OPERATIONS MANUAL

SCM2500
SCC3500

Streaming Current Monitor &

Streaming Current Controller
with Dura-Trac™ Remote Sensor
Ver 120309 JC
 Table of Contents
FIGURE TITLE PAGE ............................................................................................................................. 3
1.0 WARRANTY INFORMATION ........................................................................................................... 5
2.0 GENERAL INFORMATION .............................................................................................................. 6
2.1 DESCRIPTION OF OPERATION .................................................................................................. 6
2.2 SELECTING PROPER SAMPLE POINT ....................................................................................... 6
2.3 PROCESS CONTROL PROCEDURES ........................................................................................ 8
2.4 SYSTEM COMPONENTS ............................................................................................................. 9
2.5 TECHNICAL SPECIFICATIONS ................................................................................................. 10
3.0 MOUNTING AND INSTALLATION................................................................................................. 13
3.1 MOUNTING LOCATION ............................................................................................................. 13
3.2 POWER REQUIREMENT ........................................................................................................... 13
3.3 SIGNAL WIRING ......................................................................................................................... 16
3.4 SAMPLE CONNECTION ............................................................................................................. 17
3.5 SENSOR FLUSH OPTIONS ....................................................................................................... 18
3.5.1 Dura-Trac with Flush ........................................................................................................... 18
3.5.2 Sensor Maintenance Feature Connections (Optional) ........................................................ 19
4.0 OPERATION ................................................................................................................................... 21
4.1 MONITOR/CONTROLLER USER INTERFACE ......................................................................... 21
4.2 SCM2500XRD READOUT, MENUS, AND CONTROLS ............................................................. 22
4.2.1 SCM2500XRD Main Screen ................................................................................................ 22
4.2.2 SCM2500XRD Setup Menu (1) ........................................................................................... 23
4.2.3 SCM2500XRD Setup Menu (2) ........................................................................................... 24
4.2.4 SCM2500XRD Alarm Status Menu ..................................................................................... 25
4.2.5 SCM2500XRD Optional Flush and/or Sensor Maintenance Control Menu ......................... 26
4.3 SCC3500XRD READOUT, MENUS, AND CONTROLS ............................................................. 26
4.3.1 SCC3500 Main Screen ........................................................................................................ 26
4.3.2 SCC3500XRD Setup Menus ............................................................................................... 27
4.3.3 SCC3500XRD Alarm Status Menu...................................................................................... 28
4.3.4 SCC3500XRD Pump Control (1) Menu ............................................................................... 29
4.3.5 SCC3500XRD Pump Control (2) Menu ............................................................................... 31
4.3.6 SCC3500XRD Flow Control (3) Menu ................................................................................. 31
4.3.7 SCC3500XRD Optional Flush and/or Sensor Maintenance Control Menu ......................... 34
4.4 SYSTEM OPERATION................................................................................................................ 36
4.5 TREATMENT OPTIMIZATION PROCEDURE ............................................................................ 37
4.6 MANUAL CONTROL USING CONTROLLER ............................................................................. 38
4.7 AUTOMATIC CONTROL............................................................................................................. 38
4.8 AUTOMATIC CONTROL SETUP ................................................................................................ 40
4.9 TUNING CONSTANT SPECIFICATIONS ................................................................................... 41
5.0 GENERAL GUIDELINES ................................................................................................................ 42
5.1 STREAMING CURRENT VALUE RESPONSE FACTORS ......................................................... 42
5.2 FUNDAMENTAL STREAMING CURRENT KNOWLEDGE ........................................................ 43
6.0 TROUBLESHOOTING GUIDES ..................................................................................................... 46
7.0 MAINTENANCE PROCEDURES.................................................................................................... 48
7.1 REPLACEMENT PROCEDURES ............................................................................................... 48
7.2 CLEANING PROCEDURES ........................................................................................................ 48
7.3 REPLACEMENT PARTS............................................................................................................. 49
7.4 ORDERING INFORMATION ....................................................................................................... 52
8.0 MECHANICAL SPECIFICATIONS ................................................................................................. 54
9.0 OPTIONAL FEATURES ADDENDUM............................................................................................ 58
9.1 REMOTE CONTROL FEATURE (OPTIONAL)....................................................................................... 58
9.2 OFFSET VALUE 4-20 MA SIGNAL .................................................................................................... 60

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 LIST OF FIGURES

Figure Title Page

1 Streaming Current Profile ................................................................................. 7
2 System Components ........................................................................................ 9
3 Monitor/Controller Power Wiring ....................................................................... 13
4 Dura-Trac Sensor Power Wiring ....................................................................... 14
5a Dura-TRAC II Sensor Power Wiring .................................................................. 14
5b Dura-TRAC II Sensor with Automatic Maintenance Features Wiring…………… 15
6 Signal Wires Interconnection Diagram .............................................................. 16
7 Dura-TRAC Sensor Sample Connection ........................................................... 17
8 Dura-TRAC II Sensor Sample Connection ........................................................ 18
9 Dura-TRAC Sensor with Flush .......................................................................... 19
10 Sensor Maintenance Tubing Connections ......................................................... 20
11 Automatic Flush Timing Diagram ...................................................................... 35
12 Dura-Trac Sensor Parts Identification ............................................................... 51
13 Dura-Trac II Sensor Parts Identification ............................................................ 52
14 Streaming Current Monitor/Controller Dimensions ............................................ 53
15 Dura-Trac Sensor Dimensions .......................................................................... 56
16 Dura-Trac II Sensor Dimensions ....................................................................... 56
17 Dura-Trac Sensor with Flush Dimensions ......................................................... 57
18 Dura-Trac II Sensor with Sensor Maintenance Features Dimensions ............... 58

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 IMPORTANT INSTRUCTIONS

When using this instrument, basic safety precautions shall always be followed to
reduce the risk of fire, electrical shocks and injury to persons, including the
following:

Before attempting to unpack, set up, or operate this instrument, please

read this entire manual.

Make certain the unit is disconnected from the power source before
attempting to service or remove any component.

Follow all warnings and marked on the instrument.

Failure to follow these precautions could result in personal injury or
damage to the equipment.

Do not attempt to disassemble the unit.

Water must not be allowed to enter the housing of the unit.

Close and fasten the covers of the unit prior to any external cleaning to
prevent water ingress.

Do not drop or jar the unit.

Do not modify any internal electrical wiring or electronics.

Use a mild non-abrasive cleanser when cleaning the outer cover of the
unit.

SAFETY PRECAUTIONS
In order to provide maximum user safety this instrument was designed with all electrical
circuitry enclosed within a protective non-conductive housing. The label below will be
visible at any location where high voltage is present.

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1.0 WARRANTY INFORMATION
®
Chemtrac , Inc. warrants its equipment to be free from defects in material and
workmanship for a period of one (1) year from date of shipment to the original
purchaser. Upon receipt of written notice from purchaser, seller shall repair or
replace the equipment (at option of Chemtrac®, Inc.).
®
Chemtrac , Inc. assumes no responsibility for equipment damage or failure
caused by:
1. Improper 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®, Inc. be liable for any special, incidental,
or consequential damage such as loss of production or profits.

Should you experience trouble with the equipment, please contact:

Chemtrac, 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: [email protected]
Website: www.chemtrac.com

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2.0 GENERAL INFORMATION
2.1 DESCRIPTION OF OPERATION

The Streaming Current Monitor/Controller includes a remote sensor module placed at

the desired sample point, and a Monitor/Controller module. The monitor is a charge-
measuring device. The charge that it measures is the net ionic and colloidal surface
charge (positive and negative) in the sample being tested. Streaming current is related
to zeta potential, however, they are not the same value.

The treated water sample flows into the sample cell where it is drawn into the bore
during the upstroke of the piston cycle and is expelled from the bore on the piston down
stroke. Particles contained in the water are temporarily immobilized on the piston and
cylinder surfaces. As the water is moved back and forth by the piston, charges
surrounding these particles (+ and -) are moved downstream to the electrodes. This
movement of like charges causes an alternating current to be generated, defined as
"streaming current." A signal gain selector, accessed through the menu screen, is used
to select the best signal amplification. The signal amplification should be set where a
normal change in dosage results in a desired deviation in streaming current (normally 30
units). The displayed streaming current value (SCV) should be considered as a relative
reading due to amplification of the primary signal.

The streaming current amplitude and polarity is a function of sampling location in the
treatment process. It is important to understand why the streaming current varies at
different points in the system to properly interpret the readings, therefore, Section 2.2
should be read very carefully.

2.2 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 basin). The lag time, or the amount of
time it takes the water to travel from the point of chemical addition to the sensor, should
be no greater than 3 minutes (30 seconds to 1.5 minutes are typical lag times). If
uniform distribution and mixing is not being obtained at a selected sample point, the
streaming current reading will oscillate. If the chemical is not being properly mixed
(indicated by an oscillating monitor reading), the sample point needs to be moved
further downstream away from the mixing device to allow the chemical more time to mix
in with the water. Under rare circumstances, moving the sample point further
downstream in order to obtain a more stable reading may result in a lag time longer than
3 minutes. Steps should be taken to improve chemical mixing under these conditions.

When possible, avoid sampling from places where sludge, grit, etc., will be drawn into
the sensor sample cell. Sample lines must be sized to provide velocities that will
prevent floc/sludge accumulation. Keep sample lines as short as possible to minimize
delay in response time.

Figure 1, Streaming Current Profile, normally observed in a typical water plant. When
coagulant is added to raw water, the charge neutralization process begins immediately.
The time required for this neutralization process to go to completion is primarily a
function of mixing, time, raw water characteristics, type of coagulant, and to a lesser
degree, temperature. Untreated raw water has a net negative charge. Cationic

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 coagulant charges, (alum, polymer, etc.) can produce a net positive streaming current
early in the system. As shown on the graph, this current becomes less positive as
negative charges react with the coagulant. At the settling basin outlet, the streaming
current value can return to nearly the same as raw water. If raw water flow or sample
flow rate is increased, the total time for the sample to travel from point of coagulation
injection to the cell is decreased. This may cause a change in 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. It is important to
maintain the sample flow at +/- 10% of the rate initially set.

Based upon the above discussion, the proper sample point for a specific plant depends
upon the following conditions:
1. Point or points of coagulant feed.
2. Mixing efficiency of raw water and coagulant.
3. Magnitude of raw water flow swings.
4. Type and quantity of coagulants used.

FIGURE 1. Streaming Current Profile

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2.3 PROCESS CONTROL PROCEDURES

Model SCC3500XRD Only

In order for the monitor to be used for automatically controlling the coagulant feed
(alum, polymer, ferric chloride), the following guidelines must be followed:
1. The coagulant must be thoroughly mixed with the raw water by the time the
sample is taken.
2. “Lag time” (i.e., the time it takes for the monitor to see a change in coagulant
feed) should be no greater than 5 minutes.
3. Variability in sample flow rates should be no greater than +/- 10 % of the initial
rate.
4. Coagulant pumps 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
chart recorder is very helpful in anticipating factors that may have to be dealt with when
automatic control is started. This period, if using the monitor with a recorder for
monitoring, is also a good time to determine the optimum coagulant dosage and
establish the operating “setpoint”. This enables the system to be put on automatic
control very simply.

