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Chemtrac SCC3500XRD Operation Manual Download Page 10

Chemtrac Systems, Inc.

 

 

 

 

Page 9

 

DURA-TRAC II SENSOR

DURA-TRAC SENSOR OR DURA-TRAC SENSOR WITH FLUSH

PATENTED                                                                                                MADE IN U.S.A.

DURA-TRAC    II

CHEMTRAC

SYSTEMS, INC.

TM

SYSTEMS, INC.

PATENTED                                                                     MADE IN U.S.A.

DURA-TRAC 

TM

CHEMTRAC

Diag.

Alarm

Power

Service

SYSTEMS, INC.

CHEMTRAC

MANUAL

OPERATOR

SYSTEMS, INC.

PATENTED                                                                     MADE IN U.S.A.

DURA-TRAC 

T M

CHEMTRAC

MONITOR/CONTROLLER

SCC3500XRD

SEMSOR MAINTENANCE MODULE

 

 

FIGURE 2.  System Components 

1.4 

SYSTEM COMPONENTS 

 

The SCM2500XRD and SCC3500XRD system include the following: 

q

 

Monitor/Controller 

q

 

Dura-Trac Remote Sensor 

q

 

Dura-Trac Remote Sensor with Flush (Optional) 

q

 

Dura-Trac II Remote Sensor (Optional) 

q

 

Sensor Maintenance Module (Optional) 

 

Figure 2 illustrates system components. 

 

Summary of Contents for SCC3500XRD

Page 1: ...OPERATIONS MANUAL Streaming Current Monitor Streaming Current Controller with Dura Trac Remote Sensor R 4 8 2 06 RA SCM2500XRD SCC3500XRD ...

Page 2: ......

Page 3: ...2500XRD Main Screen 20 3 2 2 SCM2500XRD Setup Menu 1 21 3 2 3 SCM2500XRD Setup Menu 2 22 3 2 4 SCM2500XRD Alarm Status Menu 23 3 2 5 SCM2500XRD Flush Control Menu 24 3 3 SCC3500XRD Readout Menus and Controls 24 3 3 1 SCC3500XRD Main Screen 24 3 3 2 SCC3500XRD Setup Menus 25 3 3 3 SCC3500XRD Alarm Status Menu 26 3 3 4 SCC3500XRD Pump Control 1 Menu 27 3 3 5 SCC3500XRD Pump Control 2 Menu 29 3 3 6 S...

Page 4: ...er Wiring 13 5 Dura TRAC II Sensor Power Wiring 13 6 Signal Wires Interconnection Diagram 14 7 Dura TRAC Sensor Sample Connection 15 8 Dura TRAC II Sensor Sample Connection 16 9 Dura TRAC Sensor with Flush 17 10 SMM Tubing Connections to Dura Trac II Sensor 18 11 Automatic Flush Timing Diagram 33 12 Dura Trac Sensor Parts Identification 49 13 Dura Trac II Sensor Parts Identification 50 14 Streamin...

Page 5: ...low these precautions could result in personal injury or damage to the equipment R Do not attempt to disassemble the unit R Water must not be allowed to enter the housing of the unit R Close and fasten the covers of the unit prior to any external cleaning to prevent water ingress R Do not drop or jar the unit R Do not modify any internal electrical wiring or electronics R Use a mild non abrasive c...

Page 6: ...roper installation operation or maintenance of equipment 2 Abnormal wear and tear on moving parts caused by some processes 3 Acts of nature i e lightning etc This warranty represents the exclusive remedy of damage or failure of equipment In no event shall Chemtrac Systems Inc be liable for any special incidental or consequential damage such as loss of production or profits Should you experience tr...

Page 7: ...gs therefore Section 1 2 should be read very carefully 1 2 SELECTING PROPER SAMPLE POINT The sample must be taken at a point where uniform distribution and mixing of coagulant is obtained for all flow rate conditions and at a point that allows for a quick response to chemical feed changes as measured by the monitor i e after the rapid mixer or static mixer and before the slow mixer or flocculation...

Page 8: ...monitor reading in the positive direction even though the coagulant dosage PPM remains constant Conversely if raw water or sample flow rate is decreased streaming current readings may go more negative Plants that have a shifting set point caused by wide swings in raw water flows can minimize this effect by moving the sample point further downstream lengthening sample line or adding a detention pot...

Page 9: ...mps must be kept in good mechanical condition to respond quickly and accurately to process changes 5 Raw water quality should be in a stable condition turbidity pH color etc should not change rapidly or widely when setting up the system The monitor should be operated a few days in manual control to observe how it responds to normal process operation Recording streaming current changes on a strip c...

