Titan ProPAC-3 User manual

ProPAC-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

2
Table of Contents
Introduction - pg. 4
Frequently Asked Questions - pg. 5
Section 1
Batch Controller Programming. - pg. 7
Program Menu Definitions - pg. 9
Channel Section - pg. 16
Programming Guide - pg. 17
Section 2
Normal Operations - pg. 20
Single Injector – One Injection rate - pg. 21
Single Injector – Multiple injection 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 Configuration - pg. 43
Pro Pac 3 Spare Parts List - pg. 50
Easy Basic Troubleshooting Guide - pg. 51
Warranty - pg. 56

3
Standard Accessories for Pro Pac-3
External Accessories:
Internal Accessories:
1. Pro Pac-3 Mother Board.
2. Pro Pac-3 Microprocessor.
3. One Single Input module. (AC or DC)
4. One Single Output 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.

4
ProPAC-3
Introduction
Version 3.01
The Titan ProPAC-3 Additive Injector is specifically designed to inject liquid chemical additives at
petroleum product terminals. The ProPAC-3 includes patented hardware and software that assures the
additive/product ratio is always maintained within customer specifications. The ProPAC-3, when properly
integrated into a users control system, can inject within 0.5% accuracy. Injector features, when used
properly, provide the highest level of EPA regulatory compliance.
The ProPAC-3 microprocessor is a state-of-the-art high-speed microprocessor capable of operating and
accounting for additive and product on three separate channels. The three channels may be used to inject
three different additive injection rates, as with a generic additive system shared by multiple users. Injection
rates may be selected via a hardware permissive input or via software permissive. Each channel maintains
accountability for its own additive/product ratio.
The microprocessor provides all the operational, alarm, and communication functions for the injector. The
microprocessor is field replaceable. The ProPAC-3 incorporates a large graphical display enabling the
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 integrated in an
integrated control system in order to achieve user expectations.
This manual pertains to software Version 3.01.
Proprietary Notice
The information contained in this publication is derived, in part, from proprietary data and patent data, from
Titan Industries, Inc. The information herein has been prepared for the expressed purpose of assisting
management, operations and maintenance personnel in the effective use of the ProPAC-3 additive injector.
Publication of this information does not convey any rights to use or reproduce it, or to use for any other
purpose other than in connection with the installation, operation, repair, and maintenance of the equipment,
as described herein.
Copyright 1995, Titan Industries, Inc.
Printed in the U.S.A. All rights reserved.
ProPAC-3, PAC-3 and COMM-LINK are registered trademarks of Titan Industries, Inc.
Titan PAC-3 and COMM-LINK patented U.S. Patent Office, Patent Nos. 5,118,008, 5,222,027 and
5271,526. Other U.S. and foreign patents applied for.

5
Frequently Asked Questions.
1. How does the Pro Pac-3 operate?
In a typical operation, additive supply pressure (125-150 psig typical) is provided to the inlet ball valve of
the ProPAC3 injector, via a positive displacement additive pump located on or near the additive storage
tank. The injection cycle begins when the ProPAC3 microprocessor energizes the normally closed two-way
solenoid control valve, thereby, allowing additive flow to enter the injector through the inlet ball valve. The
solenoid is energized when the programmed number of product pulses has been accumulated. The flow of
additive passes through the stainless steel filter, prior to entering the ProPAC3 flow meter. The flow of
additive through the flow meter results in generation of a DC pulse train from the flow meter to the ProPac3
microprocessor, via a Hall Effect sensor. This low voltage pulse train represents the volume of additive
being injected into the product stream. The additive exits the flow meter through ½ inch stainless steel
tubing, where it flows through the two-way solenoid control valve, prior to exiting the injector through the
check valve. When the volume of additive through the flow meter equals the programmed volume for each
injection batch, the microprocessor terminates power to the solenoid control valve, thereby, terminating the
flow of additive through the injector. The ProPac3 microprocessor totals the additive injected, totals the
product treated and is in the stand-by mode, awaiting the next injection batch request.
2. What is the power requirement for 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.
For instance the injector will inject 60 cc of additive for every 40 gallon of product. In its simplest form,
the ProPAC3 requires only AC power, a product flow pulse, and pressurized additive to operate.
Auto Pac is an automatic timed injection batch controller. It is designed for situations where a product
pulse signal is not available to pace the injection process. The Auto Pac injects based on a user-
programmed time between injections and an optional maximum load volume.
MAI (Multi-Additive Injector) is a proportional injection controller. It is specifically designed to
sequentially batch inject up to eight additives at petroleum product terminals.
6. Are there any alarm features to ensure the additive/product ratio?
There are 12 alarms. Three of them are non-programmable alarms and the rest are programmable alarms.
See Alarm Section for detail.
7. Can I do on-site calibration?
Yes. As a matter of fact, the Pro Pac-3 has a feature called Auto Calibration. Once the feature is enabled,
you just need to follow the instructions displayed and the injector calibration will be done in seconds.
8. How can I configure the Pro Pac-3 injector?
There are 3 ways you can configure the Pro Pac-3 injector: internal pad buttons, Infrared Remote.
9. What is operating temperature?
Low temperature (with heater pad on) is –40°F
High temperature (with heater pad off) is +132°F

