Metafix rev.2 pH Control Operation & Service Manual

pH Control rev.2

August 2004

Operation & Service Manual

Part No. 2011

Rev. 2.0h

Copyright Notice and Disclaimer

Copyright Notice

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopied, recorded or otherwise without the prior written permission of Metafix, Inc. No liability is assumed with respect to the use of the information contained, neither is any liability assumed for damages resulting from the use of the information contained herein.

Disclaimer and Limitation of Liability

Metafix, Inc. shall not be liable to the purchaser of this product or third parties for damages, losses, costs, or expenses incurred by the purchaser or third parties as a result of: accident, misuse, or abuse of this product or unauthorized modifications, repairs, or alterations to this product.

Metafix, Inc. shall not be liable against any damages or problems arising from the use of any options or any consumable products other than those designated as original Metafix products. pH Control is a registered trademarks of Metafix, Inc.

© 2004 by Metafix, Inc.

Metafix pH Control Manual Page i

Table of Contents

Page ii

1. Health and Safety ...............................................................................................................1

2. Introduction

Your pH Control ...........................................................................................................2

Features and Benefits ...................................................................................................2

3. pH Control Components

1. Rear View: Parts Identification.............................................................................3

2. Front View: Parts Identification ...........................................................................4

3. Power Supply View: Parts Identification............................................................5

4. Preparing for Installation

Essential Steps ...............................................................................................................6

5. Installing your pH Control

1. Typical Plumbing Installation................................................................................7

2. Installation Procedures .....................................................................................8-10

3. Set Up Procedures ............................................................................................11-12

6. Operating Cycle................................................................................................................13

7. Software Overview

Scripting Levels .....................................................................................................14-21

8. Download Capability.......................................................................................................22

9. Upgrade Software (windows)

Hardware and Software requirements ....................................................................23

Preparing pH Control to receive a new software..................................................23

Preparing Computer to transfer new software to pH Control............................23

Transferring new program to pH Control ..............................................................24

10. Maintaining your pH Control

1. Probe Calibration...................................................................................................25

2. Cleaning the Spill Sensor......................................................................................25

3. Cleaning Developer Tank.....................................................................................25

11. Troubleshooting

Service Messages, Causes and Solutions ..........................................................26-28

12. Parts List, Technical Specifications & Dimensions

1. Parts List .................................................................................................................29

2. Technical Specifications ........................................................................................30

3. Dimensions.............................................................................................................31

13. Glossary of Terms.......................................................................................................... 32

14. Sales, Service, and Support...........................................................................................33

Metafix pH Control Manual

1

1 Health and Safety

Always wear gloves, protective glasses, and a lab coat while performing any maintenance or installation procedures.

Do not open the pH Control when it is plugged in.

Do not stack heavy objects on the pH Control.

Do not attempt to service the unit, or tighten the sensors.

Make sure that the power source is within the unit’s allowable range.

Do not place the pH Control in an area where it will be exposed to extreme temperatures.

Keep the pH Control in a dry and well ventilated area.

Clean the pH Control using a soft cloth or sponge. Avoid using abrasive materials or cleansers on the unit’s surface.

Metafix pH Control Manual Page 1

2 Introduction

Your pH Control

How to best treat Computer to Plate (CTP) waste? Until now, the only viable option has been hauling, which is expensive, requires storage, handling and ultimately only transfers the problem elsewhere. Today, Metafix offers the first real alternative: The Metafix CTP-pH-Control System R2. This is not just a machine, it’s a waste management/tracking system that manages and monitors CTP effluent allowing generators to discharge all types of CTP effluent including negative and positive, thermal, photo-polymer and violet plate effluent ON SITE.

2

The Metafix CTP-pH-Control system collects, measures and neutralizes the pH levels of all CTP waste effluent using a specially formulated neutralizing agent, Meta-Aid. After neutralization the effluent is safely discharged on site. It’s fully automatic so there's no handling, no storage, and no hauling of waste chemicals.

Each CTP-pH-Control installation is tracked in our MetaTrax (Environmental Management System) database.

Quarterly we issue Volume reports, Incident Reports and Sample Discharge results, all soon to be available online. As part of our integrated MetaTrax Service Plan, Metafix will monitor your system, keeping track of consumables and maintenance making sure the Metafix CTP-pH-Control system is working as hard as you are.

Don’t pay for promises, pay for results.

B

A. Water tank

B. pH

C.

D.

Neutralizer

Developer tank

C

Features and Benefits

A D

Page 2

• Controls and tracks the flow of all solutions via a programmable monitoring and metering system -

Simple and accountable effluent management.

• Small footprint - only 4.0 sq. ft.

• Eliminates costly haul-away costs.

• Eliminates storage and manifesting of hazardous chemicals — all effluent is managed and discharged on-site.

• Toll-free hotline delivers instant access to manufacturer direct service/support team.

