Model 7738 Model 7718OPERATION & MAINTENANCE FIELD GUIDE v 2.47 MiniBLOCK “Slave Injector” Chemtec Chemtec Energy Services, Inc. 11745 Cude Road Willis, Texas USA 77318 Phone 936 856 1704 Facsimile 936 856 1669 www.ChemtecEnergy.com male 1/4”. 1 PSI cracking pressure . 1 Group D locations. 300 series stainless steel. Chemraz used on the solenoid plunger seat (standard) offers a soft seat to prevent internal valve leaking (unauthorized additive flow) and excellent chemical resistance 17. accurate. Use of a resistor that is not properly sized may damage the sensor. and PULSE = BLUE. MiniBLOCK is simple in design. then terminate the Pulse wire second. In order to prevent damage to the DC powered sensor. Depending on the master controller used. Swagelok. Important Notes Related To Wiring The Hall-Effect Sensor 1. A Reed Switch type sensor is available as an option.6K ohm resistor for 12VDC powered systems and a 10K ohm resistor for 24VDC powered systems. The product serves as a “slave device” to a customer supplied “master controller”. 300 series stainless steel. OR WHITE 2. reliable and provides low pressure drop. use a 5. Both sensors are UL / CUL Listed and approved for Class 1. MiniBLOCK is machined from a single 300 series stainless steel block. Mount the resistor across the BLUE (pulse) and the RED (power) sensor wires. reliable. MiniBLOCK may be controlled by any device that is capable of controlling the solenoid valve and powering the 5-30 VDC sensor.1 watt coil (standard) ensures CORE ASSEMBLY (plunger) operation across a wide range of operating conditions Sensor The standard meter sensor operates based on proven Hall-Effect technology and operates utilizing 5-30 VDC. A “pull-up” resistor is normally NOT required. and marker additives. includes dust cap Internal. Other Components Needle Valves Calibration Fitting Strainer Check Valve INLET / OUTLET. CLEAR. high pressure rated Swagelok.Chemtec MiniBLOCK INTRODUCTION Page 2 DESCRIPTION MiniBLOCK is used to meter the injection of a wide range of liquid additives including fuel additives. 316 stainless steel basket type strainer. The oval gear design is highly accurate. The sensor is powered by the customer supplied “master” control device. Toptech Multiload. *** If a pull-up resistor is required. 60 mesh (230 micron) External mounted. 316 stainless steel. Danload 6000. terminate the Black Neutral wire first. POWER = RED. and compact Metering Positive displacement oval gears provide precise additive metering for low flow applications. and PLC based additive controllers. high quality. then terminate the RED Power wire LAST. The solenoid valve is machined into the stainless steel block and is easily serviced utilizing a standard ASCO solenoid rebuild kit. NEUTRAL = BLACK. 316 stainless steel oval gears (standard) offer enhanced chemical compatibility Flow Control Valve Additive flow control is provided by the normally closed ASCO solenoid valve. Common “master controller” devices include Accuload III. petroleum dyes. Div. a “pull-up” resistor may*** be required in order for the controller to count additive meter pulses properly. 3. thereby greatly reducing the number of potential leak points. 2-way. Wiring Power = RED. length includes installed external mounted check valve Optional Accessories Calibration Kit Thermal Relief Kit PN 77-CTK-50 (standard). normally closed. and Pulse = Blue.03 . direct acting.88” L x 4” H x 1. a solenoid valve or other blocking valve should be installed at the injection point. For DYE injection systems. The check valve provides redundant support in preventing main product from flowing through the injector in the reverse direction. basket type.3 GPM (0. (standard). 230 micron (60 mesh) Swagelok. 5-30 VDC (std). mates with PN 77-CTK-50 Stainless steel filter screen. stainless steel. 3/8” male inlet x 3/8” female outlet 8.Chemtec MiniBLOCK SPECIFICATIONS Page 2 Page 3 Performance Model 7738 Model 7718 Electrical Solenoid Sensor 0.12 .12 LPM) @ 1 cSt.2 LPM) @ 1 cSt. Div. unmounted. A 2-wire Reed Switch sensor available as option. rotates in 90 degree increments.0. supply voltage 115 VAC/60 hZ.1. each PAC pre-wired and mounted Meter access via four (4) recessed socket head bolts located under sensor Oval gear design. Whenever a valve is installed at the injection point. explosion proof. or PN 77-CTK-50HR (recommended for all dye additives) PN 77-TRK-10 (device recommended for all dye applications) Field Installation Considerations Note In addition to the use of the external mounted MiniBLOCK check valve on the injector.3 . 