6
10. What is the operating pressure?
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.

7
CONTRAST ADJUSTMENT
Section 1
Batch Controller Programming
Version 3.01
Note: Use the Up/Down arrows to change the graphical display contrast, if on
ProPac-3 power-up the display is difficult to read. Hold down until display is clear.
Press the key to ENTER the program. If lock code has been programmed, enter the lock code as
instructed. See following page for menu selections.
Use Up/Down arrows to scroll through menu selections, changing options, and
incrementing/decrementing 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 0122435B0000000E
Power On Count 3
Programming instructions and
Min./Max. Values are provided
on the graphical display screen
while in the program EDIT
X
BATCH CONTROLLER
TITAN PRO PAC-3
Min. 0.0001
Max. 9999.9999
Digit
Select Change
Cancel
Save
Ch1 Product K-Factor
1.0000

8
PRESS TO ENTER THE PROGRAMMING MODE
On entering the program, the Program Mode screen will appear for four (4) seconds.
X
BATCH CONTROLLER
TITAN PRO PAC-3
Titan
ProPAC-3
Program
Mode
Software Version 3.01
Serial ID 0122435B0000000E
Power On Count 3
Following the four (4) second viewing of the Program Mode screen, the following Menu Selection screen
will appear - ADMINISTRATION SECTION.
X
BATCH CONTROLLER
TITAN PRO PAC-3
Ch3 Additive Set
Ch3 Customer ID
Grand Additive Total
Grand Product Total
ADMINISTRATION SECTION
Edit
Exit
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 of times the Microprocessor has
been turned on
If Is pressed again this screen will be
displayed for another 4 seconds
USE TO SCROLL
THROUGH MENU SELECTIONS
USE TO EDIT SELECTION
USE TO EXIT PROGRAM
IN EDIT MODE, USE
TO SELECT DIGIT FOR EDITING
USE TO INCREMENT OR
DECREMENT SELECTED DIGIT
USE TO SAVE EDIT
USE TO CANCEL EDIT

