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3.3 Solenoid Leak Detection

Problem:

The Solenoid Leak Detection alarm is designed to prevent a gross over injection of

additive, loss of additive, and the unauthorized flow of additive. The alarm is activated when a single
injection volume exceeds twice the programmed volume.

Cause:

There are several conditions that can cause this alarm:

1.

Leakage of the solenoid control valve may occur due to worn or damaged seals in the solenoid or

the presence of a foreign object inhibiting valve closure.
Product under pressure may leak in a reverse direction through the ProPAC-3 additive flow meter, falsely
indicating additive flow. Additive installations should always include a ball valve and a check installed on
the additive line at the additive injection point.

2.

Air in the additive supply lines may cause "gear rocking" in the additive flow meter. This

rocking is registered in the injector as a leak.

3.

The injection rate may be set too low for the injector to control. In this case, the injector will

enter the alarm state almost immediately after the first injection.

4

. It is possible the microprocessor’s solid-state relay that is used to energize the solenoid control

valve could fail in the energized position causing the injector to flow additive anytime the additive pump
was pressurized.

Troubleshooting:

Turn on the additive pump and open the test port on the injector (Have a bucket

ready  under  the  test  port!!!)  If  additive  leaks  from  the  test  port,  the  solenoid  seat  is  leaking.  If
additive is  not leaking  from  the  test  port,  push the test injection  button.  If  the injection  occurs  so
fast that you can't distinguish between the solenoid opening and closing, then the injection rate is
too low for the injector to control. To fix this problem, partially close the outlet ball valve on the
injector  until  each  injection  lasts  for  1-2  seconds.  If  all  else  fails,  the  meter  gears  are  probably
rocking back and forth due to air in the additive supply lines. A riser tube installed in the additive
supply tubing will probably solve this problem.

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Содержание ProPAC-3

Страница 1: ...C 3 Chemical Additive Injector Field Manual Version 3 01a Titan Industries Inc Corporate Headquarters 22335 Gosling Road Spring Texas 77389 USA 281 353 3600 http www titan solutions com Updated 23 April 2001 ...

Страница 2: ...ection rates pg 23 Section 3 Alarm Operations pg 27 Recommended System Integration pg 27 Alarm General Information pg 29 Resetting Alarms pg 29 Alarm Description pg 29 Section 4 Field Calibration Instructions pg 34 Automated Calibration pg 34 Manuel Calibration pg 35 Section 5 Product Specifications pg 38 Section 6 Field Installation Illustrations pg 40 Pro Pac 3 Main Circuit Board I O Configurati...

Страница 3: ...module AC or DC 5 One Hall Effect Sensor 6 Two Eight Pin Wago Connectors 7 Three Five Pin Wago Connectors 8 Two Four Pin Wago Connectors 9 One Three Pin Wago Connector 10 One Wago Tool Pro Pac 3 Faceplate Pro Pac 3 Microprocessor Push to Test Button Stainless Steel Flow meter w gears Strainer Solenoid Three way Ball valve Check valve Two way Ball valve On Off Switch Explosion Proof Box ...

Страница 4: ...injector to present a large degree of information on one display screen The Titan ProPAC 3 communicates injector data via RS 485 serial communications The communications protocol is mature and well established Because the ProPAC 3 has numerous input output control options and performance features it is recommended the user contact Titan to discuss the specifics of how the ProPAC 3 may be integrate...

Страница 5: ...r Pro Pac 3 injector 120 VAC 60 Hz or 230 VAC 50 Hz 3 What type of product pulse signals can a Pro Pac 3 accept Both AC and DC signals 4 Would I be able to use Titan injector if I do not have product pulses Yes You can use Auto PAC 5 What is the difference between Pro Pac 3 Auto Pac and MAI ProPAC3 is a proportional injection controller It will inject proportional to the product pulses received Fo...

Страница 6: ...ssure The maximum operating pressure is 250 psig The maximum differential pressure is 145 psig 11 What is the injection volume per cycle The minimum is 5 cc The maximum is 685 cc 12 What is the flow meter accuracy Up to 0 05 of rate ...

Страница 7: ...ementing counters Each menu will be highlighted during scrolling Use Left Right arrows to select digit for changing when in Edit mode Use the key to EDIT SAVE Use the key for EXIT Cancel STEP 1 STEP 2 STEP 3 The graphical display screen displays a sky blue background with white alphanumeric characters X BATCH CONTROLLER TITAN PRO PAC 3 Titan ProPAC 3 Program Mode Software Version 2 50 Serial ID 01...

