Chemtec ProPAC5M Additive Injector v1.

CHAPTER 4
SIGNAL DEFINITIONS AND CONNECTIONS

Dry Contact Closure DC Input Signals

The MicroPAC controller unit provides for a total of 6 dry contact closure INPUT SIGNALS. Each of the input signals has an
open circuit voltage of 5 volts dc and a short circuit current of 1.0 mA when the signal is connected to a common ground. Two
additional input signals are also connected to high-speed counters that allow the controller to process high speed meter pulse
inputs for main product and additive.

The controller requires various input signals in order to operate the additive injector in accordance with the configurations, as
specified by programmed system parameters. The following diagram defines all input signals utilized by the MicroPAC
controller.

Signal Name Description

APLS This signal is used to indicate to the controller unit that a certain quantity of Additive A has flowed and
as such determines the amount of Additive A injected. This signal is normally connected to the
Additive A Pulse
Additive A flow meter pulse output. Within the controller unit, this signal is connected to a high speed
status digital input. High Speed Input Max = 800 pulses per second

BPLS This signal is used to indicate to the controller unit that a certain quantity of Additive B has flowed and
as such determines the amount of Additive B injected. This signal is normally connected to the
Additive B Pulse
Additive B flow meter pulse output. Within the controller unit, this signal is connected to a high speed
status digital input. High Speed Input Max = 800 pulses per second

MPLS This signal is used to indicate to the controller unit that a certain quantity of Main Product has flowed
and as such determines when an additive injection or addition takes place. This signal is normally
Main Meter Pulse connected to the main product flow meter pulse output. Within the controller unit, this signal is
connected to a low speed digital input and processed as a counter.
Low Speed Input Max = 100 pulses per second

ARM This input signal indicates to the additive injector unit that the injection of one or two additives into the
main product stream is to commence. A FALSE to TRUE transition of this signal indicates the start of
(Enable) a loading operation, will reset any ERROR condition, and reset to zero the counter of additive added
for the current load. When this signal is FALSE, output signals switch INJA and INJB to be forced to
the OPEN or OFF state. The output signals PMPA (Additive Pump A) and PMPB (Additive Pump B)
motor controls will also be turned off after a programmed delay following the time that the load ended.

Note In some configurations, the ARM signal being ON is simulated by the system software.
Depending on the system configuration and certain Parameter settings, this can be caused such
things as an authorization command from a remote control computer over the communication circuit or
an external key switch

HIFL This signal indicates to the MicroPAC that main product flow is flowing at the high rate of flow. The
change of state from HIGH-FLOW to LOW-FLOW is normally used when main product LINE FLUSH
OPERATIONS is desired. Upon change of state, the injection of additive is normally terminated,
therein, allowing for the flushing of all additive.

This signal shares the same physical connection as the ENTER/START pushbutton switch. The
interpretation of this physical signal is determined by Parameter 501 QPSIG.

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Chemtec ProPAC5M Additive Injector v1.2

Signal Name Description

PRD1 This signal along with the PRD2 and PRD3 signals indicates to the controller what is to be injected
into the main product stream. The specifications for the product by the system parameters will indicate
or the additive to be injected and the rate at which this injection is to occur. PRD1 is the low order
product select input.
INCREMENT
This signal shares the same physical connection as the INCREMENT DIGIT (^) pushbutton switch.
The interpretation of this physical signal is determined by Parameter 501 QPSIG.

PRD2 This signal along with the PRD1 and PRD3 signals is intended to indicate to the controller
what is to be injected into the main product stream. The specifications for the product by the system
or parameters will indicate the additive to be injected and the rate at which this injection is to occur.
PRD2 is the mid order product select input.
SHIFT LEFT
This signal shares the same physical connection as the SHIFT NUMBER FIELD LEFT (<) pushbutton
switch. The interpretation of this physical signal is determined by Parameter 501 QPSIG.

PRD3 This signal along with the PRD1 and PRD2 signals is intended to indicate to the controller
what is to be injected into the main product stream. The specifications for the product by the system
or parameters will indicate the additive to be injected and the rate at which this injection is to occur.
PRD3 is the high order product select input.
STOP/CLEAR
This signal shares the same physical connection as the STOP/CLEAR pushbutton switch. The
interpretation of this physical signal is determined by Parameter 501 QPSIG.

PRD1 PRD2 PRD3

Open Open Open Create Product #1
Closed Open Open Create Product #2
Open Closed Open Create Product #3
Closed Closed Open Create Product #4
Open Open Closed Create Product #5
Closed Open Closed Create Product #6
Open Closed Closed Create Product #7
Closed Closed Closed Create Product #8

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Chemtec ProPAC5M Additive Injector v1.2

Power 0utput Switch Signals

The controller unit provides a total of four (4) power switches. Each of these switches is optically isolated from the remainder
of the circuitry and has independent output connections. The AC switch is rated at 250 VAC open circuit voltage and a
continuous current of more than 2.0 amps. The DC switch is rated at 60VDC and a current of 3.0 amps

The following describes the output signals that can be generated by the MicroPAC controller.