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PROGRAM MENU DEFINITIONS
(Use with Programming Guide Section 1 pg. 17-19)
The following definitions are provided in order to assist the user in properly programming the Titan
ProPAC-3 additive injector. The definitions are also provided in order to explain the many product features
of the ProPAC-3 additive injector.
Programming features and parameters are organized into five (5) distinct sections in the ProPAC-3 program
menu. This section of the manual provides detailed definitions for the Administration, Communications,
Line Flush, and the Channel Sections of the program menu. Limited definitions are provided for the Alarm
menu, since the alarms are fully described in the dedicated Alarm Section of the manual. See Alarm
Operations Section 3.
ADMINISTRATION SECTION
Grand Additive Total - The total represents the cumulative volume of additive dispensed through
the injector. If more than Channel 1 is used, the Additive Total for all channels is accumulated in the Grand
Additive Total. If only Channel 1 is used, the volume represents the additive total for the channel. The value
is programmable and can be reset. Note: The Grand Additive Total does not change when a specific
channel total is changed or reset to zero.
Grand Product Total - The total is identical to the Grand Additive Total above except the total
represents the product treated.
Permissive Input - Represents the number of channels used. This number should correspond to the
number of rates selections, either hardware or software, from an electronic preset or terminal automation
system. Up to three (3) channels (rate selections) may be used in order to select different rates of additive.
Each of the three channels may be used and programmed with the same or 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 by sending either a software or hardware additive permissive signal to the
injector, requiring that Authorize mode be used whenever more than one channel is used. Up to three
different rates may be selected and accounted for in the injector. This does not limit the fact that an infinite
number of injection rates are available by changing the injection rates via the serial communications.
However, the injector can only accurately account for the additive/product ratio for three rates. When
Authorize is enabled, product pulses to the injector are ignored and the injector will scroll between the
Grand Total screen and the Channel Screen(s) until an additive permissive is received.
Even when only one rate or channel is used, Authorize mode is the recommended mode of injector
operation for the following reasons.
1.
Allows for simpler pulse wiring, because pulse wires can be paralleled from one pulse
source to multiple injectors.
2. Flow pulse switching via a PLC or relays is not necessary.
3. Allows for simpler load permissive circuit wiring, because load permissive circuit can be
looped per load arm (See Premised Permissive).
4. Better accountability when blended products or multiple additive rate products are loaded on the
same load arm.
5. Product pulse failures can be detected (see product pulse and Permissive timeout alarm).
Flow Switch Input - A flow switch input, when available, is an effective means to determine a
product pulse failure. Programmable Enabled/Disabled. If no flow switch is installed, program Disabled.

10
Definitions continued
Confirmation Pulse Output - The output is typically used in conjunction with electronic presets or
a PLC. The output may be used to confirm that an injection has been properly completed (End of Batch), or
it may be programmed to represent a programmed volume of additive (Scaled Pulse Amount). When
programmed and wired using the Confirmation Pulse, the confirmation pulse width (mS) must be
programmed. When programmed and wired using the Scaled Pulse, both the scaled pulse amount (cc's) and
the scaled pulse width (mS) must be programmed accordingly. The pulse width effectively allows the user
to program the on/off time of the pulse output, thereby, simplifying systems integration. The scaled pulse
signal is similar to a flow meter output. Even if the injector is in an alarm state, Scaled Pulses are generated
whenever additive is flowing. Note: If the feature is not used, (the output is not wired into the system),
program values for Confirmation Pulse Output, Scaled Pulse Amount, and the Scaled Pulse Width are
irrelevant.
Confirmation Pulse Width - Related to Confirmation Pulse Output above. This parameter defines
the amount of time that the output relay will be closed creating a pulse. The open part of the cycle will
depend on the amount of time between injections. The parameter is only relevant when confirmation pulse
is selected.
Scaled Pulse Width - Related to Scaled Pulse Output above. This parameter defines the minimum
on and off pulse width. The open contact time will be dependent upon the flow rate.
Scaled Pulse Amount - Related to Scaled Pulse Output above. This parameter defines the amount
in cc's that each closure of the scaled pulse output represents. Note: This output can continue pulsing after
each injection if this parameter and its related parameter (Scaled Pulse Width) are set such that there is not
sufficient time during the injection 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 same riser. This feature allows the injectors
that are not in alarm to operate as normal even though one injector servicing the riser is in alarm.
Programmable Enabled or Disabled. Contact Titan Industries for specific use.
Pump Start - An additive pump start output is available on the ProPAC-3. This output is turned on
when: the injector is either hardware or software Authorized, the Test Injection Button is pushed or
Calibration Mode is entered. When Authorized Mode is used, this can eliminate the direct control of the
additive pump from the automation system. The feature can also eliminate manually having to turn on the
additive pump for calibration. A dual output module is required to use this function. Programmable
Enabled or Disabled. If the feature is not used, program Disabled.
Test Injections - Enables the use of the external push-button for Test Injections. Test injections are
used for troubleshooting. Programmable either Enabled or Disabled. If the feature is programmed Disabled,
the external push-button will not generate an injection pulse, but can be used for other features.
Test Injection Add-In - Allows the user to determine whether the additive dispensed during testing
and calibration is added to the channel additive total. NOTE: During test injections, the corresponding
amount of product will also be added to the product total if the feature is programmed Enabled. If disabled,
scaled additive or confirmation pulses will not be generated.
Front Panel Lockout - Provides limited access security for entering the Pro Pac-3 programming.
Programmable Enabled or Disabled. If programmed Enabled, a numeric security code must be entered as
the Password.

