Additive Injectors

AccuPlus
Installation and Operations
Issue/Rev. 0.0 (11/12) Bulletin MN05002E

The Most Trusted Name In Measurement

Caution
The default or operating values used in this manual should not be construed as default or operating values for your system. Each system is unique and each parameter must be reviewed for that specic system application.

Disclaimer
FMC Technologies Measurement Solutions, Inc. and Smith Meter GmbH hereby disclaims any and all responsibility for damages, including but not limited to consequential damages, arising out of or related to incorrect values used in connection with the AccuPlus.

Receipt of Equipment
When the equipment is received the outside packing case should be checked immediately for any shipping damage. If the packing case has been damaged, the local carrier should be notied at once regarding his liability. Carefully remove the unit from its packing case and inspect for damaged or missing parts. If damage has occurred during shipment or parts are missing, a written report should be submitted to the Supplier. Prior to installation, the unit should be stored in its original packing case and protected from adverse weather conditions and abuse.

Proprietary Notice
This document contains information that is proprietary to FMC Technologies Measurement Solutions, Inc. and is available solely for customer information. The information herein shall not be duplicated, used, or disclosed without prior permission of FMC Technologies Measurement Solutions, Inc. FMC Technologies Measurement Solutions, Inc. will not be held responsible for loss of liquid or for damage of any kind from any cause to the person or property of others, or for loss of prot, or loss of use, or any other special, incidental, or consequential damages caused by the use or misapplication of the contents stated herein.

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Table of Contents
Section I Introduction.......................................................................................................................................... 1 Product Description ...............................................................................................................................................1 How to Use This Manual ......................................................................................................................................1 Section II Installation............................................................................................................................................2 General .................................................................................................................................................................2 Electrical Specications .......................................................................................................................................2 Coax Valve Wiring .................................................................................................................................................3 Typical Application .................................................................................................................................................3 Mounting Options ..................................................................................................................................................5 Dimensions (AccuPlus) .........................................................................................................................................7 Section III Start-Up Procedure ............................................................................................................................9 Purging Air from the Meter ....................................................................................................................................9 Section IV Operating Information .....................................................................................................................10 General Information ............................................................................................................................................10 Injection Theory ...................................................................................................................................................10 Set-Up Calculation ..............................................................................................................................................11 Example .........................................................................................................................................................11 Setting the Maximum Flow Rate of the Unit ........................................................................................................11 Section V Calibration ..........................................................................................................................................12 Section VI Related Publications ........................................................................................................................13

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Section I Introduction
Product Description
The AccuPlus is an additive unit used for injection of small amounts of liquid mediums (additives) into a mainstream product (petroleum, diesel, heating oil, fuel oil, etc.). The AccuPlus is an oscillating piston type positive displacement meter designed with high resolution electronics to control additive injections for line products. The simple yet robust design provides a modular solution either as a single or multiple product injectors. Utilizing an advanced metering technology and electronic encoder, the AccuPlus provides dependable injection over a wide range of ppm rates. This allows the injector to react faster and provide better distributed injections.

How to Use this Manual

This manual is to be used as an Installation and Operations guide for the AccuPlus. This manual is divided into six sections: Introduction, Installation, Start-up Procedure, Operating Information, and Calibration and Related Publications. The Installation section describes the basic installation guide for the AccuPlus. The Start-up Procedure section describes the manner in which the AccuPlus should be operated upon each start-up. The Operating Information section describes the pertinent information regarding the operation of the AccuPlus. The Calibration section describes the process of calibrating the AccuPlus. The Related Publications section describes other documents relating to the AccuPlus.

Inlet M18 x 1,5

Flowmeter

Outlet M18 x 1,5 Additive Valve Dosing Unit

Figure 1 Additive Unit AccuPlus

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Section II Installation
General
Local codes and standards for electrical installations must be followed when installing the AccuPlus. CAUTION: When installing the AccuPlus to the desired bracket, ensure that the HRE cover is secured tightly and that the meter is not powered.

Electrical Specications
HRE Recommended wire for use: Power: 14-30 AWG depending on approvals Pulses: 18-24 AWG stranded copper (Belden Number 9418, 8404 or equivalent)
Note: Resistance between the ground terminal and the power supply ground must not exceed 2 ohms.

