Walchem WCU Series User manual

WCU Series
Electroless Copper Controller
Instruction Manual

Notice
©2006 WALCHEM Corporation
5 Boynton Road, Holliston, MA 01746 USA
[phone]
All Rights Reserved
Printed in USA
Proprietary Material
The information and descriptions contained herein are the property of WALCHEM
Corporation. Such information and descriptions may not be copied or reproduced by any
means, or disseminated or distributed without the express prior written permission of
WALCHEM Corporation, 5 Boynton Road, Holliston, MA 01746.
This document is for information purposes only and is subject to change without notice.
Statement of Limited Warranty
WALCHEM Corporation warrants equipment of its manufacture, and bearing its
identification to be free from defects in workmanship and material for a period of 24
months for electronics and 12 months for mechanical parts from date of delivery from the
factory or authorized distributor under normal use and service and otherwise when such
equipment is used in accordance with instructions furnished by WALCHEM Corporation
and for the purposes disclosed in writing at the time of purchase, if any. WALCHEM
Corporation's liability under this warranty shall be limited to replacement or repair, F.O.B.
Holliston, MA U.S.A. of any defective equipment or part which, having been returned to
WALCHEM Corporation, transportation charges prepaid, has been inspected and
determined by WALCHEM Corporation to be defective. Replaceable elastomeric parts and
glass components are expendable and are not covered by any warranty.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER EXPRESS OR
IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANTABILITY, FITNESS FOR ANY
PARTICULAR PURPOSE OR USE, OR ANY OTHER MATTER.
P/N 180099.J1
Feb 2006

TABLE OF CONTENTS
1.0 Introduction.............................................................................................................1
2.0 Specifications .........................................................................................................1
2.2 Electrical: Input/Output..........................................................................................1
2.3 Mechanical............................................................................................................2
3.0 Unpacking and Installation ....................................................................................2
3.1 Unpacking the unit ................................................................................................2
3.2 Mounting the electronic enclosure ........................................................................3
3.3 Immersible Copper Sensor Installation .................................................................3
3.4 Flow Through Copper Sensor/Sample Loop Installation.......................................4
3.5 Control Module Installation....................................................................................8
3.6 Icon Definitions .....................................................................................................9
3.7 Electrical Installation .............................................................................................9
4.0 Function Overview ...............................................................................................14
4.1 Front Panel .........................................................................................................15
4.2 Display ................................................................................................................15
4.3 Keypad................................................................................................................16
4.4 Access Code.......................................................................................................16
4.5 Startup ................................................................................................................16
4.6 Shutdown ............................................................................................................17
5.0 Operation...............................................................................................................17
5.1 Main Menu ..........................................................................................................17
5.2 Sensor Menu.......................................................................................................18
5.3 Output 1 Menu ...................................................................................................22
5.4 Output 2, 3, and 4 Menus....................................................................................26
5.5 Clock Menu .........................................................................................................27
5.6 Alarm Menu.........................................................................................................28
5.7 4-20 mA Menu (Optional)....................................................................................28
5.8 Access Code Menu.............................................................................................29
6.0 Maintenance..........................................................................................................31
6.1 Sensor Maintenance ...........................................................................................31
6.2 Replacing the Fuses ...........................................................................................31
7.0 Troubleshooting ...................................................................................................32
7.1 Error Messages...................................................................................................32
8.0 Service Policy .......................................................................................................35

