BECS BECSys3 115VAC User manual

Installation and Technical Manual

9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132 www.becs.com
Installation and Technical Manual Rev: H10
T
TA AB BL LE E O OF F C CO ON NT TE EN NT TS S
Warnings............................................................................. 1
Unpacking........................................................................... 2
General Guidelines ............................................................. 2
Firmware Version ............................................................... 2
Environmental Conditions .................................................. 3
Electrical Specifications...................................................... 3
Applicable Sensor Operating Ranges.................................. 3
Section A: Mounting the BECSys3 Controller.................. 4
A – 1: Mounting the Controller...................................... 4
A – 2: Wrapping the Fittings.......................................... 4
A – 3: Assembling the Flow cell.................................... 4
A – 4: Plumbing the Sample Stream.............................. 4
A – 5: Free Chlorine Sensor........................................... 5
A – 5.1: CCS140........................................................ 5
A – 5.2: ECL6............................................................ 5
A – 6: Sensor Preparations............................................. 6
A – 6.1: Sensors......................................................... 6
A – 7: Opening the Sample Stream Valve ..................... 6
A – 8: Plugging in the Sensors....................................... 6
Section B: Wiring the BECSys3 Controller....................... 7
B – 1: Wiring the Unit ................................................... 7
B – 2: Opening the Cover .............................................. 7
B – 3: Removing the Safety Shield................................ 7
B – 4: Disconnecting the Ribbon Cable......................... 8
B – 5: Wiring Directly to the Unit ................................. 8
B – 6: Wiring Power ...................................................... 8
B – 7: Supplying Power To The Relays......................... 8
B – 8: Wiring Relay 1.................................................... 9
B – 8.1: Line Powered ............................................... 9
B – 8.2: Common Powered........................................ 9
B – 9: Wiring Relay 2.................................................... 9
B – 9.1: Line Powered ............................................... 9
B – 9.2 Common Powered.......................................... 9
B – 10: Wiring Relay 3 ................................................ 10
B – 10.1: Line Powered ........................................... 10
B – 10.2: Common Powered.................................... 10
B – 11: Wiring a Flow Switch ..................................... 10
B – 11.1: Paddlewheel Flow Switch........................ 10
B – 11.2: Reed Flow Switch .................................... 11
B – 12: Wiring a Timer................................................ 11
B – 13: Wiring the Temperature Sensor ...................... 11
B – 14: Wiring a Free Chlorine Sensor........................ 11
B – 14.1: CCS140.................................................... 11
B – 14.2: ECL6........................................................ 11
B – 15: RS485 Network............................................... 12
B – 15.1: BECSys RCM .......................................... 12
B – 16: Fuses................................................................ 12
Section C: Dip Switch Settings........................................ 13
C – 1: Choosing pH Feed Direction............................. 13
C – 2: Choosing On/Off Control or TBP ..................... 13
C – 3: Relay 3 Functions.............................................. 13
C – 3.1: Probe Wash ................................................ 13
C – 3.2: Alarm Relay................................................13
C – 3.3: Dual pH Control .........................................14
C – 3.4: Cl/Br Booster..............................................14
C – 4: Temperature.......................................................14
C – 5: Replacing the Cover ..........................................14
Section D: Programming the Controller...........................15
D – 1: The Program Menu............................................15
D – 1.1: Entering the Program Menu .......................15
D – 1.2: Selecting Language ....................................15
D – 1.3: pH High Alarm Point..................................15
D – 1.4: pH Low Alarm Point ..................................15
D – 1.5: ORP High Alarm Point...............................15
D – 1.6: ORP Low Alarm Point ...............................15
D – 1.7: Temperature High Alarm Point..................16
D – 1.8: Temperature Low Alarm Point...................16
D – 1.9: ORP/ppm Set point.....................................16
D – 1.10: ppm High Alarm.......................................16
D – 1.11: ppm Low Alarm .......................................16
D – 1.12: Exiting the Menu......................................16
D – 2: The System Settings Menu................................17
D – 2.1: Entering the System Settings Menu............17
D – 2.2: ORP Span...................................................17
D – 2.3: pH Span......................................................17
D – 2.4: Time Base...................................................17
D – 2.5: pH Calibration (2 Point) .............................18
D – 2.6: ORP Calibration (2 Point) ..........................18
D – 2.7: Feed Delay..................................................18
D – 2.8: Enable ppm Set point Selection..................19
D – 2.9: Failsafe Timers...........................................19
D – 2.9.1: Booster Failsafe...................................19
D – 2.9.2: pH Failsafe ..........................................19
D – 2.9.3: Chlorine/Bromine Failsafe ..................19
D – 2.10: pH Dead-zone...........................................20
D – 2.11: Relay Test.................................................20
D – 2.12: ppm Probe Calibration..............................20
D – 2.12.1: CCS140 .............................................20
D – 2.12.2: ECL6 .................................................20
D – 2.13: Temperature Enable..................................20
D – 2.14: ORP Enable..............................................20
D – 2.15: Access Codes............................................21
D – 2.15.1: Operator Access Code.......................21
D – 2.15.2: Rep Access Code...............................21
D – 2.15.3: Recovering Lost Access Codes .........21
D – 2.16: Exiting The Menu.....................................21
Section E: Normal Operation ...........................................22
E – 1: Set points ...........................................................22
E – 1.1: Displaying the Set points ............................22
E – 1.2: Modifying the Set points.............................22
E – 1.2.1: pH Set Point.........................................22
E – 1.2.2: Chlorine Set Point................................22
E – 1.2.2.1: ORP Control..................................22
E – 1.2.2.2: ppm Control (Calculated)..............22

