Model: PW – AC-EN-3

Nickel Plating Auto-Dosing System Manual

POWER WIND INDUSTRIAL PTE LTD SINGAPORE

2004

PWI © 2004

Nickel Plating Auto-Dosing System Manual

Contents: Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Introduction Overview Features Specifications Appearances

2 2 5 6

Installation General Requirements System Connections Testing Unit Inducing Tube Connections

8 9 17

`

System Operations Touch Screen Pre-Operation State Operation

18 24 24

Solving Problems with the System Operating and Alarm Messages Trouble Shooting Techniques Warnings

31 31 32

Power Wind Limited Warranty Statement Conditions

33

Appendix I Data Setting Records

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Nickel Plating Auto-Dosing System Manual

PWI © 2004

Chapter One: Introduction I. Overview: This Chemical Nickel Plating Auto-Dosing System is the latest design from Power Wind Industrial Pte Ltd. This system comes with digital controllable LCD touch screen, LED digital display and manual operational control. This Auto-Dosing system has automatic setting and cleaning functions, which increase the quality of the plating container, thus give a full control of the quality of the plating.

II. Features: The Chemical Nickel Plating Auto-Dosing System consist of one Control Unit, Testing Unit, a Dosing Unit and an additional rectifier, as for anti-plating usage for the plating container. System block diagram as show as next page (Fig. 1.1)

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Nickel Plating Auto-Dosing System Manual

Main Control Unit

Touch Screen Main Control Box

Testing Unit

Manual Controller Box Sampling

Dosing Unit

Stand. Sol.

Dosing Sol.

Rectifier

Plating Sol.

Fig. 1.1

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Nickel Plating Auto-Dosing System Manual III. Specifications: 1. Input Power: Single Phase AC 220V 5A 2. Touch Screen: 5.7 inches LCD Display 3. LED Digital Display: Three and a Half Digit Display 4. Testing Range: PH: 0.00—14.00 Nickel Concentration: 0.00—10.00 g/lit 5. Resolution: PH: 0.01 Nickel Concentration: 0.01 g/lit 6. Dosing method: Cylinder Method Adjustable Continuous Cylinder Method: 2—2 lit 7. Standard Solution: a. B4 b. B7 c. Distill Water d. Standard Plating Solution 8. Analyzing Method: Continuous 9. Calibration Method: Auto Calibration a. Periodical Auto Calibration: 8 hours b. Non Periodical PH Calibration c. Non Periodical Nickel Concentration Calibration 10. Pump: Valve:

Dosing Pump Sampling Pump Testing Valve: DC 24V. 9W Dosing Valve

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Nickel Plating Auto-Dosing System Manual IV. Appearances: Main Control Unit (Fig. 1.2)

H X W X L = 400mm X 300mm X 180mm

Fig. 1.2

Touch Screen (Fig. 1.3)

H X W X L = 127mm X 158mm X 44mm Fig. 1.3

Testing Unit (Fig. 1.4)

H X W X L = 400mm X 300mm X 180mm

Fig. 1.4

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Nickel Plating Auto-Dosing System Manual Manual Controller Box (Fig. 1.5)

H X W X L = 380mm X 550mm X 400mm Fig. 1.5

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Nickel Plating Auto-Dosing System Manual

PWI © 2004

Chapter Two: Installation I. General Requirements 1. It is important to place the system at least 15cm away from other equipment as for air ventilation. 2. The position of the standard solution container cannot be too high or too low. The top of the container should adjust from 10 to 20 cm below the Testing Unit. 3. The distance from the Touch Screen to the Main Control Unit should be around 10 meters and must not more than 15 meters. The signal cable for the Touch Screen should be placed at least 10cm away from the other parallel cables. 4. Testing Unit installation height: the bottom of the Testing Unit should be at the same height as the surface height of the plating solution. 5. The distance from the Testing Unit to the Plating Container should be minimized. The length of the inducting tube should be less than 5 meters. 6. Take note and prevent the plating solution and vapour from corroding the Dosing System.