1
1.0 Introduction
The WCU310 series copper controllers are optoelectronic on-line analyzers that may
be used in variety of applications including electroless copper baths, microetch baths
and a number of other chemistries that contain more than 0.10 grams/liter (g/L) of
copper ions.
There are four relays that may be used as control outputs that are activated
simultaneously. The direction of control is selected via software. The outputs each
have timers associated with them, that may be used to track the volume of chemistry
added, or the time that the output has been on.
An optional 4-20 mA output that is proportional to the copper concentration is
available.
Either an immersible in-tank sensor or flow-through out-of-tank sensor may be
specified.
2.0 Specifications
2.1 Measurement Performance
Electroless Copper Concentration Range: .01 - 5.5 g/L (.001 - 0.73 oz/gal)
Microetch Copper Concentration Range: .01 - 99 g/L (.001 – 13.2 oz/gal)
Concentration Resolution: .001 g/L (.0001 oz/gal)
Concentration Accuracy: .01 g/L (.001 oz/gal)
2.2 Electrical: Input/Output
Input Power
110-120 VAC or 220-240 VAC
50/60 Hz, 10A 50/60 Hz, 5A
Input Signals
Sensor Power: + 5VDC, 150 mA
Signals:0to2VDC
Interlock (optional) Isolated dry contact closure required (i.e., flow,
level, etc.)
Output
Mechanical Relays (5) @ 120 VAC, 10A resistive, 1/8 HP
@ 240 VAC, 5A resistive, 1/8 HP
internally powered, switching line voltage
4 - 20 mA (optional) Fully isolated, internally powered 600 Ωmax.
resistive load. Resolution .001% of span, accuracy
± 1% of reading.

2
Agency Approvals
UL UL 61010-1, 2nd Edition
CSA C22,2 No.61010-1 2nd Edition
CE Safety EN 61010-1 2nd Edition
CE EMC EN 61326 :1998 Annex A*
Note: For EN61000-4-6,3 the controller met performance criteria B.
*Class A equipment: Equipment suitable for use in establishments other than
domestic, and those directly connected to a low voltage (100-240 VAC) power
supply network which supplies buildings used for domestic purposes.
2.3 Mechanical
Controller
Enclosure: Fiberglass
NEMA Rating: NEMA 4X
Dimensions: 8.5" x 6.5" x 5.5"
Display: 2 x 16 character backlit liquid crystal
Operating Ambient Temp: 32 - 122°F (0 - 50°C)
Storage Temperature: -20 to 180°F (-29 to 80°C)
Shipping Weight: 7 lbs (3kg) (approximately)
Sensor
Immersible Flow Through
Enclosure: Polycarbonate/Polypro ABS
NEMA Rating: NEMA 4X NEMA 4X
Dimensions: 5.25" x 4.0" x 20.25" 6.75" x 4.75" x 2.25"
Operating Ambient Temp: 32 - 122°F (0 - 50°C) 32 - 122°F (0 - 50°C)
Storage Temperature: -40 to 185°F (-40 to 85°C) -40 to 185°F (-40 to 85°C)
Solution Temperature: 200°F (93°C) max. 200°F (93°C) max.
Maximum cable length: 80 ft . 80 ft.
3.0 Unpacking and Installation
3.1 Unpacking the unit
Inspect the contents of the carton. Please notify the carrier immediately if there are
any signs of damage to the controller or its parts. Contact your distributor if any of
the parts are missing. The carton should contain a WCU310 controller and
instruction manual. Any options or accessories will be incorporated as ordered.