• Stylish and Innovative industrial design – Looks as good as it works

• Fast treatment cycle – Keeps up with large processing volumes

• Large holding tanks – Holds all processor maintenance dumps – No jugs

• Sample ports – Easy to take samples

• Modular components – Easy to service and maintain

• Peristaltic Pumps – Reliable “clog-free” operation

• Quick release connectors – Easy Maintenance and Service

• Key operation alarms – Alert operators to any errors

• Operation log – Software retains Date/ Time log of all operation

• Easy to understand interactive display and keyboard

• Robust Industrial Grade pH Probe – Accurate pH readings

• Network communication port – RS-232 or IP Enabled Monitoring


3

3 pH Control Components

1 Rear View: Parts Identification

5 6

4

3

7

8

Diagram 3.1

11 12 13

14

2

1

9

10

Item

1 Developer overflows from processor

2 External input jack

3 City Water Inlet

4 Developer Inlet from Tank

5 Spill sensor

6 Water Inlet from Tank

7 Treated effluent to drain

8 Safety overflow

9 Water overflow from processor

10 Overflow to drain

11 Developer Tank outlet & External Wand

12 LS1

13 LS2

14 LS3


Function

Receives waste developer from processor.

Connects Dev & Water tank level sensors to the power supply.

The city water line inlet.

Receives developer from Developer Tank.

Place spill sensor near drain to alarm any leaks.

Receives water from Water Tank.

Carries treated effluent to drain (closed drain).

Discharges to safety jug in case of a reaction tank overflow.

Receives water from processor.

Discharge water to drain in case Water Tank overflows.

Carries developer to reaction tank.

Activates pH Control to begin a batch.

Indicates a developer tank overflow.

Indicates a water tank overflow.

Page 3


2 Front View: Parts Identification

7 8 9

6

5

4

3

10

11

Diagram 3.2

12

3

13

2

1

14

Item

7

8

5

6

3

4

1

2

Water Tank

Water pump

Sample pump

Mixing Pump

Reaction Tank

Sample Pump pH Probe

Developer pump

9

Neutralizer pump

10

Power Supply

11 Solenoid valve

12

Neutralizer

13

Sample pump

14

Developer tank

Page 4

Function

Collects water overflow from processor.

Pumps water from the Water Tank to reaction tank (not shown).

Allow user to take water samples from Water Tank.

Mixes the Developer, Wash water and Neutralizer together (not shown).

Developer, Wash water and Neutralizer are mixed together.

Allow user to take samples from reaction tank.

Measures pH of chemistry.

Pumps developer from the developer tank to reaction tank.

Pumps neutralizer to reaction tank.

Provides the unit with electrical power and controls all functions.

Provides city water to rinse pH Probe.

Neutralizes chemistry.

Allows user to take samples from developer tank.

Collects developer overflow from processor.


3


3 Power Supply View: Parts Identification

15

13

14

10 11 12

Diagram 3.3

Diagram 3.4

16

17

Item

1 Off

2

Hold

3

On

4

Left arrow

5 Menu

6 Right arrow

7 No

8 Reset

9 Yes

10 Cancel

11 Exit

12 Enter

13 Grenn LED’s

14 Red LED’s

15 LCD Display

16 pH Probe

17 RS 232


Function

Turns power supply Off.

Pauses the pH Control during normal operation.

Turn power supply On.

Allows user to scroll backwards thru menu.

Allows user to access the scripting level.

Allows user to scroll forward thru menu.

Indicating No to commands in Scripting mode.

Allows user to stop the current process, reset alarms and reinitialize unit.

Indicating Yes to commands in Scripting mode.

When entering setting, press cancel to exit.

Exit the Scripting mode.

When entering a value, press enter to accept.

Indicates output status

Indicates input status

Displays information on the unit’s status and functions.

pH probe connection to power supply.

Connect computer to download history of pH Control or upgrade software.

Page 5

4 Preparing for Installation

1 Essential Steps

Instructions

A

Power outlet within 4 feet of pH Control.

B

Install a city water line equipped with a shut-off valve, and a MGHT spout. The water line must be installed one meter above the floor, and within one meter of the pH Control to ensure a consistent flow of water to the unit. The allowable water pressure range is 25 to 80 PSI. A backflow preventer may be required by local plumbing codes (part No. 101-404).

C

The "Outlet to Drain" to be preferably hard plumbed to the drain by installing a dishwasher “Y” above the P-Trap on the drain pipe, minimum hose size 5/8" i.d. (16mm).

Make sure the pH Control is within 10 feet of the drain.

D

It is strongly recommended that you connect the “Safety Overflow to Drain” to a suitable sized container.

4

Note: All installations must be performed in accordance with local plumbing codes.

A

Diagram 4.1

B

C

D

Page 6 Metafix pH Control Manual

5 Installing your pH Control

1 Typical Plumbing Installation

Diagram 5.1

5

8A

10A

6B

5C

6A

10B

1B

1C

12A

5B

2A

7

3B

3A

2B



2 Installation Procedures

The following instructions will guide you through installing your pH Control.

Note: All connections involve using plastic tubing, must be secured with firmly tightened clamps. Remember to keep tubing runs as short as possible.

Instructions

1

2

Processor overflows

To drain

A. Position the pH Control Dev/Waste water tank as close as possible to the drain and water line.

B. Install 3/4" swivel fitting to "Dev Overflow from processor" of Developer Tank.

5

C. Using 3/4" I.D. tubing, connect the plate processor developer tank to pH Control dev. tank.

A. Assemble developer bypass and install inline.

B. Using 3/4" I.D. tubing, connect the bypass to drain.

To pH Control

Page 8

3

4

A. Connect the plate processor water tank to pH

Control water tank labeled “Water Overflow from

Processor”.

B. Install tubing to pH Control’s water tank labeled

“Water Overflow to drain”. Connect the other end to drain.