11
Definitions continued
Password - Used with Front Panel Lockout feature. Numeric range for Password (0-99,999). Use
only if limited access is required. Note: If used, do not fail to record the programmed Password.
End Of Load Compensation - Allows the use of the external push-button to inject the amount of
additive that will get the current compartment into spec resulting in taking the injector out of the alarm
state. Although unlikely, it is possible that at the end of a product load, the additive/product ratio
calculation may indicate a slight shortage of additive. This shortage would more than likely occur only
when utilizing the Frequency Line Flush method or if the actual Flush Volume is greater than the
programmed value for Flush Volume. Note: The following features must be programmed Enabled, in order
to utilize the End of Load Compensation feature: End of Load Compensation, Test Injections, Additive
Quantity Alarm and appropriate values must be entered for Additive Quantity Injections, the Additive
Quantity Low%. If the feature is used, the additive may be injected into the product line, or it may be
injected into an appropriate container for manual addition to the product loaded. Additive in the container
may be added to the product by hand or as company policy dictates. With this feature Enabled, the user can
utilize the external Push-button to makeup any additive shortage. Programmable Enabled or Disabled.
Additive Pre-Load - Additive may be pre-loaded, at the beginning of the product load. The feature
is normally required when utilizing any product line flush feature such as dye injection where additive that
is not injected during the line flush period at load end is pre-loaded at load start. The feature is also useful
for maintaining the minimum required 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 Section must be programmed: Pre-Load Injections and Flush Volume. See the Line Flush
Section of this manual.
Additive Units - Additive and Product totals may be accumulated in either Gallons or Liters.
Calibration Mode - Provides an auto-calibration of the ProPac-3. Programmable Enabled or
Disabled. When enabled, the user can enter the auto-calibration mode of the injector by pushing and
holding the Test Injection Button for three (3) seconds.
Load Timeout - Provides a user programmable timeout of the load status screen. See Section 2.
Current Time / Date - Sets the current time and date. These features are used only in conjunction
with the Calibration Alarm.
ALARM SECTION
Pushbutton Clears Alarms - This feature provides for the resetting of alarms, via the external
calibration pushbutton, when the feature is enabled. When an alarm occurs during the loading process,
pushing the pushbutton momentarily will reset the alarm and reset all the load totals as if a new load has
started. However, by holding the pushbutton in for three seconds until the injector beeps, the injector will
attempt to restart the previous load maintaining all load totals while making larger injections to get the load
back into spec. This is a more sophisticated way of recovering from a low additive alarm situation. This
method will assure that even when the injector goes into alarm the correct additive has been injected into
the load. Programmable Enabled or Disabled. For the following alarms, please reference the explanation
provided in the Alarm Section of this manual. Each alarm is described in detail therein.

