Hanna Instruments BL100 Series User manual

INSTRUCTION MANUAL
BL100 • BL101
pH & ORP Pump Controllers

All rights are reserved. Reproduction in whole or in part is prohibited without the written consent of the
copyright owner, Hanna Instruments Inc., Woonsocket, Rhode Island, 02895, USA.
Thank you for choosing a Hanna Instruments product.
Please read this instruction manual carefully before using this instrument.
This manual will provide you with the necessary information for correct use of this
instrument, as well as a precise idea of its versatility.
If you need additional technical information, do not hesitate to e‑mail us at
[email protected] or view our contact list at www.hannainst.com.
Dear
Customer,

3
TABLE OF CONTENTS
TABLE OF CONTENTS
1. PRELIMINARY EXAMINATION ............................................................................................... 4
2. SAFETY MEASURES............................................................................................................. 6
3. ABBREVIATIONS & CONVERSION CHARTS ............................................................................ 6
4. SPECIFICATIONS................................................................................................................. 7
4.1. BL100 pH CONTROLLER............................................................................................. 7
4.2. BL101 ORP CONTROLLER........................................................................................... 8
4.3. pH & ORP PROBE SPECIFICATIONS............................................................................. 9
5. DESCRIPTION................................................................................................................... 10
5.1. GENERAL DESCRIPTION & INTENDED USE................................................................. 10
5.2. FUNCTIONAL & DISPLAY DESCRIPTION...................................................................... 12
6. INSTALLATION.................................................................................................................. 17
7. SETUP............................................................................................................................. 24
8. PRIMING THE PUMP......................................................................................................... 31
8.1. AUTOMATIC CONTROL TYPES.................................................................................... 31
8.2. PRIMING THE PUMP................................................................................................ 32
9. EVENTS MANAGEMENT ..................................................................................................... 33
9.1. ALARMS................................................................................................................. 33
9.2. WARNINGS............................................................................................................. 34
9.3. SUMMARY OF GENERAL BEHAVIOR .......................................................................... 34
10. CALIBRATION ................................................................................................................. 35
10.1. pH CALIBRATION (BL100 ONLY)............................................................................. 35
10.2. PROCESS pH & ORP CALIBRATION.......................................................................... 37
10.3. CLEAR CALIBRATION.............................................................................................. 39
11. MEASUREMENT.............................................................................................................. 40
12. ERROR MESSAGES.......................................................................................................... 41
13. MAINTENANCE ............................................................................................................... 42
13.1. ELECTRODE CONDITIONING & MAINTENANCE .......................................................... 42
13.2. PUMP TUBING REPLACEMENT................................................................................ 42
14. ACCESSORIES................................................................................................................. 44
CERTIFICATION...................................................................................................................... 46
RECOMMENDATIONS FOR USERS............................................................................................ 46
WARRANTY ........................................................................................................................... 46

4
PRELIMINARY EXAMINATION
1. PRELIMINARY EXAMINATION
Remove the instrument and accessories from the packaging and examine it carefully. For further
assistance, please contact your local Hanna Instruments Office or email us at [email protected].
Each instrument is delivered in a cardboard box and supplied with:
pH model
BL100-00, without mounting kit
• HI10053 pH/temperature probe
• 4.01 pH Buffer solution, 20 mL (3 pcs.)
• 7.01 pH Buffer solution, 20 mL (3 pcs.)
• Power connection cable
• Instrument & electrode quality certificates
• Instruction manual
BL100-10, with in-line mounting kit
• HI10053 pH/temperature probe
• Pool controller aspiration filter
• Pool controller injector, " NPT thread
• Saddle for Ø 50 mm pipe (2 pcs.)
• 4.01 pH buffer solution, 20 mL (3 pcs.)
• 7.01 pH buffer solution, 20 mL (3 pcs.)
• Power connection cable
• Instrument & electrode quality certificates
• Instruction manual
• PVC aspiration tubing (flexible)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
• PE rigid dispensing tubing (pump to injector)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
BL100-20, with flow cell mounting kit
• HI10053 pH/temperature probe
• Flow cell for BL100/BL101
• Mounting panel assembly for BL100/BL101
• Pool controller aspiration filter
• Pool controller injector, " NPT thread
• Saddle for Ø 50 mm pipe (3 pcs.)
• 4.01 pH buffer solution, 20 mL (3 pcs.)
• 7.01 pH buffer solution, 20 mL (3 pcs.)
• Power connection cable
• Instrument & electrode quality certificates
• Instruction manual
• Rapid coupling " to 12 mm (2 pcs.)
• Flow cell valve (2 pcs.)
• PVC aspiration tubing (flexible)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
• PE rigid dispensing tubing (pump to injector)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
• PE rigid tubing (flow cell)
length: 10 m
OD: Ø 12.0 mm; ID: Ø 10.0 mm
OD: Outer Diameter; ID: Inner Diameter