A. Lift tank cover and place water pump in water tank.

B. Put water pump tubing and wiring through top of tank. Keep tubing and wiring on opposite side of level sensor protection bar. Place cover back on tank.




5

A. Place pH Control on Developer tank.

B. Connect Water pump tubing to “Water Inlet from

Tank” of pH Control.

C. Connect Water pump power cord to power supply (plug located under power supply).

5

6

A. Connect the red 3/8" I.D. wand on Developer

Tank to "Developer Inlet from tank" of pH

Control.

B. Connect “Safety Overflow to Drain” of pH

Control to drain, or to safety jug (not included) next to dev tank.

7

Connect the braided 5/8” female swivel tubing to pH

Control “Treated effluent to drain”. Connect the other end of the braided tubing to the drain. If you installed a dishwasher “Y” to the drain, make sure the tubing is clamped.

8


A. Connect the "Washing Machine Hose" to "City water Inlet" of pH Control. Then, connect other end of "Washing Machine Hose" to city water line.

B. Place the yellow "Do not turn water valve off" tag on the city water line shut-off valve.

Page 9



9

A. Place Neutralizer wand in Neutralizer jug. Place the Neutralizer jug in pH Control.

B. Connect wand tubing to “Neutralizer inlet from tank”.

C. Connect wand wiring to LS4 connector.

A. Connect the puck assembly to “Spill Detector”.

Place puck next to drain.

B. Place “phone” jack through back of pH Control and connect to “External input box”.

5

Page 10

12

Connect pH probe to side of power supply labeled

“pH Probe”. Then carefully remove the black cap on the probe. Place the probe in Reaction tank. Retain black cap for possible future use.

Note: The pH probe must always be submerged in liquid.

If the pH control must be turned Off for more than two days, use the Force Rinse feature (refer to the software overview section) to rinse the pH probe. Pour storage solution for pH electrodes in black cap and then place on pH probe.

A. Plug power cord to power supply, then into a stable power source.

B. Turn ON the city water valve.

C. If the LCD is OFF, press the ON key.


5


3 Set Up Procedures

Verify level sensors:

Lift each of the six level sensors individually. The corresponding power supply LED turns On.

LS1: Dev Tank

LS2: Dev Tank

LS3: Dev Tank

LS4: Neutralizer Wand assembly

LS5: Reaction Tank

LS6: Reaction Tank

3 on

1 off

3 on

1 off

5 menu

6

x 4

6

9 yes

x 6

TL00000 TN00000

<- - - - >

Manual Control?

<- - - - >

Mixer Pump

OFF ON

Rinse Probe

OFF ON

Rinse Probe

OFF 59 ON

Rinse Probe

OFF ON

Rinse pH Probe:

•Press

5 menu key to enter scripting level. The total liters

(TL) and total neutralizer (TN) will appear.

•Press

6

appear. key four times. Manual Mode screen will

•Press

9 yes

key to enter the Manual mode.

•Press

6

appear.

key 6 times. Rinse probe screen will

•Press

3 on key to Rinse Probe for 10 seconds.

•Press

1 off key to turn Off Rinse Probe.

4

Neutra Pump

OFF ON

Neutra Pump

OFF ON

Neutra Pump

OFF ON

Prime Neutralizer pump:

4

•Press key, Neutra Pump will appear.

•Press

3 on key to turn On Neutralizer pump until you start to see Neutralizer in reaction tank.

•Press 1 off key to turn Off Neutralizer pump.

16

4

3 on

1 off


Dev Pump

OFF ON

Dev Pump

OFF ON

Dev Pump

OFF ON

Prime Developer pump:

4

•Press key, Dev Pump will appear.

•Press

3 on key to turn On Developer pump until you start to see Developer in reaction tank.

•Press

1 off key to turn Off Developer pump

.

Page 11


3 Set Up Procedures

4

17

Water Pump

OFF ON

Water Pump

OFF ON

3 on

1 off

0 exit

Water Pump

OFF ON

TL 00000 pH 8.0

TN 00000 Waiting

Prime Water pump:

4

•Press key, Water Pump will appear.

•Press

3 on key to turn On Water pump until you start to see Water in reaction tank.

•Press

1 off key to turn Off Water pump.

•Press

0 exit key to return to main menu.

18

LS1 LS2 LS3

First batch:

A.Fill water tank until it activates level sensor 3

(LS3).

B.Fill dev tank with about 1/2” of water.

C.Lift LS1 to start a batch. Wait until batch is completed. The unit will display “Waiting Dev Water”.

5


6

6 Operating Cycle

Power On

Model Name

pH Control

Meta Rev. 2.0

Software Revision Number

Serial number

Total Developer count in Liters

Soft. 2.0h

NUU12345678-90

TL000000_pH 7.3

TN000000 Waiting

pH reading

Total Neutralizer count in Liters

1

The unit is between operating cycles

TL000000_pH 7.3

TN000000 Waiting

The pH Control begins its operating cycle by collecting spent developer, and wash water from the photo processor. The spent developer and wash water are drawn into the pH Control's developer and water tanks via the “Developer Overflow from

Processor”, and the “Water Overflow from processor”.

2

FILLING

REACTION TANK

When the level of effluent in the developer tank reaches LS1

(Level Sensor 1) and water reached LS3, the pH Control begins pumping developer and wash water into its reaction tank until operating level is reached (LS5). The combined developer and water is 12.5 liters (1 liter developer, 11.5 liters water).