1 PSIG cracking pressure. the user should always install a check valve at the injection point on the main product line. high pressure rated Swagelok quick-connect fitting with dust cap. 1/2” FNPT. non-intrusive.3.5” D (225. other elastomers available as option (2) mounting holes provide for the mounting of the device to backplane or unistrut utilizing 5/16-inch hex socket cap screw Multi-PAC configurations include 1-PAC through 6-PAC. Mechanical Elastomers Field Mounting Configuration Meter Access Meter Gears Needle Valves Calibration Strainer Check Valve Dimensions Chemraz dynamic seals & Teflon static seals (standard).1 mm).600 PPG nominal resolution 0. 3-wire. Current 17.0 GPM (1. 300 PSIG.000 PPG nominal resolution ASCO. 300 PSIG.2 .6 mm x 101. 2. 6. All sensors rated for Class 1. 300 series stainless steel (standard) 316 stainless steel with Teflon packing. White or Clear. 316 stainless steel. .6 mm x 38. The installed valve prevents unauthorized DYE leakage due to thermal expansion. Neutral = Black. a Thermal Relief Kit must be installed on the MiniBLOCK injector.1 watt (standard). Hall-Effect type. other voltages available as an option. 1 Group D hazardous areas. SSU cSt SSU cSt .Chemtec MiniBLOCK PERFORMANCE CURVES Page 4 Note Performance data provided below was generated using low differential pressure. The use of a higher differential pressure (145 PSI maximum) will result in flow rates approximating 3.0 GPM (Model 7738) and 0.7 GPM (Model 7718). All flow rates measured using 15 injection cycles per minute. Chemtec MiniBLOCK DIMENSIONAL DRAWING Page 5 . Chemtec MiniBLOCK GENERAL ASSEMBLY Page 6 . 50PSIG. Plastic. 0-160 PSIG Graduated Cylinder. 1/4" x 1/4" x 1/4" FNPT Check Valve. SS. 500 ML (Dye. SS. Viton O-ring (std. .)** T. 1/4" Tube x 1/4" FNPT Tubing. 1 1 1 1 1 1 1 1 Description Quick Connect. SS. 1/4" MNPT x 1/4" MNPT. Plastic. SS. Liquid Filled. PRODUCT ORDERING PN# 77-CTK-50 (standard) PN# 77-CTK-50HR (High Resistant Option**) Includes Chemraz O-rings installed on Check Valve & Quick Connect Fitting.Chemtec MiniBLOCK CALIBRATION KIT Page 6 Page 7 The Chemtec Calibration Kit provides service personnel with the means to Calibrate the MiniBLOCK injector. Viton** Tube Fitting. SS. 1/4". diesel additives) Graduated Cylinder. additives) Part No. SS. Note Recommended for all petroleum DYE applications 6 5 8 4 3 2 1 7 Item 1 2 3 4 5 6 7 8 Qty. SS-QCH-B-4PM SS-4-T SS-4CPI-50V SS-400-7-4 SS-T4-S-035-20 PGI-63C-PG160-LA01 3BW-47315-1000 3BW-47314-500 ** Chemraz O-ring available as an Option for Dye Additives and other fuel additives requiring higher chemical resistance . 1000 ML (IVD. Marker. The Swagelok manufactured stainless steel female Quick Connect fitting (Item 1 below) mates with the male Swagelok calibration fitting mounted on the MiniBLOCK injector.035 Pressure Gauge. User MUST utilize the Calibration Kit in order to calibrate the injector. Swagelok 1/4” Tube Fitting. 10 PSIG cracking pressure Outlet Check Valve. SS. Swagelok Part No. SS. 1/4" Tube x 1/4" FNPT Check Valve. SS-8F-K4-230 SS--6-RB-4 SS-6-ST SS-0400-1-6 SS-T4-S-035-20 SS-400-8-4 SS-4CP2-10 SS-CHM6-1 Thermal Relief Kit includes Items 2-7 only. 1/4". Swagelok. SS. SS. Swagelok Fitting.035 Elbow. Items 1 & 8 included with MiniBLOCK injector. with 1/4” tubing. SS. 1 1 2 1 2 1 1 1 Description Strainer Assembly Reducing Bushing. SS. Swagelok Street T. 3/8” MNPT x 1/4” Tube. 3/8”NPT x 3/8”NPT. .Chemtec MiniBLOCK THERMAL RELIEF KIT Page 8 PRODUCT ORDERING PN# 77-TRK-10HR Includes Chemraz O-ring in Check Valve Model 7718 With Installed Thermal Relief Kit Item 1 2 3 4 5 6 7 8 Note Qty. 3/8” MNPT x 1/4” FNPT. 3/8" MNPT x 3/8" FNPT x 3/8"F. . pre-wired and pre-plumbed to enhance field installation and wiring • Available 1-PAC through 6-PAC configuration • Provides separate AC & DC explosion proof enclosures for enhanced electrical safety • Product design facilitates future expansion OPTION 2: NEMA 12 Enclosure • Includes NEMA 12 wire trough enclosure mounted and pre-plumbed • Design