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2.4 SYSTEM COMPONENTS

The SCM2500XRD and SCC3500XRD system include the following:

Monitor/Controller

Dura-Trac Remote Sensor

Dura-Trac Remote Sensor with Flush (Optional)

Dura-Trac II Remote Sensor (Optional)

Dura-Trac II Remote Sensor with Sensor Maintenance Option (Optional)

Figure 2 illustrates system components.

MONITOR/CONTROLLER DURA-TRAC SENSOR

D URA-TRAC TM

PAT ENTED MADE IN U .S.A.

DURA-TRAC SENSOR with FLUSH DURA-TRAC II SENSOR

DU RA -TRAC TM

PAT ENTE D MA DE IN U .S.A.

DURA-TRAC TM
II
PAT ENTED MA DE IN U .S.A.

DURATRAC II SENSOR W ITH

SENSOR MAINTENANCE OPTION

OPERATOR
MANUAL
DU RA -TRA C TM
II
PAT ENTE D MADE IN U.S.A .

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2.5 TECHNICAL SPECIFICATIONS

MONITOR/CONTROLLER
Power ...................................... 85-264 VAC, 47–63 Hz
Current Load ........................... 110 VAC @ 0.5A Max
220 VAC @ 0.25A Max
User Interface.......................... Backlit Liquid Crystal Display, Menu Driven Functions,
Keypad Interface
SCV Readout .......................... -1000 to +1000
Resolution ............................... Streaming Current Units
Signal Gain .............................. User Adjustable 1X to 20X
Zero Offset .............................. Automatic, Full Scale All Ranges
Accuracy ................................. 0.5% of Full Scale
Response Time ....................... 1 Second
SCV Output Signal .................. Standard 4-20 mA (300 ohm Load)
Optional 0-10 VDC
Alarm Output ........................... 24 VDC (Solid State Relay Optional) and Auditable
Alarm for Sensor Status, High/Low Streaming Current
Value and High/Low Pump Output - SC3500XRD Only
Digital Input ............................ Dry Contacts
Enclosure Type ....................... 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: Range 1-20
SmartTrac PID Control ............ SCC3500XRD Only
Analog Input ............................ 4-20 mA
Control Output Signal .............. 4 – 20 mA (300 Ohm Load) or 0 – 10 VDC
Control Output Limits ............... Adjustable High/Low Limits

Dura-Trac REMOTE SENSOR

Power ...................................... 115 VAC, 60 Hz (standard)
230 VAC, 50 Hz (optional)
Sample Flow Rate ................... 5.0 GPM
Sample Cell Type .................... External Receiver, High Flow
Probe Type .............................. Quick Replacement Cartridge
Water Sample Connections ..... Inlet: 3/4” O.D. Barb Type, Outlet: 1” O.D.
Materials Contacting Sample ... Delrin, Nylon, Neoprene Viton, PVC, Stainless Steel

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 Dura-Trac REMOTE SENSOR (Continue)
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 ........................ 9.2”W, 7.2”H, 5.3”D (234mm W, 183mm H, 135 mm D)
Mounting Holes ....................... 7.4” W, 11.25” H (188mm W, 286mm H)
Overall Height with Sensor ...... 14.7’’ (373mm)
Weight ..................................... 10 Pounds (4.5 kg)
Operating Temperature ........... 34° F to 120° F (1° C to 49° C)

Dura-Trac WITH FLUSH (OPTION):

Flush Water Connections ........ ¼’’ Quick Connect Tube Fitting, Adaptable
Flush Water Pressure…. ......... 35 to 80 PSI
Overall Height with Sensor ...... 17.6’’ (447mm)

Dura-Trac II REMOTE SENSOR (Option)

Power ...................................... 115 VAC, 60 Hz (standard)
230 VAC, 50 Hz (optional)
Sample Flow Rate ................... 3 to 10 GPM
Sample Cell Type .................... External Receiver, High Flow
Probe Type .............................. Quick Replacement Cartridge
Water 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) without SMM Option
21.8’’ (554mm) with SMM Option
Mounting Holes ....................... 9.7”W x 10.5”H (247mm W x 266mm H)
Weight ..................................... 15 Pounds (6.8 kg)
Operating Temperature ........... 32° F to 120° F (0° C to 49° C)

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 Dura-Trac II REMOTE SENSOR W/ AUTOMATIC SENSOR MAINTENANCE
FEATURES (Option)
Power ...................................... 115 VAC, 60 Hz (standard)
230 VAC, 50 Hz (optional)
Sample Flow Rate ................... 3 to 10 GPM
Sample Cell Type .................... External Receiver, High Flow
Probe Type .............................. Quick Replacement Cartridge
Water 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
Flush Water Connections ........ ¼’’ Quick Connect, Adaptable
Flush Water Inlet PSI .............. 45 to 85 PSI
Chemical Injection Pump ......... 250 mL/min (Max)
Signal Wiring ........................... 4 Conductor, Shielded, 18 AWG (SCM Processing Card)
4 Conductor, Shielded, 18 AWG (Sensor Maintenance)
Enclosure Type ....................... NEMA 250 Type 4X, Reinforced Fiberglass
Enclosure Size ........................ 9.2”W , 7.2”H, 5.3”D (234mm W, 183mm H, 135mm D)
Overall Height with Sensor ...... 14.7’’ (373mm)
Mounting Holes ....................... 7.7”W x 8.5”H (197mm W x 215mm H)
Weight ..................................... 15 Pounds (6.8 kg)
Operating Temperature ........... 32° F to 120° F (0° C to 49° C)

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3.0 MOUNTING AND INSTALLATION

3.1 MOUNTING LOCATION

The sensor can be located several hundred feet from the monitor. The sensor must be
mounted in a vertical position with the sample flowing into the inlet (3/4” barb fitting) and
exiting from the outlet (PVC elbow). Typically, the sensor is mounted as closely as
possible to the sampling point. Minimizing sample line lengths provides quicker
response to process changes. Sample may be obtained by using a sample pump,
tapping off a pressurized line, or using gravity feed system to get sample to the sensor.
The sample flow rate should not exceed 5.0 GPM for Dura-Trac sensor and 10.0 GPM
for Dura-Trac II sensor. Draining to atmosphere (unobstructed) is required; a
closed pipe (pressurized) drain is not recommended.

The Monitor/Controller module should be installed in a location, which will allow regular
viewing of the display as well as easy access to the front panel menu keys. See
Mounting Dimension Diagrams at end of Manual.

3.2 POWER REQUIREMENT

Electrical power should be connected in the following order

Insert the ground wire into the middle terminal labeled “G”.

Insert the hot wire into the left terminal labeled “L”.

Insert the neutral wire into the right terminal labeled “N”.
For safety and proper operation, the monitor must be properly grounded through their
power cord. In cases where potential noise sources could affect the performance of the
equipment, a "surge suppressor" must be installed with the unit. The following drawings
show power terminal connections for models SCM2500XRD and SCC3500XRD
monitors, and Dura-Trac or Dura-Trac II Sensor.

Figures 3 thru 5 illustrate power-wiring connections to Monitor/Controller, Dura-Trac,

and Dura-Trac II Sensors.

FUSE

FUSE: AGC-1.5A
WARNING TURN POWER OFF BEFORE MAKING ANY WIRE CONNECTIONS 17 18 19 20
OFF TO AVOID DAMAGING THE ELECTRONIC CIRCUIT.
SMM | Sensor

*
*

ON *
* *
L G N
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND

N
L

FIELD WIRING TERMINALS

POWER CORD

FIGURE 3. Monitor/Controller Power Wiring

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 Page 14
FIGURE 5a. Dura-TRAC II Sensor Power Wiring
FIGURE 4. Dura-Trac Sensor Power Wiring
N
L1
9 10 11 12

High
Cond.
Opto (W)

N
Opto (B)
Opto (O)
8

L1
- Probe
7

+ Probe
6

Shield
5

Opto
4

Signal
3

Vdc Gnd
2

+24 Vdc
1

9 10 11 12
High
Cond.
Opto (W)
Opto (B)
Opto (O)

8
- Probe

7
+ Probe

6
Shield

5
Opto

4
Signal

3
Vdc Gnd

2
+24 Vdc

Chemtrac, Inc.
 L1
N

9 10 11 12

High
Cond.
Opto (W)
Opto (B)
Opto (O)
8

- Probe
7

+ Probe
6

Shield
5

Opto
4

Signal
3

Vdc Gnd
2

+24 Vdc
1

FIGURE 5b. Dura-TRAC II Sensor with Automatic Maintenance Features

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3.3 SIGNAL WIRING

The Dura-Trac and Dura-Trac II Sensors transmit the sensing signal to

Monitor/Controller by a multi conductor wires, see Figure 7 for signal wires
interconnection diagram. Twisted shielded cable should be used. The cable should be
enclosed in conduit for maximum protection against damage or electrical interference.
Do not run cable in same conduit with any other wiring.

CAUTIONS

Make sure the monitor’s power switch is turn to off position before making any
signal wiring connections.

FUSE

FUSE: AGC-1.5A
WARNING TURN POWER OFF BEFORE MAKING ANY WIRE CONNECTIONS 17 18 19 20
OFF TO AVOID DAMAGING THE ELECTRONIC CIRCUIT.
1 9 17
SMM | Sensor

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

L G N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND

N
L

(WHITE)
(BLACK)
(BLUE)
(RED)

1 2 3 4 5 6 7 8 9 10
Opto (W)
Opto (O)
Opto (B)
+24 Vdc
Vdc Gnd
Signal +

+ Probe
Signal -

- Probe
Shield

FIGURE 6. Signal Wires Interconnection Diagram

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3.4 SAMPLE CONNECTION

Sample shall be connected to the sample cell inlet side. A 3/4" barbed fitting connection
is provided for hose connection. The PVC elbow opposite the inlet is the outlet. The
outlet sample must flow to an open drain (sample receiver). The cell cannot operate
properly if pressurized. Do not replace either fitting with any other type of fitting.

Start treated water sample through the cell at a rate of between 1 to 5 GPM. Make sure
the 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 SCC3500XRD, the pump control output of the controller must be set in the
MANUAL mode if the sensor is flushed or cleaned or if power to the sensor is
interrupted for any reason. The controller can be placed back in AUTO once power
and sample flow is restored. For system with Dura-Trac with flush with Sensor
Maintenance Module (SMM), during Automatic Flushing cycles, the pump control
output signal is maintained at a constant value (see Flush Menu).

DURA-TRAC TM

PATENTED MADE IN U.S.A.

SAMPLE OUTLET
SAMPLE INLET
3/4" BARB FITTING

PVC Drain 4" Cup

Funnel

2" Line

FIGURE 7. Dura-TRAC Sensor Sample Connection

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 CHEMTRAC
SYSTEMS, INC.