12
Definitions continued
Alarms Reset by "Pushbutton Clears Alarm”
Additive Flow Problem
No Additive Pulse
No Product Pulse
Line Flush Failed
Permissive Timeout Error
Flow Switch Failed
Additive Permissive Failed
Additive Quantity Alarm
Solenoid Leak Alarm
Failsafe Alarm
COMMUNICATIONS SECTION
Address - When utilizing serial communications, each ProPAC-3 will be addressed with a unique
address identifying the unit. Address range (1-999). Each injector on a serial communication network
should have a unique address. (Program as required) If communications is not used then the address is
irrelevant.
Baud Rate - The baud rate must be programmed when utilizing serial communications. Baud rate
selections are: 1200, 2400, 4800, 9600, 19200, 38400 and 57600. If communications is not used then the
baud rate is irrelevant.
Accuload Serial Communications - This should be enabled whenever a Smith Acculaod is
communicating over a RS-485 communication line to the Injector. There are two modes of operation with
the Smith Accuload: 1) Product Pulses with communication verification and alarm shutdown, 2) No Product
Pulses, batch injection commands are sent to the injector via the communication link. Call Titan technical
support for detail about which mode of operation to use.
LINE FLUSH SECTION
Pre-Load Injections - When utilizing the Additive Pre-Load feature (normally only used for line
flushing) the user specifies the number of injections the pre-loading of 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 (of 39 gallons of untreated product at the end) is
eliminated. Programmable 1-99 injections. Note: In order to use the feature, the following must be
programmed: Number of Injections, Flush Volume and the Additive Pre-Load feature Enabled.
Example:
If (5) is entered for Pre-Load Injections, Additive Set (40), Flush Volume (100 gal), and Product Set
(40). Since the Flush Volume is 100 gallons Flush Volume / Product Set = number of skipped injections as
a result of the flush (100/40 = 2.5). The preload additive volume (the volume of additive not injected at
load end during the flush period) will be Additive Set x 2.5 (40 x 2.5) = 100 cc's. Then 100 cc's is pre-
loaded over the first five (5) injections. Therefore, if the preload additive volume is 100 cc's, the first five
(5) injections of the load will include an additional 20 cc's or (40 + 20) for a total of 60 cc's.
Flush Volume - User enters the volume of product used to calculate the additive to be pre-loaded.
When using product line flush, the volume should represent the actual volume of product to be flushed at
load end. The software uses the Flush Volume to calculate the amount of additive that corresponds to the
amount of product used to flush. The software calculates the preload additive volume by dividing this

13
Definitions continued .
number by the Product Set to determine the number of injections including fractional injections and then
multiplies this result by the additive set. See above Example. Programmable 1-999 gallons.
Flush Alarm Volume - The minimum amount of product that will not cause a Line Flush Alarm.
Represents the calculated volume of product from the additive injection point in the product line to the end
of the load nozzle. If the flush volume, as programmed, is not counted at the load end, the unit will alarm
"Line Flush Failed", provided the alarm has been programmed Enabled. The alarm indicates an incomplete
flush, leaving contaminated product in the product line. The alarm is used for dye applications where both
clear and dyed products are loaded from the same riser. This alarm will alert terminal personnel that the
product line may not be clear of dye. Program range 0-999 gallons. If a line flush method is not used, the
programmed value is irrelevant.
Line Flush Hardware Input - Provides the means to accomplish a product line flush by utilizing a
hardware input. Typically implemented by users demanding no co-mingling or contamination of additives
in the product line. The input may be provided from a mechanical preset, electrical preset, terminal
automation system, or any other field device with the capability of signaling the ProPAC-3. Programmable
Enabled or Disabled. Note: An actual hardware signal is not necessarily needed. When authorized mode is
enabled and Line Flush Hardware Input is enabled, Line Flush can be initiated by removing the authorize
signal while product flow continues.
Flush Frequency Method - Provides the means to accomplish a product line flush by utilizing the
product pulse input frequency (Input 1), in order to determine the flush. Programmable either Enabled or
Disabled. If Frequency Flushing is not desired, program Disabled.
Note: The product pulse input frequency must be 1:1 resolution or higher, as a turbine meter input. A 40:1
product pulse 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 frequency
over programmable number of product pulses.
Pulse Width Long Average - This average is used to determine the maximum or full flow rate.
The ProPAC-3 compares this number with the Short Average to determine if the product flow rate has
decreased by the Flush Start % Decrease. Programming the Long Average number too large will have no
adverse effect on the performance of the frequency method. There is a flush diagnostic screen in the
ProPAC-3 code. This screen will show the user the Instantaneous value, Short Average, (Max) Long
Average, and the Freq %. The first three values Inst, Aver, Max are all in units of pulses/sec. Instantaneous,
Aver and Long (Max) product pulse frequency are the average over a number of product pulses. Average
numbers should be fairly constant during normal flow. However, if the average numbers are not constant
then increasing the Short and Long Pulse Width Average numbers may be required in order to determine
both an Average (Short) and Maximum (Long) Average product flow frequency. Only used with
Frequency Line Flush.
Pulse Width Short Average - This average is used to determine the instantaneous flow rate. The
ProPAC-3 compares this number with the Pulse Width Long Average to determine if the product flow rate
has decreased by the Flush Start % Decrease. See above. Programming the Short Average number too large
can adversely affect the performance of the frequency method by delaying the detection of product slow
flow. Delaying the detection of slow flow will result in injections during slow flow, hence not allowing
sufficient product to flow after the last injection to clear the product line. It may need to necessary to
decrease Flush Start % Decrease number to balance out a larger number in the Pulse Width Short Average.
Only used with Frequency Line Flush.