3

4

READING PH

PH 8.6

The mixer pump will turn On and pH is read.

ADDING

NEUTRALIZER

If pH is not at pre set target, Neutralizer will be pumped to reaction tank in small doses until the target pH is reached without exceeding “Maximum Neutralizer” setting. Once correct pH is reached, the pH Control begins emptying Reaction tank.

5

RINSING PROBE


At the end of each batch the probe is rinsed for 5 seconds.

Page 13

7 Software Overview

Scripting Levels

The pH Control scripting levels provides a means of adjusting the unit’s internal settings. To access the Scripting Level, press the Menu key. Press the Exit key to return to main menu.

TL 00000 pH 7.5

TN00000 Waiting

5 menu

Level 1

TL00000 TN00000

<- - - ->

7 no

Total Liters (TL) of chemistry treated and

Total Neutralizer (TL) used.

Level 2

Level 3

7 no

External Wand ?

<- - - ->

9 yes

External Wand will

Transfer-In developer into reaction tank when enabled.

7

Download Record ?

<- - - ->

7 no

9 yes

See

Page

22

Using Wand

Disable Enable

# enter

Level 4

7 no

Set Parameters ?

<- - - ->

9 yes

See

Page

15

Level 5

7 no

Manual Control ?

<- - - ->

9 yes

See

Page

17

Level 6

7 no

pH Probe Serv> ?

<- - - ->

9 yes

See

Page

18

Level 7

7 no

PWP Settings ?

<- - - ->

9 yes

See

Page

19

Level 8

7 no

(00000) (00000)

<- - - ->

9 yes

Non resetable total liter and total Neutralizer count.

Level 9

7 no

System Status ?

<- - - ->

9 yes

See

Page

21


7 Software Overview

Scripting Levels

Level 4

Set Parameters ?

<- - - ->

9 yes

7 no

1 Date & Time ?

<- - - ->

9 yes

MM DD YY HH MM

07 18 04 21 : 32

A cursor will appear under the selection to be altered. Enter the desired value and press

ENTER to advance cursor to next value.

# enter

7

7 no

2 Control Type ?

<- - - ->

9 yes

System Control

PROBE RATIO

User can determine if unit will be Probe or

4

Ratio driven. Press

6

key to select PROBE or key for RATIO.

# enter

3 Chk pH Probe ?

<- - - ->

7 no

9 yes

Water Probe Chk

Disable Enable

When Enable is selected, an alarm will ring if pH of city water is outside the 6 to 10 range.

# enter

4 pH LOW alarm ?

<- - - ->

7 no

9 yes pH LOW 6.0

(4.0 to 6.5)

Determines the level upon which the Low pH

Alarm is set to. It could be set between 4.0 to 6.5.

# enter


5 pH HIGH alarm ?

<- - - ->

7 no

9 yes pH HIGH 10.0

(09.8 to 11.5)

Determines the level upon which the High pH

Alarm is set to. It could be set between 9.8 to 11.5.

See

Page

16

# enter

Page 15

7 Software Overview

Scripting Levels

Level 4

Cont’d

7 no

6 pH Target ?

<- - - ->

9 yes pH Target 8.5

(7.0 to 9.8)

Determines pH level chemistry will be discharged at. pH could be set between 7.0 to 9.8.

7 no

Probe Driven

7 Max. Neutra. ?

<- - - ->

Ratio Driven

Set Neutra Use ?

<- - - ->

9 yes

Max Neutra 150

(30 to 500 ml)

9 yes

Set. Neutra 150

(30 to 500 ml)

Maximum Neutralizer when treating a batch.

Page 16

# enter

# enter

# enter

7 no

8 Set IP Local ?

<- - - ->

9 yes

IP Address LOCAL

000.000.000.000

pH Control units equipped with network capability can enter the IP address.

# enter

7 no

9 Set FTP Port ?

<- - - ->

9 yes

FTP Port = _

FTP Port enables communication with Metafix server.

# enter

7 no

10 Drain Time ?

<- - - ->

9 yes

Drain Time 053

(40 to 120)

(40

The amount of seconds Enviro Jet will turn On when draining the Reaction tank.

# enter

7 no

11 Soak Cycle ?

<- - - ->

9 yes

Soak Mode

Disable Enable

If Soak Cycle is Enable, and pH Control goes to Waiting Dev mode, the reaction tank will fill with water upto LS5. When the level of effluent in the developer tank reaches LS1, the Mixing pump will empty the reaction tank and begin a normal operating cycle.

# enter

7 no

12 Extra Rinse?

<- - - ->

9 yes

Extra Rinse

Disable Enable

# enter

0 exit

To be used when extra rinsing capacity to the probe is needed. Factory set is Disable.

Beginning of Set

Will return to main menu


7

7

7 Software Overview

Scripting Levels

Level 5

9 yes

Manual Control ?

<- - - ->

Mixer Pump?

OFF ON

6

3 on

Mixer Pump?

OFF 59 ON

Diverter Valve?

OFF ON

6

3 on

Drain R. Tank

OFF ON

6

Water Pump

OFF ON

6

Dev Pump

OFF ON

6

Neutra Pump

OFF ON

6

3 on

3 on

3 on

3 on

Diverter Valve?

OFF 59 ON

Drain R. Tank?

