technical manual 5e-440a...se-440a - technical manual page 3 1. se-440a-enhanced 3-channel...
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Technical Manual
SE-440A Enhanced 3-Channel Controller
S-Systems
SE-440A - Technical Manual
Page 1
TABLE OF CONTENTS
Page Number
1. SE-440A - ENHANCED 3-CHANNEL CONTROLLER ............................................................................... 3
2. GENERAL DESCRIPTION ......................................................................................................................... 4
3. OPERATION SPECIFICATIONS ............................................................................................................... 5
3.1 ELECTRICAL ............................................................................................................................... 5
3.2 PLUMBING ................................................................................................................................... 5
3.3 VENTILATION ............................................................................................................................... 5
4. UNPACKING THE CONTROLLER ............................................................................................................ 6
5. ACCESSORIES ......................................................................................................................................... 7
5.1 CHART RECORDERS ................................................................................................................... 7
5.2 METERING PUMPS ...................................................................................................................... 7
6. INSTALLATION ......................................................................................................................................... 9
6.1 MOUNTING THE CONTROLLER/PUMPS .................................................................................... 9
6.2 PLUMBING INSTALLATION .......................................................................................................... 9
6.3 ELECTRICAL INSTALLATION ...................................................................................................... 10
6.4 INSTALLATION CHECK-OUT ...................................................................................................... 11
7. OPERATION ............................................................................................................................................. 12
7.1 THEORY OF OPERATION ............................................................................................................ 12
7.2 FUNCTIONS OF COMPONENTS ................................................................................................. 13
7.3 REAGENT MAKE-UP ................................................................................................................... 16
7.4 CALIBRATION.............................................................................................................................. 17
7.5 OPERATION OF THE PLC .......................................................................................................... 26
7.6 START-UP PROCEDURE ............................................................................................................. 28
7.7 SHUTDOWN PROCEDURE ......................................................................................................... 30
8. PREVENTIVE MAINTENANCE ................................................................................................................. 31
8.1 PREVENTIVE MAINTENANCE ..................................................................................................... 31
8.2 TITRATION PUMP ........................................................................................................................ 32
8.3 TROUBLESHOOTING .................................................................................................................. 32
8.4 RECOMMENDED SPARE PARTS ................................................................................................ 40
9. LIMITED WARRANTY STATEMENT ........................................................................................................ 41
10. ATTACHMENTS ...................................................................................................................................... 42
10.1 FRONT COVER ........................................................................................................... ATT 1 - PG 1
10.2 SE-413A IN LINE CELL .............................................................................................. ATT 2 - PG 1
10.3 PUMP PLATE .............................................................................................................. ATT 3 - PG 1
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10.4 PUMP PLATE - REAR VIEW .................................................................................... ATT 4 - PG 1
10.5 TERMINAL STRIP ................................................................................................... ATT 5 - PG 1
10.6 TITRATION FLOW .................................................................................................. ATT 6 - PG 1
10.7 ELECTRICAL BACK PLATE .................................................................................... ATT 7 - PG 1
10.8 pH CONTROLLER (RELAY) SET UP ........................................................................ ATT 8 - PG 1
10.9 CALIBRATION/ CONVERSION TABLES ................................................................. ATT 9 - PG 1
10.10 ELECTRICAL SCHEMATIC................................................................................... ATT 10 - PG 1
10.11 INSTALLATION OF pH SENSOR .......................................................................... ATT 11 - PG 1
10.12 PROCEDURE FOR CALIBRATION OF FMI PUMPS ............................................. ATT 12 - PG 1
10.13 SE-440A LOGO LOGIC ........................................................................................ ATT 13 - PG 1
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1. SE-440A-ENHANCED 3-CHANNEL CONTROLLER
The SE-440A is an enhanced version of the standard SE-440A three channel
Controller. It utilizes all the features of the original SE-440A plus many more.
New Features of the SE-440A Improved pH sensors
No Reagent (Acid) makeup
Pump calibration from the front panel
New alarm lights (eight separate alarms instead of only one)
Built in SE 413A Flow through Cell
Separate ON/OFF switches for A R & C pumps
Internal splash guard to isolate the liquid pump plate from the
electrical components.
Improved titration block with more reliable pH sensors (reduces the
effect of gas bubbles.)
Integrated PLC alarm and process control.
The SE-440A is functionally the same as the earlier version but includes enhancements that
make it more versatile and operator friendly.
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2. GENERAL DESCRIPTION
The S-Systems SE-440A is a three-channel solid-state process controller. It is designed to
meet the requirements of both printed circuit and plating on plastics applications by
providing precise automatic replenishment of the copper, caustic, and formaldehyde
components of electroless copper baths.
The S-Systems three-channel controller provides simplified controls and displays. Minimal
amounts of reagents are consumed. A 4-20 mA output is provided for each of the three
channels and may be used for a chart recorder or computer interface.
The SE-440A controller is enclosed in a JIC NEMA fiberglass case of the following
dimensions: Height: 24 inches; Width: 20 inches; Depth: 10.5 inches. Shipping weight: 85
pounds. For convenience of installation, the SE-440A controller has drilled wall mounting
tabs.
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3. OPERATION SPECIFICATIONS
3.1. ELECTRICAL
P/N 75024 US Standard 120V, 60 Hz, 10 A
P/N 75035 International 240V, 50 Hz, 5 A
P/N 75037 SE-413A
NOTE: If electronic diaphragm pumps are to be used for replenishment, separate power
outlets should be provided. NOT AVAILABLE IN 240 VOLTS.
3.2. PLUMBING
The SE-440A requires a sample flow rate of 600 ml/min which can be provided by a tap off the
process tank recirculation pump.
3.3. VENTILATION
No ventilation required.
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4. UNPACKING THE CONTROLLER
The SE-440A is ruggedly built and packaged to withstand reasonably rough handling. S-
Systems, however, recommends the controller crate be opened as soon as it is received and
any damage immediately reported to the carrier.
After uncrating the controller, the packing list should be compared with the items received
and any shortages immediately reported to S-Systems.
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5. ACCESSORIES
5.1. CHART RECORDERS
A chart recorder is available for the SE-440A controller:
6-Channel Strip Chart Recorder (P/N 75851); 4-20 mA input. Used for copper,
caustic, and formaldehyde.
NOTES:
1. Rated power voltage: 100-240 VAC (50/60 Hz).
2. Included is one roll of chart paper which should last approximately 30 days when the
controller is operated 24 hrs/day.
3. P/N 75855 Chart Paper for 6-Channel Strip Chart Recorder.
4. Supplied with each recorder is a 20-foot cable, P/N 75318, which is wired to the
terminal strip. A longer cable may be specified when ordering, P/N 75319.
5.2. METERING PUMPS
Two lines of metering pumps for use with the SE-440A are available from S-Systems.
Gorman-Rupp Bellows Pumps:
The bellows pumps operate from the switched AC controller circuitry. If the proper size
pump for the applicable flow rate is selected, this style pump should be adequate for most
shop needs. An extension cord (20 ft) with 4 outlets will be provided.