Страница 8: ...Scroll to desired menu selection for Editing Modify value if necessary and then save Minimum and maximum values for each menu selection will be displayed in the upper left corner of the graphical display X BATCH CONTROLLER TITAN PRO PAC 3 Min 0 0001 Max 9999 9999 Digit Select Change Cancel Save Ch1 Product K Factor 1 0000 Microprocessor Software Version Unique Microprocessor Serial Number Number o...

Страница 9: ... different injection rates Consequently a single Pro Pac 3 injector may be used to document the additive product ratio for up to three different injection rates Menu selection 1 2 or 3 Authorize Represents a more sophisticated way of controlling the additive injector Authorization must be accomplished either by serial communications command or by hardware permissive Rate selection is accomplished ...

Страница 10: ...njection for the pulses to be generated Permissed Permissive Feature is used in conjunction with permissive signal allowing simpler permissive circuit wiring A permissive for each riser can be looped rather than parallel wiring per individual injector Some terminals install injectors where an alarm on one injector will prohibit the injection of additive by other injectors that are operating on the...

Страница 11: ... additive product ratio For example depending on where the load meter stops at load end from one to 39 gallons of product will typically be loaded without any additive Utilizing the preload feature one extra injection of additive can always be provided at load start to make up for the potential loss of additive at load end Note When Enabled at a minimum the following items in the Line Flush Sectio...

Страница 12: ... additive will take place beginning at load start The preload feature may be used even when not utilizing any line flush method For example when the injector is configured to inject every 40 gallons of product and if the product total is not an even multiple of 40 there could be up to 39 gallons of untreated product However by preloading enough additive to treat 39 gallons of product the problem o...

Страница 13: ...ulse cannot be used Additionally it has been found some electronic presets do not provide a 1 1 product frequency that accurately represents the actual load frequency These presets due to limitations in their processing abilities send product pulses in bursts thereby not representing the actual load frequency The ProPAC 3 minimizes this problem by allowing the user to average product pulse frequen...

Страница 14: ...requency Example If Flush Start Decrease is set to 20 when average Aver is 80 of Max average the injector will begin to flush Maximum Product Pulse Frequency Max This is the Long Average frequency Frequency Freq This is the percentage of the full flow rate Spec This is the instantaneous actual additive percentage as a percentage of the product volume As the load progresses is number should approac...

Страница 15: ...led by the ProPAC 3 microprocessor and it is opened energized when additive dye injections are prescribed for a product load The valve is used primarily to prevent additive or dye from entering the product line during all periods where additive dye is not called for Without the feature implemented thermal expansion and pressure relief in the product line can cause small amounts of dye to leach int...

Страница 16: ...rate product loads may be documented and accounted for Ch 1 Product Set Defined as product units gallons or Liters per injection request Used to designate the volume of product units gallons or Liters to be counted prior to initiating an injection request Typical injections are made every 20 or 40 gallons of product Program range 1 9999 gallons The following displays the relationship between the v...

Страница 17: ...d Enabled Disabled Scaled Pulse End of Batch 1 32 000 mS 1 32 000 mS 10 32 000 cc s Enabled Disabled Enabled Disabled Enabled Disabled Enabled Disabled Enabled Disabled 0 99 999 Enabled Disabled Enabled Disabled Gallon Liter Enabled Disabled 1 900 Enabled Disabled Enabled Disabled Enabled Disabled Enabled Disabled Enabled Disabled RECOMMENDED PROGRAM SETTING none none enter the number of channels ...

Страница 18: ...19200 38400 57 600 Enabled Disabled 1 99 1 999 0 999 Enabled Disabled Enabled Disabled 1 50 1 50 1 99 RECOMMENDED PROGRAM SETTING Only when using a permissive input Used only when using flow switch input Used only with software Authorize As desired Enabled 5 injections As desired but not zero 0 As desired but not zero 0 Enabled As required As required Use only when communicating with Smith Acculoa...

Страница 19: ...or Authorize programmed Enabled RANGE PROGRAM SELECTION Enabled Disabled 0 9999999999 99 0 0001 9999 9999 1 9999 0 0000 999999999 9999 0 0001 9999 9999 2 0000 9999 9999 1 999 999 2 0 versions alphanumeric RECOMMENDED PROGRAM SETTING Program Enabled when blocking control valve is installed and used None As desired See Section 1 pg 14 As desired See Section 1 pg 14 None Determined by injector calibr...

Страница 20: ...he input voltage provided See Field Installation section Minimum recommended product features for implementation Permissive Output AC or DC used to terminate product loading in the event of an injector alarm ProPAC 3 power failure or the ProPAC 3 power switch being positioned OFF Serial Communications used to document regulatory compliance for additive product loaded as well ell as record injector...

