WACO ENAMEL RATER II

Operating Instructions

INTRODUCTION

The WACO Enamel Rater II offers many new features not found on earlier models, which make testing for
metal exposure faster, more reliable, and more accurate:

• A redundant can contact sensor which displays the word “open” and prevents a test from
starting unless good electrical contact to the can has been established.

• A fill-height sensor which starts the test automatically only when the proper electrolyte fill
level has been reached.

• Remote sensing of electrode voltage, insures that the proper voltage for testing is available at
the electrode, regardless of any system resistance.

• 4 second/Continuous/Programmable testing modes give the operator improved flexibility and

accuracy for testing.

• Improved RS/232 serial communication options for compatibility with printers, computers,
and data collectors.

• Improved, all-plastic can holder, for corrosion resistance and long life.

• Sealed membrane keypad for durability and corrosion resistance.

• Improved electronic design for reliable, accurate performance.

CAN HOLDER SETUP

Remove nylon hex nut #1 and the flat washer from the nylon bolt protruding from the bottom of the arm
assembly. Attach the arm assembly to the top of the baseplate by inserting the nylon bolt through the hole
that is located in the center of the base near the rear edge. Secure the arm to the base with the flat washer
and hex nut #1 (finger tighten at this time). Position the arm so the stainless steel electrode is centered over
an imaginary line extending from the bottom can contact (the pointed screw protruding up from the
baseplate) to the center of the hole the arm is mounted in. Tighten hex nut #1 sufficiently to prevent the
arm assembly from rotating when the arm is raised and lowered.

The can holder will accommodate #200 through #610 diameter cans. The following adjustments are
required to tailor the can holder to a given size can:

• Can centering stop pegs

• Bottom contact

• Electrode immersion depth

• Fill height sensor depth

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The can centering stop pegs on the baseplate should be adjusted to approximately center the can under the
1/4” diameter stainless steel electrode. This is accomplished by loosening the nylon screws on the
underside of the base and sliding the stops to the correct position. Do not over-tighten the nylon screws.

The can holder is equipped with three can contacts. The can must make contact with the left side contact
and either the right side or bottom contact before the instrument will allow a measurement to be completed.
(The left and right side contacts are commonly used with three-piece cans. All three contacts are commonly
used with 2-piece cans.) Loosen hex nut #2 and adjust the bottom contact height so that when the can is in
position to be tested (up against the left and right side contacts), the bottom edge of the can farthest from
the pegs is held approximately 1/32” above the base. Tighten hex nut #2 to secure the wire terminal after
the height adjustment is completed.

Set the electrode depth by first loosening hex nut #3. Then loosen the screw which locks the 1/4” diameter
electrode into its holder and adjust the electrode depth so that at the arm assembly’s lowest position the
electrode is approximately 1-1/2” from the bottom of the can. Tighten the screw first and then hex nut #3.

Place a can on the can holder and fill the can with water to the correct level for testing. Loosen hex nut #5
and the screw that secures the fill height sensor (the 1/8” diameter rod). With the arm at its lowest position,
adjust the fill height sensor so that it penetrates approximately 1/8” into the water. Tighten the screw and
then hex nut #5.

CAN HOLDER ASSEMBLY

ORIENT TERMINAL
AS SHOWN
HEX NUT #5
(ON BACK SIDE-
NOT VISIBLE)

FILL HEIGHT SENSOR

HEX NUT #3

STAINLESS STEEL
ELECTRODE

HEX NUT #4

RIGHT SIDE ARM ASSEMBLY

CAN CONTACT
(LEFT SIDE
CAN CENTERING PEG NOT VISIBLE)

BASEPLATE

LOCK WASHER TO
ENAMEL RATER

RED WIRE FROM RIGHT

SIDE CAN CONTACT CABLE CLAMP
HEX NUT #2 NYLON FLAT WASHER

HEX NUT #1
BOTTOM CAN CONTACT

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INSTRUMENT SETUP

Connect the can holder and power supply connectors to the appropriate sockets on the back panel. When
the power supply is plugged into an electrical outlet, the Enamel Rater II will power-up in a self-check
function. All segments on the display will light up, indicating “8.8. 8.8.8.8.” for approximately 5 seconds.
Next, the output voltage (factory set at 6.3) will be displayed. The ER II will then enter the standby mode
and will display “-- ---.-”.