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Electronic Diaphragm Pumps:
Electronic diaphragm pumps (modified by the manufacturer for S-Systems), are
recommended when more than two components from a single channel are required to
maintain solution operating ranges. These pumps provide maximum accuracy and
reproducibility. They are powered from a standard 120V wall outlet.
Selecting a Metering Pump:
Operation of an Automatic Process Controller depends to a large degree upon proper
installation, selection of the type and size, and calibration of the metering pumps.
As a general rule, most metering pumps are fairly accurate between 30 % and 90 % of their
maximum output rating. Above and below this range, the varying inlet suction pressure and
output head pressure will have too large an impact on pump delivery rates to permit
accurate and permanent pump calibration.
When using a Controller, the replenishment rate ratio between various replenishers is
VERY important. Selection of proper size metering pumps will permit trouble-free
operation for long periods of time when properly installed and calibrated.
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6. INSTALLATION
6.1. MOUNTING THE CONTROLLER/PUMPS
1. Mount the SE-440A controller as close to the work tank and replenishment tanks as
possible. Do not exceed 20 feet from either work tank or replenishment tanks. The
SE-440A is provided with mounting flanges for easy installation of the NEMA ,
fiberglass case.
2. Mount reagent tank shelf under the SE-440A controller, leaving enough space to
remove reagent lines and reagent containers.
3. Mount each replenishment pump as close as possible and above its respective
container. Run outlet tubing to work tank. Install injector valve if provided. Install a
foot valve on a piece of tubing. With the foot valve installed, cut the length of the
tubing so that the valve sits on the bottom of the tank and just reaches the suction
side of the pump.
Notes:
1) Tubing on pressure side of the pump must be pressure rated (=> pump
outlet max pressure).
2) Replenishment pumps are not included with SE-440A System.
6.2. PLUMBING INSTALLATION
The plumbing installation for the SE-440A controller is a simple matter of connecting the
sample line, the reagent tanks and the dosing pump tubing. Actual routing of the lines may
vary from installation to installation due to specific machine configurations. A description
of each step follows:
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SAMPLE LINE:
Installation of the sample line is accomplished by connecting a 3/8" OD polyethylene tubing
between the process tank and the controller and the SE-413A mounted on the left hand side of
the controller (and return).
Tapping from the recirculation pump:
Material Required:
3/8" OD polyethylene tubing
Plumbing Tee (same size as recirculation plumbing) with reducer to 1/2" NPT X
3/8 tubing connector
REAGENT TANKS
Installation of the reagent tank plumbing is a simple matter of inserting the 1/4" OD Tygon
tubing from the bottom of the controller into the correct tank.
Route the tubing through the poly tubing fittings on the top of the tank. Be sure that the number
on the tubing matches the number of the tank.
* Waste lines must not be submerged in solution.
** Keep waste lines separate from reagent lines.
DOSING PUMPS
In order to insure accurate dosing, and prevent siphoning, S-Systems recommends that a foot
valve be installed in the replenishment reservoir and an injector valve be installed at the outlet
end of the dosing line.
6.3. ELECTRICAL INSTALLATION
The electrical terminal strip is located in the upper right hand (inside) corner of the controller.
Terminal connections are shown in the drawing a the back of this manual.
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6.4. INSTALLATION CHECK-OUT
S-Systems completely wet tests each controller before it leaves the factory, therefore, no
special procedures for initial start-up or check-out is required.
It is recommended that the normal Start-up and Calibration procedures in Section 7
(Operation) of this manual be carefully followed.
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7. OPERATION
7.1. THEORY OF OPERATION
7.1.1. Copper Channel
As the copper concentration of an electroless plating solution increases, the color of the
solution intensifies. Light which is passed through the solution is partly absorbed by the
solution. The greater the intensity of the color, the greater the amount of light which is
absorbed.
The SE-440A makes use of this principle to control the amount of copper replenishment
components to the solution. Solution flows through a cell, on one side of which is a light
source, on the other side of which is a photovoltaic device. As light from the source passes
through the solution, the amount absorbed varies directly as the color intensity, which in
turn is a function of the concentration of the solution.
Conversely, the amount of light which is transmitted through the solution, hence the
amount of light which reaches the photovoltaic device, varies inversely as the color
intensity. The output in millivolts, of the photovoltaic device is directly proportional to the
amount of light which reaches it.
Thus as the concentration increases, the millivolt output from the photovoltaic device
decreases. It is this millivolt output which is fed into the SE-440A and processed to control
solution replenishment. In order to increase the sensitivity, the light source (a 12volt bulb),
is powered by 8-10 volts. This situation causes the bulb to emit more heavily in the red
spectral region which is the band of wavelengths which are absorbed by electroless
solution.
7.1.2. Caustic Channel
Sodium hydroxide (caustic) concentration is determined by continuously mixing a constant
flow of the plating solution with an equal flow of acid of preselected concentration. When
the plating solution is at the desired concentration with respect to hydroxide, the pH of the
mixed stream is at the inflection point (pH 10.2) of the titration curve. The pH of the mixed
stream is measured and compared to a set point (pH 10.2).
A reading below set point corresponds to a low hydroxide concentration and will activate
the caustic replenishment circuitry. A reading above set point corresponds to a high
hydroxide concentration and will deactivate the caustic replenishment circuitry.
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7.1.3 Formaldehyde Channel
Formaldehyde concentration is determined by reacting a constant flow from the caustic
channel with an excess of sodium sulfite solution. This reaction yields sodium hydroxide
which raises the pH of the solution. The solution is then mixed with a constant flow of a
second acid of preselected concentration.
When the plating solution is at the desired concentration with respect to caustic and
formaldehyde, the pH will be at the 10.2 inflection point. The pH is then measured and
compared to a set point (10.2).
A reading below set point when the caustic is in range, corresponds to low formaldehyde
concentration and will activate the formaldehyde replenishment circuitry. A reading above
set point will deactivate the formaldehyde replenishment circuitry.
If the caustic reading is below a pre-selected set point (9.8 pH), there is an PLC interlock
which prevents the formaldehyde replenishment circuitry from activating, and an alarm
light will turn on indicating low caustic. When the caustic comes within range, the
interlock is deactivated allowing any necessary formaldehyde replenishment.
7.2. FUNCTIONS OF COMPONENTS
OUTSIDE THE ENCLOSURE
Power Switch
The power switch turns power ON/OFF to the controller. Switch lights indicate the
controller is powered.
Pump Switches
In the manual position, power is supplied to the pump control relay allowing continuous
replenishment. The switch light remains ON, indicating replenishment. In the Automatic
position, power to the control relay is supplied from the controller as required. The switch light is
ON only during replenishment.
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Copper Process Controller
The Process controller is a compact proportional, integral, derivative microprocessor
controller which operates in two modes (User Mode and Set-Up Mode).
In the User Mode, the operator is able only to monitor outputs and adjust the set point value.
In the Set-Up Mode, the microprocessor is fully accessible, thus enabling the operator to
adjust all control parameters.
