Fabrication & Manufacturing Inc

Powell

Hypo Batch Controller with Temperature Indicator (Digital ORP/ORP/Temperature System) 2400 Series
Introduction
A sodium hypochlorite batch controller has been designed for bleach producers. The batch controller measures and displays the chlorine content of the bleach on a solid state digital D.C. millivolt meter as the sodium hydroxide is chlorinated. The sodium hydroxide must be at a predetermined strength before chlorination of the batch is begun. The batch controller utilizes two ORP meters that perform a redundant safety feature. If the control meter should fail, the safety meter will still alarm. A temperature meter has been installed to alarm and shutdown on high batch temperature. The digital meters are installed inside of a 30"h x 24"w x 8"d NEMA 4 case with a window in the front of the cabinet for easy visibility of the meters. The oxidation-reduction method utilizing silver and platinum electrodes immersed in the bleach solution measure the chlorine content of the bleach. The standard electrode holders are constructed of PVC plastic and are designed for 2" or larger pipe. An optional holder designed to mount between any size pipe flange is available. Two complete chlorine control loops are provided with the batch controller, one is referenced as "Chlorine Control Indication", and the other as "Chlorine Safety Indication." As the sodium hydroxide is chlorinated, a voltage is produced proportional to the degree of chlorination and is displayed on the digital D.C. millivolt meter, with two adjustable set points. When the chlorine is added to the sodium hydroxide, the voltage increases until the low set point of the chlorine control meter is reached, thus turning on the chlorine control alarm light and alarm horn. Usually, the low set point is used only to notify the operator that the batch is nearing completion. After the alarm horn sounds, it is silenced by the alarm silence button. The first set point will sound a horn, which may be silenced by the operator. After the operator silences the alarm, he can reduce the rate of chlorine flow being added to the batch if he desires. He then waits for the chlorine control shutdown light to turn on and the alarm horn to sound. If the optional automatic chlorine valve is installed, it will shut off when the chlorine control shutdown activates, and indicate valve open on the controller pilot light. If an automatic valve is not installed, the operator is expected to manually shut off the chlorine at this point. When the temperature alarm is reached the operator needs to slow the rate that chlorine is added to the system. If the temperature continues to raise the shutdown will close the optional chlorine valve. The batch controller has been designed to lockout the chlorine valve so that it can not open automatically after the ORP shutdown alarm has been reached. If the millivoltage drops below the shutdown set point and the operator turns the chlorine valve control switch to the "release" position and then back to the on position, the shutdown alarm will reset to the normal mode and the chlorine valve will turn on. The operator has full control of the optional chlorine valve and can turn it on or off as desired. Since the alarms for both meters are adjustable, the operator has a choice on the alarm and shutdown points of each meter. The temperature alarm does not lock out the automatic valve and will automatically reopen the chlorine valve when the batch cools.

6. The positive and negative wire from the second set of electrodes attached to the low voltage terminal board of the batch controller low voltage terminal #3 and #4 using #16 THHN copper wire. Thread the spring loaded RTD probe holder into the well a little more than hand tight. 3. The set of electrodes should be installed in the suction side of the recirculating bleach pump line. Conduit is connected from the batch controller to the horn. and should be in the pipe line so that the line will always be completely full when the bleach is pumped. taping. power and limit switch. . Install the set of positive and negative electrodes opposite each other as described by the electrode instruction sheet. the ORP ring will fit between flanges. is wired in conduit to the batch controller. which defeats the backup or redundancy of the second meter reading of an individual batch. Optionally. causing the redundancy for an independent backup input and alarm of the batch chlorination. The temperature of the area must be between 140F and 1400F for the meters to operate correctly. These adapters can be installed into PVC cross with threaded bushings or by drilling. Installation NOTE: Recommended installation of the digital batch controller provides for dual ORP readings from the same bleach tank. The chlorine shutoff valve. the limit switch is connected to the high voltage terminal #8 and #9. Often this is accomplished by inserting a threaded bushing into an end outlet of a tee. 7. The electrodes are installed into the pipe line using PVC electrode adapters that are designed to screw into a ¾" NPT thread. and gluing the PVC pipe. optional. or through a tank wall with field fabricated and installed bulkhead fittings. To indicate valve open position. The power for the chlorine liquid valves is connected to the high voltage terminal #6 and #7. The horn is located in the area of choice. 1. the batch controller is placed at a convenient operator location with the alarm horn remotely mounted in any location within hearing range. Insert the threaded titanium well into the piping to the tank. 5. Make sure there are no obstructions the well will contact when screwing the titanium well into the adapter. and #7. The electrodes are usually placed on the suction side of a recirculation pump for the batch. The horn is connected to the high voltage terminals #4 and #5. please call the plant for suggestions. Wiring or plumbing. #6. The electrodes can also be installed into the chlorination tank and since there are many ways this can be accomplished. 2.Typically. 4. Special electrode holders will be designed for any application. The well has a ½" NPT thread. Make sure the well is in the main stream of bleach flow or tank wall for good heat transfer. is not recommended by Powell Fabrication & Manufacturing. Connect temperature probe wiring as shown on the electrical print from the RTD probe to low voltage to terminals #5. The positive and negative wire from the first set of electrodes attached to the low voltage terminal board of the batch controller low voltage terminals #1 and #2 using #16 THHN copper wire. Inc. Locate the batch controller in an area of choice.

