terminate
product loading instead of the alarm output signal
The ERROR signal is normally OPEN and CLOSES on
ERROR however this may be reversed so that the signal
is normally closed and opens on ERROR. This would be
the operating mode if the error output were used as a
permissive signal for another system.
The ERROR condition may be cleared (reset) when one of
the following three conditions exist:
ƒ MicroPAC power is cycled
ƒ receipt of a new ARM signal
ƒ receipt of serial communication reset command
Allocation of Volumes to Totalizing Counters
Flow as measured by the various flow meters is allocated
to totalizing counters. These counters are set up in terms
of end products (in accordance with each one of the 8
possible product select codes) and in terms of individual
base products (Main Product and Additive A or Additive
B). When the unit is under control of a remote computer
and authorization is made specifying the desired blend
ratio, then the Main Product volume is always allocated to
Totalizer #021.
Initial ERROR Inhibit
The controller may be configured to ignore additive blend
ratio ERRORS for a certain number of time slots at load
start. This feature is useful in very low temperatures
where the additive is not preheated and may have
congealed within the additive injection system.
Transaction Log (optional)
MicroPAC maintains a transaction log of all significant
events. Events include ERROR conditions, power
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”.
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ProPAC5M Additive Injector v1.2
System Phase Log
MicroPAC maintains in a 16 entry push down stack the
last 16 phases or operational steps of the system.
Note The phase push down stack can be accessed only
using the RS485 communications circuit
The push down stack will show in detail the last 16 steps
in the processing of a load. This log is not required for
normal operation of the unit but is beneficial in analyzing
any malfunction of the system. The possible phases that
the system can be in are detailed in Chapter 6, ProPAC5M
Protocol Manual.
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
control computer can over-ride either the top or bottom
line or both lines of the unit’s display. The remote
computer can also cause the displays to revert back to the
normal displays as are generated by the unit itself. This
feature allows for a very convenient method of advising
the operator of a problem or special condition. For
example, if a load rack was out of service for some reason
an appropriate message could be sent down by the
remote control computer.
Flow Simulation
To assist in testing and maintenance, MicroPAC may be
programmed to simulate Main Product flow as well as
Additive flow. Parameter #896 provides for the flow
simulation of Main Product, Additive A, and Additive B to
be enabled independently.
If simulation of Main Product is enabled, then the Main
Product flow meter pulses will be simulated whenever the
LOAD PERMISSIVE output is ON. The speed at which
these pulses are simulated is determined by Parameter
#897.
If simulation of an Additive is enabled, then that additive
flow meter pulses will be simulated whenever the additive
solenoid valve is ENERGIZED. The speed at which these
additive flow meter pulses are simulated is determined by
Parameter #899.