There is a four digit LED display which reads the actual value of the parameter being shown,
and a graphic display which indicates relative deviation from set point both in magnitude and
direction. The display also includes various legends which tell the operator which parameter
is being displayed.
Alarm Lights
Eight "red" alarm lights are provided to indicate the status of the caustic, formaldehyde and
copper channels. They indicate pump status and when the process is out of range (high or
low).
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INSIDE THE ENCLOSURE
WARNING: There are no protective interlocks to provide interruption of power when
cover is open.
Control Relay(s) - Provides signals to the replenishment pumps.
DC Power Supply - Provides 8-10 VDC power to light source in copper probe.
PLC - To provide integrated process control and alarm functions, the SE-440A uses a Logo
24L PLC and power supply. All logic control functions for the SE-440A are pre-
programmed and do not require any operator input. The SE-440A does however provide
eight timer/counter functions that can be changed by the operator. The procedure to change
timers and counters is in Section 7.4.5 Timer/Counter Settings.
Timer/Counter Description Factory Setting
Bl Power ON Delay Timer - Allows a preset 15 minutes
amount of time for the process and the
controller titration system to stabilize before
making any chemical adds.
B4 Timer Pump Z - Maximum On cycle time 3 minutes
for pump Z.
B7 Timer Pump Z - Maximum OFF cycle time 2 minutes
for Pump Z
B10 Timer Pump Y - Maximum On cycle time 3 minutes
for pump Y.
B13 Timer Pump Y - Maximum OFF cycle time 2 minutes
for Pump Y
B21 CTV - Counter Pump Z - Maximum 6
number of cycles for pump Z (NaOH)
B24 CTV - Counter Pump Y - Maximum 6
number of cycles for pump Y (HCHO)
B27 Timer Copper Alarm - Maximum ON for 10 minutes
Copper Pump
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These timer counters provide better process control by:
• When the SE-440A controller is first activated, no process replenishment will
be allowed until the titration system has had a chance to stabilize.
• During replenishment, the Y and Z pumps are cycled ON/OFF thus allowing
for process stabilization without overshooting the set point.
• Should replenishment times exceed a given number of cycles, an alarm will
sound indicating a possible problem.
Should the copper replenishment pump exceed a pre-set amount of time, it
will sound an alarm indicating a possible problem.
Any interruption of power to the controller causes timers and counters to reset.
Replenishment will be delayed for the preset interval.
Terminal Strip - The Terminal Strip is used to bring external wiring (i.e.
replenishment/sample pump/computer interface) into the controller.
Titration Pump Assembly - Brings reagents and sample into controller and mixes and
delivers them to pH sensors. (See Pump Plate Drawing Attachment 3 at end of this
manual).
PH Electrode Assembly - Two temperature-compensated, combination pH/ reference
electrodes in flow-through block.
7.3. REAGENT MAKE-UP
DI/THIO: Add 2 g of Thiourea (0.25 g/1 to poison the sample so that it will
not plate out inside the controller). Stir until all the Thiourea is
dissolved.
Acid: Use standard 0.1N HC1
Sodium Sulfite:
Sodium Sulfite solution should be made up fresh daily at
20 g/l.
Note: Sodium sulfite is a reagent in excess, and need not be
weighed to extreme accuracy.
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1. Multiply 20 g/1 by the volume (in liters) which you desire to make.
2. Weigh this amount of sodium sulfite, and put it into the container
labeled Sodium Sulfite.
3. Bring to volume with DI water.
4. Stir until all the sodium sulfite is dissolved.
Example:
Plant is only running one shift, and Sodium Sulfite must be made up fresh
daily.
Solution is consumed at 5 ml/min.
5 ml/min X 60 min/hr X 8 hr = 2400 ml
Make up 2 liters.
20g/1X21=40g
1. Weigh 40g of Sodium Sulfite ±2g.
2. Put this into the container labeled Sodium Sulfite.
3. Pour in 2 liters of DI water.
4. Stir until the Sodium Sulfite is completely dissolved.
7.4. CALIBRATION
7.4.1. Replenishment Pump
Since pumps of different types and manufacture differ in the manner in which they are
calibrated, this section will not attempt to discuss the mechanics of calibration, only the
general principles.
The SE-440A independently controls three channels (Cu, NaOH and HCHO), pump flow
ratios (from one to another) are not critical. If, however, there is more than one pump tied
to a channel, the flow ratio of one to the other is critical. Pumps should be set for 1½ to 2
times bath depletion rate.
Yield figures and ratios of one replenishment component to another are available on
product data sheets.
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Procedure:
1. Determine pump rate.
2. Set up pump in accordance with the manufacturer's instructions.
3. Prime the pump and fill the line with solution.
4. Fill an appropriately sized graduated cylinder with solution to be pumped.
5. With outlet side of pump connected to the system as it will be used, place inlet tube
(complete with foot valve if any) in cylinder.
6. Pump for a given time period.
7. Read volume in cylinder. Subtract from full volume.
8. Divide Volume difference by time to get the rate.
9. Adjust pump and repeat steps 4 thru 8 until desired rate is obtained.
10. Replace inlet tube in replenisher drum. Calibration is complete.
7.4.2. Signet Controller
pH CHANNEL
When power is first applied to the unit, it will display pH and temperature.
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STANDARDIZATION OF pH ELECTRODE (Should be performed biweekly.)
1. Turn the sample pump off.
2. Into a clean 250 ml beaker pour approximately 100 ml of pH 7.00 buffer
solution.
3. Remove the pH electrode from the titration block and thoroughly rinse it
with TAP water. Blot dry (do not wipe) with a lab tissue.
4. Place the electrode and the thermometer into the pH 7 buffer solution
and allow it to stabilize for 1 to 2 minutes. If pH is ± .1 and the
temperature is within 2 degrees, no adjustments are necessary.
5. Remove electrode and thermometer from buffer 7 solution. Rinse
electrode thoroughly with tap water and blot dry (do not wipe) with a lab
tissue.
6. Place the electrode into buffer 10 solution and allow it to stabilize for 1
to 2 minutes, to check the slope. Thermometer is not necessary. If within
± .1 units, then no adjustments are necessary.
CALIBRATION OF THE pH SENSOR
1. Turn the sample pump off.
2. Into a clean 250 ml beaker pour approximately 100 ml of pH 7.00 buffer
solution.
3. Remove the pH electrode from the titration block and thoroughly rinse it
with TAP water. Blot dry (do not wipe) with a lab tissue.
4. Place the electrode into the pH 7 buffer solution and allow it to stabilize
for 1 to 2 minutes.
5. Select menu directory by pressing the up arrow key once.
6. Press right arrow key once, arrow down to calibration. Hit enter.
7. The display will read:
8. Press arrow down key once. The display will read:
pH1 Cal at:
instrument
Set pH1 Std
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9. Press right arrow key once. Display will read:
10. Press UP arrow key three times, press DOWN arrow key once. Display
will read:
If not displaying 7.00, use the appropriate arrow keys to adjust the
reading to 7.00 on the display.
a. If mV is ±30 mV or greater, replace electrode.
b. Go back to step 5 and repeat calibration.