www.becs.com 9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132
Installation and Technical Manual Rev: H10
E – 1.2.2.3: ppm Control (Probe)..................... 22
E – 1.2.3: Booster Trigger Point .......................... 22
E – 1.2.4: Booster End Point................................ 22
E – 2: Single Point Calibration .................................... 23
E – 2.1: Single Point Calibration - pH ..................... 23
E – 2.2: Single Point Calibration - Temp................. 23
E – 2.3: Single Point Calibration – ppm .................. 23
E – 2.3.1: Calculated ppm.................................... 23
E – 2.3.2: ppm Probe............................................ 23
E – 2.4: Probe Error................................................. 23
E – 3: Alarms............................................................... 23
E – 3.1: pH High/Low alarms.................................. 23
E – 3.2: ORP High/Low alarms ............................... 23
E – 3.3: ppm High/Low alarms................................ 23
E – 3.4: Temperature High/Low alarms................... 23
E – 3.5: No Flow Alarm........................................... 24
E – 3.6: Flow Restored Delay.................................. 24
E – 3.7: Cl/Br Lockout............................................. 24
E – 3.8: pH Failsafe ................................................. 24
E – 3.9: Cl/Br Failsafe ............................................. 24
E – 3.10: Booster FAILSAFE.................................. 24
E – 4: Resetting a Failsafe Alarm ................................ 24
Section F: Troubleshooting.............................................. 25
F – 1: Calibration Error................................................ 25
F – 2: Probe Error ........................................................ 25
Section G: Upgrading Firmware...................................... 25
Section H: Maintenance................................................... 26
H – 1: Potentiometric Sensors (pH and ORP).............. 26
H – 1.1: Electrode Cleaning:.................................... 26
H – 1.2: Long-Term Storage:................................... 26
H – 2: CCS140 Free Chlorine Sensor.......................... 26
H – 2.1: Cleaning..................................................... 26
H – 2.2: Long-Term Storage.................................... 26
H – 2.3: Filling electrolyte....................................... 26
Section I: Feed Charts...................................................... 27
I – 1: Spa Feed Charts.................................................. 27
I – 2: Pool Feed Charts................................................. 28
Section J: Installation Diagrams ...................................... 29
J – 1: Pressure Filter Installation.................................. 29
J – 2: Vacuum Filter Installation.................................. 29
Section K: Replacement Parts.......................................... 30
Section L: Warranty......................................................... 31

Page 1
9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132 www.becs.com
Installation and Technical Manual Rev: H10
W
Wa ar rn ni in ng gs s
Pay particular attention to the following warnings encountered in the pages of the
BECSys3 Installation and Technical Manual:
Warning: Various other warning boxes may be
found throughout the manual text.
Caution: Various other caution boxes may be found throughout the manual text.