Страница 21: ...e every 40 gallons of product loaded The Load Product counter will increment in accordance with the receipt of the 1 1 product pulses At 40 gallons product loaded the Batch counter upper right corner of display will increment from 0 0 to the value injected 100 2 As the Batch counter increments the Load Additive counter will increment accordingly reflecting the total additive loaded during each pro...

Страница 22: ...n the alarm occurs the Alarm State Screen will alternate 5 second intervals with the Load State Screen Fig 5 as depicted in the example below Note 1 The termination of product loading during periods of active injector alarms is absolutely necessary if the user intends to insure no product leaves the terminal without the minimum concentration of additive 2 The alarm display will show inverted color...

Страница 23: ...Hz 230 VAC 50 Hz 2 Product Pulse AC or DC 3 Authorize feature programmed Enabled 4 Permissive Input feature programmed 1 2 or 3 Recommended product features for implementation 1 Permissive Output AC or DC used to terminate product loading in the event of an injector alarm ProPAC 3 power failure or the Pro PAC 3 power switch being positioned OFF 2 Serial Communications used to document regulatory c...

Страница 24: ...nnels is programmed for a different injection rate the user will not be able to determine whether the additive to product ratio is correct from the Grand Total Screen However the additive to product ratio for each of the channel screens should always be within prescribed specifications Note Anytime Authorize is enabled the graphical display will scroll through the channels in the Idle State The nu...

Страница 25: ...4 4 200 100 2 Note The Channel ID defaults Ch1 Ch2 Ch3 can be changed to a six character alphanumeric ID The Channel ID has been changed to Red Dye in Fig 6 next page Load Additive 0 000 Load Product 0 and the Batch Injection 0 0 shall be displayed on the receipt of product pulses Provided 1 1 product pulses are provided to the injector on receipt of each pulse the Load Product total shall increme...

Страница 26: ...Alarm State Screen will indicate injector alarms occurring during the Load State The Alarm State Screen will alternate 5 second intervals with the channel specific Load State Screen until the alarm has been reset When the Multiple Station Injector is in the Idle State no Permissive Input selected and an alarm is active the Alarm Screen will cycle at 5 second increments with the various Idle State ...

Страница 27: ...ification 4 Over injection of additive ratio of additive to product is more than specification 5 Other alarm conditions not specifically related to the additive product ratio permissive timeout calibration excessive temperature 1 1 Recommended System Integration It is recommended at a minimum that the ProPAC 3 Permissive Output be integrated into the control system so product loading can be termin...

Страница 28: ...hereby making the alarm highly noticeable to local terminal personnel See screens below The Load Additive total A 0 00 and the Load Product total P31 will be displayed on the alarm screen in addition to the alarm description No Additive Pulse Alarm Cycle Screens Fig 2 X BATCH CONTROLLER TITAN PRO PAC 3 Alarm No Additive Pulse A 0 00 P 31 SCREEN CYCLE 5 SECOND INTERVAL X BATCH CONTROLLER TITAN PRO ...

Страница 29: ...for each alarm condition is provided herein 3 1 Non Programmable Alarms There are two 2 Non Programmable alarms These alarms by their nature are always considered to be critical alarms Therefore there is no ability to disable any of the non programmable alarms 3 11 Fail Safe Alarm Problem Although it is highly unlikely it is possible there could be a failure of the microprocessor programming or ot...

Страница 30: ...ounting is accomplished via a Hall Effect sensor It is possible the additive flow meter pulse counts from the Titan flow meter are not received by the microprocessor following an injection request This problem could cause the solenoid to remain energized open for an extended period of time in an attempt to complete the injection request The No Additive Pulse Alarm will provide an indication to ter...

Страница 31: ...meout Error Permissive Timeout Problem It is possible a Permissive Input hardware or software is received by the injector yet no product pulses are received If the injector software recognizes a new product load is to commence reason for the permissive however no product pulses are received within 120 seconds the software can not determine whether there has been a product pulse failure or whether ...

Страница 32: ...ve Quantity Alarm Problem Although it is unlikely during most normal operations it is possible the injector may under inject or over inject additive during a load without the injector entering any of the previous alarm states The following may contribute to this condition 1 Additive pre load feature is used and the product load is terminated soon after the start of the product load Under this cond...

Страница 33: ...te may be set too low for the injector to control In this case the injector will enter the alarm state almost immediately after the first injection 4 It is possible the microprocessor s solid state relay that is used to energize the solenoid control valve could fail in the energized position causing the injector to flow additive anytime the additive pump was pressurized Troubleshooting Turn on the...