Page 10: ...CHEMTRAC MANUAL OPERATOR SYSTEMS INC PATENTED MADE IN U S A DURA TRAC TM CHEMTRAC MONITOR CONTROLLER SCC3500XRD SEMSOR MAINTENANCE MODULE FIGURE 2 System Components 1 4 SYSTEM COMPONENTS The SCM2500XRD and SCC3500XRD system include the following q Monitor Controller q Dura Trac Remote Sensor q Dura Trac Remote Sensor with Flush Optional q Dura Trac II Remote Sensor Optional q Sensor Maintenance Mo...

Page 11: ...e NEMA 250 Type 4X Reinforced Fiberglass Enclosure Size 9 2 W 11 2 H 6 3 D 234mm W 285mm H 161mm D Mounting Holes 11 25 W 7 4 H 286mm W 188mm H Weight 6 Pounds 2 72 kg Control Output Alarms Adjustable High Low Alarms Operating Temperature 32 F to 120 F 0 C to 49 C Following Parameter are for SCC3500XRD Only PID Tuning Parameters Proportional Gain Range 0 1000 Integral Time Range 0 1000 PID Rate Ra...

Page 12: ...er Sample Connections Inlet 3 4 O D Barb Type Outlet 1 1 2 O D Materials Contacting Sample Delrin Nylon Neoprene Viton PVC Stainless Steel Output Wiring 4 Conductors Twisted Shielded Pair 20 AWG 6 Conductors Twisted Shielded Pair with Flush Option Enclosure Type NEMA 250 Type 4X Reinforced Fiberglass Enclosure Size 11 2 W 9 2 H 6 3 D 285mm W 234 mm H 161mm D Overall Height with Sensor 18 8 477mm w...

Page 13: ...ll as easy access to the front panel menu keys See Mounting Dimension Diagrams at end of Manual 2 2 POWER REQUIREMENT Electrical power should be connected in the following order R Insert the ground wire into the middle terminal labeled G R Insert the hot wire into the left terminal labeled L R Insert the neutral wire into the right terminal labeled N For safety and proper operation the monitor mus...

Page 14: ...Vdc Gnd 2 Probe 6 11 9 10 12 8 7 Opto O Opto W Opto B Cond Probe High L1 N FIGURE 5 Dura TRAC II Sensor Power Wiring Probe 6 5 4 3 Probe Shield Signal Opto 1 24 Vdc Vdc Gnd 2 L1 N 11 9 10 12 8 7 Opto O Opto W Opto B Cond High FIGURE 4 Dura Trac Sensor Power Wiring ...

Page 15: ...S R Make sure the monitor s power switch is turn to off position before making any signal wiring connections BLACK 24 Vdc 1 RED Opto W 10 Shield Signal Signal Vdc Gnd 5 4 3 2 Opto O Probe Probe Opto B 6 8 7 9 WHITE BLUE WARNING TURN POWER OFF BEFORE MAKING ANY WIRE CONNECTIONS TO AVOID DAMAGING THE ELECTRONIC CIRCUIT 3 SMM Sensor 4 6 5 7 8 1 2 11 14 13 12 15 16 1 9 10 3 2 4 8 6 5 7 19 9 20 12 11 1...

Page 16: ...e outlet is free of obstructions Continuous reliability of the sample flow is essential Interruption of the sample flow will result in erroneous readings on the Monitor Controller For Controller model SCC3500XRD operating in AUTO mode loss of flow to the Dura Trac sensor will result in improper coagulant dosing A suitable flow alarm is recommended for maximum reliability IMPORTANT On the SCC3500XR...

Page 17: ... water supply If potable water is used for flush water a backflow prevention device should be installed on the flush water line to prevent contamination of the potable water source The flush water needs to maintain a pressure of 35 PSI min to 80 PSI max 2 5 1 Dura Trac with Flush Connect the male NPT end of the MNPT to Quick Connect Tube adapter fitting supplied with the unit to the flush water su...

Page 18: ...er supply 1 4 Quick Connect Tube adapter fitting and the SMM s flush water inlet quick connect fitting A manual control valve should be installed on the flush water line in close proximity of the unit so that the flush water may be shut off during sensor maintenance Do not open flush water supply valve until all connections have been made w Connect an appropriate length of semi rigid Teflon tubing...

Page 19: ...n During the automatic flush cleaning cycle the chemical pump injects a cleaning solution into the sensor This cleaning solution prevents the buildup of fouling agents which can overtime affect the sensitivity and response of the instrument Periodic checks of the chemical carboy should be made to ensure the chemical storage tank is at least 1 4 full CAUTIONS R Acid concentration shall not exceed 1...