DURA-TRAC TM
II
PATENTED MADE IN U.S.A.

SAMPLE OUTLET
45 DEGREE ELBOW

SAMPLE INLET
3/4" BARB FITTING

4" Cup PVC Drain

Funnel

2" Line

FIGURE 8. Dura-TRAC II Sensor Sample Connection

3.5 SENSOR FLUSH OPTIONS

The SCM2500XRD and SCC3500XRD are available with one of two options for
automatic sensor flushing/cleaning. The first option is the Dura-Trac with flush and is
composed of a valve mounted onto the Dura-Trac sensor, which is connected to flush
water. The second option is the SMM and is composed of a flush valve, sample
isolation valve, and chemical injection pump. The Dura-Trac with flush is recommended
for Drinking Water applications where high turbidity is often experienced. The SMM is
recommended for Waste Water applications. These options are only supplied if
specified at the time of purchase. The line of monitors offered by Chemtrac® can be
upgraded to include one of these two options. To upgrade to the Dura-Trac with either
options, the Dura-Trac sensor will need to be returned to the factory.

Potable water or the best quality plant water available shall be used for the flush 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.
3.5.1 Dura-Trac with Flush

Connect the male NPT end of the ¼’’ MNPT to ¼’’ Quick Connect Tube adapter fitting
(supplied with the unit) to the flush water supply. Connect a sufficient length of ¼’’
Teflon tubing between the flush water supply (¼’’ Quick Connect Tube adapter fitting)
and the valve’s ¼” quick connect fitting (see Figure 10 on the next page). The flush
valve’s outlet should already be connected to the probe flush assembly. The third valve
outlet (located on the bottom of the valve and pointed towards the ground) is the drain
outlet. Run this outlet to an appropriate drain using ¼’’ semi-rigid tubing. A manual
control valve should be installed on the flush water line in close proximity of the unit so

Chemtrac, Inc. Page 18

 that the flush water may be shut off during sensor maintenance. Do not open flush
water supply valve until all connections have been made.

CHEMTRAC
SYSTEMS, INC.

DURA-TRAC TM

PATENTED MADE IN U.S.A.

FLUSH WATER
CONNECTION
1/8" NPT TO 1/4"
COMPRESSION

FLUSH VALVE

25 PSI
CHECK
VALVE

FIGURE 9. Dura-TRAC Sensor with Flush

3.5.2 Sensor Maintenance Feature Connections (Optional)

Figure 10 shows tubing connections for the Dura-Trac II sensor maintenance features.
Semi-rigid Teflon tubing (1/4” OD) should be used for making the connections. .

Note: 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.

 Connect an appropriate length of ¼’’ semi-rigid Teflon tubing between the flush
water supply line and the PINCH VALVE assembly quick connect fitting (located
on the valve port marked “P”).
 Connect an appropriate length of ¼’’ semi-rigid Teflon tubing between the flush
water supply line and the SENSOR FLUSH VALVE inlet quick connect fitting
(located on the valve port marked “P”).
 Connect an appropriate length of ¼’’ semi-rigid Teflon tubing between the
SENSOR FLUSH VALVE outlet quick-connect fitting (located on the valve port
marked “A”) and quick-connected fitting on probe flush assembly (located on the
bottom of the probe assembly).
 Connect an appropriate length ¼’’ semi-rigid Teflon tubing between the
“Chemical Wash” PUMP INLET quick connect fitting (Marked “IN”) on the bottom
of the DuraTrac II sensor and the chemical carboy.

Chemtrac, Inc. Page 19

  Connect an appropriate length ¼’’ semi-rigid Teflon tubing between the
“Chemical Wash” PUMP OUTLET quick connect fitting (Marked “OUT”) on the
bottom of the DuraTrac II sensor and the chemical injection port located on the
side of the probe block.
The PINCH VALVE assembly has a drain port on the actuator valve that should be
piped to the nearest drain using an appropriate length of ¼’’ semi-rigid Teflon tubing

During the automatic flush/cleaning cycle, the chemical pump injects a cleaning solution
into the sensor. This cleaning solution helps prevent 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.

Flush Water

DURA-TRAC TM
II
PATENTED MADE IN U.S.A.

CARBOY
TANK

FIGURE 10. Sensor Maintenance Tubing Connections

Chemtrac, Inc. Page 20

4.0 OPERATION
4.1 MONITOR/CONTROLLER USER INTERFACE

The Monitor/Controller is equipped with user interface keys, LED indicators, and audible
beeps. The interface keys are up (
), down (), left (), right (), and function keys.

= UP key

 = DOWN key

Graphically define function

keys. Acsess by pressing on
button directly below.

 = LEFT key  = RIGHT key

There are four LED lights to the left of the graphical display. These are:

Power –Green LED that illuminates when there is power to the unit.

Service - Yellow LED displays the status of the electronics.

Diag. – Green LED that blinks to give a diagnostic status of the remote sensor.
When this LED stops blinking, the remote sensor diagnostic alarm is in alarm
condition.

Alarm – Red LED that illuminates when the Monitor/Controller is in alarm condition.

The Monitor/Controller provides the user with an audible beep feedback every time a
button is pressed.

The menu navigation of the Monitor/Controller is by using buttons 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
or  key, the text
cursor will move to a different menu text line.
3. To modify the parameter setting on the active menu text, first press the  key
to gain access to the parameter and then press the
or  key to scroll
through the parameter range. By holding down the
or  key, the number will
increased or decreased with larger unit changes.
4. When finished making the parameter change, press  key to store the value.
At this point, the new parameter has not been saved. After all parameters
modification are completed, press the SAVE function key to accept the change
or press the MAIN function key to discard the changes.

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4.2 SCM2500XRD READOUT, MENUS, AND CONTROLS

The menu system for the SCM2500XRD is simple to navigate, below you will find the
different screens accessible through the function keys (SETUP, ALARM, and FLUSH):

4.2.1 SCM2500XRD Main Screen

The MAIN screen on the SCM2500XRD is the screen used under normal operation of
the instrument. From this screen, all other features and menus can be accessed. The
menu screen shows with Flush option.

 




Definitions
 Streaming Current Value (SCV) ranges from –1000 to +1000
 Gain, signal amplification factor, adjustable from 1X to 20X
 Next Flushing Cycle (optional): If the unit include sensor flush feature, the
menu display the time when the next flush will occur in days, hours, and minutes.
 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 chemical dosage has been obtained, the user can null the reading so
that the setpoint becomes referenced to zero for easier interpretation (see Setup
Screen Menu).
 Function Keys – There are four main menu selections across the bottom for the
four buttons below. The four menus are:
SETUP – SCV Setup Menu
ALARM – Alarms Status
FLUSH – Sensor Flush Control Menu
Pressing one of these keys directly below these menu selections accesses the
functions within that menu.

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4.2.2 SCM2500XRD Setup Menu (1)

From the MAIN screen, press SETUP function key, the SETUP screen will display.
Within the SETUP screen menu, the GAIN, OFFSET, and SCV ALARMS settings can
be modified.








Definitions

 Sensor Gain: Signal amplification factor, adjustable from 1X to 20X. The gain
should be adjusted so that a regular change in dosage results in a noticeable
deviation (e.g. 20 to 30 units). To select the proper gain setting let the reading
stabilize for 10 minutes and record the reading. Make a normal dosage change
and then allow another 5 to 10 minutes for the reading to fully stabilize. If the
reading did not change noticeably, simply increase the gain setting and repeat
testing. If the reading changed, but did so by more than 50 units, it is suggested
to decrease the gain setting. Ideal change in Streaming Current for a normal
dosage change is anywhere between 20 to 50 units. If the reading seems
unstable when flow, dosage, NTU, and PH are stable, then check to ensure the
probe is clean and that the sensor is getting a well mixed sample.
 Offset Mode: Offset mode can be changed to IN or OUT. Changing the Offset
mode 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 value will display at the line below. On the Main Display, the
raw Streaming Current value (with offset) will be displayed to the right of the
Zero Offset: IN. The different between the Streaming Current value and the raw
is the offset value. To disengage the Offset, simply change the Offset mode to
“OUT” and the true Streaming Current Reading will be displayed.
 Offset Value: The Offset value indicates the amount of offset that has been
applied to the reading in order to offset the reading to zero. So that, at any time
the operator can see what the offset value is and if anyone has changed it from a
previous offset. To disengage the offset, simply change the Offset Mode to
“OUT” and the true Streaming Current Reading will be displayed. This is also
the method used to re-zero the reading if the current offset no longer
corresponds to optimum coagulant feed. To re-zero the reading when Offset
mode is “IN”, increased or decreased the Offset Value then press Enter to
SAVE.

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  SCV Lo (Low) Alarm - This is the streaming current low value alarm
(-1000 to +1000). This alarm should be set so that it correlates to a reading
which indicates an under dosage of chemical. Once properly set, if there is an
under dosage (or total loss) of chemical feed, the streaming current value will
drop below this alarm threshold and the alarm will be activated (meaning that the
Main Display will show “Alarm: On” and the Alarm Output will be engaged. Once
the streaming current value returns above the alarm threshold, the Alarm will
deactivate.
 SCV Hi (High) Alarm - This is the streaming current high value alarm
(-1000 to +1000).and works the same way as the SCV Low alarm except this
alarm value should be set to correlate to a reading which indicates an over
dosage of chemical.
 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.

SAVE Function Key – Pressing this key will save current setting modifications
and brings up the MAIN screen.
4.2.3 SCM2500XRD Setup Menu (2)

From the SETUP MENU (1), continue pressing the down arrow key until SETUP MENU
(2) menu screen display. SETUP MENU (2) menu screen is a continuation of the
SETUP MENU (1) menu screen.

Definitions

 SCV Filter: The filter function activate rolling average of the Streaming Current
value over time. The SCV filter can be set to OFF, 30, 60, 90, or 120 seconds.
The default setting is OFF.
 Control: The control function only applies to the SCC3500. It should always be
set for Reverse when the SCC3500 is being used to control cationic
coagulant/polymer. If an anionic coagulant/polymer is being controlled, then the
Control function needs to be changed to Direct.

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4.2.4 SCM2500XRD Alarm Status Menu

From the MAIN screen, press ALARM function key, the ALARM STATUS screen will
display. Within the ALARM STATUS menu you can view which Alarm has been
triggered, as well as, turn the Monitor/Controller’s audible alarm feature on and off.