14
Definitions continued
Suggested Settings for Brooks Presets using Frequency Line Flush
All Brooks electronic presets send 1:1 product flow signals out in bursts that do not reflect the actual flow
rate of the product. Hence averaging of product pulse frequency is a necessity when using the frequency
method of line flush with a Brook preset.
Short Average 40
Long Average 45%
Decrease 50%
To enable the diagnostic screen press the up arrow and check simultaneously.
The diagnostic screen is only displayed while a truck is loading.
Flush Diagnostic Screen
To disable the diagnostic screen press the up arrow and check simultaneously or cycle injector power.
Instantaneous Product Pulse Frequency (Inst) - This is the instantaneous frequency of the
product pulses (Pluses per second).
Average Product Pulse Frequency (Aver) - This is the Short Average frequency. 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 approach 100 %. With the Preload feature enabled the load spec
will be 150 % high and approach 100 as the load progresses through line flush. With Preload disabled the
% spec will start at 0 and approach 100%. Variations in the % spec are related to the fact that the injector
treats in fixed gallon increments. The Quantity Alarm % spec high and low parameters will assure that the
automation system is alerted if a load terminates with an additive to product ratio outside the spec range.
Product Line Flush (PLF) - This is the amount of product that is included in the line flush. This
number should start at zero and counts up toward the Product Line Flush Volume.

15
Definitions Continued
Flush Start % Decrease - Feature provides the user with the ability to define the initiation of the
flush. The programmed value entered for % Decrease defines the decrease of normal steady-state product
flow (Long average) when the flush begins. Example: Normal product loading 600 gpm, Flush Start %
Decrease programmed 20%. During slow flow, as the product flow rate decreases by 20% to 480 gpm, the
flush will be initiated at 480 gpm flow rate. Only used with Frequency Line Flush.
Blocking Control Valve - The blocking control valve is typically used in conjunction with product
line flushing. However, it may be used in conjunction with typical additive installations as well. The
blocking control valve is typically a solenoid control valve installed at the additive injection point. This
solenoid valve is in addition to the solenoid control valve located on the ProPAC-3 injector. The blocking
control valve is controlled 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 into the product line causing a section of dyed product to flow into a clear truck. By using the
Blocking Control Valve, this problem is minimized. The blocking control valve is opened when the first
injection is made and is closed at the initiation of line flush. See Dye System Considerations Section 6 -
pg.3 for installation recommendations. Programmable Enabled or Disabled.
When authorize mode is enabled, the Blocking Control Valve is not opened until the first injection is made.
This prevents situations where a lane permissive is provided to a number of injectors even though flow is
not definite on the dyed product riser, hence allowing the dye line to relieve into the product line. See Dye
System Considerations Section 6 - pg.3.