the alarm and shutdown points may need to be adjusted. #2 and #3 on the high voltage terminal board according to the terminal board connection diagram. Titrate your bleach as you chlorinate and make sure that the alarm and shutdown points are set to achieve the results you desire. Press "D" key consecutively until desired parameter appears. the controller set points can be adjusted. Example: Action Press "D" Release "D" Press "D" Release "D" pressed) Display "I" Input (MVDC Reading) "P" Peak (Peak value since last time "X" was Press "D" Release "D" Press and release > Press and release ^ "S1" Set point one (Setpoint one) Flashing Digit Scroll to desired digit *Repeat previous steps until desired set point is displayed. The meters have been factory programmed. Pressing "X" will cancel the current operation and return the display to the scaled input value. Press and release E To enter value and resume normal display Press "X" To return to normal display at any time 10. 9. The only way to determine the correct end point voltage for your system is to produce a batch of bleach by the titration method and record the millivoltage at the end of the batch. prepare your caustic dilution and begin chlorination. Depending on the strength of bleach you manufacture. Using this end point for a reference.8. press the ">" key until the right most digit flashes and press the "E" key to store the new value into memory. put 120-volt power to the batch controller and adjust the meters to the desired settings. Normal Set Points Please note the batch controller will control the end point of the bleach reaction since the lower the residual caustic. the end point voltage will vary. When set point is correct. then press the ">" key to select the next unit to be changed. Pause until the set point appears. and the "^" key to obtain new value. however. Without the chlorine car turned on. . After the alarms are set. The 120-volt control power for the unit is connected to terminal #1. The meters are adjusted to the desired set points by entering keystrokes into the lower front panel keypad. the higher the voltage from the electrodes.

SP1. setting of the contacts is the operator’s job. Chlorine Safety Meter (right unit) Set Point 1 . but if you have any problems.570 MVDC Results in alarm only Temperature Meter (Bottom Unit) Set Point 1 .540 MVDC Results in shutdown of optional chlorine valve and sounds alarm horn.560 MVDC Results in alarm only Set Point 2 .85oF Results in alarm only Set Point 2 .87oF Results in shutdown of optional chlorine valve and sounds alarm horn. the controlling meter can be set to alarm and shutdown the chlorine valve by SP2 contact first. Chlorine Safety Meter Set Point 1 .550 MVDC Results in shutdown of optional chlorine valve and sounds alarm horn.530 MVDC Results in alarm only Set Point 2 . Therefore. SP2. can be set higher than the high alarm. Effectively the low alarms in both meters are not being used in this example.Below are two examples for reference only. . Set Point 2 .85oF Results in shutdown of optional chlorine valve and sounds horn. please call us. Example #1 Chlorine Control Meter (left unit) Set Point 1 . As mentioned above.560 MVDC Results in shutdown of optional chlorine valve and sounds alarm horn. Temperature Meter (Bottom Unit) Set Point 1 .550 MVDC Results in alarm only Set Point 2 . The above example show an important feature of the controller and that is the low alarm. or the safety meter would shutdown the system using its SP2 contact. The set points of the alarm contacts are your choice.90oF Results in alarm only Set Point 2 . The above example is set up to have the system operate from the control meter for ORP and use the contacts of the safety meter for redundant control.530 MVDC Results in shutdown of optional chlorine valve and sounds alarm horn. Example #2 Chlorine Control Meter Set Point 1 . as in example #2.

Resistive at 75% P.com n www. Electrical Relay Contacts: Inductive at 35% P.powellfab. wiring diagrams.681. 15-amp circuit NOTE: Cabinet is internally fuse protected by 2-5 amp fast blow fuses. External wiring provided by customer: Standard Equipment: ------Two digital ORP controllers. Maintenance As consecutive batches are chlorinated and titrated. Two silver electrodes with Kynar holder and PVC dust cap. Break .Specifications Power Requirements 120 volt. MI 48880 Phone 989.doc . results are compared with the set point values. and Break -5 amps Voltage Meter Range: Temperature Meter Range: 0-2 VDC with two alarm contacts -336o to +1560o Control power.F.com L:\Literature\Batch Controllers\1800 rev2.1. 100 ohm RTD probe with titanium well PVC electrode holder (Four required).5 amps. Two platinum electrodes with Kynar holder and PVC dust cap.F. the end point alarm will begin to drift indicating dirty electrodes.5 amps Make .2158 n Fax 989. horn and optional chlorine shutoff system. Continuous . Powell Fabrication & Manufacturing Inc 740 East Monroe Road n St. Louis. Continuous.5013 e-mail info@powellfab. Instructions and set up procedure.681. one digital temperature meter in NEMA 4 case. Alarm horn. Refer to electrode maintenance to clean and replace electrodes.15 amp. cabinet to electrodes and thermocouple. 1 phase. Make.

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