Press enter to save the entry.
11. Press arrow down key once. Display will read:
Remove electrode from buffer 7.00. Clean with DI water and immerse
electrode into pH 10.00 buffer solution. Allow to stabilize (1-2 min.) Press
right arrow key once. pH value will flash.
If not displaying 10.00 use the appropriate arrow keys to adjust the reading
to 10.00 on the display. Press enter to save the entry.
12. Press arrow down key once. Display will read:
Use a separate thermometer to determine the buffer solution. Once the
temperature is determined press the right arrow key, input thermometer
value, hit enter and return the electrode to the “T” fixture. Quick press the up
and down arrow keys simultaneously twice to return to the “view” mode.
Enter password
Set pH1
standard (pH value
flashing)
Set pH1 Slope
Set Temp T1
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ENTERING ALARMS & SET POINTS
The Signet 8900 contains four 120 VAC 5 amp relays which are used for RLY 1, RLY 2,
RLY 3 and RLY 4 functions.
Set points are entered as follows.
Relay Caustic Formaldehyde
Relay 1 is low
Set relay 1 10.20 10.20
Set HYS 1 00.02 00.02
Relay 2 in high
Set relay 2 11.00 (11.00+)
Set HYS 2 00.02 00.02
Relay 3 is low
Set relay 3 09.40 09.40
Set HYS 3 00.02 00.02
Relay 4 is high
Set relay 4 09.80 11.00
Set HYS 4 00.02 00.02
1. Select UP arrow key, menu directory will appear.
2. Press right arrow key.
3. Arrow DOWN to RELAY, press enter.
4. Press enter to select, RELAY 1 SOURCE pH 1 will display.
5. Depress DOWN arrow to display RELAY 1 MODE: LOW. Depress right arrow key
and enter password (up arrow 3 times, down arrow once.) Press enter.
6. Arrow DOWN to RELAY1 SET POINT. To modify RELAY 1 SET POINT, depress
right arrow key, first digit will start flashing. Use right arrow key and UP and DOWN
arrow keys to make changes. Hit enter to save new settings.
7. Depress DOWN arrow to RELAY 1 HYS. Depress right arrow key, first digit will
start flashing. Hysteresis is set at the factory at 00.02. Hit enter to save setting.
8. Depress DOWN arrow key to RELAY 2 SET POINT. To change value, press right
arrow key. Use right arrow and up and down arrow keys to change values. Press enter
to save new set point for relay 2.
9. Press DOWN arrow key to RELAY 2 HYS. Hysteresis is set at 00.02. Hit enter to
save.
10. Repeat steps 1-9 for relay 3 and relay 4.
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7.4.3. Copper Controller Calibration
SET POINT
Before calibrating Cu, adjust bath to desired concentration, insure that there is solution flow
through the SE-413A.
1. Adjust fine calibration knob to 5.0 on the dial.
2. Turn Main Power Switch to ON position. This will cause the entire display on the
Process controller to activate momentarily. The millivolt output of the sensor will
then be displayed.
3. Coarse Adjustment:
4. Adjust the coarse potentiometer knob until the mV reading is as close to 250 mV as
possible (Turning CCW will decrease the signal; CW will increase the signal).
5. Fine Adjustment:
6. Adjust Fine Calibration Knob to 250 mV.
ALARM CIRCUIT
The Process Controller has the ability to turn on an alarm whenever the mV reading
deviates from set point by a predetermined amount. This amount is preset at 30mV, but
may be changed if desired. As delivered, when the mV reading deviates ±30mV from set
point, the alarm circuitry will activate, causing the ALM1 to display on the front panel.
NOTE: Except to change the alarm values, there should be no necessity to put the controller
into SET-UP Mode, since all other parameters are preset by S-Systems.
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SET-UP MODE
PUT THE CONTROLLER INTO SET-UP MODE
1. Depress and SCROLL and LOWER buttons simultaneously and release.
2. To return the controller back to normal display, press up and down keys at the same
time.
ADJUSTING A PARAMETER IN THE USER MODE
3. Press and hold SCROLL button for 3 sec. Use SCROLL button to step through
its sequence of displays. Each display will show the value of the selected
parameter in the lower display and the legend which identifies that parameter in
the upper display. To change a value, push either up or down while the value is
being displayed. The values which have been preset by S-Systems appear below.
NOTE: The Instrument continues to function as a controller when it is in Set-up
Mode.
PRESET FUNCTION VALUES-COPPER CONTROLLER
PARAMETERS LEGEND RANGE VALUES
Band Alarm Value A1DV 0 to span from Set Point 30
PV1 Shift (Offset)
Value SHiF -3600 to 3600 0
Proportional band PB1 0 to 500 mV 5
Integral Time Constant TI1 0 sec to 1000 sec 300
Derivative Time
Constant TD1 00 sec to 360 sec 00
Output PL1 0 - 100% 100
Set point high and low limit may be used to lock in a desired set point, i.e., if you
had a set point of 260 mV you could set your low limit to 259 mV and your high
limit to 261 mV. No other set point could be entered other than 260 by the
operator. Must be in Set up Menu.
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7.4.4 FMI Titration Pumps
A timer is provided in the upper right corner of the front cover of the controller. This timer
is used to accurately "time" the operation of the titration pumps. By placing the "discharge"
tube from one of the pumps into a graduated cylinder and running the pump (one minute
for example), the flow rate of the pump can accurately be determined.
(See Attachment # 14 for a Detailed Procedure)
7.4.5 Timer/ Counter Settings
All timer and counter settings are adjusted through the Logo PLC located inside the controller
cabinet.
Procedure for changing Timer and Counter Values
l. Power is turned on and Logo is in RUN position.
2. Hit ESC. Display will read:
3. "Set Clock" and "Set Parameters" appears.
4. Hit down arrow to set parameters - hit OK.
Stop
Set Param
Set Clock
Prs name
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5. B1:T appears
6. To change values hit OK.
7. The first digit will flash - use UP or DOWN arrow to change values.
8. Use the RIGHT arrow to move the cursor.
9. When the new value is entered hit OK.
10. Hit the UP arrow to move to the next Timer parameter. Repeat step #4.
11. When finished setting parameters hit ESC twice. This will bring you back into
RUN mode
NOTE: You cannot change the units (seconds, minutes, hours) in this setup.
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7.5. OPERATION OF THE PLC
This section describes the basic operation of the PLC and how it controls the pumps and
timers. Even when operating pumps in a manual mode, the actual output of the pump is
controlled by the PLC therefore, you will see the pumps cycle ON and OFF. Operating in
manual mode, simply overrides the input signals from the controller and allows the
operator to make adds to the work tank. The PLC however, still controls the add and
provides an alarm if the pre-set number of add cycles is exceeded. This alarm requires
operator intervention and therefore minimizing the possibility of an over add.
Operation of the PLC is fully automatic and requires no operator interface.
Making replenishment adds of NaOH or HCHO:
l. A manual add can be made from the SE440 A controller when the three position
switch labeled "NaOH or HCHO" is in the manual position. This will start the
PLC ON-OFF cycle for the appropriate pump(s).