CONTROL FUNCTIONS

The WACO Enamel Rater II has 9 control functions on the keypad:

4 SEC Selects the 4-second mode test, which displays only the industry standard 4
second reading. A green LED indicates when this mode is selected.

↑ Selects the programmable mode test, which displays the reading at any time
duration selected by the operator. The ↑ and ↓ keys are used to select the
desired time constant. A green LED indicates when this mode is selected.

CONT Selects the continuous mode test, which displays the reading each second until
the test is stopped. Both the RECALL 4 SEC and RECALL PROGM keys can
be used to recall the reading. A green LED indicates when this mode is selected.

↑&↓ Assists in selecting the time constant when the program mode is selected.

CAL CHECK Tests the internal circuits of the ER II to insure correct operation. A shorting
strap (supplied) or empty can must first be connected between the two side
contacts. When the CAL CHECK key is pressed, the display will indicate
“Good”, “Bad”, or “Open”. A display of “Open” means the side contacts have
not been shorted properly. A “Bad” on the display indicates an internal problem.
Call the WACO service department for assistance. Press the CAL CHECK key
again to toggle this function off.

VOLT REV This function is useful to find the location of metal exposure. When this
function is activated, the timer continues to count, but the “MILLIAMPERES”
display reads “REV”. Bubbles of gas will form on the can wherever exposed
metal is found.

RECALL 4 SEC Pressing this key recalls the reading at 4 seconds. Pressing it again returns to
active 4-SEC display.

RECALL PROG Pressing this key recalls the reading at the programmed time value. Pressing it
again returns to active display.

DISPLAY HOLD Pressing this key during a continuous mode test freezes the values on the display.
Pressing it again returns to active display.

When in the standby mode, pressing this key for ≈ 5 seconds causes the Enamel
Rater to display the “UNIT” menu that is used to configure the instrument for
testing cans or ends. Pressing it again returns the instrument to the standby
mode.

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PASSWORD PROTECTED FUNCTIONS

The WACO Enamel Rater II may be programmed to store a number of operating conditions in its non-
volatile memory. Items such as test voltage, communication parameters, etc., need only be set once, and the
instrument will store those settings even though the power has been removed.

The following list shows each password protected menu number, the menu items in the order in which they
appear when scrolling through the menu, and the options available to the user for each particular menu item.

PASSWORD MENU ITEM OPTIONS (* = FACTORY DEFAULT)

None -
Press and hold the UNIT *CAN, CAN END
“Display Hold” key ↓
for 5 seconds
_____________________________________________________________________________________

BAUD RATE 300, 1200, 2400, 4800, *9600, 19200

↓
PARITY *NONE, ODD, EVEN
↓
BITS PER CHARACTER 7, *8
↓
STOP BITS 1, *2
↓
DATA STRING TERMINATOR *CR-LF, CR, NONE
↓
37 TEST MODE *4-SEC., CONT., PROG.
(Default on Power-Up)
↓
CONTINUOUS TEST 1-99 Seconds, (*60)
(Maximum Duration)
↓
PROGRAMMABLE TEST TIME 1-99 Seconds, (*15)
(Default Value on Power-Up)
↓
TEST VOLTAGE 4.0-9.0 VDC, (*6.3)
(Default on Power-Up)
↓
USE FILL SENSOR *YES, NO
(Can Ends Only)

_____________________________________________________________________________________

57 RESTORE FACTORY DEFAULTS FACTORY DEFAULTS

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CHANGING MENU OPTIONS

To change any of the options except “UNIT” in the above list from the factory default settings, do the
following:

1. Unplug the power connector at the rear of the unit.

2. Press and hold the RECALL PROGM button while plugging the power connector into the rear
of the unit. (The unit will display “88. 8.8.8.8.” for a few seconds and then enter a self-test
mode which will be indicated by various numbers and letters flashing on the display.)