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Nickel Plating Auto-Dosing System Manual II. System Connections 1. Interfacing Port Main Control Box TB

TA E

1

1

6

38

Interfacing Port TA & TB Fig. 2.1

Touch Screen

CA

TD 5

TC 1

3

Fig. 2.2

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1

Plug CA Interface Port TC & TD

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Nickel Plating Auto-Dosing System Manual

Testing Unit TE 20

1

Interfacing Port TE Fig. 2.3

Manual Controller Box

TF 1

20 Interfacing Port TF Fig. 2.4

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Nickel Plating Auto-Dosing System Manual Dosing Unit

1

TG TG

12

Interfacing Port TG Fig. 2.5

Level Testing Unit 1

TH 1

10

Interfacing Port TH Fig. 2.6

Level Testing Unit 2

TI 1

12

Interfacing Port TI Fig. 2.7

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Nickel Plating Auto-Dosing System Manual 2. Cable connections

Main Control Unit

1

Cable A

2

B

3

C

4

D

5

E

6

F

7

G DC24V

8

H AC230V

Testing Unit

Touch Screen Manual Controller Box

Level Testing Unit 1 Level Testing Unit 2 Cable I Dosing Valves Unit Dosing Pump Unit

Fig. 2.8

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J

PWI © 2004

Nickel Plating Auto-Dosing System Manual 3. Detail Connections Testing Unit TG Main Control Box TB Cable A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Cable B

Alarm Signal

Fig. 2.9

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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Nickel Plating Auto-Dosing System Manual Main Control Box TA

Touch Screen Cable C

TC

E Shields

1 2 3 4 5 6

Blue Red Green

Black White

Fig. 2.10

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1 2 3 TD

1 2 3 4 5

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Nickel Plating Auto-Dosing System Manual Main Control Box TB

Manual Controller Box Cable D

TF

18 19 20 21 22 23 24

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Fig. 2.11

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（PH Output） （PH Input） （C Output） （C Input） （A Output） （A Input） （-DC 24V） L

N E L N E L N E L N E

Dosing Pump 1

Dosing Pump 2

Dosing Pump 3

AC 230V

PWI © 2004

Nickel Plating Auto-Dosing System Manual TB

Cable E

TH

1 2 3 4 5 6 7 8

25 26

B4 Level Test B7 Level Test Distill Water Level Test Ni Solution Level Test

Fig 2.12

TB

TI

Cable F

27 28 29 30 31 32 33 34 + 35 36 N 37 L 38 E

1 2 3 4 5 6 7 8 9 10 11

DC 24V

AC230V

A Dosing Cyl. Level Test B Dosing Cyl. Level Test PH Dosing Container Level Test A C Dosing Container Level Test

12

Fig. 2.13

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Nickel Plating Auto-Dosing System Manual III. Testing Unit Inducing Tube Connections

Wastewater out

NIS in

B4

Sampling Pump

Sample out: Empty: NIS in: B4: B7: DI water in: Sample in:

Sample Solution Out Empty Ni Standard Solution In Buffer Solution PH4 Buffer Solution PH7 Distill Water In Sample Solution In

Fig. 2.14

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B7

DI water in

Sample in

Nickel Plating Auto-Dosing System Manual

PWI © 2004

Chapter Three: System Operations I. Touch Screen 1. Introduction Figures and operation status are shown on the Touch Screen. User can input data through the Touch Screen, and direct control the system through it. There are 13 screens in total, as shown as follows:

Fig. 3.1

Fig. 3.2

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Nickel Plating Auto-Dosing System Manual

Fig. 3.3a

Fig. 3.3b

Fig. 3.4

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Nickel Plating Auto-Dosing System Manual

Fig. 3.5

Fig. 3.6

Fig. 3.7

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Fig. 3.8

Fig. 3.9

Fig. 3.10

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Fig. 3.11

Fig. 3.12

Fig. 3.13

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Nickel Plating Auto-Dosing System Manual 2. Program Flow Chart for the Touch Screen:

Main Screen

Screen Selections

Calibration Screen

Clear MTO Screen

Manual Dosing Screen

Alarm Data Screen

Data Adjustment Screen

Password Screen

Data Setting Screen

Dosing Time Setting Screen

MTO Data Setting Screen

Note: User can select back to Main Page from any page Fig. 3.15

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Calibration Data Setting Screen

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Nickel Plating Auto-Dosing System Manual II. Pre-Operation State

1. Fill up the Standard Solution Containers (B4, B7, Nickel Solution and Distill Water). Note: User should use the make-up solution as Standard Nickel Solution. 2. Check if the tubes are in place.