Definitions:

 Diagnostic: Display sensor diagnostic alarm condition. When the sensor is in

diagnostic alarm, it will show ALARM, the green LED (Diag.) will also stop
blinking, and the Streaming Current value will show “---“. Most likely cause for a
diagnostic alarm is that the motor in the
sensor is not turning. Check to ensure the
motor is turning. If the motor is turning,
ensure the blade of crank is passing cleanly
through the opto-switch. If the blade is
rubbing against the opto-switch, make an
adjustment by loosening the setscrew of the
crank and sliding it over so that the blade
lines up in the middle of the opto-switch. If the blade was rubbing, it will be
necessary to use compressed air to remove any debris (dust) that may be
blocking the optics of the opto-switch. Finally, check the interconnect wiring if no
other 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.
 SCV Lo (Low): The SCV Lo Alarm indicates that the SCV fall below the SCV Lo
Alarm threshold.
 SCV Hi (Low): The SCV Hi Alarm indicates that the SCV rises above the SCV
Hi Alarm threshold.
 Dry Contact: Digital input status (normally open) indicates the state of digital
input. When digital input is close, the ALARM condition will display.
 MAIN Function Key – Pressing this key will bring up the MAIN screen.
 Audible Alarm Indication – The Monitor/Controller is equipped with audible
alarm feature. The audible alarm will beep and the red LED light will come on
when any alarm condition occurred. The  symbol will appear when the audible
alarm is enabled, see Special Function Key’s definition below to activate and
deactivate the audible alarm. There are two audible alarm sound lever; high and
low. When the audible alarm is enabled and alarm condition occurs, high-level
beep will be generated. The method of acknowledging the alarm is to press the
ALARM function from the MAIN screen, the alarm beep will switch to low level. If
any new alarms occur, the high-level beep will be generated to notify the user of
the new alarm.

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 Special Function Key – The audible alarm can be toggled ON and OFF by
pressing both  and
keys. The  symbol will only appear when the audible
alarm is enabled. Once the audible alarm is disabled, the only way to enable is
to toggle with this Special Function key.

When any alarm is triggered, a +24 Vdc signal will be present on the Monitor’s digital
alarm output terminals. This signal can be connected to a SCADA/DCS system to alert
the operators to an Alarm condition. In lieu of a +24VDC signal, an optional solid state
relay output is available (must be specified with order).

After being properly adjusted by the operator to match up with the upper and lower SCV
readings that typically correlate to the acceptable window of process performance, the
Hi and Lo Alarms alert the operator as to whether the SCV has exceeded acceptable
limits. A Lo Alarm signify an underfeed of chemical (even possible loss of chemical
feed) and a Hi Alarm signify an overfeed.

4.2.5 SCM2500XRD Optional Flush and/or Sensor Maintenance Control Menu

This flush feature is an option that is available for both the SCM2500XRD and the
SCC3500XRD. See Section 3.3.7 for detailed description.

4.3 SCC3500XRD READOUT, MENUS, AND CONTROLS

The menu system for the SCC3500XRD is simple to navigate; below you will find the
different screens accessible through the function keys (SETUP, ALARM, FLUSH, and
CTRL). The menu screen shows with Flush option.

4.3.1 SCC3500 Main Screen










Definitions
 Streaming Current Value (SCV) ranges from –1000 to +1000
 Gain, signal amplification factor, adjustable from 1X to 20X
 Next Flushing Cycle (optional): If the unit include sensor flush feature, the
menu display the time when the next flush will occur in days, hours, and minutes.
 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.

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 Offset Value: -1000 to +1000
The Offset function is used to automatically zero the current reading. Once an
optimum chemical dosage has been obtained, the user can null the reading so
that the setpoint becomes referenced to zero for easier interpretation (see Setup
Screen Menu).
 Coagulant Pump Control Mode
Mode: AUTO or MAN
PID Control Output: 0-100.00%
SP (Setpoint): SCV control setpoint (-1000 to +1000)
 Function Keys – There are four main menu selections across the bottom for the
four buttons below. The four menus are:
SETUP – SCV Setup Menu
ALARM – Alarms Status
FLUSH – Sensor Flush Control Menu
CTRL – Coagulant Pump Control and Flow Based Control Menu
Pressing one of the keys directly below these menu selections 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  and
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 signal to the
coagulant pump, which corresponds, to the manual value. The manual control
value can be changed by the operator by pressing the
or  key, see Section
3.7 for more detail.

4.3.2 SCC3500XRD Setup Menus

From the MAIN screen, press SETUP function key, the SETUP screen will display.
Within the SETUP screen menu, the GAIN, OFFSET, SCV ALARMS, and SCV Filter
settings can be modified. The SETUP Menus are the same for SCM2500XRD and
SCC3500XRD see Sections 3.2.2 and 3.2.3 for detail descriptions.

Note: See the Addendum section if your SCC3500 has the Remote Control Option.

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4.3.3 SCC3500XRD Alarm Status Menu

From the MAIN screen, press ALARM function key, the ALARM STATUS screen will
display. Within the ALARM STATUS menu you can view which Alarm has been
triggered, as well as, turn the Monitor/Controller’s audible alarm feature on and off.

 






Definitions:

 Diagnostic: Display sensor diagnostic alarm condition. When the sensor is in

diagnostic alarm, it will show ALARM, the green LED (Diag.) will also stop
blinking, and the Streaming Current value will show “---“. Most likely cause for a
diagnostic alarm is that the motor in the sensor is not turning. Check to ensure
the motor is turning. If the motor is turning, ensure the blade of crank is passing
cleanly through the opto-switch. If the blade is rubbing against the opto-switch,
make an adjustment by loosening the setscrew of the crank and sliding it over so
that the blade lines up in the middle of the opto-switch. If the blade was rubbing,
it will be necessary to use compressed air to remove any debris (dust) that may
be blocking the optics of the opto-switch. Finally, check the interconnect wiring if
no other 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.
 SCV Lo (Low): The SCV Lo Alarm indicates that the SCV fall below the SCV Lo
Alarm threshold.
 SCV Hi (Low): The SCV Hi Alarm indicates that the SCV rises above the SCV
Hi Alarm threshold.
 Pump Output Lo (Low): The Pump Output Lo Alarm indicates that the pump
output has exceeded the lower Alarm threshold.
 Pump Output Hi (High): The Pump Output Hi Alarm indicates that the pump
output has exceeded the upper Alarm threshold.
 Dry Contact: Digital input status (normally open) indicates the state of digital
input. When digital input is close, the ALARM condition will display.
MAIN Function Key – Pressing this key will bring up the MAIN screen.

Audible Alarm Indication – The Monitor/Controller is equipped with audible
alarm feature. The audible alarm will beep and the red LED light will come on
when any alarm condition occurred. The  symbol will appear when the audible
alarm is enabled, see Special Function Key’s definition below to activate and
deactivate the audible alarm. There are two audible alarm sound lever; high and
low. When the audible alarm is enabled and alarm condition occurs, high-level
beep will be generated. The method of acknowledging the alarm is to press the

Chemtrac, Inc. Page 28

 ALARM function from the MAIN screen, the alarm beep will switch to low level. If
any new alarms occur, the high-level beep will be generated to notify the user of
the new alarm.
 Special Function Key – The audible alarm can be toggled ON and OFF by
pressing both  and
keys. The  symbol will only appear when the audible
alarm is enabled. Once the audible alarm is disabled, the only way to enable is
to toggle with this Special Function key.

When any alarm is triggered, a +24 Vdc signal will be present on the Monitor’s
alarm terminals 13 (+) and 14 (-). This signal can be connected to a
SCADA/DCS system to alert the operators to an Alarm condition. In lieu of a
+24VDC signal, an optional solid-state relay output is available (must be
specified with order).

After being properly adjusted by the operator to match up with the upper and
lower Streaming Current readings that typically correlate to the acceptable
window of process performance, the Streaming Current Value (SCV) Hi and Lo
Alarms alert the operator as to whether the streaming current value has
exceeded acceptable limits. A Lo Alarm will signify an underfeed of chemical
(even possible loss of chemical feed) and a Hi Alarm will signify an overfeed.
4.3.4 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 PUMP CONTROL (1) Menu screen, the PID tuning
parameters can be adjusted.









Definitions

 Pump Ctrl: The Controller’s pump output control has two mode of operation;
AUTO or Manual. In AUTO mode, the pump output percent will increased or
decreased automatically in response to deviations from the setpoint. In MAN
mode, the pump output percent can be increased or decreased manually by
setting the Man Output. The two mode can be toggle by pressing the
or 
key.
 Man Output: In MAN mode, the pump output percent % can be increased or
decreased by pressing the
or  key. The Man Output value can be changed
from 0 to 100% at 0.1% increment. This parameter is saved in non-volatile
memory. When running in Automatic mode, the Man Output setting is ignored.
When switching from AUTO to MAN, the pump output will be locked into
whatever output % it was at when the control was set to Man. In other words,

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 the transfer from Auto to Man is bumpless and no sudden jumps in the output
will occur.
 SCV Setpoint: The SCV setpoint is the SCV value that the controller is
programmed to maintain when in AUTO mode. The SCV setpoint value can be
changed from -1000 to +1000 at one unit increment by pressing the
or  key,
see Section 4.7 for determine the optimum setting. To determine the setpoint,
the operator must first adjust the chemical feed manually until an optimum
dosage is reached. Once the optimum dosage has been reached, the operator
simply records the Streaming Current Value seen on the display and enters this
as the Setpoint value. It is important that the correct polarity (+/-) be entered
when programming the setpoint.
 Proportion Band: The Proportional Band setting determines the level of
response, or amount of change to the pump output, when the SCV deviates from
the setpoint. The Proportional Band value can be changed from 1 to 1000 at 1
unit increment by pressing the
or  key. As a general rule, the Proportional
Band is set for the difference between the Raw (Untreated) and Treated reading.
If Raw water produced a reading of -350 and Treated water read -175, the
Proportional Band would be set for 175. Lowering this value will result in larger
adjustments being to the pump output, while raising this value will result in
smaller adjustments. See Section 4.7 for more info on determining the optimum
setting.
 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

or  key. As a general rule, the Integral Time is set to equal the number of
seconds in lag time between the coagulant injection point and the sensor. For
example, if it takes 90 seconds for the SCM to respond to a chemical feed
change, the Integral Time would be set for 90. Lowering this value will result in
larger adjustments being to the pump output, while raising this value will result in
smaller adjustments. See Section 4.7 for determining the optimum setting.
 PID Rate: The PID Rate function serves to improve the controller’s response
when higher Proportional Band and Integral Time settings appear to be too
responsive for the application. The PID Rate setting is usually left at 1 for most
applications since proper setting of Proportional Band and Integral Time are
capable of providing proper response. Higher PID Rate settings will serve to
buffer the responsiveness of the controller. The PID Rate value can be changed
from 1 to 20 at 1 unit increment by pressing the
or  key, see Section 3.7 for
determining the optimum setting.
MAIN Function Key: Pressing this key will ignore any setting modifications on
this screen and brings up the MAIN screen.

SAVE Function Key: Pressing this key will save current setting modifications
and brings up the MAIN screen.

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4.3.5 SCC3500XRD Pump Control (2) Menu

From the PUMP CONTROL (1) menu screen, continue pressing the down arrow key
until PUMP CONTROL (2) menu screen display appears. PUMP CONTROL (2) menu
screen is a continuation of the Pump Control (1) menu screen.