Electrical Inputs HRE DC Power Range: 10 to 30 Vdc Input Current Quiescent Current (No Load): 20 mA @ 10 Vdc, 15 mA @ 24 Vdc, 15 mA @ 30 Vdc Output Signal 10 Vdc Input Power Supply: No Load: 9.7 0.3 Vp-p square wave 270 Load: 7.6 0.3 Vp-p square wave (minimum) 24 Vdc Input Power Supply: No Load: 23.7 0.3 Vp-p square wave 270 Load: 16 0.3 Vp-p square wave (minimum)
Figure 2 HRE Board

The HRE circuit board (Hall Rotary Effect) takes the rotation of the magnetically coupled meter and electronically senses the rotation to produce output pulses. The encoder is completely isolated from the product and meter internals. CAUTION: When handling the HRE board, ensure that proper grounding and static buildup is not present in order to prevent damage to the board. Improper handling and static discharge will cause failure to the board. If handling, try to use the one hand rule where one hand is on the piping and the other used to handle the board.

30 Vdc Input Power Supply: No Load: 29.7 0.3 Vp-p square wave 270 Load: 21 0.3 Vp-p square wave Output Source Current (A & B @ 270 Load): 70 mA @ 10 Vdc, 130 mA @ 24 Vdc, 160 mA @ 30 Vdc Output Current per Channel (A & B): Maximum Sink Current: 300 mA @ 30 Vdc Maximum Source Current: 80 mA @ 30 Vdc COAX Solenoid Valve Nominal Voltage: 240 VAC, 60 Hz Current: 150 mA Power Consumption: 27.3 W 315 to 450 mA inline fuse recommended Approval: Ex II 2G EEx m II T4 und II 2 D PTB 03 ATEX 2045 X IP 68 (EN 60529) CE 0102 NEMA 4X IP 68 T130C

Terminal 1 Terminal 2 Terminal 3 Terminal 4 Terminal 5 Terminal 6 Terminal 7 Terminal 8

+10 to +30 Vdc A Signal (Leading) B Signal Logic Common (Ground) No electrical connection on circuit board.

Table 1 CN1 Terminal Connections

Note: To maintain ATEX approval, the earth grounding screw on the owmeter must be properly wired.

Signal Cable Three-wire shielded for single-channel transmission. Sizes Distance # 20 AWG (0,75mm2) Up to 2,000 ft. (610 m) # 18 AWG (1,00mm2) Up to 3,000 ft. (915 m) # 16 AWG (1,50mm2) Up to 5,000 ft. (1,525 m)

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Section II Installation (continued)

Coax Valve Wiring

Fuse BL 315 - 450mA

+ L1

BR

L2

Figure 3 Coax Valve Wiring

Typical Application

Figure 4 Application Flow Diagram (example for less than 1000ppm).

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Section II Installation (continued)

Typical Application
Typical application for marker injection with less than 1,000 ppm:

8
AccuPlus

Flow Direction

Figure 5 Typical Application Less than 1,000 ppm

Typical application for market injection with more than 1,000 ppm:

8
AccuPlus

Flow Direction

Figure 6 Typical Application above 1,000 ppm

Local weights and measures recommended practices should be followed overall.

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Section II Installation (continued)

Strainer Back Pressure Valve

Pump

Additive Tank

Pump

Fine Filter

Gasoline or Diesel Tank

Tank Field Area

Pump

Pump

Loading Bay Area

Isolation Valve Optional Filter

AccuPlus
Isolation Valve

Check Valve

Spray Valve

Flow Control Valve

Filter

Gas Extractor

Meter

Figure 7 Simplied Additive System Application

Mounting Options
To ensure proper functionality of the AccuPlus it is highly recommended to follow the installation procedures in this manual. The AccuPlus should be mounted with two M8-1.25 bolts to a solid construction or bracket. An upstream and downstream isolation ball valve should be installed to allow a good start-up procedure and maintenance. If isolation valves are installed, a thermal pressure relief must be provided. If possible, the AccuPlus should be kept out of direct sunlight. To allow access to the AccuPlus for maintenance and cleaning, ensure there is 254mm (10") of clearance above the HRE cover and below the Dosing Unit. For additional congurations please consult the factory.

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Section II Installation (continued)

Installation Orientation

Mounting Holes

Figure 8 Mounting Bolt Attachment Holes (M8)

Critical: The AccuPlus must be mounted with the monoblock in the horizontal plane with the HRE cover facing up.

Figure 9 Proposed Installation Using Mounting Bolt Attachment Installation

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Section II Installation
Dimensions (AccuPlus Shown with a single additive valve)
mm (inches)
Side View Dimensions

120 (4.7)

Cable gland M20x1,5 for cable 7-12 mm Cable gland M16x1,5 2xM8x1,25 10 mm deep 173 (6.8) 109 (4.3)

72 (2.8) 31 (1.2) 37 (1.5) 42 (1.7)

60 (2.4) 64 (2.5)

5 (.2)

Top View Dimensions

2xM8x1,25 15 mm thru 9 (.4) M18x1,5 M18x1,5 7 (.3) 113 (4.4) 129 (5.1)

140 (5.5) 188 (7.4)

62 (2.5) 79 (3.1)

Figure 10 AccuPlus Product Dimensions

Note: Dimensions Millimetres to the nearest whole mm (inches to the nearest tenth), each independently dimensioned from respective engineering drawings.