III. Operation 1. Switching On the System: a. Plug in the power for the System b. Switch on the System Power c. Plug in the Sampling Pump power d. Switch on the Sampling Pump; sampling solution will flow out from the Testing Unit tube in less than a minute. 2. Switching Off the System: Switch Off the System and the Sampling Pump. Note: If the system will not be used for a long period, please pour distill water in through the sampling pump input as to clean the internal tubes of the Testing Unit. 3. Manual Operation: Manual Operation Box front panel

A In

A Output

C In

PH In

B Output

PH Output

A Pump

PH Pump

C Pump

EMG Push Button

Fig. 3.16

a. Switch on Dosing Pump A, B and C b. Switch the Dosing Valve control to “Auto” position

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Nickel Plating Auto-Dosing System Manual

Note: Dosing Valve switch is at “Manual” position temporary only when it’s necessary. 4. Operation of the Touch Screen: a. Different display on the Touch Screen: Example: The Main Screen A D C

B

E Fig. 3.17

i. Descriptions (A): only for the display description ii. Operation Buttons or Switches (B): screen change to a different screen or to operate when pressed. iii. Data display (C): show the operating data. iv. Set the data value (D): press the data area of the screen allow user to enter or change the set value of the data. v. Keyboard: use to input values for the data. vi. Operation Status (E): show the user the operational status of the system. b. Normal Operation: For the calibrated system, it will enter normal operation mood once power is turned On. The system will auto-start online testing and control continuously, thus it will start auto-dosing. The system will not input dosing solution to the container within the first three minutes after the system power is turned On, and this included the ten seconds declaration display screen shown at the beginning. Afterward, the system will do an auto-calibration every eight hours. c. Setting the Set Point Set Points are the setting values for the PH and Nickel Concentration for the plating solution during the normal operation.

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Nickel Plating Auto-Dosing System Manual Here shows how to set the PH Set Point: Display

Operation Steps Button (switch) Name PH Set Point

Display Screen Main Screen

Keyboard

Key in the setting values for the Set Points on the keyboard and press ‘ENT’ on the keyboard, the value is set. d. Calibration Enter calibration screen for calibration. Operation Steps Button (switch) Name Screen Selections

Display Screen

Calibration

Screen Selections Screen

Main Screen

Display Screen Selections Screen Calibration Screen

Calibration Screen included five types of operations and able to switch to another two screens. i. Cancel Auto-Calibration: Press the “Cancel Periodic Auto-Calibration” button (button display will change to “Periodic Auto-Calibration”); the system will cancel the Periodic Auto-Calibration. As to be back to the Periodic AutoCalibration, press the “Periodic Auto-Calibration” button (button display will change to “Cancel Periodic Auto-Calibration”), and the system will auto-calibrate every eight hours. ii. Calibrate within the first 20 minutes after system power on: Under normal operating condition, system testing will reach the standard level only 20 minutes after the system power on. But for convenient during testing stages of installation of the system, press the “Calibration with the first 20 minutes” will allow user to calibrate the system within the first 20 minutes after the system power on. iii. PH Calibration: This is used under Manual Operation condition, which is to allow user to do auto-calibration manually by pressing down the button once. Press “PH Calibration” button, the system will do an auto PHcalibration. iv. Nickel Concentration Calibration:

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Nickel Plating Auto-Dosing System Manual

Press “Ni Calibration” button, the system will do an auto Nickel concentration calibration. v. Stop Calibration: It will need average 10-25 minutes for one time calibration. As to stop calibration by user due to any circumstances, press the “Stop Calibration” button once. vi. Manual Dosing: User can switch to “Manual Dosing Screen” when it’s needed. Press the “Manual Dosing” button once to switch to the appropriate screen. vii. Clear MTO: When start using a new container, MTO must be cleared to Zero. Display

Operation Steps Button (switch) Name Clear MTO Clear MTO

Display Screen Screen Selections Screen Clear MTO Screen

“Clear MTO” MTO value: 0.00

viii. Data Settings: Necessary data are needed to allow the system to operate. This should be done by a technical personal, as password is given, (The password to enter the data setting screen is “1234”, this the default factory setting and cannot be changed) this is to prevent system break down due to faulty data entry by the operation personals. 1. Entering to the Data Setting Screen: Operation Steps Button (switch) Name Data Setting “*”

“1” “2” “3” “4” “ENT”

Display

Display Screen Screen Selections Screen Data Setting (Enter Password: *) Data Setting

Data Setting (Enter Password: *) Data Setting (Keyboard shown) Data Setting

(Keyboard shown)

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Nickel Plating Auto-Dosing System Manual