 



Definitions

 Pump Out Min: This setting is used to prevent the pump control signal from
dropping below a user defined limit. The minimum percent (%) value can be
increased or decreased by pressing the
or  key. The minimum percent (%)
value can be changed from 0 to 100% at 0.1% increment.
 Pump Out Max: This setting is used to prevent the pump control signal from
going above a user defined limit. The maximum percent (%) value can be
increased or decreased by pressing the
or  key. The maximum percent (%)
value can be changed from 0 to 100% at 0.1% increment.
 Output Lo: This setting defines the low alarm value of the pump control output
signal. The low alarm percent (%) value can be increased or decreased by
pressing the
or  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.
 Output Hi: This setting defines the high alarm value of the pump control output
signal. The low alarm percent (%) value can be increased or decreased by
pressing the
or  key. The high alarm percent (%) value can be changed
from 0 to 100% at 0.1% increment. When the pump control output signal rise
above the high alarm value, alarm condition will occur.
 MAIN Function Key: Pressing this key will ignore any setting modifications on
this screen and brings up the MAIN screen.
 SAVE Function Key: Pressing this key will save current setting modifications
and brings up the MAIN screen.
4.3.6 SCC3500XRD Flow Control (3) Menu

From the PUMP CONTROL (2) menu screen, continue pressing the down arrow key
until FLOW CONTROL (3) menu screen display appears. FLOW CONTROL (3) menu
screen is a continuation of the Pump Control (2) menu screen.

When ENABLED, the FLOW CONTROL function allows the user to control the chemical
feed based on the process FLOW rate and the Streaming Current Value PID control
output. The flow control is a proportional pump output control base on the process flow

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 rate. The proportional pump output control is set by using the four parameters; Flow
Min, Pump Output Min, Flow Max, and Pump Output Max.

Flow control 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 control is enabled, the
pump control output is proportionally changed by the amount of process flow changes in
conjunction with the PID loop based on the SCV setpoint. The following are parameters
used in the flow control:









Definitions

 Flow Ctrl: The flow control modes are ENABLED or DISABLED. When the
flow control is ENABLED, pump output percent % will increase or decrease
automatically in response to process flow changes and SCV deviation from the
setpoint. When the flow control is DISABLED, the pump output percent will
increase or decrease automatically in response PID control only and not to
changes in the flow signal. Switch between ENABLED or DISABLED control
mode by pressing either
or  key.

 Band: The Band setting determines how much the PID can adjust above or
below the pump output value that is determined by the Flow Control settings (see
Flow Min/Max, Pump Output Min/Max). This allows the user to limit the range in
which the SCM PID can operate within. The graph on the following page
provides an example of how the + and – Band settings are used. The SCV
control band percent (%) value can be increased or decreased by pressing the

or  key. The SCV control band percent (%) value can be changed from 0 to
100% at 1% increment.
 Flow Min: Minimum process flow input signal (in percent) that will result in the
minimum pump control output signal (as determined by Pump Output Min). The
percent (%) value can be increased or decreased by pressing the
or  key.
The percent (%) value can be changed from 0 to 100% at 0.1% increment.
NOTE: When the Flow signal drops below the Flow Min setting, the
Pump Output will go to 0% (4mA) and the PID control goes into a Hold
status. So, when setting the Flow Min, keep in mind that it should be set to
a value that will always be higher than the actual flow signals produced
when the process is running.

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  Pump Output Min: Pump control output for the minimum process flow set
above (Flow Min). The percent (%) value can be increased or decreased by
pressing the
or  key. The percent (%) value can be changed from 0 to
100% at 0.1% increment.
 Flow Max: Maximum process flow input signal (in percent) that will result in the
maximum pump control output signal (as determined by Pump Output Max). The
percent (%) value can be increased or decreased by pressing the
or  key.
The percent (%) value can be changed from 0 to 100% at 0.1% increment.
 Pump Output Max: Pump control output for the maximum process flow set
above (Flow Max). The percent (%) value can be increased or decreased by
pressing the
or  key. The percent (%) value can be changed from 0 to
100% at 0.1% increment.
MAIN Function Key: Pressing this key will ignore any setting modifications on
this screen and brings up the MAIN screen.

SAVE Function Key: Pressing this key will save current setting modifications
and brings up the MAIN screen.

The above graph illustrates how the Flow Control settings work together to determine the Pump
Output. The solid line represents the Pump Output as determined by the Flow Control settings
(Flow Min, Flow Max, PO Min, PO Max) and the two dashed lines represent the upper and
lower limits that the SCC PID must operate within as determined by the +Band and –Band
settings.

The first step in establishing the proper flow control settings is to determine the % Flow Min
and % PO Min settings. Generally, these can both be set for 0%. The %Flow Max should be
set for whatever is the maximum flow signal the SCM will see when the plant is operating at
higher flows. And the %PO Max would be set to equal the Pump Output that produces near
optimum quality finished water at the higher flow rate during normal turbidity conditions.

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As an example, let’s assume the flow meter that is tied to the SCC is setup to measure a flow of
0 to 1000 gpm and the plant is currently operating at its highest flow rate of 800 gpm. This
would produce a Flow Input Signal of around 80%. While the plant is operating at this flow rate,
and while the raw water turbidity conditions are normal, the operator would manually adjust the
pump output to establish an optimum feed rate. Let’s assume that requires the operator to
manually set the pump output for 40% on the SCC3500. Using these two variables (80% flow
signal and 40% Pump Output), we can now establish our % Flow Max and % PO Max settings
as shown above. Note: Assuming the SCC is being used to control the speed of a pump that
also has a manual stroke setting, the % PO Max setting should be changed if any manual
adjustment is made to the Pump’s Stroke setting.

Once the Flow and PO Min/Max settings are determined, the next thing to determine is the +
and – Band settings. If the % PO Max setting was established under “normal” turbidity
conditions, and assuming the turbidity doesn’t generally go much lower than what is considered
“Normal”, then the – Band setting can be set to something like 5 to 10% because it can be
assumed the SCC doesn’t typically need to reduce the coagulant dosage by very much from
what is considered normal. The + Band setting on the other hand needs to be set to a value
large enough to allow the SCC to increase the Pump Output by large enough % in order to
handle the larger turbidity/organics excursions.

Since there are several variables and situations to consider when using the flow pacing feature,
it is recommended to contact Chemtrac, Inc. (770-449-6233) to discuss your unique application
requirements so that you can be better advised on what settings to use.
4.3.7 SCC3500XRD Optional Flush and/or Sensor Maintenance Control Menu

Sensor Flush is only available with the optional Dura-Trac Flush feature or Sensor Maintenance
Features added to the Dura-Trac II Sensor

From the MAIN screen, press FLUSH function key, the FLUSH CTRL MENU screen will
display. The goal of the sensor flush is to minimize the need for operator involvement for
maintenance purposes. This feature greatly enhances the reliable operation of the Streaming
Current Monitor. Within the FLUSH CTRL MENU screen, the flush parameter settings can be
modified.




 



Definitions

 Auto Flush: The Sensor Maintenance option or Dura-Trac with Flush runs
an automatic flushing/cleaning sequence and will continue to flush according
to the flush parameter settings. The Auto Flush can be set to ENABLED or

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 DISABLED. When it is in ENABLED mode, the Monitor/Controller will begin
flushing based on Flush time value setting. When it is in DISABLED mode,
the flushing will be de-activated.
 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  key to gain access to the parameter
and then press the
or  key to scroll through the parameter range. To
modify the next parameter setting (number’s unit), press the  key to gain
access to the parameter and then press the
or  key to scroll through the
parameter range. When finish, press the  twice to get to the next menu
line.
 Flush Period: The flush period setting determines the duration of water
flush to the sensor. With each flushing sequence, there are actually two
flushes performed. One at the beginning of the flush cycle (before the wash)
and one after the wash. The Flush setting determines the duration of each of
these flushes. So that, if Flush is set for 30 sec., the actual total time of flush
duration will be 60 seconds (30 seconds for each flush). The value can be
increased or decreased by pressing the
or  key. The value can be
changed from 1 to 99 at 1 second increment.
 Chemical Period: The Chemical period setting determines the duration of
the chemical pump on time. It is recommended to use default value of 8
seconds. Excessively long chemical period (or too highly of a concentrated
chemical like Acid) can damage the probe. The value can be increased or
decreased by pressing the
or  key. The value can be changed from 1
to 20 at 1second increment. This feature is only available on the optional
Dura-Trac II with Sensor Maintenance Features.
 Wash Period: The Wash period setting is only applicable for the optional
Dura-Trac II with Sensor Maintenance Features. For the Dura-Trac with
flush option, this setting should be left at 30 sec. The Wash Period setting
determines the duration of the sensor’s chemical washing. Harder to remove
scale or deposits will require longer Wash times. It is recommended to only
use a Wash duration that is no longer than required to remove
scale/deposits. Excessively long Wash durations (or too highly of a
concentrated chemical like Acid) can damage the probe. The value can be
increased or decreased by pressing the
or  key. The value can be
changed from 1 to 99 at 1second increment.
 Hold Period: The Hold period setting determines how long the monitor’s
output will be held stable (or frozen at last output value before the flush) after
the flushing is finished. Flushing will cause the actual monitor reading to
fluctuate, thus it would adversely affect an automatic chemical feed control
program running through a Supervisory Control 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 proper Hold setting, record the streaming current value before
the flush starts and then time how long it takes for the monitor to reach the
previously recorded reading after the flush is completed (this must be done
while the monitor is online with treated water passing through the sensor).

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 The simplest way of doing this will be to record the reading and then change
the Man. Flush from “Off” to “On” as this will activate the flush sequence. If it
takes 30 seconds for the reading to stabilize to the previously recorded
reading, then set the Hold setting for 1 minute. If it takes 50 seconds, then it
is recommended to set the Hold for 2 minutes. The value can be increased
or decreased by pressing the
or  key. The value can be changed from 1
to 99 at 1 minute increment.
MAIN Function Key: Pressing this key will ignore any setting modifications
on this screen and brings up the MAIN screen.

FLUSH Function Key: Pressing this key will activate a one-time manual
flush. This can be done at anytime regardless of the Auto Flush mode.
 SAVE Function Key – Pressing this key will save current setting
modifications and brings up the MAIN screen.

Figure 11 shows the timing diagram of the Sensor Flush.

ON
PUMP OUTPUT HOLD
HOLD PERIOD

OFF

ON
SAMPLE ISOLATION
OFF

ON
SENSOR FLUSH FLUSH RINSE
AND RINSE
OFF

ON
CHEMICAL PUMP WASH PERIOD

OFF

TIME (SECONDS)

FIGURE 11. Automatic Flush Timing Diagram

NOTES

Sample Isolation and Chemical Wash only apply to instruments with the optional
Dura-Trac II with Sensor Maintenance Features. The Dura-Trac with flush option
does not include the sample isolation or chemical pump feature; however, there
will still be a delay between sensor flush and rinse.