OFF 59 ON

Water Pump?

OFF 59 ON

Dev Pump?

OFF 59 ON

Neutra Pump?

OFF 59 ON

Press

3 on key to activate Mixer Pump.

Pump will turn ON for 60 seconds or press

1 off key to turn Off. Press

6

key to advance to next screen.

Press

3 on key to activate Diverter

Valve. Diverter valve will turn ON for 60 seconds or press

1 off key to turn Off. Press key to advance to next screen.

6

Press

3 on key to drain reaction tank.

Reaction tank will drain for 60 seconds or press


6

to next screen.

key to advance

Press

3 on key to activate Water pump.

Water pump will turn ON for 60 seconds or press

1 off key to turn Off. Press advance to next screen.

6

key to

Press

3 on key to activate developer pump. Dev pump will turn ON for 60 seconds or press


6

key to

Press

3 on key to activate Neutralizer pump. Neutralizer pump will turn ON for 60 seconds or press

1 off key to turn Off. Press key to advance to next screen.

6

See

Page

18


7 Software Overview

Scripting Levels

Level 5 Cont’d

Rinse Probe

OFF ON

6

3 on

Rinse Probe?

OFF 59 ON

Output Pump

OFF ON

6

3 on

6

Aux. Output 120

OFF ON

0 exit

3 on

Beginning of Manual

Control


Output Pump?

OFF 59 ON

Aux. OUTPUT 120?

OFF 59 ON

Press

3 on key to rinse probe. Probe will be rinsed for 60 seconds or press

1 off key to turn

Off. Press

6

key to advance to next screen.

Press

3 on key to activate output pump.

Output pump will turn ON for 60 seconds or press


6

key to

Press

3 on key to activate aux output.

Aux. output will be turned ON for 60 seconds or press


6

key to

7

Level 6

6 pH Probe Serv> ?

<- - - ->

9 yes pH = 7.5

Cal to 7? Y or N

9 yes

Displays the present pH.

If the pH is below 6.6 or above 7.4 calibrate the probe.

Remove the probe from the reaction tank and put in buffer

7.0 solution. Press the

9 yes

key to calibrate the probe.

See

Page

19


7 Software Overview

Scripting Level

Level 7

PWP Settings?

<- - - ->

9 yes

# enter

Enter Password

-

7

A cursor will appear to enter password.

Press

# enter key once password is entered.

7 no

Set Dev Counter ?

<- - - ->

9 yes

Dev Counter

00000


ENTER once completed.

# enter

7 no

Set Neu Counter ?

<- - - ->

9 yes

Neut Counter

00000


ENTER once completed.

# enter

7 no

Instal. Date ?

<- - - ->

9 yes

Instal. MM DD YYY

Date 00 / 00 / 00


ENTER to advance cursor to next value.

# enter

7 no

Reset Record?

<- - - ->

9 yes

Clear Record ?

NO YES

Press the

7 no key to NOT clear record or

7 no or

9 yes

See

Page

20


7 Software Overview

Scripting Level

Level 7

Cont’d

Record to Network

<- - - ->

7 no

9 yes

Network

Disable Enable

pH Control units equipped with network capability can Disable Record to Network by

# enter

Page 20

7 no

Upgrade soft?

<- - - ->

9 yes

You are sure ?

NO YES

Before upgrading software refer to page 23.

Press the

7 no key to NOT upgrade or clear record.

9 yes

key to

7 no or

9 yes

7 no

Diverter Volt.?

<- - - ->

9 yes

Diverter Voltage

24 120

For future use.

For 2.0h software the Diverter voltage must be set at 120.

# enter

7 no

Dev Pump RATE?

<- - - ->

9 yes

Dev. Rate : 440 ?

(300 to 600)

Once a year or if pump has to be replaced, verify the calibration of dev pump. Disconnect the outlet line (#2) on top of reaction tank and place in graduated cylinder. Turn On the pump for one minute. Repeat three times and enter the average of the three samples.

# enter

7 no

Neu. Pump RATE?

<- - - ->

9 yes

Neu. Rate : 300 ?

(200 to 500)

Once a year or if pump has to be replaced, verify the calibration of Neutralizer pump.

Disconnect the outlet line (#1) on top of reaction tank and place in graduated cylinder. Turn On the pump for one minute. Repeat three times and enter the average of the three samples.

# enter

Beginning of

PWP Settings

0 exit



7

7 Software Overview

Scripting Level

Level 9

System Status

<- - - ->

9 yes

6

Network Statues will indicate the current settings to download record to the Metafix server.

6

6

EDsoftVersionNam eDmod-200 V5.2.4

MAC 00:02:F2:

ADDR 01:02:18

DHCP Status

Not Active

Ethernet Link

Not Active

6

7

6

CurrentIPAddress

0.0.0.0

CurrentIPGateway

0.0.0.0

6

CurrentIPmask?

0.0.0.0

6

FTP Port = 21

6

6

FTP Server metafix.com

FTP Put Path metatrax_upload

6

6

FTP User Name anonymous

Checksum reader

794AB819

0 exit



Page 21

8 Download Capability pH Control units include the capacity to download recorded data directly into a computer.

This allows for an immediate record of the system’s functioning as well as a brief history of the unit. This ability to retrieve data from the unit’s memory allows for rapid analysis of the units function and quick turn-around for any adjustment that may be required for the system.