PWI © 2004

2. Setting Calibration Data: Calibration data: PH value for the PH standard solution, it should be found on the product label. E.g.: B4, the PH value will be 4.01 B7, the PH value will be 6.86 Nickel Concentration for the Ni Standard solution: (g/lit) The Ni concentration value should be the same as the Ni concentration of the make-up solution (Note: the PH vale should be adjusted to the working value). The value will get with titration at the lab. E.g.: 6.00 g/lit All calibration data are set as the same as the data setting method. 3. Dosing Time Setting: Continuous dosing time: This is the time limit for dosing, if the actual dosing time exceeded the set time, an Error signal will be given by the system. The reason for causing dosing exceeded the set time might be due to no dosing, or over dosed or Test Unit faulty, that is no dosing or over dosed. This is an abnormal working condition for the system; thorough system check is needed. Cylinder Dosing Time: As it need a certain time to fill up the cylinder by the dosing pump, that is the Cylinder Dosing Valve opening time. Therefore, the Cylinder Dosing Time must set to be longer than the Cylinder Dosing Valve opening time. Cylinder Output Time: As it need a certain time to output the dosing solution from the cylinder to the plating container, which is the Cylinder Output Valve opening time. Therefore, the Cylinder Output Time must set be longer than the Cylinder Output Valve opening time. Dosing and Output Interval Time: This is the interval between Cylinder Dosing Valve closing time and the Cylinder Output Valve opening time. Dosing solution will be overflowed during this interval time as to ensure the dosing solution in the cylinder is at the setting point. Therefore, the Dosing and Output Interval Time must set to be longer than the overflowed time.

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Nickel Plating Auto-Dosing System Manual

4. MTO Data Setting: Container Capacity: the capacity of the plating container (lit) Cylinder Capacity: the cylinder volume when the overflow pipe has been set. Dosing Nickel Concentration: (g/lit) MTO Compensate Coefficient: Due to the plating container’s MTO increases from time to time, the tested Ni Concentration will be different from the data got from the titration method. As to make these two figures as closest as possible, MTO Compensation is needed. MTO Compensate Value = MTO Compensate Coefficient X MTO Value ix. Alarm Data Setting: User can set PH, Ni concentration upper and lower limit alarm data in the Alarm Data Setting Screen. Operation Steps Button (switch) Name Alarm Data

Display

Display Screen Screen Selections Screen

Alarm Data Setting Screen

(Setting Method is the same as the other data setting) x. Data Adjustment: Due to some objective reasons, the system-displayed data might be different from the actual data. Therefore, an adjustment for the data is needed. The adjustment can be considered as ‘one-point calibration’. (Auto-calibration is ‘two-point calibration.) Note: the Adjustment data will re-set to zero on the next system Power On.

1. Entering to the Data Adjustment Screen: Operation Steps Button (switch) Name Data Adjustment

Display

Display Screen Screen Selections Screen

Data Adjustment Screen

2. Data Adjustment Setting: Page 29 of 35

Nickel Plating Auto-Dosing System Manual

PWI © 2004

Press on the adjustment data figure to change the adjustment data. (Setting Method is the same as the other data setting) 3. PH Adjustment Data and Ni Concentration Adjustment Data Button: Press the above-mentioned button. When the color of the adjustment data has changed to a darker color, it shows the system-displayed data has been adjusted. Note: the Adjustment data will re-set to zero on the next system Power On.

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Nickel Plating Auto-Dosing System Manual

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Chapter Four: Solving Problems with the System I. Operating and Alarm Messages During working condition, the screen will have an information section showing the current machine working condition. There are a total of fourteen messages will be shown in two type of conditions, one is under normal working condition, and another is during system alarm condition. 1. Normal Operating Messages: a. System Running b. Auto-Calibrating c. PH Manual Calibrating d. Ni Concentration Manual Calibrating e. A, C Ni Solution Dosing f. PH Solution Dosing 2. Alarm Messages: a. Standard Solution Container? b. Dosing Solution Container? c. Ni Dosing Time Out! d. PH Dosing Time Out! e. PH Electrode? f. Ni Sensor? g. PH Over Limit! h. Ni Concentration Over Limit!

II. Trouble Shooting Techniques When Alarm occurred, the message area of the touch screen will start blinking and the system buzzer will give out a loud alarm sound to alert the operating personal to solve the problem. Operating personal need to release the alarm by pressing the “Alarm Reset” button at the right hand lower corner of the touch screen for about one second. Then the screen will stop blinking and as well as the alarm sound. The operating personal can troubleshoot the system by looking at the Alarm message shown on the screen. The system will give a long alarm sound again in 10 minutes if the system error is not cleared. Note: please make sure the data are set correctly.

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Nickel Plating Auto-Dosing System Manual

No. A

Alarm Message Standard Solution Container?

B

Dosing Solution Container?

C

Ni Dosing Time Out!

D E

PH Dosing Time Out! PH Electrode?

F G

Ni Sensor? PH Over Limit!

H

Ni Concentration Over Limit!