Page 2
www.becs.com 9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132
Installation and Technical Manual Rev: H10
U
Un np pa ac ck ki in ng g
Your Shipping package should contain these items:
A. The BECSys3 Controller
B. pH Sensor
D. Flow Cell Kit
E. Rotary or Reed flow switch
F. This manual (not shown)
G. Optional Sensors (not shown)
A B C D
G
Ge en ne er ra al l G Gu ui id de el li in ne es s
Proper installation and use of the BECSys controller depends on the specific needs of the application. Read the manual
completely before starting the installation and ensure all guidelines and recommendations are followed. All components
should be mounted and the flow cell plumbing installed and pressure tested before wiring the controller. Ensure
compliance with all applicable plumbing and electrical codes during the installation as well.
F
Fi ir rm mw wa ar re e V Ve er rs si io on n
This manual was written for firmware v2.06. If you received newer firmware but did not receive a copy of the manual
covering that version of firmware, please contact your distributor.
Warning: The Sensors are very fragile and must be handled with care. The tips of the probes must be kept
wet at all times, requiring the wetting caps to remain in place until they are ready to be installed. The probes
must be stored in temperatures above freezing.
Rotary
Reed
or
Caution: The BECSys controller should not be installed where it is accessible to the public.

Page 3
9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132 www.becs.com
Installation and Technical Manual Rev: H10
E
En nv vi ir ro on nm me en nt ta al l C Co on nd di it ti io on ns s
The BECSys3 is housed in a NEMA 4X (IP65) enclosure. It should not be used in explosive environments. The
BECSys3 should be mounted so that adequate ventilation is provided around the enclosure, preventing general
environmental specifications from being exceeded (see table below).
Environmental Specifications
Specification
Rating
Storage Temperature
-30 to 60 Deg C
Ambient Operating Temperature
-18 to 40 Deg C
Ambient Humidity
95% non condensing maximum humidity
E
El le ec ct tr ri ic ca al l S Sp pe ec ci if fi ic ca at ti io on ns s
The BECSys3 may be ordered in either an 115VAC model or a 230VAC model. Following are the electrical
specifications for each model:
Controller Ratings
115VAC Model
230VAC Model
Voltage:
115VAC 60Hz
230VAC 50Hz
Phase:
Single
Single
Current:
9.25 Amps Full Load
4.625 Amps Full Load
(¼ Amp – Controller)
(⅛ Amp – Controller)
(9 Amps – Relay Outputs, 3A X 3)
(4.5 Amps – Relay Outputs, 1.5A X 3)
Relay Output Ratings
115VAC Model
230VAC Model
Relay 1 (K1)
115VAC (max) – 3 Amps
250VAC (max) – 1.5 Amps
Relay 2 (K2)
115VAC (max) – 3 Amps
250VAC (max) – 1.5 Amps
Relay 3 (K3)
115VAC (max) – 3 Amps
250VAC (max) – 1.5 Amps
A
Ap pp pl li ic ca ab bl le e S Se en ns so or r O Op pe er ra at ti in ng g R Ra an ng ge es s
Standard Sensors
pH
0.0 to 14.0 pH
Reed Flow Switch
Switch Point (On): 2.0 gpm
Rotary Flow Switch
Switch Point (On): 1.5 gpm
Optional Sensors
Temperature
32°F to 212°F (0°C to 100°C)
ORP
-1500mV to 1500mV
Amperometric ppm
0 ppm to 20 ppm

Page 4
www.becs.com 9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132
Installation and Technical Manual Rev: H10
S
Se ec ct ti io on n A A: : M Mo ou un nt ti in ng g t th he e B BE EC CS Sy ys s3 3 C Co on nt tr ro ol ll le er r
A – 1: Mounting the Controller
The BECSys3 Controller and flow cell are mounted
separately. The BECSys3 enclosure should be
mounted to the wall with four anchor bolts, one
installed in each corner of the enclosure base. To
mount the BECSys3 properly, please use the
included mounting template and hardware. Drill the
holes for the anchors using a 3/16” drill bit. Install
the anchors in the wall. Remove the lid from the
unit and place the included screws in the four
corners of the box. Attach the screws into the
anchors. The BECSys3 and flow cell should be
mounted in a location that is free from chemical
fumes and excessive heat, isolated from electrical
interference, and near a power source protected by a
ground fault interrupter. The BECSys3 has a
NEMA4 weather resistant enclosure but should still
be protected if mounted outdoors.
A – 2: Wrapping the Fittings
When assembling the flow cell, first open the bag of
flow cell fittings and wrap each fitting two times
around clockwise with Teflon tape.
A – 3: Assembling the Flow cell
Assemble the flow cell as shown below:
When installing the pH or ORP (if included) sensors,
remove the wetting cap, and then remove any
existing Teflon tape from the sensor threads. Re-
wrap the threads with new Teflon tape. Rinse the
sensor tip in de-ionized water and install as shown.
A – 4: Plumbing the Sample Stream
Install the sample stream; ½-inch tubing is
recommended for sample stream pickup and return.
Make sure that you tap the supply off the
discharge side of the recirculation pump,
upstream of the chemical injection points. The
sample should be filtered water. Connect the sample
stream pickup line to the flow cell and run the
sample stream return line from the flow cell to the
suction side of the main recirculation pump. Install
½-inch ball valves to allow isolation of the sample
lines.
Warning: These sensors should be hand-
tightened only. Tools are not necessary for
installing the pH or ORP sensor and will
damage the sensor housing.