3
3.2 Mounting the electronic enclosure
The WCU series controller is supplied with mounting holes on the enclosure. It
should be wall mounted with the display at eye level, on a vibration-free surface,
utilizing all 4 mounting holes for maximum stability. Use M6 (1/4" diameter)
fasteners that are appropriate for the substrate material of the wall. The enclosure is
NEMA 4X rated. The maximum operating ambient temperature is 122° F (50° C).
The enclosure requires the following clearances:
Top: 2"
Left: 8"
Right: 4"
Bottom: 7"
3.3 Immersible Copper Sensor Installation
The immersible copper sensor is designed for direct in-tank monitoring of
electroless copper and microetch solutions. By monitoring the copper content
directly in the solution, control lag and hydraulic problems are eliminated.
The sensor is constructed such that a constant path length exists between the fiber
optic light guides. The solution between the light guides absorbs light at specific
wavelengths in proportion to the copper concentration. The lamp and electronics are
located under the cover of the sensor. In order to avoid a shift in calibration due to
condensation, the sensor's cover should NEVER be opened.
The immersible sensor is provided with a mounting plate and 20 feet of cable.
Extension cable is available if the sensor can not be mounted within 20 feet of the
controller. The maximum cable length is 80 feet.
While the positioning of the sensor is not particularly sensitive to the tank layout,
the following suggestions are given to aid installation:
Do not place the sensor beside heaters; if solution flow stops, the polypropylene
guard may melt.
Do not immerse the entire sensor, or the cable.
Place the sensor where the loads of parts will not strike it.
Place the sensor in an area of good solution movement, but not directly in the
path of any air agitation.
Mount the sensor securely to the rim of the tank using the holes provided. If the
tank is rimless, use a block to provide the support for the mounting plate.
Attach the cable's connector to the WCU controller. The connector is keyed, do not
force! The sensor you receive with the controller has already been calibrated.

4
3.4 Flow Through Copper Sensor/Sample Loop Installation
The copper flow through sensor is designed for out-of-tank monitoring of electroless
copper and microetch solutions.
The sensor is designed with a glass tube that contains the copper solution that forms
a fixed path length between the lamp and receptor module. The solution absorbs
light at specific wavelengths in proportion to the copper concentration. In order to
avoid a shift in calibration caused by condensation, the sensor cover should NEVER
be removed!
The flow through sensor is provided with a mounting plate and 20 feet of cable.
Extension cable is available if the sensor can not be placed within 20 feet of the
controller. The maximum cable length is 80 feet.
The sample loop consists of a shut off valve, a cooling coil or plate, a sensor and a
pump or any combination thereof. The shut off valve is to quickly isolate the system
if necessary. A cooling coil or plate is necessary to cool the copper solution down to
a temperature acceptable to a sample pump. Cooling the solution is also
recommended to help reduce the amount of plate out which may form in the sample
loop. The pump may be either a stand alone sample pump (which typically have
temperature restriction) or a high temperature pump (which is usually just a branch
off the recirculation pump).

5
Figure 1 Typical Installation
CONVEYORIZED SPRAY EQUIPMENT
COPPE R CON TRO LLER
CU OUT 3OUT 2 OUT 4
NEXTPREV.
EXIT ENTER
COPPER CONTROLLER
CU OUT 3OUT 2 OUT 4
NEXTPREV.
EXIT ENTER
COPPER
CAUSTIC FORMAL-
DEHYDE
STABILIZER
POWER
POWER
20 FT
IMMERSIBLE
SENSOR
PLATING BATH
WCU with Immersible Sensor
SODIUM
PERSULFATE
CIRCULATING
PUMPS
MANUAL
VALVE FLOW
THROUGH
SENSOR
WCU MICROETCH CONTROLLER
METERING PUMPS
TO
WASTE
TREATMENT
"BLEED"
3/8" TUBING
(< 20' PERFERRABLE)
WCU WITH FLOW-THROUGH SENSOR
(TYPICAL MICROETCH APPLICATION)
WCU WITH IMMERSIBLE SENSOR
(TYPICAL ELECTROLESS COPPER APPLICATION)
WCU310 Series Co
pp
er Controller
(80 FT MAX.)
80 FT. MAX.