PWI © 2004

Troubleshooting 1) Check standard solution container’s water level; if the water level is too low please add standard solution. 2) Else, check if the level sensor is working properly. 1) Check dosing solution container’s water level; if the level is too low please add standard solution. 2) Else, check if the level sensor is working properly. 1) Same as B 2) Check if the sampling tube is being blocked, if too many gas bubbles, check if there is a leak, or too much Ni residue in it. 3) Check if the pump is functioning 4) Check if the dosing tube is being blocked 5) Check if the Electro Valve is functioning Same as C 1) Check the standard solution container’s water level 2) Check the level sensor 3) Check the standard solution data value 4) Check if the PH sensor is functioning Same as E 1) Check if the sampling tube is being blocked, if too many gas bubbles, check if there is a leak, or too much Ni residue in it. 2) Check if the dosing pump is functioning 3) Check if the dosing valve is functioning Same as G

III. Warnings a. As to ensure proper safety of the system and as well as the working personals, the system must be correctly wired. Note: the polarity of the DC power connection b. The touch screen battery has to be changed in every two year as to maintain the data memory for the set values.

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Nickel Plating Auto-Dosing System Manual

Chapter Five: Power Wind Limited Warranty Statement

Power Wind Product

PW— AC-EN Series

1

1

No

1

Yes

No

Conditions 1. Any PW- AC-En-3 System has 1yr parts, 1yr labour, 1 year on-site Service. 2. On-site coverage is from 9.00am to 5.00pm, Monday to Friday and excludes public holidays. Or additional charges applied. 3. Next Business Day Warranty Service is fulfilled only through the Power Wind Direct Replacement Program. 4. Onsite response: Power Wind will respond on-site, at the customer's location, by the business day following request for warranty service, based on the standard office hours in the country where the call is placed. Next Business Day Warranty Service is based on commercially reasonable best effort. In some countries and under certain supplier constraints, response time may vary. If your location is outside of the customary service zone, response time may be longer or there may be an additional charge. Additional charges applied to outside of regular business hours in the country where the call is placed. 5. Limited On-site warranty: The customer must be located within 80kms of the nearest Authorised Service Provider. 6. Options have a 1 year parts and labour warranty or the remainder of the warranty period for the Power Wind product in or on which the option is installed, whichever is the longer. If the Power Wind product in which the option is installed is covered by any Power Wind on-site service offering, that on-site service will apply to the option as well. 7. The inherent warranty on product batteries is limited to one year only. This applies to those batteries purchased as options, and those batteries that are a standard item built into the Systems themselves, regardless of the inherent warranty of that System. 8. Next Business Day onsite is only available on standard system configurations. 9. This only applies to the PW-AC-EN series. 10. Proof of purchase is required for all warranty claims. 11. Service carried out by Power Wind only. 12. Onsite response is Next Business Day only. 13. Onsite response is 3 hours limited warranty. 14. This is a 'limited' warranty against faulty materials and workmanship. It does not cover damage caused by misuse or normal wear & tear.

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Nickel Plating Auto-Dosing System Manual

PWI © 2004

15. Free Parts Replacement Only for Repair (Parts only). If the Power Wind product is covered by parts-only replacement warranty, the defective parts will be supplied free of charge during the warranty period. The product can be sent or carried in, at the customer's own cost and risk, to Power Wind to be repaired. Following repair, the repaired product should be collected, at the customer's own cost and risk, from Power Wind. Before you deliver your product for warranty service it is your responsibility to keep a separate backup copy of the system data. You will be responsible for reinstalling all such data. Power Wind is not liable for any damage to or loss of any data, or other information stored on any media, or any Power Wind product or part not covered by this warranty. Recovery and reinstallation of system user data are not covered under this Limited Warranty. Note: 1. The labour costs for repair are not included in this warrant. 2. Power Wind does not include protection against accidents. 3. This warranty applies only to hardware product manufactured by or for Power Wind and this warranty does not apply to any non-Power Wind hardware products or any software. 4. Software distributed by Power Wind with or without the Power Wind brand name (including, but not limited to system software) is not covered under this Limited Warranty. Refer to the licensing agreement accompanying the software for details of your rights with respect to its use.

This literature is subject to change without notice. Power Wind Industrial Pte Ltd assumes no responsibility for editorial errors or omissions herein.

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Nickel Plating Auto-Dosing System Manual

Appendix I:

Data Setting Records Data PH

B4 B7 Ni Std. Sol. Conc. PH Hi Limit PH Low Limit Ni Conc. Hi Limit Ni Conc. Low Limit Plating Container Capacity Ni Dosing Sol. Conc. Dosing Volume Dosing Time Empty Time Dosing Out Time

MTO

Compensate Coefficient

Model

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