5
PRELIMINARY EXAMINATION
ORP model
BL101-00, without mounting kit
• HI20083 ORP/temperature probe
• ORP test solution (3 pcs.)
• Power connection cable
• Instrument & electrode quality certificates
• Instruction manual
BL101-10, with in-line mounting kit
• HI20083 ORP/temperature probe
• Pool controller aspiration filter
• Pool controller injector, " NPT thread
• Saddle for Ø 50 mm pipe (2 pcs.)
• ORP test solution (3 pcs.)
• Power connection cable
• Instrument & electrode quality certificates
• Instruction manual
• PVC aspiration tubing (flexible)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
• PE rigid dispensing tubing (pump to injector)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
BL101-20, with flow cell mounting kit
• HI20083 ORP/temperature probe
• Flow cell for BL100/BL101
• Mounting panel assembly for BL100/BL101
• Pool controller aspiration filter
• Pool controller injector, " NPT thread
• Saddle for Ø 50 mm pipe (3 pcs.)
• ORP test solution (3 pcs.)
• Power connection cable
• Instrument & electrode quality certificates
• Instruction manual
• Quick tubing fitting " to 12 mm (2 pcs.)
• Flow cell valve (2 pcs.)
• PVC aspiration tubing (flexible)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
• PE rigid dispensing tubing (pump to injector)
length: 5 m
OD: Ø 6.0 mm; ID: Ø 4.0 mm
• PE rigid tubing (flow cell)
length: 10 m
OD: Ø 12.0 mm; ID: Ø 10.0 mm
OD: Outer Diameter; ID: Inner Diameter
Note: Save all packing material until you are sure that the instrument works correctly. Any damaged
or defective item must be returned in its original packing material with the supplied accessories.

6
SAFETY MEASURES
2. SAFETY MEASURES
• Do not use chlorine tablets, granular chlorine or other non-liquid chlorine applications.
• Do not use the pump controller in a pool utilizing electrolytic chlorine generation
(salt electrolysis).
• Do not add stabilizer (e.g. cyanuric acid) to the swimming pool while using the pump
controller. To remove stabilizer from the pool, the pool must be drained and cleaned.
• Always disconnect the pump controller from power when making electrical connections.
• Do not run other cables with the power cabling.
• Do not touch the metallic part. Hot surface.
3. ABBREVIATIONS & CONVERSION CHARTS
FDA Food and Drug Administration
NPT American National Standard
Taper Pipe Thread
ID Inner Diameter
OD Outer Diameter
LED Light Emitting Diode
PE Polyethylene
PVC Polyvinyl Chloride
ORP Oxidation-Reduction Potential
REDOX Reduction & Oxidation
SPDT Single Pole Double Throw
METRIC vs INCHES
Metric (mm) Inches - Decimal Inches - Fractional
4.0 mm 0.16" "
6.0 mm 0.24" "
10.0 mm 0.39" "
12.0 mm 0.47" "
20.0 mm 0.79" "
25.4 mm 1.00" 1"
50.0 mm 1.97" 1 "
63.0 mm 2.48" 2 "
75.0 mm 2.95" 2 "
METRIC vs FEET & INCHES
Metric (m) Feet (') Inches (") Feet (') Inches (")
2 m 6' 7" 6.56' 78.74"
5 m 16' 4" 16.40' 196.85"
10 m 32' 9" 32.80' 393.70"
ABBREVIATIONS & CONVERSION CHARTS