Items required:

•Computer

• 9-pin standard serial cable (the connector port on the pH Control is female).

Page 22

step 1 step 2 step 3 step 4 step 5

Turn on computer. Load up a terminal type program (such as Windows Hyper

Terminal) with the following settings (which may be saved to avoid this every time a download is performed):

• Bits per second = 9600

• data bits = 8

• stop bits = 1

• Parity = none

• Flow control = X on/X off

Connect the serial cable from the output of the pH Control to the computer.

To download the data, press the

5 menu

The following message will appear: key to access the Scripting level.

External Wand ?

< - - - - >

Press the

Press the

6

9 yes

key to advance to the following screen:

RECORD DOWNLOAD SAMPLE

Download Record ?

< - - - - >

key to download.

Metafix pH Control II

Software Version:..............................................................2.0h

Serial Number:. .........................................NUA12345678-90

Current Date (MM/DD/YY):..................................12-27-04

Total Developer:....................................................00000 Liter

Total Neutralizer:..................................................00000 Liter

Installation Date: .....................................................00/00/00

Control: ..............................................................Probe Driven

Soak: ...........................................................................Disabled

Developer Pump Rate:.......................................440 ml/min

Neutralizer Pump Rate:.....................................300 ml/min

Diverter Voltage:..........................................................120Vac

Drain Time:...................................................................053 sec

Water Probe Check:...........................................................ON

Extra Probe Rinse: ............................................................OFF

Last Probe Calibration: ..................................00/00 0.0-0.0

pH LOW Alarm:..................................................................6.0

pH HIGH alarm: ...............................................................10.0

pH Target: ............................................................................8.9

Maximum Neutralizer:................................................150 ml

Network Connection: ..............................................Disabled

(00000) (00000)

Ctrl Date Time pH pH Neu

8.3

Status


8

9 Upgrade software Procedure (Windows)

Hardware and Software Requirements:

Hyperterminal.

• Standard communication cable with 9 pin male/ 9 pin female connectors.

• Metafix pH Control 2 software revision 2.0 or higher.

Preparing pH Control to receive a new software:

1. Press the MENU key.

2. Scroll with the

6

key and answer YES when the PWP settings? question appears.

3. Enter password, then press ENTER.

4. Scroll with the

6

you sure!

key and answer YES when the Upgrade soft? question appears.

5. If you are really sure you want to upgrade the software, then answer YES to the question Are

WARNING: Answering YES to (Are you sure?), will totally and irreversibly erase the program.

9

6. Disconnect the power cord.

The pH Control is now ready to receive its new software.

Preparing Computer to transfer new software to pH Control:

1. Open Hyperterminal.

2. Choose a name and icon for the new connection.

3. In the “Connect to” box, choose an unused serial port such as COM1, or COM2.

4. In port settings, set Bits per second at 9600, Data bits at 8, Parity to none, Stop bit to 1, Flow control to X on/X off.

computer.

The computer is now ready to transfer the software to the pH Control.


9 Upgrade software Procedure (Windows)

Transferring new program to pH Control:

1. Connect the power cord. The following menu should appear in the Hyperterminal window.

Metafix BootLoader a) Erase Flash b) Program Flash c) Start Program

?

2. Press “a”. The same menu will be duplicated after a few seconds, indicating that the flash is erased.

3. Press “b”. The following menu will appear:

Metafix BootkLoader a) Erase Flash b) Program Flash c) Start Program

? b

Select file .s19

4. From the transfer menu of Hyperterminal, click on Send text file…

5. Choose the proper text file having a .S19 extension, and click Open. The download progress is indicated by a progression of stars. The download is complete when no new stars appear. The process require a few minutes to complete.

6. Close Hyperterminal, remove the communication cable.

7. Disconnect the pH Control power cord for 5 seconds and reconnect.

9


10 Maintaining your pH Control

1 Probe Calibration

Your pH Control is equipped with a probe which reads the pH of the effluent in the reaction tank. To test the efficiency of the probe, you must occasionally perform a probe calibration.

• Press and hold the

5 menu key to enter the Scripting Level.

The message on the display will be:

External Wand?

<- - - ->

6

• Press the key 4 times.

The message on the display will be:

PH Probe Serv.?

Y N

• Press

9 yes

key. The message will be:

pH = 8.3

Cal to 7? Y or N

10

•

•

Dip the probe in buffer 7.01 solution.

This will provide a current pH reading of the solution. If the pH is below 6.6 or above 7.4 remove probe from Neutralizer tank and put in buffer solution. Press

9 yes

key to

Note: The pH probe must always be submerged in liquid. If the pH Control must be turned Off for more than two days, use the Rinse Probe feature (refer to the Software Overview section) to rinse the pH probe. Pour storage solution for pH electrodes in black cap and then place on pH probe.

If the probe has been sitting idle for a long period of time, place the probe in hot water (about 50° C) for 5-10 minutes. Then place the probe in a saturated KCI (potassium chloride) solution and allow it to cool to room temperature. This procedure should dissolve and KCI crystallization or blockage that may have formed at the end of the reference junction inside the probe body.

2 Cleaning the Spill Sensors

To keep the spill sensors working effectively, you must keep the surface of the sensors clean at all times.

• Wash under warm soapy water.

• Use a clean dry cloth to wipe away any dust or residue that has accumulated on the surface of the spill sensor connected to the containment tray and the puck near the drain.