Page 5
9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132 www.becs.com
Installation and Technical Manual Rev: H10
A – 5: Free Chlorine Sensor
The BECSys3 can be ordered to accept two different
Free Chlorine Sensors: the CCS140 or the ECL6.
A – 5.1: CCS140
The CCS140 Free Chlorine Sensor can be
connected to the BECSys3 using the appropriate
option board. The CCS140 Free Chlorine Sensor
is mounted in a flow cell which includes a flow and
psi restrictor assembly as shown below:
The CCS140 Free Chlorine Sensor requires a
constant flow rate and a constant pressure. This
helps ensure that the ppm level will remain stable.
Here is the recommended method for plumbing
the free chlorine sensor flow cell:
Admission pressure must be above the regulated
pressure (15 psi is the limit on the sensor). Run
the sample stream through a flow restrictor valve
(to maintain flow rate, minimum flow rate
requirement is 8 gph). Take the stream through
the flow cell. Discharge the sample stream to a
free outlet (for example into a surge tank).
The CCS140 Free Chlorine Sensor is supplied with
a yellow protective cap. This cap has an inner
sponge that is used to keep the sensor membrane
hydrated. This cap should be saved for long-term
storage.
The sensor can remain in the flow cell for short-
term interruptions in measurement. To prevent
membrane dehydration, the flow cell must not
drain off. If this is not ensured, then remove the
sensor from the flow cell and slide the yellow
protective cap, moistened at the inner sponge,
onto the measuring end of the sensor.
The voltage applied by the controller to the
CCS140 Free Chlorine Sensor polarizes the surface
of the gold cathode. The polarization period (30
minutes) must elapse before calibration is
performed based on the results acquired through
the use of a DPD test kit.
See Section H - 2.3 for filling the electrolyte.
A – 5.2: ECL6
The ECL6 Free Chlorine Sensor can be connected
to the BECSys3 using the appropriate option
board.
Caution: Amperometric chlorine sensors
require the use of a temperature sensor and
a properly calibrated pH sensor. Refer to
the instruction pamphlet included with the
sensor at the time of installation.
Warning: Negative pressure will damage the
sensor membrane.

Page 6
www.becs.com 9487 Dielman Rock Island Ind Dr, St. Louis, MO 63132
Installation and Technical Manual Rev: H10
A – 6: Sensor Preparations
NOTE: As soon as you install the sensors,
immediately move on to the next step to insure that
they always stay wet.
A – 6.1: Sensors
The pH and ORP (if included) sensors are shipped
with a wetting cap covering the measuring end.
This cap contains a solution of pH 4 buffer
saturated with potassium chloride (KCl). Gently
remove the wetting cap by unscrewing the sensor
and sliding the cap off of the sensor body.
It is a good idea to save the wetting cap and
the box that the sensor came in for future
long-term storage.
During shipping, the air space inside the pH glass
may have moved into the bulb. Grasp the sensor
near the cable end and gently swing it through an
arc to force the internal electrolyte into the pH
bulb. Rinse the measuring ends of potentiometric
sensors with de-ionized or distilled water before
installation into a flow cell.
A – 7: Opening the Sample Stream Valve
Open the sample stream valve and check for leaks.
Note the reading on the compound pressure gauge
and make sure that it shows a positive and steady
pressure. The sample stream should be about 2-20
psi at the flow cell. If this is not the case, then adjust
the valves or relocate the point at which the sample
stream is connected to the recirculation system.
Negative pressure will destroy the sensors. Once
you have a positive and steady pressure, open the wet
test valve and make sure that it generates a vigorous
stream.
A – 8: Plugging in the Sensors
Remove the protective covers from the BNCs. Plug
the pH sensor into the coded BNC jack and the
ORP (if included) sensor into the coded BNC jack
on the bottom of the BECSys3 controller by twisting
them a quarter of a turn. Allow the sensors to rinse
in the sample water while you do the wiring (Section
B).