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Section II Installation (continued)

Dimensions (AccuPlus Shown with 8 additives and a proportioning valve)
mm (inches)

79 (2.9)

140 (5.5) 180 (7) 35 (1.4) 9 (.4) 120 (4.7)

79 (2.9) 365 (14.4) 79 (2.9) 444 (17.5)

175 (6.9) 108 (4.3) M18x1,5

79 (3.1)

7 (.3) M18x1,5 306 (12.1)

95 (3.7)

79 (3.1)

217 (8.5)

87 (3.4)

50 (2)

87 (3.4)

Figure 10 AccuPlus Product Dimensions

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Section III Start-Up Procedure

After installation and connection of the plumbing, the unit ow rate can be adjusted, as required. Once the desired ow through the inlet needle valve is set, the holes will be sealed with a sealing label. Critical: The outlet needle valve is normally 100% open to avoid delayed meter pulses after the inlet solenoid valve has closed. Delayed pulses may cause injector alarms to occur.
Inlet Needle Valve Outlet Needle Valve

Sealing Label

Sealing Label

Strainer

Figure 12 Flow rate adjustment and strainer location

Purging Air From The Meter

When the meter is rst installed in the line, air is present inside the meter. The air may take some time to work out. If the meter is subjected to hydraulic shock during this vulnerable time, the meter can be damaged. Following the procedure listed below will greatly reduce the likelihood of meter damage: 1. If possible, a gravity head (not pump pressure) should be used to initially ll the meter as air is vented from a high-point vent. 2. Close the upstream inlet needle and ensure that the meter can ow freely with no restrictions downstream of the meter, this includes opening the outlet needle valve to 100%. 3. Energize the pump. 4. Energize the Additive Control Solenoid. If required, use a service mode from an AccuLoad III or microLoad.net preset. 5. Slowly open the inlet needle valve. It is important that the inlet needle valve is gradually opened to ensure that the meter will be operated at a very low ow. 6. Vent air from a junction downstream of the meter until there is no sign of air. Once all air has been released, continue venting for an additional 30 seconds. Ensure no air pockets are present in the upstream piping. 7. Adjust the ow rate with the inlet needle valve only.
Note: This procedure should be used whenever air has entered the system.

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Section IV Operating Information

General Information
To obtain maximum service, it is strongly recommended that detail records be maintained throughout the life of the AccuPlus. Data such as model, serial number, operating rate, type of product, totalizer readings, meter factor and other pertinent information should be recorded. Such information is an excellent guide in scheduling a preventive maintenance program.

Injection Theory
It is typically desired to have additives injected as stable as possible. There are two operation modes available: 1. Continuous Injector Flow Rate Continuous Injector Flow Rate is proportional to the main stream ow rate. This mode requires the injector ow meter to ow at various ow rates. This potentially introduces an error from a meter factor, related to ow rate and hydraulic conditions. 2. Pulsed Injection Mode A xed ow rate is initialized proportional to the main stream. This mode requires the injector ow meter to ow at one ow rate only. The acceleration and stop inuence can be compensated via calibration at operating conditions.
Note: The AccuPlus is designed to operate in Pulsed Injection Mode.

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Section IV Operating Information (continued)

Set-Up Procedure
Recommended Set-up Parameters: Operate the AccuPlus between the minimum and maximum ow rate to ensure optimum accuracy A minimum injector on time of 1.0 sec A maximum frequency of 30 cycles/min A maximum duty cycle of 50% Example: Main product ow rate is 2,500 LPM 100 PPM of additive to be injected 10 injections/minute 50% duty cycle maximum 1. Amount per injection 2,500 l/min x (100/1,000,000) 10 injections/min

= 0.025 l/injection

Note: Value used for AccuLoad set-up in Recipe parameter 17, 20, 86 Injector Volume

2. Calculate injector ow rate to maintain maximum 3 second injector on time Time cycle 60 sec = 6 sec/cycle 10 cycles 50% Duty Cycle 6 sec/cycle x 0.5 = 3 sec/injection (injector on time) 3. Injector minimum ow rate (to maintain 50% duty cycle) 0.025 l/injection x 60 (sec/min) = 0.50 l/min 3 sec/injection 4. Injector maximum ow rate (to ensure minimum 1 sec on-time): 0.025 l/injection x 60 (sec/min) = 1.5 l/min 1 sec/injection
Note: Flow rate minimums or maximums (Calculations 3 and 4, or AccuPlus specication limits) must not be exceeded. Adjust injection rate (number of injections per minute), if the minimum or maximum ow rates cannot be maintained.