Страница 34: ... are two recommended methods which may be used to calculate the Additive K Factor the Automated Calibration method and Manual Calibration method Automated Calibration The ProPAC 3 incorporates unique software that automatically calculates the additive K Factor for the user The user is required to use a graduated cylinder follow directions displayed on the graphical display and enter the actual vol...

Страница 35: ...ng the ProPAC 3 Calibration Sheet next two pages note each batch injection value as each injection is made See attached example The batch injection value is located in the upper right corner of the graphical display Total all batch injection volumes obtained during the calibration testing as the total shall be used in the calculation formula Also record the actual volume of additive in the graduat...

Страница 36: ...on 3 Test Injection 4 Test Injection 5 Test Injection 6 Test Injection 7 Test Injection 8 Test Injection 9 Test Injection 10 Test Injection 11 Test Injection 12 Test Injection 13 Test Injection 14 Test Injection 15 Test Injection 16 Test Injection 17 Test Injection 18 Test Injection 19 Test Injection 20 Injector Total cc Cylinder Total cc New K Factor ...

Страница 37: ...ion 5 45 5 44 43 43 Test Injection 6 45 5 44 45 45 Test Injection 7 45 5 45 44 44 Test Injection 8 45 5 45 46 46 Test Injection 9 46 45 44 44 Test Injection 10 46 44 5 46 46 Test Injection 11 Test Injection 12 Test Injection 13 Test Injection 14 Test Injection 15 Test Injection 16 Test Injection 17 Test Injection 18 Test Injection 19 Test Injection 20 Injector Total cc 453 6 448 450 0 450 0 Cylind...

Страница 38: ...ProPAC 3 120 VAC 60 HZ or 230 VAC 50 HZ Auto range capable Except solenoid valve 30 WATTS WITH HEATER OFF 130 WATTS WITH HEATER ON 120 VAC Input Module standard product DC Input Module available as an option 90 140 VAC 115 VAC typical 20 msec 20 msec 14 KW 20 VAC 8 30 VDC 15 VDC typical 0 025 msec 0 025 msec 900 W No modules in standard product AC or DC modules optional 12 VDC HALL EFFECT type Lit...

Страница 39: ...39 ...

Страница 40: ...ll DC I O and serial communications wiring should be shielded Belden cable in order to protect the signal integrity 6 The ProPAC 3 utilizes solid state relays for all inputs Because of the potential for current leakage when using a solid state device never provide inputs to the ProPAC 3 which originate from a solid state device unless a resistor is installed to bleed down the current leakage 7 The...

Страница 41: ... flow through the ProPAC 3 in a reverse direction The solenoid control valve is not designed to prevent flow in a reverse direction Product flow through the injector flow meter will cause the injector to alarm indicating a Leak Alarm Strainer PRODUCT Check Ball Valve Additive Flow 6 In order for additive to inject into a product line the additive pressure at the point of injection must be a minimu...

Страница 42: ...rminals 1 and 2 on P2 This output is only available by installing a dual output module into output module location 1 10 PSI Product Line S 50 PSI N C Block Solinoid Valve ProPAC 3 S S N O Relief Solinoid Valve Note A Snubber network should be installed across the Blocking Control Valve The Snubber will eliminate electrical back feed that is generated by de energizing the Control Valve solenoid Thi...

Страница 43: ...er module Some advanced features of the ProPAC 3 require the use of optional dual input and or dual output modules Dual modules have either two inputs or two outputs per module location The B portion of each module can only be accessed when a dual I O module is installed The following chart defines the mapping of each I O module to its corresponding wiring termination Step 2 Based on your applicat...

Страница 44: ...on Input Voltage Rating Input Resistance Frequency Response Off On IDC5D Standard DC Input Module 0 1 0 2 5 28 VDC 900 Ohms 400 Hz IDC5 Low Frequency DC Input Module 0 3 0 10 32 VDC 1500 Ohms 100 Hz IDC5K High Frequency DC Input Module 0 1 2 5 16 VDC 500 Ohms 5000 Hz IAC5 120 VAC Input Module 45 90 140 VAC 14K Ohms 25 Hz IAC5A 240 VAC Input Module 80 180 280 VAC 43K Ohms 25 Hz Types of modules tha...

Страница 45: ...tions and across D and D for 2 wire communications Recommended for communication rates higher than 9600 baud or network cable lengths that exceed 1000 feet Install only on the last injector on a network JP8 JP13 Connects signal ground to DC ground This is generally not recommended JP3 JP10 Connects R to T Converts ProPAC 3 to 2 wire RS 485 communications D connector becomes either the T or R termi...