6
The flow through sensor/sample loop must be installed according to the following
guidelines:
Mount the sensor on a vibration-free, vertical surface so that the sensor tubing
inlet connection is at the bottom and the outlet is at the top. The vertical
orientation will prevent air bubbles from being trapped in the sensor.
Install a shut-off valve at the beginning of the sample loop so that the system
may be shut off quickly if necessary.
If a sample pump is to be used, it must be installed last, after the flow through
sensor and the cooling coil or plate, if applicable.
Other installation guidelines which may be helpful in the overall system:
Mount the sensor as close to solution as possible. Keep tubing distances to the
sensor inlet as short as possible to avoid hydraulic lag time. Maximum
recommended length of tubing from solution to sensor is 25 feet. If this is not
possible, see Application Notes below.
The solution inlet should draw sample from an area of good solution movement
in order to respond quickly to chemical additions. However, the solution inlet
should not draw too near to where the chemistry is added to avoid artificial
'spikes' in concentration.
The solution discharge should be open to atmospheric pressure in order to ensure
proper flow.
The cable connector to the controller is keyed, do not force!

7
Application Notes
If the distance from the solution to the sensor is further than the recommended
length of 25 feet, the maximum lagtime must be calculated from the desired control
band to determine a pump flow rate based on a given distance of standard, uniform
tubing. The maximum lagtime is the maximum allowable time for the solution to
continuously get to the sensor in order to achieve the desired control band.
To calculate maximum lagtime:
Max. Lagtime = Desired Control Band*
4 x Depletion Rate
where Control band = Maximum deviation of concentration
Depletion rate = Rate at which the bath will deplete per unit
of time
* The deadband should be adjusted so that it is 1/4 the desired control
band.
For Example: The set point is 4.00 g/L.
If the desired control band is 0.20 g/L (± 0.10 g/L or 2.5%) and the bath is
depleting at a rate of 1.25 g/L every 15 minutes (0.08333 g/L every minute),
then Max. Lagtime = 0.20 g/L
4 x (0.08333 g/L /min)
= 0.60 minutes
So, 0.60 minutes is the maximum time it should take for the solution to reach the
sensor.
To calculate pump flow rate:
Minimum Pump Flow Rate = Volume of System*
Maximum Lagtime
where Volume of system = ( Tubing I.D.)2 x Length of tubing
2
Maximum lagtime = Previously calculated time to get solution to
sensor.
* Volume is based on length from solution to sensor, not the return.
For Example: If the system parameters are: Tubing is 3/8" O.D. x 1/4" I.D.
Length is 30 feet (360 inches)
then the volume of the system = ( 0.25 in )2 x (360 in) = 17.7 in3
2

8
Note: 1 U.S. Gallon = 231 U.S cubic
inches
1 Liter = 61.03 U.S. cubic inches
Volume of Cooling Coil: 0.018 Gallons
0.068 Liters
Volume of Cooling Plate: 0.023 Gallons
0.088 Liters
Volume of 3/8" O.D. x 1/4" I.D. (0.59 in3/ft): 0.00255 Gallons/linear ft
0.00965 Liters/linear ft
Volume of the system = 17.7 in3 = 0.0765 gallons
231 in3 / gallon
Maximum lagtime = 0.60 minutes (previously calculated)
So, the minimum pump flow rate
= 0.0765 gallons
0.60 minutes
= 0.127 gal/min (483 mL/min)
Caution: The calculated pump flow rate is the minimum required to obtain the
desired control band, however, if the flow rate increases over the recommended rate
of 500 mL/min (approx. 0.13 gal/min) the rate of cooling will decrease. This may be
compensated for by re-evaluating the system criteria: length / desired control band
or to double up on the cooling plate/coil.
Consult factory with any further installation questions.
3.5 Control Module Installation
Once the enclosure is mounted, the output pumps may be located at any distance
from the controller. The sensor may be placed up to 80 feet from the controller.
Shielded cable is preferable. Always route AC voltage wiring in conduit that is
separated a minimum of 6 inches away from low voltage DC signal lines (such as
the sensor signal).