Setting the Flow Rate of the Unit 1. Close the upstream isolation valve 2. Close the outlet needle valve located in the dosing unit 3. Remove the dosing unit calibration port plug 4. Properly install the calibration male quick connect tting 5. Connect the calibration set 6. Place the graduated cylinder below the calibration set nozzle 7. Energize the pump 8. Energize the additive solenoid valve 9. Open the upstream isolation valve to allow ow, until the graduated cylinder is full 10. Close the upstream isolation valve 11. Operate the unit and determine the volume collected in graduated cylinder for a suitable time period 12. If the ow rate is too high, reduce the inlet needle valve opening

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Section V Calibration
Calibration
To gain maximum accuracy from using the AccuPlus, a eld calibration is required. The calibration should be performed after start-up and at typical operating conditions. Below are some general guidelines: During calibration it is important that sufcient quantity can be measured by a suitable graduation cylinder Furthermore, the graduation cylinder should provide sufcient resolution and accuracy. The calibration chamber must be located downstream of the AccuPlus. The calibration chamber should be done equally to the operating conditions. If required, a temporary back pressure valve should be used for lling the calibration chamber. With back pressure valves installed, too long and/or soft hoses can cause calibration repeatability problems. Calibration can be done either in continuous mode or for maximum accuracy in normal operations pulsed injection ON/OFF mode. It is recommended repeating each test 3 times and verifying the repeatability of the results. It is recommended calculating and averaging a result of 3 successful repeats. The determined meter factor should be programmed by the meter pulse receiving device. Proper Personal Protection Equipment (safety glasses, rubber gloves, etc.) should be worn at all times while calibrating the AccuPlus.

Calibration of the additive unit is done using the Calibration Kit.

The Calibration is Performed as Follows: Close the upstream isolation valve Close the outlet needle valve
Pressure Gauge

Remove the plug by the outlet of calibration Mount the quick connect part of the calibration set Connect the rest of the calibration set

Ball Valve

Place the hose and the graduated cylinder so that the uid exits the nozzle into the graduated cylinder. Open the upstream isolation valve Perform the calibration by lling the calibration chamber with a predefined injection volume (ex. 0.0225ml x 40 injections = 900ml). This will allow an accurate comparison of input volume to output volume. After the calibration, remove the hose and tting of the calibration set from the additive unit Re-install the plug and open outlet needle valve
Nozzle

AccuPlus

Calibration Quick Connect Hose

Graduated Cylinder

Figure 13 Calibration Set

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Section VI Related Publications

The following literature can be obtained from FMC Technologies Measurement Solutions Literature Fulllment at measurement.fulllment@fmcti.com or online at www.fmctechnologies.com/measurementsolutions. When requesting literature from Literature Fulllment, please reference the appropriate bulletin number and title.

AccuPlus Installation/Operation.................................................................................................................... Bulletin MN05002E Maintenance ................................................................................................................................. Bulletin MN05003E Parts List....................................................................................................................................... Bulletin PO05001E Specications ................................................................................................................................Bulletin SS05001E

The specications contained herein are subject to change without notice and any user of said specications should verify from the manufacturer that the specications are currently in effect. Otherwise, the manufacturer assumes no responsibility for the use of specications which may have been changed and are no longer in effect. Contact information is subject to change. For the most current contact information, visit our website at www.fmctechnologies.com/measurementsolutions and click on the Contact Us link in the left-hand column.

Headquarters: 500 North Sam Houston Parkway West, Suite 100, Houston, TX 77067 USA, Phone: +1 (281) 260 2190, Fax: +1 (281) 260 2191 Measurement Products and Equipment: Erie, PA USA +1 (814) 898 5000 Ellerbek, Germany +49 (4101) 3040 Barcelona, Spain +34 (93) 201 0989 Beijing, China +86 (10) 6500 2251 Burnham, England +44 (1628) 603205 Dubai, United Arab Emirates +971 (4) 883 0303 Los Angeles, CA USA +1 (310) 328 1236 Melbourne, Australia +61 (3) 9807 2818 Moscow, Russia +7 (495) 5648705 Singapore, +65 6861 3011 Integrated Measurement Systems: Corpus Christi, TX USA +1 (361) 289 3400 Kongsberg, Norway +47 (32) 286700 Dubai, United Arab Emirates +971 (4) 883 0303

Visit our website at www.fmctechnologies.com/measurementsolutions

Printed 13 in U.S.A. 11/12 FMC Technologies Measurement Solutions, Inc. All rights reserved. MN05002E Issue/Rev. 0.0 (11/12) Page MN05002E

Issue/Rev. 0.0 (11/12)