4.4 SYSTEM OPERATION

After sample flow is established and power has been applied to the sensor and
streaming current monitor, allow 10-15 minutes or longer for the reading to stabilize.
The reading may fluctuate 5 to 10 units, even under stable conditions due to the
chemical not being thoroughly mixed. If readings fluctuate widely, refer to
Troubleshooting Guide. The monitor’s reading may be negative, zero, or positive. The
monitor is simply indicating the streaming current value of the sample. In most
applications, the reading will be slightly negative (anionic).

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 After the reading has had ample time to stabilize, adjust the chemical dosage by 10% to
20% to test the response of the monitor. For model SCC3500XRD, use the
or 
key to manually adjust chemical feed (Note: the control mode must be set to Manual in
order to manually adjust the pump speed). For a 10% dosage change, the reading
should respond by changing 10 to 30 SCV units. If the response is less than 10 units,
increase the gain. Likewise, if the response is greater than 30 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 performed to determine the Raw SCV reading. This will help
determine the Proportional Band setting, LO SCV Alarm setting, and give a better
understanding of instrument response. To determine the Raw SCV reading, shut off
sample flow to the sensor and turn the outlet fitting up. Slowly pour a 2 liter sample of
raw untreated water into the sensor and allow the reading to stabilize and then record
the reading. This reading should serve as an absolute alarm value, which if measured
by the monitor will indicate a loss of chemical feed. It is recommended to set the Lo
SCV Alarm value (see Alarm setup menu) between the Raw SCV measurement and the
setpoint value. Further testing will help to determine the best ideal alarm value. The HI
Alarm value should be set above the setpoint value and at a point where testing shows
an unacceptable amount of overfeed.

After verifying proper response, the next step should be to optimize the process to
establish an SCV setpoint. The SCV setpoint can then be zero’d so that the setpoint will
be adjusted to a reading of zero (0). This is done by entering the Setup menu and
changing the Offset mode to “IN”. Offsetting the SCV is not necessary for normal
monitor operation as it is only provided so that an easier reference of zero can be used
for monitoring changes in the process. For example, if the true SCV setpoint reading
was –150, and the user switched the Offset Mode to “IN”, then a value of +150 will be
added to whatever the true SCV reading is. For example, if the true SCV reading goes
from -150 to -145, then the offset reading would go from 0 to +5 because -145 + 150 =
+5. Once the setpoint has been zero’d, it is easier to determine whether chemical is
being under or overdosed since going negative (anionic) from 0 would be an under-dose
and going positive (cationic) would be an overdose. A setpoint of zero (0) is also easier
for multiple operators (night and day shift) to remember. Since the setpoint will change
seasonally, adjusting the setpoint so that it equals zero (0) helps to avoid confusion.

Eventually, a new setpoint might need to be established due to seasonal changes,

changes in sources of water, more than 0.5 pH changes, or large excursions in turbidity.
But under normal conditions, the setpoint should not require adjustment on a daily or
even weekly basis. It is recommended to use the monitor for a few weeks in Manual
mode with the Offset “Out” in order to become familiar with the operation and response
of the unit.

4.5 TREATMENT OPTIMIZATION PROCEDURE

The treatment optimization process should be done slowly and stepwise. Assuming that
the plant is producing acceptable water with present chemical dosages, trim
approximately 10%, wait for the reading to stabilize, and record the reading as the
setpoint. You may need to change GAIN setting to increase magnitude of response. If
the settled and finished water quality is still acceptable at the reduced dosages, trim
another increment, wait for the reading to stabilize, and record the reading as the new
setpoint. Continue this process, being sure to wait long enough each time to see the full
effect of the chemical feed changes on the process (i.e. settled water turbidity,

Chemtrac, Inc. Page 37

 appearance of floc). In between these dosage changes it will be necessary to maintain
the setpoint. Failure to maintain the setpoint while trying to reach a lower dosage level
could result in under dosing the chemical if turbidity starts to increase. By maintaining
the setpoint, the chemical dosage is kept in check with process changes (i.e. turbidity,
flow rates).

If the Offset function is being used, re-zero the monitor reading as described in section
4.2.2 after each reduction in chemical feed. If a cationic coagulant is being used, the
streaming current value will become more negative with each reduction in dosage. The
"optimum setpoint" is obtained when a minimum dosage of coagulant is being fed and
produces desired results for the particular treatment process. This setpoint will remain
very close to the same reading even when raw water turbidities increase or decrease.
Simply adjust the coagulant dosage to maintain this setpoint reading on the monitor.
This procedure may need to be repeated on a monthly to seasonal basis to ensure the
setpoint remains representative of optimum process performance.

NOTE - If automatic control is used, refer to Section 4.7 on Automatic Control.

4.6 MANUAL CONTROL USING CONTROLLER

Only available on model SCC3500XRD.

Make electrical connections between Streaming Current Controller and the chemical
feed pump. The AUTO or Manual control mode is indicated on the MAIN screen. To
switch between AUTO or Manual control mode can be done by pressing both
and 
keys from the MAIN screen. Once in Manual control mode, the pump control output
percentage can be increased or decreased by pressing the
or  key.

The AUTO or Manual control mode can also be change from the Pump Control (1)
menu. Once Pump Control (1) menu is display, move the text cursor on the far left hand
side of the screen () to “Pump Ctrl:” then press  the control text will blink. The
control mode can be set by pressing the pressing
or  key, this will toggle between
AUTO and MAN mode. Set the controller to MAN. Once completed, press  key then
press
or  key to get to next parameters on that screen. Next press  key to “Man
Output:” then press  the control number will blink. The percent (%) number will blink,
the manual chemical feed control value output can now be increased or decreased the
by pressing
or  key to the desire manual control value. When completed, press 
key to get to other parameters on that screen. The SAVE Function Key must be
pressed to save current setting modifications and brings up the MAIN screen.

4.7 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
constants" termed Proportional Band, Integral Time, and Rate. Controllers with these
three functions are sometimes called "3-mode controllers," or "PID controllers". In
order to explain the purpose of these functions, a brief review of how a simple
proportional controller works may be helpful.

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 Many water treatment plants have "flow controlled" coagulant feed, i.e., when raw water
flow increases, a signal is sent to the coagulant pump that immediately increases the
feed rate. In other words, there is no "lag time" between water flow increasing and
coagulant increasing. This controller works extremely well in maintaining proper dosage
as long as the water flow is the only thing changing. However, if turbidity is changing,
the proper chemical dosage cannot be maintained with a simple proportional controller.

Since the SCV is taking its sample downstream of the coagulant feed point, there will be
some "lag time" before it can sense a change in turbidity, alum feed, raw water flow, etc.
Because this “lag time” exist, the controller must have a way to account for it, otherwise
the result would be continuous cycling above and below the setpoint,. The Proportional
Band, Integral Time, and PID Rate functions provide a way to eliminate cycling due to
the lag time between coagulant additions and streaming current sensing.

The following are description of parameters used in the PID control loop algorithm:

Process Variable: This is the Streaming Current Value (SCV), and it is what the
controller is constantly comparing to the Setpoint to determine what changes in
PID Output are required.

Setpoint: The process variable “target” that the controller is trying to maintain.

PID Output: The 4-20mA output signal produced by the controller. The output is
used to control the coagulant pump in an effort to keep the process variable near
the setpoint..

Proportional Band: This setting determines the controller’s response to changes
that occur in the SCV. Raise this value and the controller will make a smaller
adjustment when the SCV drifts away from setpoint.

Integral Time: This setting accounts for the lag time in the process between
coagulant injection point and the sample point for the SCM. If lag time is 60
seconds, the Integral Time should be set for 60.

PID Rate: The value is a function design to improve the PID response in
applications with exceedingly long lag times.

Maximum Output: Defines the maximum value for the output signal to the
coagulant pump.

Minimum Output: Defines the minimum value for the output signal to the
coagulant pump.

The Controller’s PID loop is designed for reverse acting; process variable goes down will
cause the output to go up. To set the loop to be direct acting, go to the second page of
the Setup menu and change the setting to Direct.

The following describe each PID parameter in detail.

Proportional Band
The proportional band setting is dependent upon the response of the sensor to process
changes. The more responsive the Controller the higher the proportional band constant
should be set.
The simplest way to determine a good starting point for the Proportional Band setting is
to measure Raw water (no coagulant) and subtract the optimum treated water reading
from it and use the difference as your Proportional Band setting. For example, if Raw
water is -350 SCV and the SCV of the treated water is -150, then Proportional Band
should be set to equal the difference which is 200.

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 The Proportional Band is the setting that is generally used to further tune the controller
for the desired response. This setting should be lowered if the controller seems to be
sluggish and it takes over 10 to 15 minutes to get close to the setpoint. Raise this
setting if the controller appears to be adjusting the coagulant dosage too quickly (usually
indicated by a constant overshooting of the setpoint and an oscillation in both the Pump
Output and SCV signals). When making adjustments, it is recommended to adjust this
setting by 10% at a time and then monitor performance before making further
adjustments.
Integral Time
A basic rule for setting the Integral Time constant setting is that the longer the lag time,
the higher integral time constant should be. To determine a good starting off value,
place the controller into manual and then decrease the Pump Output by 10 to 20%.
Start a timer and see how long it takes (in seconds) to see a response. If response
takes 75 seconds, then set the Integral Time to 75.

PID Rate
The PID Rate setting is usually left at 1 for most applications. 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 should not exceed 10.

Output Limits (Min and Max)

The output limits define the maximum and minimum values of the pump control output
signal. This control can be used to limit the % output of the controller, high or low. On a
4-20 mA controller with Max: 50%, the Output would never be greater than 12 mA, i.e.,
the chemical pump could not go above 50% output. This function can be used as a
safety measure to prevent overfeed or underfeed.

4.8 AUTOMATIC CONTROL SETUP

The controller can be programmed while it is operating in the AUTOMATIC mode.

When the controller is in the SET-UP mode, displays can be altered to review and adjust
the tuning constants. Control action continues undisturbed, except for the normal
consequences of changing a certain parameter.

The AUTO or Manual control mode is indicated on the MAIN screen. To switch between
AUTO or Manual control mode can be done by pressing both
and  keys from the
MAIN screen. When in AUTO control mode, the pump output percent will increase or
decrease automatically in response to deviations from the setpoint.

The AUTO or Manual control mode can also be changed from the Pump Control (1)
menu. When Pump Control (1) menu is displayed, move the text cursor on the far left
hand side of the screen () to “Pump Ctrl:” then press  key, the control text will blink.
The controller mode can be set by pressing
or  key, this will toggle between AUTO
and MAN modes. Set the controller to AUTO. When completed the change, press the
 key then press
or  key to get to other parameters on that screen. The
Proportional Band, Integral Time, and PID Rate can be changed by following the same
procedures. The SAVE Function Key must be pressed save current setting
modifications and brings up the MAIN screen. The MAIN Function Key can be used to
discard any new modification made to this screen and brings up the MAIN screen.