9
3.6 Icon Definitions
Symbol Publication Description
IEC 417, No.5019 Protective Conductor
Terminal
IEC 417, No. 5007 On (Supply)
IEC 417, No. 5008 Off (Supply)
ISO 3864, No. B.3.6 Caution, risk of electric shock
ISO 3864, No. B.3.1 Caution
3.7 Electrical Installation
Based on the model number, the following voltages are required:
WCU310-1xx 120 VAC, 50/60 Hz
WCU310-4xx 120 VAC, 50/60 Hz
WCU310-5xx 240 VAC, 50/60 Hz
The various standard wiring options are shown below. Your WCU series controller
will arrive from the factory prewired or ready for hardwiring. Depending on your
configuration of controller options, you may be required to hardwire some or all of
the input/output devices. Refer to figures 3 and 4 for circuit board layout and wiring.
Note: When wiring the optional 4-20 mA output or a remote flow switch, it is
advisable to use stranded, shielded, twisted pair wire between 22-26 AWG. Shield
should be terminated at the controller ground stud (see figure 4).

10
CAUTION! There are live circuits inside the controller even when the power
switch on the front panel is in the OFF position! The front panel must never be
opened before power to the controller is REMOVED!
If your controller is prewired, it is supplied with a 8 foot, 18 AWG power cord with
USA style plug. A tool (#1 phillips driver) is required to open the front panel.
CAUTION! When mounting the controller, make sure there is clear access to the
disconnecting device!
CAUTION! The electrical installation of the controller must be done by trained
personnel only and conform to all applicable National, State and Local codes!
CAUTION! Proper grounding of this product is required. Any attempt to bypass
the grounding will compromise the safety of persons and property.
CAUTION! Operating this product in a manner not specified by Walchem may
impair the protection provided by the equipment.
Figure 2 Conduit/Wiring Configuration
Bottom View
Power Output 2 Cu
Supply Output
Alarm Output 3 Output 4
4-20 mA Output Optional Optional Sensor
(optional) Input Input Connector
Inputs
Outputs
Sensor
Connector
4-20 mA (optional)
Strain reliefs (230 VAC) or Holes for
Hardwiring of Input Power and Control Outputs
Side View Bottom View
Optional
Input
Optional Input
Hardwired Option WCU310
WCU310 Prewired Option

11
Figure 3 Inputs (for power relay board #191236)

12
Figure 3a Inputs (for power relay board #190873)
NEU NEUTRAL HOT
F2
TB3
TB2
F1
(Grounding
Stud)
(INPUTS - ALL MODELS)
(Polarity
not
critical)
BLK (115V)
BRN (230V)
+
_
4-20mA
Panel Mount
Connector Flow or Level
Switch
Power Supply
(115 VAC or 230 VAC)
(Optional 4-20 mA Board)
GRN (115V)
GRN/YEL (230V)
WHT (115V) BLU (230V)
COM VM
FLOW
SWITCH FM
To Grounding
Stud
Orange
Blue
White
w/Blue
Stripe
Green
White
w/Green Stripe
190873

13
Figure 4 Outputs (for power relay board #191236)
Note: The Alarm Relay is non-programmable.
Refer to the Main Menu diagram on page 16
for the list of error conditions that trigger the
alarm relay.
Note: All relay outputs are
internally powered switching
line voltage.

14
Figure 4a Outputs (for power relay board #190873)
NEU NEUTRAL HOT
F2
TB3
TB2
F1
(Grounding
Stud)
+
4-20mA
_
Chart
Recorder
Alarm Pump(s)
GRN
GRN
GRN
BLK
BLK
GRN
GRN
BLK
WHT
WHT
WHT
WHT
WHT
(Optional 4-20 mA Board)
OUT2
N.O.
OUT3
N.O.
OUT4
N.O.
A
LRM
N.O.
OUT1
N.C. N .O.
OUTPUTS
190873