3. Press the RECALL PROGM button again. (The display will begin alternately flashing
“PASS” and “0”.)

4. Press the ↑ button as many times as necessary until the desired menu number appears on the
display. (If the ↑ or ↓ button is held continuously, the display will begin incrementing or
decrementing slowly at first, and after a few seconds, very rapidly. Release the button as you
approach the desired menu number and then repeatedly press the appropriate arrow button to
move to the desired number. If you overshoot the desired number, press the arrow button
opposite the direction you were moving to go back to the desired number.)

5. Press the RECALL PROGM button again. (The display will alternately flash the first item for
the selected menu number and the option for that particular menu item.)

6. Press the ↑ (or ↓) button to scroll through the options for that particular menu item. When the
desired option appears, press the RECALL PROGM button. (The display will briefly flash
“nnnn”, indicating the option has been stored in non-volatile memory.) NOTE: The
RECALL PROGM button must be pressed, and the display must flash “nnnn”, to save an
option setting. If the RECALL PROGM button is not pressed, the previously stored option
will not be changed.

7. Press the CONT button to move to the next menu item. (If you want to move backwards
through a given menu, press the VOLT REV button.)

8. Press the DISPLAY HOLD button if you wish to return to the Password entry part of the
program to select a new menu number. If you are finished programming the instrument, press
the DISPLAY HOLD button one more time to return to the normal standby mode (the unit
will display “6.3 volt” and then “-- ---.-”.

Note: Once a password protected menu has been entered, if the instrument is allowed to sit idle for
approximately one minute without pressing any buttons, the instrument will automatically return
to its normal standby state. You must then begin at step number one again.

To change the “UNIT” menu item at the top of the table on page 4, press and hold the DISPLAY HOLD
button for ≈ 5 seconds. When the display flashes “Can Unit” or “Can End Unit”, proceed to step 6 above.
After completing step 6, press the DISPLAY HOLD button again to return the instrument to the standby
mode. (See TESTING CANS or TESTING ENDS for a complete step by step procedure.)

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TESTING CANS

Testing cans requires that the “UNIT” menu item at the top of the table on page 4 be set to “Can” (this is
the default setting as shipped from the factory). If the instrument is currently configured to test can ends, do
the following:

1. Press and hold the DISPLAY HOLD button (≈ 5 seconds) until the display flashes “Can End
Unit”.

2. Press the ↑ or ↓ button once. (The display will flash “Can Unit”.)

3. Press the RECALL PROGM button once. (The display will briefly flash “nnnn”.)

4. Press the DISPLAY HOLD button again. (The unit will return to the standby mode.)

5. Plug the can holder cable into the mating “Test Fixture” receptacle on the back of the Enamel
Rater II. The instrument is now ready to test cans.

Fill the can to be tested with electrolyte solution, and place it on the can holder against the side contacts.
Lower the electrode arm, and the test should start.. If the “Milliamperes” display shows “open” it means
that good electrical contact to the can has not been established. Raise the arm high enough to withdraw the
1/8” diameter fill height sensor out of the electrolyte, re-position the can and start again. When good
electrical contact to the can has been established, the “Seconds” display will start counting and the
“Milliamperes” display will indicate the can current at the end of the test period.

NOTE: If the “Seconds” display does not start counting when the electrode and fill height sensor
are lowered into the electrolyte solution, readjust the fill height sensor to a slightly greater
depth and try again.

If the message “over” is displayed, it means the ER II’s maximum rating of 500 milliamperes has been
exceeded. The cause may be excessive metal exposure inside the can or a short circuit between the
electrode and the can.