Turn the switch back to the auto position after making the add. Do not leave this
switch in the manual position, otherwise adds will repeat until Alarm
Counter counts out.
2. An add can be made from the SE-440A controller when the three position switch
labeled "NaOH or HCHO" is in the auto position. The output from the Signet pH
controllers will start the PLC ON-OFF cycle for the appropriate pump(s).
Typical operation of the PLC program for a NaOH add:
1. The PLC receives a signal from the Signet pH controller or the manual switch and
starts the add cycle:
A. Starts the NaOH Pump ON Timer
B. Starts the maximum counter
C. Turns on the NaOH pump
D. Count one to maximum count
2. When the NaOH Pump ON Timer times out:
A. Resets the NaOH Pump ON Timer
B. Turns off the NaOH pump
C. Turns on the Pump OFF Timer
3. When the NaOH Pump OFF Timer times out:
SE-440A - Technical Manual
Page 27
A. Resets Pump Off Timer
B. The cycle counter is incremented by 1
C. One add cycle is complete
4. Steps 1, 2, 3 will continue until a pH of 10.2 is reached or a maximum of cycle
counts is reached.
5. If the cycle counter reaches its maximum preset count and the bath has not reached its set
point, the NaOH pilot light and the audible alarm will indicate a failure and no more
adds can be made.
A. Check pH controller on SE-440A.
B. If pH is low, trouble shoot the SE-440A controller.
C. Check replenishment chemicals levels - a manual add may be required.
D. Turn NaOH selector switch to the OFF position to reset the alarm circuit.
Notes:
When corrections are made, make sure the selector switch is in the Auto position.
The counters are set for a maximum of 5 adds: When the signal from the pH controller or
manual switch turns OFF, counter will reset.
The function of the Pump OFF timer is to allow time for the replenishment add to mix in the
work tank and for the SE-440A controller to detect any change in the NaOH concentration.
This provides a more uniform process control.
If the counter reaches its maximum count, the system will stop making adds and will go
into NaOH maximum count alarm.
Making replenishment adds to the copper:
A manual add can be made directly from the SE-440A controller. The CU selector switch, must
be turned to the manual position and A-R-C selector switches in the auto position. Be sure to turn
the CU switch back to the auto position after making the add.
Do not leave this switch in the manual position. Pumps will stay ON until timer in PLC
times out and an alarm activated.
An add can be made from the Copper controller if the CU selector switch and the A-R-C selector
switches are in the auto position. The output from the CU controller will start the following
sequence.
SE-440A - Technical Manual
Page 28
1. The PLC receives a signal from the Copper controller:
A. Start CU maximum ON timer
B. Turns on CU pumps
2. When signal from the CU controller turns OFF it resets the CU maximum ON timer
alarm (Q8).
3. If the pre set time for the maximum ON timer is exceeded the alarm turn ON and
turns OFF CU pumps.
Although not necessary for the operation of the SE-440A, a copy of the PLC logic is
provided in Attachment 15.
7.6. START-UP PROCEDURE
CAUTION: DO NOT START SYSTEM UNTIL ALL OPERATING PARAMETERS ARE
IN RANGE (CU / NaOH / HCHO) ON THE SE-440A CONTROLLER
Before the operation of your SE-440A can begin, the PLC must be in the "RUN" mode.
Once the system has been up and running, this is the default mode and you should not
have to make any adjustments. However, should you try to start the controller and
"nothing happens", you need to check the status of the PLC. Follow this simple
procedure.
Make sure the power to the controller is ON.
Open the front door and observer the PLC display.
If the display indicates RUN, all is OK with the PLC.
If the PLC display indicates NO PROGRAM - contact S-Systems.
If the main menu is displayed: (see below)
SE-440A - Technical Manual
Page 29
Do the following:
A. Press the down arrow until the arrow indicates "START"
B. Press the OK button
C. The PLC should now be in the RUN mode.
1. Fill reagent tanks with fresh reagents.
2. Place reagent lines into reagent tanks. #1 - DI water/Thio, #2 - sodium sulfite,
#3 - Acid (0. 1N HCl).
3. Turn replenishment pump switches (NaOH, HCHO, Cu, A, R, & C) to AUTO
position.
4. Turn reagent pump switch to AUTO and MTRl and MTR2 switches to ON
(up).
5. Turn ON the valve on the SE-413A marked "Sample".
6. Turn Replenishment pump switches to the Auto Position.
7. Turn the power switch on controller face to ON position. An adjustable (0 -1
hour) time delay (TD1) will start. This will allow the reagents and copper sample
to enter the system and stabilize. The replenishment pumps will not be activated
until the delay startup timer times out. Set at factory 15 min.
8. Check set points on Signet Controllers.
SE-440A - Technical Manual
Page 30
7.7. SHUTDOWN PROCEDURE
1. Turn replenishment switches to OFF (NaOH, HCHO, Cu, A, R, & C).
2. Turn titration pumps switches to the OFF (MTR1 & MTR2).
3. Turn sample IN valve OFF and TAP water valve ON (SE-413A). This will
flush out the SE-413A with TAP water (10 second will be enough).
4. Remove sulfite tube from reagent tank and put into TAP water reagent tank.
Do not remove DI/Thio or acid tube from reagent tank. This will extend the
life of the electrode when controller is not in use.
5. Set pump calibration time for 10.00 minutes. (Auto shut off)
6. Turn titration pumps ON (MTRl & MTR2).
7. Turn the titration pump switch to "Time".
8. Wait 10 minutes for system to flush out completely.
9. Turn Controller Power switch OFF. Turn all other switches to OFF.
NOTE: Never shut down system for extended periods of time (in excess of 4 hours)
without flushing out pumps. Never run titration pumps dry.
SE-440A - Technical Manual
Page 31
8. PREVENTIVE MAINTENANCE
8.1. PREVENTIVE MAINTENANCE
Maintenance Schedule
DAILY
Check reagent tank level every shift. Approximate operating time from full to
empty is 36 hours. Sodium sulfite must be made up fresh daily.
Check water and reagent tanks for algae and/or dirt. Clean and refill if necessary.
Flush out titration system with city water during shutdown. (Unless particularly
dirty, city water is preferred since it has less propensity to develop algae.)
NOTE: This instruction is for nightly shutdown. For short periods such as
power outages etc., this process is not necessary.
WEEKLY
Run stripping etch through sample loop with titration pump switch ON. This process
is most easily carried out while stripping the work tank. If work tank is not stripped at
least once a week, however, stripping etch should be made up and run through the
Sample Block. If plate-out is noted in between stripping times, strip immediately.
Flush with water for 6.6 minutes (follow procedure in 6.6).
When stripping, do the following:
1. Turn Off the replenishment pumps.
2. Place all reagent lines in TAP water source.
3. Allow stripping solution (from the tank or a separate container) to flow
through the SE-413A IN LINE CELL and through the pumps. Be sure to
clean ALL the Sample Lines.