Page 20: ...tons at the front panel The following steps explain general menu navigations 1 From the MAIN screen pressing any function key will gain access to other menu screens 2 At the menu screen on the far left hand side of the text there is a text cursor that indicates the active line on the menu By pressing the p or q key the text cursor will move to a different menu text line 3 To modify the parameter s...

Page 21: ...feature the menu display the time when the next flush will occur in days hours and minutes x Zero Offset Conditions Offset OUT Offset condition OUT actual SCV is display Offset IN Offset condition IN adjusted SCV is displayed and the actual SCV value will be display to the right of OUT Offset Value 1000 to 1000 The Offset function is used to automatically zero the current reading Once an optimum c...

Page 22: ... to from OUT to IN will automatically zero or null the current Streaming Current reading For example if the current reading was 150 and the Zero Offset was changed to IN then the adjusted Streaming Current value is displayed on the Main Screen would be zero The reading will not stay exactly at zero since the reading is always slightly changing as a result of slight changes in charge The Offset val...

Page 23: ... value should be set to correlate to a reading which indicates an over dosage of chemical z SCV AO Scale The analog output s scaling of the streaming current value can be set for 1000 750 500 or 250 This setting allows the analog output to change based on different scale settings MAIN Function Key Pressing this key will ignore any setting modifications on this screen and brings up the MAIN screen ...

Page 24: ...er cause can be found for the diagnostic alarm A loose connection or a terminal that is screwed down on the insulation of the wire instead of the wire itself can cause the diagnostic alarm to activate v SCV Lo Low The SCV Lo Alarm indicates that the SCV fall below the SCV Lo Alarm threshold w SCV Hi Low The SCV Hi Alarm indicates that the SCV rises above the SCV Hi Alarm threshold x Dry Contact Di...

Page 25: ...mits A Lo Alarm signify an underfeed of chemical even possible loss of chemical feed and a Hi Alarm signify an overfeed 3 2 5 SCM2500SRD Flush Control Menu This flush feature is an option that is available for the SCM2500XRD see Section 3 3 7 for detail description 3 3 SCC3500XRD READOUT MENUS AND CONTROLS The menu system for the SCC3500XRD is simple to navigate below you will find the different s...

Page 26: ...lections accesses the functions within that menu Special Function Key For the coagulant pump control mode the control mode can be toggled between AUTO and MAN by pressing both q and p keys at the same time When AUTO is present the instrument is operating in automatic mode sending a control signal to the coagulant pump When MAN is present the instrument is operating in manual mode sending a control...

Page 27: ... the diagnostic alarm A loose connection or a terminal that is screwed down on the insulation of the wire instead of the wire itself can cause the diagnostic alarm to activate v SCV Lo Low The SCV Lo Alarm indicates that the SCV fall below the SCV Lo Alarm threshold w SCV Hi Low The SCV Hi Alarm indicates that the SCV rises above the SCV Hi Alarm threshold x Pump Output Lo Low The Pump Output Lo A...

Page 28: ... Lo Alarm will signify an underfeed of chemical even possible loss of chemical feed and a Hi Alarm will signify an overfeed 3 3 4 SCC3500XRD Pump Control 1 Menu From the MAIN screen press CTRL function key the PUMP CONTROL 1 Menu screen will display There are PUMP CONTROL 1 PUMP CONTROL 2 and FLOW CONTROL 3 menus under CTRL function key Use up or down arrow key to navigate between menus Within the...

Page 29: ...value can be changed from 1 to 1000 at 1 unit increment by pressing the p or q key see Section 3 7 for determine the optimum setting y Integral Time The Integral Time setting determines how much adjustment is made to the pump output while the SCV is away from the setpoint The Integral Time value can be changed from 1 to 1000 at 1 unit increment by pressing the p or q key see Section 3 7 for determ...

Page 30: ...the p or q key The low alarm percent value can be changed from 0 to 100 at 0 1 increment When the pump control output signal fall below the low alarm value alarm condition will occur x Output Hi The pump output limit define the high alarm value of the pump control output signal The low alarm percent value can be increased or decreased by pressing the p or q key The high alarm percent value can be ...

Page 31: ... up to 60 maximum and down to 50 minimum The SCV control band percent value can be increased or decreased by pressing the p or q key The SCV control band percent value can be changed from 0 to 100 at 0 1 increment w Flow Min Minimum process flow in percent set for the produce the minimum pump control output for the parameter below Pump Output Min The percent value can be increased or decreased by ...