TESTING ENDS

Testing can ends requires that the “UNIT” menu item at the top of the table on page 4 be set to “Can End”.
To change the setting from the factory default “Can” setting to “Can End”, do the following:

1. Press and hold the DISPLAY HOLD button (≈ 5 seconds) until the display flashes “Can
Unit”.

2. Press the ↑ or ↓ button once. (The display will flash “Can End Unit”.)

3. Press the RECALL PROGM button once. (The display will briefly flash “nnnn”.)

4. Press the DISPLAY HOLD button again. (The unit will return to the standby mode.)

5. Plug the 10788-17 adapter cable into the “Test Fixture” receptacle on the back of the Enamel
Rater II and plug the End Panel Holder into the receptacle on the adapter cable. The
instrument is now ready to test can ends.

All WACO End Panel Holders are compatible with the WACO ER II. A special cable adapter/footswitch,
catalog #10788-17, is required. The test runs as long as the footswitch is held down. All functions of the
ER II remain the same.

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NOTE: The WACO #10778-17 adapter cable used on the earlier WACO #10778 series Digital Enamel
Rater is not compatible with the WACO #10788 series Enamel Rater II.

TEST RESISTORS

These devices are useful to verify correct operation of the WACO ER II. When connected properly to the
ER II, they simulate a can with a known metal exposure. The following values are available:
10788-19 Reads 6.3 ma
10788-20 Reads 12.6 ma
10788-25 Reads 126 ma
10788-30 Reads 252 ma

RS/232 SERIAL OUTPUT

The Enamel Rater II is equipped with a RS-232, serial port, configured as a DTE (Data Terminal
Equipment), and as such, is equipped with a 25-pin, male “D-sub” connector. It may be connected directly
to a computer RS-232 serial port with a standard null modem cable (with the appropriate gender and
number of pins on each end of the cable). Handshaking is not supported. Please refer to the list of
password protected functions for the various communication parameter options.

The data string, which is comma delimited, consists of the test time and the reading in milliamperes. It is
automatically transmitted each time the “Milliamperes” display is updated.

ELECTROLYTE SOLUTION

Aluminum Cans - 1% Sodium Chloride Solution

10.2 Grams Sodium Chloride

1 Liter Water

Steel Cans - 2% Sodium Sulfate Solution

386.4 Grams Anhydrous Sodium Sulfate

4.5 Grams Aerosol OT-B
5 Gallons Water

The chemicals to make the above solutions are available from WACO.

S 3320-33 Sodium Chloride, 500 Grams

S 3320-35 Sodium Chloride, 2.5 Kg
S 6200-33 Anhyd. Sodium Sulfate, 500 Grams
S 6200-35 Anhyd. Sodium Sulfate, 2.5 Kg
A 0825-84 Aerosol OT-B, 100 Grams

A pre-measured mixture of the 2% Sodium Sulfate dry chemicals is available to make 5 gallons of
electrolyte. Order WACO #S 6080-78.

Rev. July 5, 1995 WILKENS-ANDERSON COMPANY, Chicago, Illinois

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 Can Holder Wiring Diagram

CAN HOLDER
CONNECTOR

(-) ELECTRODE BLACK ELECTRODE

1
(-) SENSE GREEN
FILL SENSOR
3
FILL SENSOR WHITE
5

CAN
(+) SENSE BROWN
4
RIGHT CAN
(+) CAN RED RED CONTACT
2
BOTTOM CAN
CONTACT
LEFT CAN
CONTACT

10788-17 ADAPTER CABLE

DIAGRAM

FEMALE CABLE CONNECTOR

(-) ELECTRODE (-)

1

(-) SENSE
3 RECEPTACLE
(+) CONTAINER (+)
2

(+) SENSE
4 2 COND. CABLE

FOOT SWITCH
7
FOOT
FOOT SWITCH SWITCH
8

2 COND. CABLE