Sample valve on SE-413A should be OPEN.
TAP water valve on SE-413A should be CLOSED.
4. When all copper residue has been removed, place sample line and
reagent lines in TAP water and flush thoroughly (See Section 6.6).
Sample valve on SE-413A should be CLOSED.
TAP water valve on SE-413A should be OPEN.
SE-440A - Technical Manual
Page 32
BIWEEKLY
Standardize electrodes. Refer to standardization and sloping procedure for
information.
8.2. TITRATION PUMP
The FMI titration pumps supplied with the SE-440A controller are very precise
metering pumps which under normal operation should give many years of service. The
key element in insuring maximum life out of your FMI pump is to keep it clean. Daily
flushing with fresh TAP water (at shut down) is the single most important maintenance
step.
Should any problem be suspected with any of the FMI pumps, first check the titration
pump troubleshooting guide, then consult the FMI manual in the vendor data section at
the end of this manual for disassembly and repair procedures.
8.3. TROUBLESHOOTING
The following trouble shooting guides are provided at the end of this section.
TS-1 Channel - Copper
TS-2 Channel - Caustic
TS-3 Channel - Formaldehyde
TS-4 Pump - Titration
TS-5 Alarms
SE-440A - Technical Manual
Page 33
TS-1 CHANNEL - COPPER
Problem
Probable Cause
Corrective Action
Bath being controlled at
other than desired C
concentration
Bath color changed as
function of age
Adjust bath to desired
concentration and recalibrate
controller
Millivolt meter reads 0
regardless of calibration
adjustment
Light bulb in cell failure
Replace bulb
Photocell short or open
circuit
Repair circuit or replace
photocell
Plate-out on optics
Strip plate-out with stripping
etch
Millivolt meter reads off
scale regardless of
calibration adjustment
Copper cell not filled with
solution due to sample flow
blockage or leak
Remove obstruction or repair
leak
Calibration circuit open due
to potentiometer failure
Replace potentiometer.
Millivolt level fluctuating
greatly
Air bubbles between optics
Reposition probe to less
turbulent area, or use flow-
through cell with cross flow
filter if necessary. Repair.
Loose electrical
connections. Power
supply damaged
Replace power supply.
Investigate cause. (usually
solution leakage into
electrical enclosure of probe
or cell causing short across
light bulb circuit)
Photo cell Replace
SE-440A - Technical Manual
Page 34
TS-2 CHANNEL - CAUSTIC
Problem
Probable Cause Corrective Action
Bath being controlled below
the desired caustic
concentration
Acid 1 reagent tank empty
Refill tank
Blockage in Acid line (usually
indicated by air bubbles
introduced at acid pump)
Remove obstruction
Acid pump pumping air (no
obstruction in line) or leaking
Replace pump seals
pH electrode characteristic
change Standardize with pH 7.0 buffer,
slope to pH 10 with pH 10.0
buffer
Reagent pumps incorrect flow rates
Calibrate and read just flow
rates
Bath being controlled above
the desired caustic
concentration
Blockage in sample stream
(usually plate-out at sample
intake to controller)
Remove obstruction.
If plate-out, run stripping etch
through controller until
completely stripped Air being pulled through seals
of sample titration pump (No
blockage in line.)
Replace pump seals
pH electrode characteristic
change
Standardize with pH 7.0 buffer,
slope to pH 10 with pH 10
buffer
Reagent pumps incorrectly
flow rates
Calibrate and readjust flow
rates
Controller unable to control
bath
Faulty pH electrode Replace pH electrode
Ground fault Find and repair
SE-440A - Technical Manual
Page 35
TS-3 CHANNEL -FORMALDEHYDE
Problem Probable Cause Corrective Action
Bath being controlled
below the desired
formaldehyde
concentration
Caustic channel malfunction Measure pH of effluent from
caustic channel on lab meter.
If significantly different from
reading on controller,
troubleshooting caustic
channel
Acid reagent tank empty Refill tan
Blockage in acid line Remove obstruction
Acid pump pumping air
(no line blockage)
Replace pumps seals
pH electrode characteristic Standardize with pH 7.0
buffer, slope to pH 10 with
pH 10 buffer.
Reagent pumps
incorrect flow rates
Calibrate and readjust
flow rates
Bath being controlled above
the desired formaldehyde
concentration
Caustic channel
malfunction
Measure pH of effluent from
caustic channel on lab meter. If
significantly different from
reading on controller,
troubleshoot caustic channel
Sulfite reagent tank
empty Refill tank with freshly
made sulfite solution
Sulfite solution old (degraded) Discard and refill tank with
freshly made sulfite solution
Blockage in sulfite line Remove obstruction
Sulfite pump pumping
air (NO blockage inline) Replace pump seals
(cont.)
SE-440A - Technical Manual
Page 36
Problem Probable Cause Corrective Action
Bath being controlled above
the desired formaldehyde
concentration (continued)
pH electrode characteristic
change
Standardize with pH 7.0 buffer,
slope to pH 10 with pH 10 buffer
Ground fault Find and repair
Reagent pumps
incorrect flow rates
Calibrate and readjust
flow rates
Once reagent pump flow rates are set, they do not change unless someone changes them. For
example: inadvertently turning the dial while changing seals. For this reason, DO NOT
touch the pumps unless all else has failed.
SE-440A - Technical Manual
Page 37
TS-4 PUMP - TITRATION
Problem Probable Cause Corrective Action
All pumps don't turn Pump Switch OFF Turn Switch ON
Drive Chain Broken Repair or Replace Chain
Pump Motor Inoperative Replace Motor
Pump Frozen Check sulfite pump first.
Clean/replace
One pump doesn't turn Drive gear slipping Tighten set screw on Drive
Gear
Pump leaks solution Worn seals Replace Seals
Pump leaks air Seal problem Reset Seals
if problem
continues
Replace Seals
Pump runs backwards Failure of sample
pump motor starting
capacitor
Replace capacitor
SE-440A - Technical Manual
Page 38
TS-5 ALARMS
The following list eight different alarm conditions and suggested responses.