Страница 46: ...r a minimum of 32 driver receiver pairs to be connected on a communication network with a maximum length of 4 000 feet The cable of choice for RS 485 applications is shielded two twisted pair with ground The shield should maintain continuity throughout the entire network and should be grounded at a single end usually the communication master end ...

Страница 47: ...er is Pre wired with 18 leads This is the only connector with external leads provided Shown with bold lines 2 Input 1 Opto 22 AC solid isolated state Input Module used for Product Pulse Input 3 Output 1 Opto 22 mechanical relay Output Module used for injector Load Permissive Output 4 The following connectors are pre wired and connected to ProPAC 3 system components P5 OFF ON Switch P3 Solenoid P6 ...

Страница 48: ...DUCT PULSE PRODUCT PULSE AC INPUT MODULE 1 SOLID STATE PERMISSIVE OUTPUT MODULE 1 MECHANICAL RELAY FG SOLENIOD HEAT CONFIRMATION CONFIRMATION CONFIRMATION PULSE OUTPUT MODULE 2 AC DC OR MECHANICAL PRE WIRED FIELD WIRED GND I O Configuration Recommended This Configuration utilizes many of the commonly used ProPAC 3 product features 1 Connector P4 AC Power is pre wired with 18 leads This is the only...

Страница 49: ...polarity considerations Connector P7 RS 485 Shielded Belden cable must be used Note 1 When converting from a PAC 3 to a ProPAC 3 Only the two 2 red wires should be connected to pins 1 and 2 on the Test connector P1 Pins 3 and 4 are used for future purposes If a lighted pushbutton is installed on the ProPAC 3 disconnect the black and white wires Place wire nuts on the end of each wire to prevent el...

Страница 50: ... meter gears 1 4 3235 Flow meter gasket 1 8 3320 Flow meter gasket 1 4 3250 Pad Heater 220 VAC 3352 Strainer 3400 Strainer Screen 3415 Strainer cap O ring 3418 1 4 Nupro Check Valve 10PSI 3455 Needle Valve 3460 Ball Valve 2 way 3465 Ball Valve 3 way 3470 Asco Solenoid 220 VAC 3501 Hall effect Sensor 3530 Solenoid Rebuild Kit 3535 Dc Input Module 2 5 28 VDC 3635 AC Input Module 240 VAC 3625 DC Outp...

Страница 51: ...st If the injector is unable to complete 3 consecutive injection requests the alarm will activate Anytime the solenoid is energized continuously for 30 seconds thereby attempting to complete just one injection request the injector will activate the alarm Reduced additive pump pressure check pressure 125 150 PSIG typical when several injectors are in used simultaneously Closed or restricted Ball Va...

Страница 52: ...tor additive flow meter falsely indicating additive flow make sure the Ball Valve and Check Valve is installed properly Air in the additive supply lines may cause gear rocking in the additive flow meter this rocking is registered in the injector as a leak install a riser tube in the additive supply tubing The microprocessor s solid state relay that is used to energize the solenoid control valve ha...

Страница 53: ...played Conditions whereby additive flow is occurring but at a reduced flow rate It is likely a second injection request may be received by the PAC3 ProPAC3 microprocessor while the injector is attempting to complete a previous injection request If the injector is unable to complete 3 consecutive injection requests the alarm will activate Anytime the solenoid is energized continuously for 30 second...

Страница 54: ...m will activate when the batch count count up from zero to the programmed Additive Set value exceeds 2 times the scaled Additive Set Damaged seals in the solenoid or the presence of a foreign object inhibiting valve closure check and replace solenoid Product under pressure may leak in a reverse direction through the injector additive flow meter falsely indicating additive flow make sure the Ball V...

Страница 55: ...LC every 40 gallon of product pulses If it does not light up replace the module 20 Inconsistent calibration Flow meter gears damaged inspect and replace gears Improper calibration check procedure read Section 4 Field Calibration Instructions Inconsistent pressure differential during calibration test make sure the differential does not fluctuate greatly during calibration test WARRANTY Titan Indust...

Страница 56: ...ed Titan Industries Inc shall not in any case be liable for special incidental consequential indirect or other similar damages arising from the use of the Titan ProPAC 3 Injector ALL OTHER WARRANTIES EXPRESSED OR IMPLIED ARE EXCLUDED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Titan Industries Inc 22335 Gosling Road Spring Texas U S A 1 ...

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