Chemtrac, Inc. Page 40

 To adjust tuning constants (refer to section 3.2):

Follow these three guidelines when establishing correct tuning constants:

1. Change only one control action at a time. Making two or more corrections is
confusing and can cause the controller to get out of control.
2. Never make a large change in a tuning constant. Make a small change and
observe the effect it has on the control action.
3. Allow plenty of time for the process to stabilize before making another change,
making changes in an unstable process can be misleading.

4.9 TUNING CONSTANT SPECIFICATIONS

Tuning constants are stored digitally in non-volatile memory and can be changed 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

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5.0 GENERAL GUIDELINES

5.1 STREAMING CURRENT VALUE RESPONSE FACTORS

Upscale Excursions: (Streaming Current Value (SCV), goes more positive)

Caused by:

Decrease in pH

Decrease in raw H20 flow

Decrease in color

Decrease in raw water turbidity

Decrease in lime

Decrease in caustic

Decrease in anionic polymers Increase in aluminum sulfate, or PAC

Increase in cationic polymers Increase in chlorine

Downscale Excursions: (Streaming Current Value (SCV) goes more negative)

Caused by:

Increase in pH

Increase in H20 flow

Increase in color

Increase in raw water turbidity

Increase in lime

Increase in caustic

Increase in anionic polymers

Decrease in aluminum sulfate, or PAC

Decrease in cationic polymers

Decrease in chlorine

Assumes that this is only parameter changing at the time.

NOTES

Potassium Permanganate usually has no appreciable effect on the SCV (at
normal dosages of 1-2ppm).

Increasing conductivity will drive the SCV toward zero.

Change in lag time may affect the SCV.

Chemtrac, Inc. Page 42

5.2 FUNDAMENTAL STREAMING CURRENT KNOWLEDGE

Introduction
It can take several days, weeks, or possibly even a few months for an operator
who has come to rely on Jar test, eye-balling, turbidity readings, or any other
method for determining coagulant dosage to become comfortable using the
Streaming Current Monitor as a tool for controlling coagulant feed. Very few
plants install an SCM and start controlling in Automatic mode in the first few
weeks. Monitoring the response and repeatability of the monitor through several
different turbidity excursions is the way most operators prove to themselves the
capabilities and reliability of Streaming Current technology.

The Importance Of Trending And Manual Control

It is suggested to hook up a chart recorder, or connect the monitor to SCADA, so
that the response and trend of the SCM can be monitored and compared to
turbidity & TOC readings, flow rates, and coagulant dosage adjustments. The
information derived from comparing the streaming current value to these other
parameters will assist the operator in understanding how the monitor responds to
changing conditions. During the first few days to weeks of operation, the monitor
should be used in Manual mode and all 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 responses will speed up the process of the
operators becoming comfortable with using the monitor to determine or
automatically control the coagulant dosage.

Setpoint – Why Does It Change?

It is important for the operator to understand that the ideal monitor setpoint can
occasionally change due to changes in water chemistry and wear on the probe
and piston assemblies. For example, a WTP may find that under the exact same
turbidity conditions a setpoint of -150 works great in the summer, but that a
setpoint of -50 works best in the winter. Unfortunately, there is no calibration
technique that can be used to correct for the monitor’s response to seasonal,
chemistry changes. This is the reason the monitor is considered a relative
reading. The dominating cause for the setpoint changing is due to seasonal
water chemistry changes (e.g. changes in temp, alkalinity, PH, TDS, and Color /
Organics). Seasonal additions of chemicals such as Potassium Permanganate
or Powder Activated Carbon can also have an effect on the monitor’s setpoint.
Because the monitor’s setpoint can change, occasional verifications of the
setpoint need to be made. If Jar testing or operator experience show that the
setpoint currently being used may no longer be ideal, simply readjust the
chemical feed manually to re-optimize the process and establish the new
stabilized reading as the new ideal setpoint. Verifying the setpoint once every
few weeks, or after chemistry changes occur, should be adequate for most
applications.

Chemtrac, Inc. Page 43

 Maintenance Issues
To keep the monitor working properly, occasional maintenance will be
necessary. Cleaning only takes a few minutes to perform and is usually needed
once every 2 to 6 weeks (depending upon water quality conditions). An easy
test to see if the sensor needs to be cleaned is to first verify the reading has not
become “noisy” or “bouncy” and then make small changes in chemical feed to
make sure the sensor has not become unresponsive. As long as the monitor is
stable, responsive, and the response is no less than it has been noted in
previous response testing, the sensor does not need to be cleaned. If the
reading does appear to be less responsive or unstable, then record the amount
of response or noise (signal drift as measured in a one minute period) and then
remove the probe and piston for cleaning. First look to see if there is any
obvious buildup or solids in the probe or on the piston. Then, clean the probe
with a test tube brush and a suitable cleaner (such as Comet/Ajax or
Rover/CLR). Finally, rinse the parts and install them back into the sensor. After
allowing the sensor time to stabilize, compare response and noise (if any) to
previous results to verify the cleaning did indeed improve response. If not, the
piston and/or probe may need to be replaced.

Eventually the moving parts of the monitor will wear. Most notably, the probe
and piston will wear the fastest and require replacement once every two years on
average (sooner if there is too much in the way of abrasive solids in the
sample). The Gain setting is provided as a way to compensate for wear that
occurs, but eventual these parts will need replacing. To determine if the probe
and piston need to be replaced simply make small chemical feed adjustments. If
the probe is unresponsive and cleaning and/or adjusting the Gain setting 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. Sensor maintenance will also include replacing
other mechanical parts like the linkage between the motor and piston, and the
motor itself. When these parts start to develop noticeable loose motion, they
can cause the reading to become less stable. If the reading starts to become
slightly unstable, and cleaning or replacing the probe and piston does not
eliminate the unstable reading, check the linkage and shaft of the motor to see if
it has excessive movement. If so, replace the worn parts.

The Usefulness Of Spare Parts For Determining Probe/Piston Wear

If a new spare probe and piston are on hand, it is suggested to keep these put
aside for comparing with the set in use and for replacing the old set when they
become worn. Always having a new, unused set on hand ensures you have a
point of reference for determining when your old set absolutely needs to be
replaced. For example, to compare the readings of your old probe and piston to
a new set, simple close the sample valve and drain all the sample out of the
probe block by removing the probe (you will also probably want to clean the
probe and piston at this time). Re-insert the probe and turn the outlet fitting 180
degrees so that it is pointing up. Next, pour a sample of untreated, raw water
into the probe block through the upturned outlet fitting. Allow the reading to
stabilize and record the reading and any amount of signal oscillation (bounce) as
seen in a one minute interval. Finally, remove the old probe and piston and
install the new set and pour in the raw water sample. Compare the readings of
the new probe and piston to the old set. If the readings from the old probe are
less than 50% of what the new probe reads and/or noticeably less stable, it is

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 recommended to replace the old set unless the operator feels confident that the
old set was performing satisfactorily. Once the signal strength from a probe and
piston set has degraded down to 50% to 25% of what a new set’s signal strength
is, the parts should be considered worn and probably in need of replacing.

It may not be necessary to replace both the piston and the probe at the same
time as usually the piston wears faster than the probe. To check this, simply
install a new piston with the old probe and compare those readings to the ones
obtained with the new piston and new probe combination. If the old probe and
new piston combination produce a reading that is within 50% or more of the new
set, then the probe can still be used as long as the new piston is installed. The
same procedure should be followed with a new probe and old piston to
determine if the old piston is still suitable for use. Using this procedure, the
operator can determine which part, if not both, needs to be replaced. Be sure to
order a replacement part(s) to have on hand as a spare once you have installed
the new probe and/or piston to replace the worn part(s).

Simple Functionality Test

The procedure 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 simple method of checking the monitor’s performance is to
pour untreated, raw water into the probe as outlined above. First, verify that the
raw water reading is significantly different from the treated water reading. The
raw water reading should be more negative than the treated water sample by at
least 50 units (taking into consideration that the gain has been properly set and
that coagulant dosage is near an optimum range). The raw water reading will
also normally be greater than –100 on 1X gain (except with samples that have a
higher alkalinity/conductivity). The reading on the raw water should also be
stable and not erratic or oscillating. Finally, add an optimum dosage of
coagulant to the raw water sample, mix it quickly, and then immediately pour the
sample into the sensor to verify the reading responds by moving in the positive
direction. If the unit responds as outlined above, the unit is most likely
performing within specifications. If you are unsure about your results, or cannot
find another cause for whatever problems you are having with the monitor (e.g.
lack of response, erratic reading), then contact the factory.

Sensor Conditioning
It is important to realize that a recently cleaned probe and piston will need time to
condition (or stabilize) after they have been cleaned. In some cases, the
conditioning time can take as little as 15 minutes or up to 1 hour. The time it
takes depends on the type of coagulant and dosage level, as well as other water
quality parameters like NTU, TOC, and alkalinity. Because this conditioning has
to occur after each cleaning, it is advised to avoid cleaning the probe more often
than what proves to be necessary. For example, don’t assume that cleaning
once a day or even once a week is optimum. In this case, cleaning to frequently
can create problems as operators might not wait long enough for the sensor to
fully recondition before putting the unit back into automatic control. One way to
shorten the conditioning time after a cleaning is to temporarily increase the
coagulant dosage by 10 to 20% for 5 to 10 minutes. This will help condition the
probe more rapidly.

Chemtrac, Inc. Page 45

6.0 TROUBLESHOOTING GUIDES

PROBLEMS POSSIBLE CAUSE(S) CORRECTIVE ACTION

1. Display fluctuates A. Incomplete dispersion or A. Check stability of readings on
rapidly and widely mixing of coagulant(s) in raw or finished water. If stable,
on treated sample. raw water at point of incomplete mixing is the
sampling. problem. Move sampling point
further downstream, or resolve
B. Chemical feeders erratic or
mixing problems.
partially plugged.
B. Fix feeders.
C. Raw water flow-turbidity
fluctuating. C. Check R/W flow controls/charts,
and turbidity.
D. GAIN setting too sensitive.
D. Decrease GAIN setting.
E. Cell bottom plug loose or
E. Tighten plug. Check O-ring
O-ring missing.
(See Cleaning Procedures).

2. Display does not A. GAIN setting too low. A. Increase GAIN setting.
change with
B. Wrong sample point or B. Select correct sample point.
change in
insufficient mixing..
coagulant dosage. C. Clean cell (see Cleaning
C. Sample cell dirty. Procedures).
D. Excessive “lag time” D. Move sampling point closer to
between coagulant coagulant feed point and/or
injection point and sensor decrease sample TRANSPORT
sample cell. time (See Selecting Proper
Sample Point).

3. Display indicates A. No water sample to sensor. A. Establish proper sample flow.

0.00, or closely
B. Motor not turning. B. Turn on motor.
thereto, and does
not change with C. Dirty or inoperative probe. C. Clean or replace probe.
change in
D. Opt switch misaligned. D. Adjust opt switch position for
coagulant dosage.
maximum meter reading on
E. Opt switch inoperative.
water sample and tighten
F. Sensor output connections securely in place.
incorrect.
E. Replace opt switch.
G. Circuit card component
F. Check wiring.
faulty.
G. Replace circuit card.