16
CHANNEL SECTION
Ch1 Product Total - Provides product total in gallons, for Channel 1.
Note: If using a 40:1 product pulse, the total provides a count of the injection requests, not gallons, when
the Product K-Factor is programmed to 1.00. However, if the Product K-Factor is set to 0.025 and the
Product Set is programmed 40, the unit will increment by 40 gallons for each 40:1 product pulse input
(injection request). When using a 40:1 product pulse, this is the preferred method of accounting for the
product treated. This is very useful when using the Comm-link monitoring or ticketing systems for
documenting additive and product throughput.
Ch1 Product K-Factor - Defined as product pulses per gallon. Provides the user the ability inject
additive via a wide range of product pulse inputs. Range 0.0001-9999.9999.
Note 1: When a 40:1 pulse is provided, 0.025 is programmed for the Product K-Factor, and the Product Set
is programmed 40, the Channel Product Total will increment by 40 gallons on each injection request. When
the a 20:1 pulse is provided, 0.05 is programmed for the Product K-Factor, and the Product Set is
programmed 20, the Channel Product Total will increment by 20 gallons, on each injection request. When
using a 1:1 pulse or a turbine meter pulse input, provided the program values are correct, the Channel
Product Total will increment 1 gallon for each gallon of product loaded.
Note 2: It is recommended to use a 1:1 product pulse or turbine meter pulse as the ProPAC-3 product input
pulse so accurate 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 various product program menu selections:
Ch1 Additive Total - Reflects the total additive volume, in gallons, dispensed through the
ProPAC-3 flow meter for Channel 1. If Channel 1 is the only channel used, then the Channel 1 Total should
match the Grand Additive Total. Programmable 0.0000-999999999.9999.
Ch1 Additive K-Factor - The additive K-Factor is determined via a calibration test. K-Factor is
defined as pulses per unit volume, consequently, an Additive K-Factor of 2700 would designate there are
2700 additive pulses per gallon of additive. Calibration testing insures the actual volume dispensed through
the injector is accurately reflected by the unit display. This number is automatically calculated when that
Auto-Calibration feature is used. See Calibration Section 4.
Ch1 Additive Set - Used to designate the volume of additive, in cc's, per injection request. The
user must calculate the injection rate, in cc's, for the Product Set value programmed. The calculated
injection rate must be entered into the program. Program range 2.0000-9999.9999.
Ch1 Customer ID - User may enter a unique customer identification number, if desired. Program
range 1-999,999. Alphanumeric entry.
Product Pulse Type
40:1
20:1
1:1
Turbine Meter
Recommended Product K-
Factor
0.025
0.05
1
As Specified On Meter
Product Set
40
40
40
40

17
PROGRAMMING GUIDE
The following menu selections are programmable in the ProPAC-3 Program Mode, Version 3.01
MENU SECTION
ADMINISTRATION SECTION
GRAND ADDITIVE TOTAL
GRAND PRODUCT TOTAL
PERMISSIVE INPUT
(Hardware or software)
AUTHORIZE (hardware or software)
FLOW SWITCH INPUT
CONFIRMATION PULSE OUTPUT
CONFIRMATION PULSE WIDTH
SCALED PULSE WIDTH
SCALED PULSE AMOUNT
PERMISSED PERMISSIVE
PUMP START
TEST INJECTIONS
TEST INJECTION ADD IN
FRONT PANEL LOCKOUT
PASSWORD
END OF LOAD COMPENSATION
ADDITIVE PRE-LOAD
ADDITIVE UNITS
CALIBRATION MODE
LOAD TIMEOUT
ALARM SECTION
PUSHBUTTON CLEARS ALARMS
ADDITIVE FLOW PROBLEM
NO ADDITIVE PULSE
NO PRODUCT PULSE
LINE FLUSH FAILED
RANGE / PROGRAM
SELECTION
0.0000 - 9999999999.9999
0.00 - 99999999999.99
1,2, or 3
Enabled / Disabled
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
R
ECOMMENDED PROGRAM
SETTING
none
none
enter the number of channels used
3 channels available for rate selection
normally not used
Output typically wired to load preset
Used with Confirmation Pulse only
Used with Scaled Pulse only
Used with Scaled Pulse only
As desired, if authorize is enabled
When using pump start feature
Enabled
Enabled
Enabled- when using Password
Enter number when Lockout Enabled
Used with Additive Quantity Alarm
Typically used with product line flush
Gallon for USA
Enabled
180 sec. for 3 min load timeout
Enabled
Enabled
Enabled
Requires use of flow switch input
Used only when using line flush feature