facilitates direct field wiring from “master” controller to each MiniBLOCK • Eliminates need for intermediate wire splices • Includes WAGO connectors in each “T” box • Available in 1-PAC through 6-PAC configuration • Product design facilitates future expansion 3-PAC EXP. Configuration 6-PAC Load Rack Mounted .Chemtec MiniBLOCK PAC CONFIGURATIONS Page 9 OPTION 1: Explosion Proof (EXP) Enclosures • Mounted. Configuration (designed for future expansion) 3-PAC With NEMA 12 Enclosure 6-PAC EXP. Chemtec MiniBLOCK ADDITIVE SYSTEM P&ID Page 10 . Chemtec MiniBLOCK DYE SYSTEM P&ID Page 11 . The final Additive K-Factor is always derived from performing an accurate field calibration using the additive to be metered. PLC. MiniBLOCK serves as a “slave” device to the “master” controller. and the volume of additive injected for each injection cycle. Equipment Requirements: • Safety goggles or glasses and protective gloves and clothing • Graduated cylinder (1. thus necessitating the need for seasonal calibrations. Multiload. The specific quantity dispensed for each meter pulse can only be determined by performing an accurate calibration check in the field. as well as prevent the solenoid valve from opening. a final calibration MUST be performed in the field utilizing the specific additive to be metered. such as an Accuload III preset. In order to minimize the adverse effect of these variables.000 ML for standard fuel additives and 500 ML for dye & marker additives) • Chemtec Calibration Kit PN# 77-CTK-50 Note The Chemtec Calibration Kit MUST be utilized in order to calibrate the injector . Note When new injectors are installed. a K-Factor of 2. K-Factor is defined as pulses per unit of measure. The Additive KFactor affects the volume of additive ACTUALLY DELIVERED verses the volume DISPLAYED by the “master” control device. MiniBLOCK Control MiniBLOCK injectors are typically controlled by a customer supplied “master” control device. Note The displayed volume of additive in the “master” control device is accurate ONLY when an accurate Additive K-Factor has been entered into the program following completion of the injector calibration.For initial testing. Additive viscosity for most fuel additives changes with temperature.600 pulses = 1 US gallon). Always refer to the product manual for the “master” control device utilized.000 PPG for Model 7718. Air in the additive lines may adversely affect meter calibration and meter accuracy. meter to meter variation. (Example: 2. MiniBLOCK Meter & Sensor MiniBLOCK utilizes a positive displacement flow meter for metering additive. whereby each meter pulse represents a specific quantity of additive dispensed through the injector. or other electronic control device capable of counting high speed meter pulses and controlling the solenoid control valve.600 PPG may be used for the Model 7738 and 6. Note An accurate “Additive K-Factor” for each MiniBLOCK meter must be entered into the program of the “master” control device.Chemtec MiniBLOCK FIELD CALIBRATION Page 12 Background The accuracy of an injector calibration may be affected by several variables including additive viscosity. trapped air in additive lines is a common occurrence. Some “master” control devices may incorporate an automated calibration feature. Additive flow through the flow meter generates electrical pulses via a Hall-Effect sensor. pump pressure. Danload 6000 preset. Ensure all air is eliminated prior to performing a Field Calibration. Step 6 6A Following the completion of the ten (10) calibration injections into the graduated cylinder. ensure that no trucks are loading at a position whereby product pulses may be sent to the injector being calibrated 1C Assemble Calibration Kit equipment and prepare Calibration Form (Reference last page) Step 2 2A Record the current “Additive K-Factor” if a factor is already entered in the “master” control device. Note If air is trapped in the additive line. initiate ten (10) injections into the 1. 