Signal Name Description

INJA This signal is intended to control the inject valve of the Additive A product.
This power output switch is turned on whenever sufficient main product flow has occurred to start an
Injector Solenoid
A injection of Additive A. This signal is turned of when the required amount of additive for the injection
has been observed. This switch is also opened when the unit detects an ERROR condition and
terminates loading operation.

INJB This signal is intended to control the inject valve of the Additive B product.
This power output switch is turned on whenever sufficient main product flow has occurred to start an
Injector Solenoid
B injection of Additive B. This signal is turned of when the required amount of additive for the injection
has been observed. This switch is also opened when the unit detects an ERROR condition and
terminates loading operation.

PMPA This signal controls the Additive A pump motor. This signal is turned on at the start of a product
transfer if Additive A is to be injected. This signal is turned off at a programmed period of time after the
Pump Motor A
load is completed. This switch is turned off immediately when the unit detects an ERROR condition.

PMPB This signal controls the Additive B pump motor. This signal is turned on at the start of a product
transfer if Additive B is to be injected. This signal is turned off at a programmed period of time after
Pump Motor B
the load is completed. This switch is turned off immediately when the unit detects an ERROR
condition. This relay output can be configured as an ERROR/ALARM output via Parameter 501. This
ERROR/ALARM contact can be “Fail Safe” (Normally Closed – Open on Error) or (Normally Open –
Close on Error)

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Chemtec ProPAC5M Additive Injector v1.2

DC Output Signals

The MicroPAC controller unit generates two (2) low level DC output signals. Each output is an open collector output of an
opto-isolator. The output is rated at an open circuit voltage of 60 VDC and a closed circuit current of more than 30 mA.

Signal Name Description

PRMS +/- Load Permissive Output - positive/negative terminals.

This signal is intended to provide a Load Permissive Signal (Load Enable) from the ProPAC5 back to
the supervisory computer. The signal is optically isolated from the remainder of the circuitry so that a
number of these Load Permissive signals can be connected in series. This switch is CLOSED under
the following conditions:
Load Permissive ƒ POWER-ON
Output ƒ ARM INPUT signal is Enabled
ƒ NO ERRORS

When an ERROR CONDITION is detected by the controller, then the switch will be forced OPEN.
This signal is typically wired to the supervisory computer and used to terminate product loading.

Note The signal can be reversed by means of Parameter 501 QPSG5 so that this output signal is
normally closed and made open or error

ERROR +/- Error Output - positive/negative terminals.

Alarm Output
This signal is intended to provide an alarm signal whenever the unit detects an ERROR CONDITION.
The signal is optically isolated from the remainder of the circuitry so that a number of these error
signals can be connected in parallel.

The logic of this signal can be reversed by means of Parameter 501 QPSG5 so that this output signal
is normally closed and made open or error.

Serial Communication Signals

The unit provides a half-duplex party line serial communications circuit operating at RS-485 voltage levels. Communications
will normally be at 9600 baud with 1 start bit, 8 data bits and 2 stop bits.

Signal Name Description

COMM + This is the positive signal line for the differential serial communications link.
J2 Terminal 3

COMM - This is the negative signal line for the differential serial communications link.
J2 Terminal 1

COMM GND This is the common ground line for the differential serial communications link
J2 Terminal 2

Note
Internal to the unit this is connected to the system logic ground through a 100 ohm resistor

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Note When the communications circuit is idle and no data is being transmitted, COMM+ should be
more positive than COMM-

DC Pulse Power

The MicroPAC controller unit makes available DC power for external flow meter pulse or other circuits.

Note Care must be exercised since the amount of power available is limited

Signal Name Description

+ 5 VDC This +5 volt power is the same as that used to power all integrated circuits. The current drawn should
not exceed 50ma. This power source shares the same ground as the logic and signal ground. This
power is available on Terminal 11 of J1.

+15 VDC This +15 volt power is a separate power source that is available to power external pulsers or other
circuitry. This power source shares the same ground as the logic and signal ground. The current
draws should not exceed 100ma. This positive voltage power is available on Terminal 6 of J3.
Terminal 5 of J3 serves as the ground or negative voltage connection.

System Power

The additive blender controller unit can be powered from a 115 or 230 VAC power source or from a 24DVC power source or
12VDC power source. MicroPAC power is fuse protected. Power connections to the controller unit are:

Signal Name Description

LINE This is the line side of the 115 or 230 VAC power to the unit and represents
the positive terminal of the 12 or 24VDC power supply.

GRND This is the earth ground connection to the injector.

NTRL This is the neutral side of the 115 or 230 VAC power to the unit and represents
the negative terminal of the 12 or 24VDC power supply.

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