You should also take this opportunity to wipe away any other dust or residue that has accumulated on the pH Control.

3 Cleaning Developer tank


11 Troubleshooting

1 Service Messages, Causes and Solutions

The pH Control service messages are intended to alert users of a potential problem. In the event of a potential problem the pH Control LCD will display one of the following service messages:

Service Messages Causes Solutions

WARNING !

Check Water Pump

If the Wash pump takes more than 60 seconds to reach LS5 (Level Sensor 5) during the normal operational cycle, the alarm will alert user of a potential problem with the pumps.

•Water pump power cord not plugged to power supply.

•The pumps grill could have sediment buildup.

• Connect Water pump to power supply.

• Disconnect Water pump from power supply. Remove pump from water tank. Remove and clean the pump grill.

WARNING !

Reac. Tank Over.

Alerts users of a potential overflow from the reaction tank. This will occur if the effluent level reaches LS 6

(Level Sensor 6).

•Level sensor 5 is dirty or defective.

•Dirty reaction tank.

•Leaking solenoid valve.

•Remove reaction tank cover and clean level sensor 5 with a damp cloth. If problem continues replace level sensor.

•Remove reaction tank cover and clean tank with damp cloth.

•Replace solenoid valve.

11

•Clean spill and dry puck sensor.

•Spill on the floor near drain.

WARNING !

WET FLOOR

If effluent comes in contact with puck sensor near the drain, the alarm will alert users of a spill.

Page 26

WARNING !

Dev Tank Over

Alerts users of a potential overflow from the

Developer Tank. This will occur if the effluent level reached the LS 2 (Level

Sensor 2).

•The pH Control has been turned

OFF for a long period of time.

•The Dev pump not working.

•Processor maintenance caused a tank overflow.

• Turn pH Control ON.

• Peristaltic tube is worn out. Replace pump.

• Drain processor developer into pH

Control. Drain water used to clean processor tank to drain.

Contact Metafix if the pH Control continues to display the service message after troubleshooting the unit.

11 Troubleshooting


Service Messages

WARNING !

Neutralizer Low

Causes

•

Neutralizer level is below the level sensor.

Solutions

•Neutralizer solution has to be added to the tank.

Alerts users if the

Neutralizer tank is empty.

WARNING ! pH to Low

If the pH is below the pH

Low setting, the alarm will alert users.

•Developer pump is not working properly.

•Probe defective.

•Preventive maintenance on CTP processor and water not bypassed from pH-Control dev tank.

•Wrong Neutralizer.

• Verify the Developer pump is working. perform Dev Pump test.

• Remove the probe from the

Reaction Tank and put in buffer solution to verify the calibration.

• Contact Metafix for assistance.

• Contact your service representative to confirm correct Neutralizer.

11

WARNING ! pH to High

If the pH is above the pH

High setting, the alarm will alert users.

•No solution in Neutralizer tank.

•Neutralizer pump is defective.

•Neutralizer inlet filter could be clogged.

•Probe defective.

•“Maximum Neutralizer” setting is to low.

•Wrong Neutralizer.

• Neutralizer solution has to be added to the tank.

• Verify the Neutralizer pump is working. Perform Neutralizer pump test.

• Disconnect the tubing connected to "Neutralizer Inlet from Tank".

Clean or replace the yellow inlet filter.

• Remove the probe from the

Reaction Tank and put in buffer solution to verify the calibration.

• Increase “Maximum Neutralizer”.

• Contact your service representative to confirm correct Neutralizer.

WARNING ! check pH Probe

When the Probe Check feature is turned On the probe will be rinsed with city water for 3 seconds before starting an operation cycle.

If the pH is below 6 or above 10 the alarm will alert users.

•The pH probe is out of calibration.

•The pH probe is damaged.

•Probe wiring is unplugged or defective.

• Enter the pH Probe Serv Level. The present pH is displayed. If pH is below 6.6 or above 7.4, submerge probe in 7.0 solution and press the

YES key to calibrate probe. Clean the probe with a tissue (do not touch the probe with your fingers).

Verify calibration again. If the pH is still out of range, replace the probe.

• Replug wiring. Replace wiring if necessary.



Failing to contact Metafix may result in additional complications.

Page 27

11 Troubleshooting


Service Messages Causes Solutions

•Connect diverter to power supply.

WARNING !

Chk Divert. Valve

Once batch is completed

Level Sensor 5 is still active after 45 seconds.

•Diverter is not connected to power supply.

•Tubing going to the drain is kinked.

•Level sensor 5 is stuck.

•Bad diverter valve.

•Replace kinked tubing.

•Remove reaction tank cover and clean Level Sensor 5 with a damp cloth.

•Replace the Mixing pump.

WARNING !

Wet Tray

If effluent comes in contact with the containment tray spill sensor in the pH control, the alarm will alert users of a spill.

•Tubing or internal parts leaking.

•Verify all connections and firmly tighten clamps.

11

Page 28


12

Parts List, Technical Specifications & Dimensions

12

1 Parts List:

D escription: .....................................................................................................................Item No.