3B Following the completion of Step 3A. Air in the additive line may prevent the solenoid from opening. as programmed in “master” control device 2C When ready to calibrate. utilize the 500 ML graduated cylinder dedicated for dye additive. as displayed by controller) 6B Following completion of all injection cycles and after all air has escaped from the additive in the graduated cylinder. install a Calibration Kit to the MiniBLOCK via the quick-connect fitting Step 4 4A Prior to performing the calibration test. ensure the selector switch for the additive pump & motor is positioned ON Step 3 3A Initiate several injections into the additive line or bucket prior to starting the calibration test. 2B Record the “Additive Set” value (CC’s per injection request). enter the standard Additive K-Factor for the MiniBLOCK being calibrated. CAUTION! DO NOT overfill the beaker.000 ML graduated cylinder. This action ensures pump pressure is adequate and that the injector is working properly. Do not splash additive. For Dye Additives using an Additive Set of < 50 CC’s.Chemtec MiniBLOCK FIELD CALIBRATION Page 10 Page 13 Manual Calibration Procedure Step 1 1A Comply with all safety procedures 1B Prior to initiating a calibration test. then EXIT program . ensure there is NO residual additive in the graduated cylinder 4B Position the graduated cylinder under Calibration Test Kit tubing and prepare for the test 4C Partially close the Inlet needle valve in order to prevent high pressure splashing of additive into the cylinder Step 5 5A With an Additive Set of < 100 CC’s and with the proper Additive K-Factor entered. clear all air prior to performing calibration test. record the “Additive Volume” in the graduated cylinder 6C Calculate the “revised” Additive K-Factor utilizing the folowing formula: New Additive K-Factor = (Current K-Factor X *Additive CC’s Displayed) Actual Additive CC’s In Graduated Cylinder * Note Use the Calibration Form located at the end of this document 6D Enter the New Additive K-Factor in the “master” control device program. record the volume of additive as displayed by the “master” controller (“Cummulative CC’s”. For new installations. The MiniBLOCK is now ready to resume normal operation. of product per pulse) Injection Cycles per 1000 gal.Chemtec MiniBLOCK FIELD CALIBRATION Page 14 Step 7 7A Repeat Steps 5 through 7 until the “actual volume of additive” in the graduated cylinder equals the “displayed volume of additive.0 Calculation: 2710 X 453.0 User Action: User Enter program for “master” control device and modify the programmed value to reflect the New Additive K-Factor of 2587. = 25 (1000/40 = 25) Calculation: 0.44 = 113. Calculating A New Additive K-Factor: Example (Current K-Factor X Additive CC’s Displayed) = New Additive K-Factor Actual Additive CC’s in Graduated Cylinder Example Assumptions: Current Additive K-Factor = 2710 Additive CC’s Displayed (cummulative total following end of test injections) = 453.44 = Additive Set (CC’s per 40 gallons of product) 25 Injection Cycles Example Assumptions: Injection Rate = 0.91 (New Additive K-Factor) 475.750 gal.56 CC’s (Additive Set) 25 Note US gallon = 3785.785 Liters . additive per 1000 gal.44 CC US gallon = 3.6 Actual Additive CC’s in Graduated Cylinder = 475.6 = 2587. of product CC’s per gallon = 3785.750 X 3785. remember to OPEN the Inlet needle valve and remove the Calibration Kit 8B Re-position the additive pump & motor selector switch to “Automatic Position”. as indicated on the “master” control device Step 8 8A On completion of calibration.44 Product Pulse = 40:1 (40 gal. X 3785.91 Calculating Additive Set Value: Example Treat Rate per 1000 gal. Calibration Form Customer Location Injector ID Calibration Performed By Date Beginning Additive K-Factor Additive Set (CC’s per injection) TEST RESULTS (CC’s) Test Injections Record CC’s after each injection cycle (1 thru 10) Test 1 Test 2 Test 3 Test 4 Test 5 1 2 3 4 5 6 7 8 9 10 Additive CC’s DISPLAYED Additive CC’s ACTUAL New Additive Factor Notes: 1. One (1) US Gallon = 3785. record the raw data (cc’s injected). CAUTION! DO NOT OVERFILL graduated cylinder 2.44 CC’s 6. For each Test Injection. Always wear eye protection and protective clothing while performing testing 3. Calculation: New Additive Factor = (Current K-Factor X Additive CC’s Displayed) Actual Additive CC’s in Graduated Cylinder Comments/Recommendations: Signature Date . as indicated by master controller 4. Following testing. ATTENTION! You MUST enter any new Additive K-Factor into the “master” controller program. return all valves & switches to “normal” operating position 5.