15
4.0 Function Overview
4.1 Front Panel
Front Panel
4.2 Display
A summary screen is displayed while the WCU controller is on. This display shows
a bar graph of the copper concentration relative to the set point, a digital display of
the copper concentration, and the current operating conditions.
Towards the center of the bar graph is an (S), which represents the set point. For
each 1% rise above the set point a vertical line appears to the right of the (S). For
each 1% drop below the set point a vertical bar appears to the left of the (S). There
are small breaks in the bars at each 5%. If high or low alarm limits are reached, then
either an (H) or (L) will appear.
The operating conditions which may be displayed on the bottom line of the display
are: Control Delay 30* (number counts down), Sensor Error, Light Bulb Out, No
Sample, Plate Out, Manual Output* Interlock, Output Disabled*, Pump Overrun,
High/Low Alarm, Turnover Limit, Calibration Time, Outputs On* and Normal*
*These messages do not activate the diagnostic alarm relay.
Summary Display
CO PPER CO NTROLLER
CU OUT 3OUT 2 OUT 4
NEXTPREV.
EXIT ENTER
On/Off Power Switch
Backlit LCD Display
Output LEDs
Setting Adjustment Keys
Menu/Function Keys

16
4.3 Keypad
The keypad consists of 4 directional arrows and 4 function keys. The arrow keys are
used to move the adjustment cursor and change settings, while the function keys are
used to enter values, and navigate the various menu screens. The function keys are
ENTER, EXIT, NEXT and PREV (previous). NEXT and PREV scroll through the
various menu choices. ENTER is used to enter a menu and to enter a value. EXIT is
used to back up one menu level. If you are at the main menu level, EXIT will return
you to the summary screen.
To change a value or option in a submenu, the left/right arrow keys move the cursor
left and right to each digit or option that can be changed. The up/down arrows will
change numeric values up or down, or scroll through option choices. Press ENTER
only when you have finished making ALL of the changes for that menu screen.
4.4 Access Code
The WCU series controller is shipped with the access code disabled. If you wish to
enable it, see Section 5.8 for operation. With the access code enabled, any user can
view parameter settings, but not change them. Note that this provides protection
only against casual tampering. Use a lock on the cover latch if you need more
protection.
4.5 Startup
Initial Startup
After having mounted the enclosure and wired the unit, the controller is ready to use.
CONTROL DELAY: The display will show the WCU series model number then
revert to the top level summary screen with "Control Delay" for a status message. This
message will be displayed for approximately 30 seconds. In some situations, the user
may not want the unit to be controlling and possibly turning on pumps when it is first
powered on. This allows you enough time to enter the Output menus and disable the
outputs. The only difference in the controller operation during these 30 seconds is that
it will not activate any outputs. All measurements are live and all menus are
accessible. Scroll through the menus, calibrate the sensor, and set the control
parameters as detailed in Section 5, Operation.

17
To return to the summary screen, press the EXIT key until you return to this screen.
The controller will automatically return to this screen after 10 minutes.
Normal Startup
Startup is a simple process once your set points are in memory. Simply check your
supply of chemicals, turn on the controller, calibrate the sensor if necessary and it
will start controlling.
4.6 Shutdown
To shut the WCU controller down, simply turn off the power switch. Programming
remains in memory.
5.0 Operation
These units control continuously while power is applied. Programming is
accomplished via the local keypad and display.
To view the top level menu, press any key. The menu structure is grouped by inputs
and outputs. Each input has its own setup menu for calibration and unit of measure
selection as needed. Each output has its own setup menu including set points, timer
values, direction of control, etc as needed. After 10 minutes of inactivity in the
menu, the display will return to the summary screen. Keep in mind that even while
browsing through the menus, the unit is still controlling.
5.1 Main Menu
The exact configuration of your WCU controller determines which menus are
available as you scroll through the settings. Certain menus are only available if you
select certain options. All settings are grouped under the following main menu
items:
Sensor
Out 1
Out 2
Out 3
Out 4
Alarm
Time
4-20 mA (Only if 4-20 mA option circuit board is installed)
Access Code
The NEXT key travels forward through this list while the PREV key travels
backwards through the list. Pressing ENTER will enter the lower level menu that is
currently displayed.