1. NaOH maximum count alarm:
a. check replenishment pump
b. check sample line
c. check pH sensor, motors, pumps, and tubing inside controller
d. check pH controller
2. NaOH Lo alarm:
a. check replenishment pump
b. check sample line
c. check pH sensor, motors, pumps, and tubing inside controller
d. check pH controller
3. NaOH Hi alarm:
a. check replenishment pump
b. check sample line
c. check pH sensor, motors, pumps, and tubing inside controller
d. check pH controller
4. HcHo maximum count alarm:
a. check replenishment pump
b. check sample line
c. check pH sensor, motors, pumps, and tubing inside controller
d. check pH controller
5. HcHo Lo alarm:
a. check replenishment pump b. check sample line
c. check pH sensor, motors, pumps, and tubing inside controller
d. check pH controller
6. HcHo Hi alarm:
a. check replenishment pumps
b. check reagent tank
c. check pH sensor, motors, pumps, and tubing inside controller
d. check pH controller
7. Copper maximum time alarm:
a. check replenishment pump
b. check sample line
c. check in-line cell (bulb, photocell)
d. check calibration on copper controller (coarse and fine adjustment)
SE-440A - Technical Manual
Page 39
8. Copper out of range alarm:
a. check replenishment pump
b. check sample line
c. check in-line cell (bulb, photocell)
d. check calibration on copper controller (coarse and fine adjustment)
SE-440A - Technical Manual
Page 40
8.4. RECOMMENDED SPARE PARTS
Part Number Quantity Description
76429 1 Mixing Coil - 17 Turn
76432 1 Mixing Coil - 10 Turn
76441 1 Titration Pump
75696 5 Tubing Connector
75697 5 Female Luer
*76111 1 25 m motor 120 V
77219 1 Replacement pH sensor
77218 1 Pre-Amplifier
75700 2 Lamp 13 volt
75860 1 10 turn dial
75859 1 1K calibration potentiometer
75714 1 20 K calibration potentiometer
75723 1 Lamp holder
75300 1 Photo Cell
75573 1 Piston Assembly. For Titration Pump
75583 10 Lip Seals for RH1CKC-LF 76441
75530 2 "O" ring for pH sensor
* Note: For 220V, use P/N 76110 – 25 RPM Motor
SE-440A - Technical Manual
Page 41
9. LIMITED WARRANTY STATEMENT
S-Systems warrants equipment of its manufacture to be free from defects in workmanship
and material for thirty days -- parts and labor, and for ninety days -- parts only, from date of
delivery under normal use and service when such equipment is used in accordance with
instructions furnished and for the purpose for which the equipment was designed. The
liability of S-Systems, under this warranty, shall be limited to the replacement or repair of
any defective equipment or part. Replaceable elastomeric parts are expendable and are not
covered by warranty either expressed or implied.
THERE ARE NO OTHER WARRANTIES CREATED HEREBY OR ARISING WITH
RESPECT TO THE SAME EITHER EXPRESSED OR IMPLIED INCLUDING,
WITHOUT LIMITATION, WARRANTIES AS TO DESCRIPTION, QUALITY,
MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR
ANY OTHER MATTER.
Under no circumstances shall S-Systems be liable to the buyer or any third party for any
loss of profits or other direct or indirect cost, expense, losses or consequential damages
arising out of or as a result of any defects in or failure of its products or any part or parts
thereof.
SE-440A - Technical Manual
Page 42
10. ATTACHMENTS:
10.1. Front Cover
10.2. SE-413A In Line Cell
10.3. Pump Plate
10.4. Pump Plate - Rear View
10.5. Terminal Strip
10.6. Titration Flow
10.7. Electrical Back Plate
10.8. pH Controller (Relay) Set Up
10.9. Calibration/ Conversion Tables
10.10. Electrical Schematic
10.11. Installation of pH Sensor
10.12. Procedure for Calibration of FMI Pumps
10.13. SE-440A Logo Logic
SE-440A - Technical Manual
10.1 Front Cover
Attachment 1 - Page 1
6 4
10
5
2 2
3
13
2
3
13
2
13
3
10
5
2
10
5
2
10
5
2
8
6
1
8 7
6
2
14
6 9 11 12 9
SE-440A - Technical Manual
10.1 Parts List for Front Cover
Attachment 1 - Page 2
ITEM QTY DESCRIPTION P/N
75024 (120 VAC)
75035 (220 VAC)
1 1 1 Timer 75515
2 16 16 Contact Block N/O 77003
3 3 3 3-Position Switch 77000
4 1 1 Push Button 77946
5 4 4 2-Position Switch 77001
6 8 8 Alarm Light 28 VDC 75507
7 1 0 mV Controller FDC 8300 (93 volts) 75867
8 2 0 pH Controller 77226
9 2 2 10 turn dial 75860
10 4 0 Light Module Green 120 V 77006
0 4 Light Module Green 240V 77004
11 1 1 1K Pot 75859
12 1 1 20K Pot 75714
13 3 3 Light Module Green 24V DC 77005
14 1 1 3 Position Switch non Illuminated 77002
SE-440A - Technical Manual
10.2 SE-413A In-Line Cell
Attachment 2 - Page 1
(Mounted on the left hand side of the Controller)
ITEM QTY DESCRIPTION P/N
1 2 1/4" LABCOCK 75596
2 4 AMP PIN 75783
3 1 RECEPTACLE 75782
4 1 LAMP HOLDER 75723
5 1 PHOTO CELL 75300
6 1 BULB 13 VDC 75700
7 1 Plug 75777
8 1 Plug 75778
9 4 Pin 75779
10 1 4 Conductor Cable -16 inches 75763
11 2 Glass Rods 75818
12 1 Teflon Block 75410
13 2 Glass Rod Fittings 75305
14 1 Strain Relief 75780
15 1 Sonar Alert 120V 75686
16 1 Sonar Alert 220V 75691
NOTICE: When flushing; Turn "Sample IN" valve OFF and "TAP WATER IN"
valve ON. Allow water to flow for 5 to 10 seconds.