Page 32: ...de activated v Flush Time The flush time period setting determines how often the flushing will take place when the Auto Flush is set to ENABLED There are two parameters on this menu line that can be modified number 1 to 99 at 1 unit increment and number s unit DAY HRS or MIN To modify the first parameter setting number press the u key to gain access to the parameter and then press the p or q key t...

Page 33: ...trol and Data Acquisition SCADA or Distributed Control Systems DCS For this reason the Hold feature has been provided and must be properly set to avoid the flushing sequence from interfering with Automatic Chemical feed control The Output of the monitor is automatically held stable during the flush however the operator must determine the Hold duration after the flush is finished To determine the p...

Page 34: ...l SCC3500XRD enter the Control menu to manually adjust chemical feed For each dosage change the reading should respond by changing 20 to 50 SCV units If the response is less than 20 units increase the gain Likewise if the response is greater than 50 units it is recommended to decrease the gain especially if the monitor is to be used for automatic chemical feed control Next a test should be perform...

Page 35: ...setpoint and not the offset function Eventually a new setpoint might need to be established due to seasonal changes or large excursions in turbidity but under normal conditions the setpoint should not be changed on a daily or even weekly basis It is recommended to use the monitor for a few weeks in the Offset Out mode to become familiar with the operation and response of the unit 3 5 TREATMENT OPT...

Page 36: ... Key must be pressed to save current setting modifications and brings up the MAIN screen 3 7 AUTOMATIC CONTROL Only available on model SCC3500XRD Automatically controlling the treatment process with the Streaming Current Controller SCC3500XRD is a very simple operation once you know how the controller works Most controller manuals do not explain in simple terms the purpose of so called tuning cons...

Page 37: ...r in detail Proportional Band The proportional band constant setting is dependent upon the response of the controller or and also to some degree the lag time The more responsive the Controller and or the longer the lag time the higher the proportional band constant should be set Only through trial and error can any tuning constant be correctly established To test proportional band constant setting...

Page 38: ...nge the Integral Time constant setting accordingly PID Rate The PID Rate function serves to improve the controllers response when higher Proportional Band and Integral Time settings appear to still be too responsive for the application The PID Rate setting is usually left at 1 for most applications since proper setting of P Gain and Integral Time are capable of providing proper response Higher PID...

Page 39: ...trol is a feature that allows the Controller to perform coagulant pump control in the process that is varying their process flow During large process flow variation the PID control alone may not be able to response to the flow changes The Controller monitors the process flow and uses it in the flow control calculation The Controller is equipped with auxiliary analog input 4 20mA When the flow cont...

Page 40: ...by front panel keys Table below shows default PID Parameters preset by Chemtrac PID Tuning Parameters Default Setting Proportional Band 150 Integral Time 60 PID Rate 1 Experience has shown these values to be a good starting point for most applications However significant changes may be necessary to tune the controller to your specific operation ...

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Page 42: ...rs Increase in chlorine Downscale Excursions Streaming Current Value SCV goes more negative Caused by R Increase in pH R Increase in H20 flow R Increase in color R Increase in raw water turbidity R Increase in lime R Increase in caustic R Increase in anionic polymers R Decrease in aluminum sulfate or PAC R Decrease in cationic polymers R Decrease in chlorine Assumes that this is only parameter cha...

Page 43: ...ll the operators should become familiar with how to interpret the monitor reading If the reading moves in the negative direction from the setpoint as a result of an increase in turbidity the operator should manually increase the dosage to re establish the setpoint and feel free to run a Jar test to compare the results with Following this procedure and closely reviewing the monitor trends and respo...

Page 44: ... once every two years on average Once again to determine if the probe and piston need to be replaced simply make small chemical feed adjustments If the probe is unresponsive and cleaning does not improve the result the probe and piston most likely need to be replaced Having a new set on hand to compare against is the best method of determining if the parts need to be replaced The motor in the moni...

Page 45: ... of pouring raw water into the probe block to check the probes for wear can also be used to check the probe s response and or troubleshoot the system Many times when there is a problem associated with the monitor the operator will assume the instrument is at fault If the operator does not have an easy method of testing the monitor s functionality he will most likely not look for another cause A si...

Page 46: ...with change in coagulant dosage A GAIN setting too low B Wrong sample point or insufficient mixing C Sample cell dirty D Excessive lag time between coagulant injection point and sensor sample cell A Increase GAIN setting B Select correct sample point C Clean cell see Cleaning Procedures D Move sampling point closer to coagulant feed point and or decrease sample TRANSPORT time See Selecting Proper ...