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7.0 MAINTENANCE PROCEDURES

The Dura-Trac sensor is supplied with two (2) probes and (2) pistons so freshly cleaned parts
can always be on hand.

7.1 REPLACEMENT PROCEDURES

The following steps describe probe replacement:

1. Disconnect the lead wire from the enclosure and remove the lower retaining slip nut
from the probe.
2. Remove probe by pulling on the tab. You may need to twist slightly.
3. Remove the piston using a ¼” flatblade screwdriver.
4. Clean any debris from cell housing.
5. Screw clean piston into place. Do not over tighten. Only slight torque is necessary.
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 the Offset to OUT position. After SCV reading is stabilized, set the zero
Offset to the IN position to re-zero the SCV reading.

CAUTIONS

If monitor is being used for automatic dosage control, put the controller into
MANUAL mode before starting replacement procedure.

7.2 CLEANING PROCEDURES

Depending on the type of contamination, see table below for different cleaning
procedures recommended.

Chemtrac, Inc. Page 48

 TYPE OF CONTAMINATION CLEANING PROCEDURE
Mineral scale from alum/lime addition Comet or other Abrasive Cleaner
Deposits caused by raw water ROVER (available from Hach Chemical)
iron/manganese, or where ferric salts or 1 spoonful per pint tap water
potassium permanganate is used for
treatment.
Organics from raw water or where Comet or other Abrasive Cleaner
polymers are used.
Oil/Grease Comet or other Abrasive Cleaner

A “soak and brush” method is recommended 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

Do not soak entire probe cartridge, only soak inside the bore. Acid concentration
shall not exceed 15% concentration.

7.3 REPLACEMENT PARTS

Figure 12 AND 13 illustrates Dura-Trac and Dura-Trac II sensor parts identification with
part numbers. Table below lists recommended replacement parts.

Part Number Description Replacement Interval

1701 Delrin Piston 1 to 2 years
8601 Probe Cartridge 1 to 3 years
1301 110VAC Drive Motor 3 to 5 years
5017 Viton Diaphragm 3 to 5 years
8702 Probe Washer If Lost

Chemtrac, Inc. Page 49

 6-32 SCREWS

WASHER
(1608)
VITON SEAL
110 CRANK (7701)
ASSEMBLY
(5302) MOUNTING NUT
(1607)

NEOPRENE
110 MOTOR
WASHER
(1301)
(5016)

OPTO
SWITCH 4-40 SET
(1308) SCREW
MOTOR BRACKET
ROD END (3311)
(3707)

DURA NUT
YOKE PIN (4200)
(5720)
EXTENSION
(5611)
YOKE
(5710)

3/4" BARB INLET

PROBE BLOCK
(5021)
(5622)

GUIDE
(8711)

PISTON
(1701)

PROBE
WASHER
(7703)

PROBE
(8601)

DURA NUT
(4200)

O-RING
(1605)

DURA PLUG
(8606)

FIGURE 12. Dura-Trac Sensor Parts Identification

Chemtrac, Inc. Page 50

 6-32 SCREWS

WASHER MOTOR CRANK

(1608) (3300)
DOUBLE THICK
VITON SEAL
(7702)
MOUNTING NUT
(1607)

NEOPRENE WASHER
(5016) ROD END
110V MOTOR
OPTO (3707)
(5470)
SWITCH
4-40 SET (1308)
SCREWS
MOTOR YOKE PIN
BRACKET (5720)
(3311)

YOKE
(5710)
DURA NUT
(4200)

WW EXTENSION
(5611)

3/4" BARB INLET

(5021)

WW PROBE BLOCK
(5630)

GUIDE
(7720)

PISTON
(1710)

PROBE
WASHER
(7703)

PROBE
(8601)

DURA NUT
(4200)

O-RING
(1605)

DURA PLUG
(8606)

FIGURE 13. Dura-Trac II Sensor Parts Identification

Chemtrac, Inc. Page 51

7.4 ORDERING INFORMATION
®
To place an order for spare parts you may either call, email, or fax Chemtrac directly or
contact your local distributor or representative. The following information should 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, 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: [email protected]
Website: www.chemtrac.com

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8.0 MECHANICAL SPECIFICATIONS

The following Figures 14 thru 19 illustrate enclosure and mounting dimensions for Streaming
Current Monitor/Controller, Dura-Trac Sensor, Dura-Trac Sensor with Flush, Dura-Trac II
Sensor, and Sensor Maintenance Module.

9.2" [234mm] 6.3" [161mm]

7.7" [196mm] 6.1" [155mm]

SCC3500XRD
13.6" [345mm]
11.2" [285mm]

12.5" [317mm]
Power
Service
Diag.
Alarm

CHEMTRAC
SYSTEMS, INC.

7.71" [196mm]

FIGURE 14. Streaming Current Monitor/Controller Dimensions

Chemtrac, Inc. Page 54

 9.2" [234mm]
7.7" [196mm] 5.3" [135mm]

CHEMTRAC
SYSTEMS, INC.

8.5" [215mm]

7.2" [183mm]
DURA-TRAC TM

14.7" [373mm]
PATENTED MADE IN U.S.A.

FIGURE 15. Dura-Trac Sensor Dimensions

11.2" [285mm]
9.7" [247mm] 6.3" [161mm]
10.5" [266mm]
9.2" [234mm]

18.8" [477mm]

DURA-TRAC TM
II
PATENTED MADE IN U.S.A.

FIGURE 16. Dura-Trac II Sensor Dimensions

Chemtrac, Inc. Page 55

 9.2" [234mm] 5.3" [135mm]
7.7" [196mm]

CHEMTRAC
SYSTEMS, INC.

8.5" [215mm]

7.2" [183mm]
DURA-TRAC TM

17.6" [447mm]
PATENTED MADE IN U.S.A.

FIGURE 17. Dura-Trac Sensor with Flush Dimensions

Chemtrac, Inc. Page 56

 11.2" [285mm]
9.7" [247mm] 6.3" [161mm]
10.5" [266mm]
9.2" [234mm]

18.8" [477mm]
DURA-TRAC TM
II
PATENTED MADE IN U.S.A.

FIGURE 18. Dura-Trac II Sensor with Sensor Maintenance Features

Dimensions

Chemtrac, Inc. Page 57

9.0 OPTIONAL FEATURES ADDENDUM
9.1 Remote Control Feature (Optional)

The Remote Control Feature is an optional and is only supplied on the SCC3500 when
specifically ordered by the customer.

The Remote Control Feature allows certain parameters on the controller to be remotely
set by digital input (relay) and 4-20mA signals which would generally be controlled
through the customer’s DCS/SCADA. The parameters which can be remotely set
include CONTROL MODE, S ETPOINT, and MANUAL PUMP OUTPUT. The below text
explains

From the SETUP MENU (1), continue pressing the down arrow key until SETUP MENU
(2) menu screen display. SETUP MENU (2) menu screen is a continuation of the
SETUP MENU (1) menu screen.

 






Definitions

 SCV Filter: The filter function activate rolling average of the Streaming Current
value over time. The SCV filter can be set to OFF, 30, 60, 90, or 120 seconds.
The default setting is OFF.
 Control: The control function only applies to the SCC3500. It should always be
set for Reverse when the SCC3500 is being used to control cationic
coagulant/polymer. If an anionic coagulant/polymer is being controlled, then the
Control function needs to be changed to Direct.
 Remote SP Control: This setting must be Enabled in order for the Setpoint to
be controlled remotely via a 4-20mA signal. The 4-20mA signal to control the
Setpoint is connected to Aux 2 terminals 19 (+) and 20 (-). The scaling on the 4-
20mA signal is -1000 to +1000.

Chemtrac, Inc. Page 58

  Manual PO Control - This setting must be Enabled in order for the Pump Output
to be controlled remotely via a 4-20mA signal. The Pump Output can only be set
remotely when the Control Mode is set to Manual. The 4-20mA signal to control
the Pump Output is connected to Aux 3 terminals 20 (+) and 21 (-). The scaling
on the 4-20mA signal is 0 to 100%.
 SCV Out Offset – There will be a small amount of error in the 4-20mA signal
coming off of terminals 9 and 10 (SCV Output). To correct for this erro, use this
setting to match the SCV reading on the DCS/SCADA User Interface to what is
shown on the SCC3500.
 Remote SP Ofst – There will be a small amount of error in the 4-20mA signal
coming from the DCS/SCADA into Aux 2 input terminals 19 and 20 (Remote SP
Control input). To correct for this error, use this setting to match the Setpoint
reading on the SCC3500 to what is shown on the DCS/SCADA User Interface.

Remotely Setting The Control Mode (Auto/Manual)

In order to remotely change the Control mode from Manual to Auto, either the
Remote SP Control or Manual PO Control must be enabled.

To remotely set the Control mode to Auto, a closed dry contact must be applied
across terminals 15 and 16. Open the contact to switch back to Manual mode.

Input Voltage: 110-240 V~

Power

Frequency: 50-60 Hz WARNING !! TURN POWER OFF BEFORE MAKING ANY WIRE
POWER SWITCH Max Current: 1.5A @ 120V~ CONNECTIONS TO AVOID DAMAGING THE ELECTRONIC CIRCUIT.

25 26 27 28
SMM | Sensor

FUSE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
GND

N
L

Power
Terminals 11 & 12 (Analog Out) - Pump Control Signal (4-20mA)
Terminals 15 & 16 (Digital In) - Control Mode (Relay)
Terminals 17 & 18 (Aux1 Input) - Flow Signal (4-20mA)
Terminals 19 & 20 (Aux2 Input) - Setpoint Value (4-20mA)
Terminals 21 & 22 (Aux3 Input) - Manual Pump Out (4-20mA)

1 2 3 4 5 6 7 8 9 10
Opto (W)
Vdc Gnd

Opto (O)
Opto (B)
+24 Vdc

Signal +

+ Probe
Signal -

- Probe
Shield

Chemtrac, Inc. Page 59

9.2 Offset Value 4-20 mA Signal

An optional feature of the SCM2500XRD is an analog output (4-20mA) representing the Offset
value. On units that have this option, the signal is provided at terminals 11 and 12; see figure
below. Terminal 11 is labeled Offset Value (AO+) and terminal 12 is labeled Offset Value (AO-
). The scaling for the Offset value analog output is from -1000 to +1000 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).

FUSE

FUSE: AGC-1.5A
WARNING TURN POWER OFF BEFORE MAKING ANY WIRE CONNECTIONS
17 18 19 20
OFF TO AVOID DAMAGING THE ELECTRONIC CIRCUIT.
1 9 17
SMM | Sensor

2 10 18
3
4
11
12
* 19

5 13
* 20

6 14

ON
7 15 *
8 16 * *
L G N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND

N
L

Signal Wires Interconnection Diagram

Chemtrac, Inc. Page 60