12
2
3
15
11
13
14
10
1
4
5
6
7
8
9
SE-440A - Technical Manual
10.3 Pump Plate
Attachment 3 - Page1
SE-440A - Technical Manual
10.3 Parts List for Pump Plate
Attachment 3 - Page 2
ITEM QTY DESCRIPTION P/N
1 4 Titration Pump RHICKC-LF 76441
2 1 Titration Pump RHOCKC-LF 76440
3 1 10 Turn mixing coil 76432
4 1 17 Turn mixing coil 76429
5 2 Pre Amp 77218
6 2 pH Sensor 77219
7 1 Male hose barb 77173
8 2 25 rpm motor - 120 VAC 76111
25 rpm motor - 220 VAC 76110
9 1 Titration Block 75450
11 13 Male Luer 75696
12 19 Female Luer 1/4-28 75697
13 7 Male Luer 3/32 ED 77172
14 2 Tubing Tee 77192
15 14' Tubing 3/32 ID 77177
16 3' Tubing 1/8 ID 75559
SE-440A - Technical Manual
10.4 Pump Plate - Rear View
Attachment 4 - Page 1
ITEM QTY P/N
1 14EM31S-13 4 76104
2 14EM31S-16 1 76630
3 14EM95S-44 1 76633
4 14EM95S-48 1 76631
5 RC14SS-CHAIN 1 76107
6 RC14SS-CL LINK 2 76108
5
6
1
1
3
6
4
1
1
2
5
SE-440A - Technical Manual
10.5 Terminal Strip
Attachment 5 - Page 1
Item Description Qty
1 75771 End Clamp 2
2 75766 GF6B End Barrier 1
3 75768 Terminal Black 30
4 75770 Rail 9 in. 1
5 75823 Two Tier Block 5
6 77216 GF6 Fuse Holder 1
7 75765 BAF 10A Fuse 1
SE-440A - Technical Manual
10.6 Titration Flow
Attachment 6 - Page 1
Was
te
SE-440A - Technical Manual
10.7 Electrical Back Plate
Attachment 7 - Page 1
ITEM QTY DESCRIPTION P/N
1 4 Relay Base 75745
2 1 Relay Base 75879
3 1 Relay Base 77933
*4 2 Relay 120 V 75746
5 2 Relay 1 Pole 24 VDC 75822
6 1 Relay 4 Pole 24 VDC 77928
7 2 Relay 2 Pole 24 VDC 77920
8 2 Toggle Switch 75831
9 1 Power Supply 75760
10 1 Power Supply Logo 24V 2.5_A 77950
11 1 Logo 24L PLC 77949
12 1 I/O expanded 24L PLC 77948
*For 220V system, use relay 75744
1
4
2
5
3
6
1
7 7
1
5
2 8
4
1
9
10 11 12
SE-440A - Technical Manual
10.8 - pH Controller (Relay) Set Up
Attachment 8 - Page 1
Relay Caustic Formaldehyde
Relay 1 is low
Set relay 1 10.20 10.20
Set HYS 1 00.02 00.02
Relay 2 in high
Set relay 2 11.00 (11.00+)
Set HYS 2 00.02 00.02
Relay 3 is low
Set relay 3 09.40 09.40
Set HYS 3 00.02 00.02
Relay 4 is high
Set relay 4 09.80 11.00
Set HYS 4 00.02 00.02
SE-440A - Technical Manual
10.9 Calibration/Conversion Tables
Attachment 9 - Page 1
NaOH
Acid Pump
HCHO
Acid Pump
Pump
mls g/1
NaOH
Pump
mls g/1
HCHO
4.4 7.04 1.7 2.04
4.5 7.20 1.8 2.16
4.6 7.36 1.9 2.28
4.7 7.52 2.0 2.40
4.8 7.68 2.1 2.52
4.9 7.84 2.2 2.64
5.0 8.00 2.3 2.76
5.1 8.16 2.4 2.88
5.2 8.32 2.5 3.0
5.3 8.48 2.6 3.12
5.4 8.64 2.7 3.24
5.5 8.80 2.8 3.36
5.6 8.96 2.9 3.48
3.0 3.60
3.1 3.72
3.2 3.84
3.3 3.96
SE-440A - Technical Manual
10.10 Electrical Schematic
Attachment 10 - Page 1
SE-440A - Technical Manual
10.10 Electrical Schematic
Attachment 10 - Page 2
S-Systems
Norwood, MA
Tel. 781-762-7726
SE-440A Controller
SE-440A - Technical Manual
10.11 - Installation of pH Sensor
Attachment 11 - Page 1
pH Sensor Installation
Removal from block:
• pH sensor is not fastened or connected to the block - therefore no tools are required.
• Holding the block with one hand and the sensor with the other, turn the sensor 1/4 to 1/2 turns to the right while pulling straight back.
• Stop when the 'O' ring enters the drain chamber.
• Wait until the solution drains from the block - drain line is clear.
• Continue turning the sensor to the right and pull Slowly (More solution may flow out).
Installation of sensor:
Push sensor fully into the block and turn 1/4 turn to the right. This will seat the
electrode.
Replacing the sensor:
• Remove the sensor (with preamp) from the block.
• Twist counter clockwise until alignment marks are aligned.
• Pull preamp and sensor apart.
• Reverse procedure to install the new sensor:
016 EPDM 0-
Ring (75530)
Titration Block
SE-440A - Technical Manual
10.12 Procedure for Calibration of FMI Pumps
Attachment 12 - Page 1
Factory Settings:
The DI/Thio, Sample, and Sulfite pumps are factory set and do not need calibration except
when replacing. Normal calibration of the SE-440A is accomplished using the - NaOH and
HCHO pumps.
Factory Setting: NaOH - 5.1 ml/min @ 8.16 g/l
HCHO - 2.8 ml/min @ 3.36 g/l
Before you start:
TURN OFF ALL REPLENISHMENT PUMPS.
TURN OFF THE SAMPLE VALVE TO THE SE-413A AND FLUSH WITH TAP
WATER.
Calibration Procedure:
1. Remove reagent lines from there respective tanks and place them in the TAP water
tank.
2. Remove the sample line from the inside of the controller cabinet (disconnect the luer
fitting); attach a "sample line"; and place in the TAP water tank.
3. Run all titration pumps for 3 minutes to completely flush the system.
4. Calibrate the DI/Thio pump and Sample pump.
NOTE: THE DI/THIO PUMP MUST BE CALIBRATED BEFORE THE
SAMPLE PUMP.
a. Set Pump Switches
Titration Pump to OFF
MTR-2 (Acid Sulfite Pump Motor) OFF.
MTR-1 (Sample/DI) ON
b. Set Calibration Timer to 1 to 3 minutes (See end of this procedure).
c. Remove luer fitting from the pump to be calibrated and connect the
calibration tub and burette.
d. Read the level of solution in the burette (if no solution, run the pump until the line
is purged and some solution is in the bottom of the burette).
e. Switch the calibration timer to "time" position.
f. When the timer is complete, the pump will turn OFF - read the solution level in
the burette. The Titration Pump Switch must be turned OFF to reset the timer.
SE-440A - Technical Manual
10.12 Procedure for Calibration of FMI Pumps
Attachment 12 - Page 2
g. The difference divided by the time is the pumps calibration rate.
h. Adjust the pump (up or down) and re-test until the proper calibration rate is reached.
i. Repeat calibration procedure for the Sample pump.
5. Calibrate Acid and Sulfite Pumps.
a. Set Pump Switches
Titration Pump to OFF
MTR-2 (Acid Sulfite Pump Motor) ON.
MTR-1 (Sample/DI) OFF
b. Set Calibration Timer to 1 to 3 minutes (See end of this procedure).
c. Read the level of solution in the burette (if no solution, run the pump until the line is
purged and some solution is in the bottom of the burette).
d. Switch the calibration timer to "time" position.
e. When the timer is complete, the pump will turn OFF - read the solution level in the
burette. The Titration Pump Switch must be turned OFF to reset the timer.
f. The difference divided by the time is the pumps calibration rate.
g. Adjust the pump (up or down) and re-test until the proper calibration rate is reached.
h. Repeat calibration procedure for the remainder of the pumps.
6. When calibration is complete, return all pump tubing to its original position and follow the
normal start up procedures to run the controller.
SE-440A - Technical Manual
10.12 Procedure for Calibration of FMI Pumps
Attachment 12 - Page 3
To Set the Timer:
1. Turn the Titration Pump Timer switch OFF.
2. Press "Set" button.
3. Set each digit one at a time using the small button below the display.
4. Press the "Enter" button.
To Calibrate, You Need:
Burette
Sample Line
Calibration Line
Reminder!
When calibration is complete; MTR switches must be ON and the Titration
Pump Switch in Auto to run the controller.
SE-440A - Technical Manual
10.13 SE-440A Logo Logic
Attachment 13 - Page 1
SE-440A LOGO LOGIC
SE-440A - Technical Manual
10.13 SE-440A Logo Logic
Attachment 13 - Page 2
SE-440A LOGO LOGIC