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Page 48: ...ssary 6 Insert clean probe into cell housing 7 Slip retaining nut over probe lead wire and tighten onto probe Finger tight is adequate be careful to avoid cross threading the nut 8 Connect probe lead wire to side of enclosure 9 It may take several minutes for monitor readings to stabilize with a new probe Sensitivity to process changes may also be greater If the Offset is used the user must set th...

Page 49: ...ed for any contaminant Soak only long enough to dissolve remove the material Probe surfaces should be thoroughly washed with clean water to remove any residual cleaning compound CAUTIONS R Do not soak entire probe cartridge only soak inside the bore Acid concentration shall not exceed 15 concentration 6 3 REPLACEMENT PARTS Figure 12 AND 13 illustrates Dura Trac and Dura Trac II sensor parts identi...

Page 50: ... 1701 GUIDE 8711 110 CRANK ASSEMBLY 5302 MOUNTING NUT 1607 NEOPRENE WASHER 5016 YOKE 5710 ROD END 3707 YOKE PIN 5720 PROBE BLOCK 5622 3 4 BARB INLET 5021 DURA NUT 4200 4 40 SET SCREW MOTOR BRACKET 3311 WASHER 1608 6 32 SCREWS VITON SEAL 7701 OPTO SWITCH 1308 EXTENSION 5611 FIGURE 12 Dura Trac Sensor Parts Identification ...

Page 51: ...DURA NUT 4200 4 40 SET SCREWS 3 4 BARB INLET 5021 110V MOTOR 5470 DURA NUT 4200 NEOPRENE WASHER 5016 DOUBLE THICK VITON SEAL 7702 MOUNTING NUT 1607 MOTOR BRACKET 3311 YOKE PIN 5720 YOKE 5710 MOTOR CRANK 3300 ROD END 3707 6 32 SCREWS WASHER 1608 OPTO SWITCH 1308 WW EXTENSION 5611 FIGURE 13 Dura Trac II Sensor Parts Identification ...

Page 52: ...uld be included in your request Model number of your monitor part number s qty description of parts required and purchase order number Please contact Chemtrac for up to date pricing Parts order normally ship within 24 hours Chemtrac Systems Inc 6991 Peachtree Industrial Blvd Building 600 Norcross GA 30092 Phone 1 800 442 8722 Inside US only 770 449 6233 Fax 770 447 0889 Email sales chemtrac com We...

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Page 54: ...sions for Streaming Current Monitor Controller Dura Trac Sensor Dura Trac Sensor with Flush Dura Trac II Sensor and Sensor Maintenance Module 11 2 285mm 13 6 345mm 12 5 317mm 7 71 196mm CHEMTRAC SYSTEMS INC SCC3500XRD 9 2 234mm 7 7 196mm Service Alarm Power Diag 6 1 155mm 6 3 161mm FIGURE 14 Streaming Current Monitor Controller Dimensions ...

Page 55: ...RA TRAC II PATENTED MADE IN U S A CHEMTRAC SYSTEMS INC TM 6 3 161mm 18 8 477mm FIGURE 16 Dura Trac II Sensor Dimensions 14 7 373mm 8 5 215mm 7 2 183mm TM PATENTED MADE IN U S A DURA TRAC 9 2 234mm 7 7 196mm CHEMTRAC SYSTEMS INC 5 3 135mm FIGURE 15 Dura Trac Sensor Dimensions ...

Page 56: ...Chemtrac Systems Inc Page 55 17 6 447mm 8 5 215mm 5 3 135mm 7 2 183mm PATENTED MADE IN U S A DURA TRAC TM 9 2 234mm 7 7 196mm SYSTEMS INC CHEMTRAC FIGURE 17 Dura Trac Sensor with Flush Dimensions ...

Page 57: ... 11 2 285mm 6 3 161mm 9 2 234mm 10 5 266mm FIGURE 19 SMM Dimensions 9 7 247mm 11 2 285mm PATENTED MADE IN U S A SYSTEMS INC CHEMTRAC 6 3 161mm DURA TRAC II TM 21 8 554mm 9 2 234mm 10 5 266mm FIGURE 18 Dura Trac II Sensor with SMM Dimensions ...

Page 58: ...0 streaming current value The two analog outputs are provided to allow the customer to monitor the SCV Signal and Offset value remotely The explanation of the Offset mode and Offset value are described in Section 3 2 2 SCM2500XRD Setup Menu 1 WARNING TURN POWER OFF BEFORE MAKING ANY WIRE CONNECTIONS TO AVOID DAMAGING THE ELECTRONIC CIRCUIT 3 SMM Sensor 4 6 5 7 8 1 2 11 14 13 12 15 16 1 9 10 3 2 4 ...

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