18
PROGRAMMING GUIDE
MENU SECTION
ALARM SECTION CONTINUED
PERMISSIVE TIMEOUT ERROR
FLOW SWITCH FAILED
ADDITIVE PERMISSIVE FAIL
CALIBRATION ALARM
ADDITIVE QUANTITY ALARM
ADD. QUANTITY INJECTIONS
ADD. QUANTITY LOW PERCENT
ADD. QUANTITY HIGH PERCENT
SOLENOID LEAK DETECTION
COMMUNICATIONS SECTION
ADDRESS
BAUD RATE
ACCULOAD SERIAL
COMMUNICATIONS
LINE FLUSH SECTION
PRE-LOAD INJECTIONS
FLUSH VOLUME
FLUSH ALARM VOLUME
LINE FLUSH HARDWARE INPUT
FLUSH FREQUENCY METHOD
PULSE WIDTH LONG AVERAGE
PULSE WIDTH SHORT AVERAGE
FLUSH START (% DECREASE)
RANGE / PROGRAM SELECTION
Enabled / Disabled
Enabled / Disabled
Enabled/Disabled
Enabled/Disabled
Enabled / Disabled
1-999
0-99%
0-99%
Enabled / Disabled
1-999
1200, 2400,4800, 9600, 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 Accuload preset
5 injections
Typically used with product line flush
feature
Used with product line flush
Used to determine preload amount
Enter actual volume of product to
flush at initiation of product slow flow
Used with flush alarm
Enter calculated flush volume
(injection point to end of load arm)
should be < Flush Volume above
As required by user
As required by user
25 pulses
Increase if variations in product
pulse frequency cause line flush
detection in the middle of load
15 pulses (see above comment)
25%

19
PROGRAMMING GUIDE
MENU SECTION
BLOCKING CONTROL VALVE
CHANNEL SECTION
Ch1 PRODUCT TOTAL
Ch1 PRODUCT K FACTOR
Ch1 PRODUCT SET
Ch1 ADDITIVE TOTAL
Ch1 ADDITIVE K FACTOR
Ch1 ADDITIVE SET
Ch1 CUSTOMER ID
Note:
Ch2 AND Ch3 menu sequence the
same as for Ch1.
Ch.2 and Ch3 may be used only
when: Permissive Input
programmed 1,2,3
or
Authorize programmed-Enabled.
RANGE / PROGR
AM 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 calibration
Additive volume (cc's) per injection
As required by user
Used as ID for channels on channel
screens defaults ch1, ch2, ch3

20
Section 2
Normal Operations
Version 3.0
1.0 Introduction
The injector may be used in its simplest form as a single station injector requiring only power and product
pulses in order to operate, or it may be programmed, wired and used to operate as a multiple station (rate)
injector, thereby, taking advantage of the many system features designed into the product.
2.0 Use as: Single Station Injector - One Rate
The ProPAC-3 may be used in its simplest form as previous injectors that are used to inject a single additive
at a single injection rate. In this example, the "Authorize" feature is programmed Disabled, and Permissive
Inputs are not used. Note: Although the injector is used as a single station injector, it may be used to inject
multiple injection rates, via the RS-485 serial communications.
When the ProPAC-3 is used as a single station injector with no serial communications installed, the
following is required as a minimum, in order for the injector to operate:
1. Power (120 VAC/60 Hz. / 230 VAC/50 Hz.)
2. Product Pulse (AC or DC)
Note: The product pulse input module located at position “Input 1” on the ProPAC-3
Motherboard must conform to the 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 alarms
Confirmation Pulse Output (AC, DC, or mechanical) - used to terminate product loading in the
event of the failure of the product pulse. Typically used when a flow switch input is not used.
Note: The confirmation pulse output module is located at position Output 2, on the Pro PAC-3
main circuit board. See Field Installation Section
2.1 Single Station Injector - Idle State Operation
The ProPac-3 is in the idle state when waiting for product pulses. The ProPac-3 displays the screen below
when in the idle state, on which both the Additive and the Product totals are indicated. When used as a
single station injector (one rate), Channel 1 (Ch1) is the designated channel used to accumulate totals. The
additive total and the product total are both cumulative totals, since system start-up, or since the totals have
been reset.
Idle State Screen - Single Station Injector
Fig. 1
X
BATCH CONTROLLER
TITAN PRO PAC-3
Additive
Product
2,145.200
1,416,755