Buffer solution (7.0 pH).....................................................................................................C30971

Circulation Pump...............................................................................................................C30945

Developer pump ................................................................................................................C30963

Dip tube assembly..............................................................................................................C30966

Dispenser pump assembly...............................................................................................M90589

Ethernet Card......................................................................................................................C30972

Level Sensor 1 (LS1)...........................................................................................................C30939

Level Sensor 2 (LS2)...........................................................................................................C30940

Level Sensor 3 (LS3)...........................................................................................................C30941

Level Sensor 5 (LS5)...........................................................................................................C30942

Level Sensor 6 (LS6)...........................................................................................................C30943

Liquid detector (Puck assembly) .....................................................................................C30908

MetaAid - Neutralization Solution - CA50....................................................................A10846



MetaAid - Neutralization Solution & Service Contract - CA50 - 2000 liters ..........SC10052


MetaAid - Neutralization Solution & Service Contract -CA50 - 5000 liters ...........SC10054

MetaAid - Neutralization Solution & Service Contract -CA50 - 10000 liters .........SC10055















MetaAid Wand Assembly.................................................................................................C30919

Neutralizer pump ..............................................................................................................C30962

pH Probe CTPR2 ................................................................................................................C30964

pH Probe replacement element........................................................................................C30899

Power Head ........................................................................................................................C30936

Probe Basket........................................................................................................................C30946

Service Kit, Universal ........................................................................................................C30968

Solenoid ...............................................................................................................................C30965

Water / Dev Tank..............................................................................................................M90730

Water/Dev tank..................................................................................................................C30967

Water Pump ........................................................................................................................C30944


12


2 Technical Specifications:

Voltage................................................................................................................. 120 volts, 60 Hz

Amps.............................................................................................................................. 2A (120 v)

Water ..............................................................................................................25 to 85 PSI, 10 lpm

Waste water tank capacity.................................................................................................25 liter

Developer tank capacity ....................................................................................................90 liter

Neutralizer jug capacity.....................................................................................................20 liter

Overall dimensions:.................................................25.0 in. wide, 26.0 in deep, 50.5 in. high.

Shipping weight..................................................................................................................130 lbs

Developer manage capacity....................................................................180 - 205 liter per day

12


12


3 Dimensions

50.5"

18"

12

13"

25"

Dev and water Tank ..........................................................................................................................20"H x 25"W x 26"D

Neutralizer Tank .............................................................................................................................15"H x 10"W x 11.5"D pH Control....................................................................................................................................30.5"H x 24"W x 16.5"D


13 Glossary of Terms

Control Panel: ...........The display on front panel of your unit,which consists of an LCD screen keypad and status LED’s.

Hard-Plumbed: ..........Connecting your unit to a closed drain pipe.

MGHT Spout: ...........The valve connected to your city water line which controls the flow of water.

Neutralizer (metaAid):Neutralizes chemistry.

Pumping: ...................The process your unit uses to discharge effluent.

pH: ..............................Refers to acidity or alkaline levels (acidic < 7, neutral = 7, alkaline >7)

pH Probe:.....................Measures pH of chemistry.

Level sensor 1 (LS1): .When effluent reaches Level sensor in developer tank it activates pH Control to begin a batch.

Level sensor 2 (LS2): .Indicates a developer tank overflow.

Level sensor 3 (LS3): .Sufficient water in water tank to start a batch.

Level sensor 4 (LS4): .Neutralizer tank is empty.

Level sensor 5 (LS5):Reaction tank operational level.

Level sensor 6 (LS6): .Indicates a reaction tank overflow.

Spill Sensor

/Detector: .....................Are used to detect spills inside the pH Control.

Vacuum Breaker

Backflow Preventor: A device which prevents liquid from flowing into the city water line from your unit.


13

14 Sales, Service, and Support

1925 46th Avenue

Lachine, Quebec

H8T 2P1

Canada

Tel: 1-800-667-8921

(514) 633-8663

Fax.: (514) 633-1678 e-mail.:[email protected]

[email protected]

Visit our web site: www.metafix.com

Our office hours are Monday–Friday 8:30

AM

–5:00

PM

, E.S.T


Metafix rev.2 pH Control Operation & Service Manual

Assistant Bot

pH Control rev.2

Operation & Service Manual

Copyright Notice

Disclaimer and Limitation of Liability

Your pH Control

Features and Benefits

1 Rear View: Parts Identification

2 Front View: Parts Identification

3 Power Supply View: Parts Identification

1 Essential Steps

1 Typical Plumbing Installation

2 Installation Procedures

2 Installation Procedures

2 Installation Procedures

3 Set Up Procedures

3 Set Up Procedures

Scripting Levels

Scripting Levels

Scripting Levels

Scripting Levels

Scripting Levels

Scripting Level

Scripting Level

Scripting Level

Hardware and Software Requirements:

Preparing pH Control to receive a new software:

Preparing Computer to transfer new software to pH Control:

Transferring new program to pH Control:

1 Probe Calibration

2 Cleaning the Spill Sensors

3 Cleaning Developer tank

1 Service Messages, Causes and Solutions

1 Service Messages, Causes and Solutions

1 Service Messages, Causes and Solutions

1 Parts List:

2 Technical Specifications:

3 Dimensions

Our office hours are Monday–Friday 8:30

–5:00

, E.S.T

Key Features

Frequently Answers and Questions

How does the Metafix pH Control system work?

What types of CTP effluent can the Metafix pH Control system handle?

What are the benefits of using the Metafix pH Control system?

What is Meta-Aid?

Is the Metafix pH Control system fully automatic?

How is the Metafix pH Control system monitored?

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