7
SPECIFICATIONS
4. SPECIFICATIONS
4.1. BL100 pH CONTROLLER
Range
0.00 to 14.00 pH *
–5.0 to 105.0 °C (23.0 to 221.0 °F)*
* The range may be limited by the probe’s limits.
Resolution 0.01 pH
0.1 °C (0.1 °F)
Accuracy
@ 25 °C / 77 °F
±0.10 pH
±0.5 °C (±0.9 °F)
Calibration
• User calibration:
automatic, one or two-point with buffer solution (4.01, 7.01, 10.01 pH)
• Process calibration:
single point, adjustable (±0.50 pH around measured pH)
Temperature
Compensation Automatic
High or Low Mode
Operation
Pump Control
• On/Off control using adjustable set point (6.00 to 8.00 pH)
with adjustable hysteresis (0.10 to 1.00 pH)
• Proportional control using adjustable set point (6.00 to 8.00 pH)
with adjustable proportional band (0.10 to 2.00 pH)
• Startup delay timer at power-on (0 to 600 sec.)
• Pump flow control 0.5 to 3.5 Liter/hour (0.13 to 0.92 Gallon/hour) and
maximum output pressure 1 atm (14 psi)
• Manual control for pump priming (defined in setup)
pH Alarms
• High & Low with enable or disable option
• Triggered after 5 sec. if the controller records consecutive readings
over or under threshold values
• Level with enable or disable option
• Overtime protection (1 to 180 min. or Off)
Controller
Alarm System
• Intuitive alarm system, using red, light-green and green color coded backlight
• User-selectable, alarm setup options
Alarm Relay Output • SPDT 2.5A / 230 Vac
• Activated by pH-selectable alarm conditions
Probe Input • Quick connect DIN connector
• Galvanic isolation
Level Sensor Input
(Digital Input)
• External switches can be attached to stop the pump and activate the
alarm (low reagent level) when the switch is open and level alarm is
configured in Setup
• Galvanic isolation

8
SPECIFICATIONS
Power Supply 100 - 240 Vac, 50/60 Hz
Power Consumption 15 VA
Environment 0 to 50 °C (32 to 122 °F), max. 95% RH non-condensing
Dimensions 90 x 142 x 80 mm (3.5 x 5.6 x 1.8")
Weight 910 g (32 oz)
Casing Wall mounted, built-in pump, IP65 rated
4.2. BL101 ORP CONTROLLER
Range
–2000 to 2000 mV
–5.0 to 105.0 °C (23.0 to 221.0 °F)*
* The range may be limited by the probe’s limits.
Resolution 1 mV
0.1 °C (0.1 °F)
Accuracy
@ 25 °C / 77 °F
±5 mV
±0.5 °C (±0.9 °F)
Calibration Process calibration: one-point, adjustable (±50 mV around measured ORP)
High or Low Mode
Operation
Pump Control
• On/Off control using adjustable set point (200 to 900 mV)
with adjustable hysteresis (10 to 100 mV)
• Proportional control using adjustable set point (200 to 900 mV)
with adjustable proportional band (10 to 200 mV)
• Startup delay timer at power-on (0 to 600 sec.)
• Pump flow control 0.5 to 3.5 Liter/hour (0.13 to 0.92 Gallon/hour) and
maximum output pressure 1 atm (14 psi)
• Manual control for pump priming (defined in setup)
ORP Alarms
• High & Low with enable or disable option
• Triggered after 5 sec. if the controller records a set of consecutive readings
over or under threshold values
• Level with enable or disable option
• Overtime protection (1 to 180 min. or Off)
Controller
Alarm System
• Intuitive alarm system, using red, light-green and green color-coded backlight
• User-selectable, alarm setup options
Alarm
Relay Output
• SPDT 2.5A / 230 Vac
• Activated by ORP selectable alarm conditions
Probe Input • Quick connect DIN connector
• Galvanic isolation

9
SPECIFICATIONS
Level Sensor Input
(Digital Input)
• External switches can be attached to stop the pump and activate the
alarm (low reagent level) when the switch is open and level alarm is
configured in Setup
• Galvanic isolation
Power Supply 100 - 240 Vac, 50/60 Hz
Power Consumption 15 VA
Environment 0 to 50 °C (32 to 122 °F), max. 95% RH non-condensing
Dimensions 90 x 142 x 80 mm (3.5 x 5.6 x 1.8")
Weight 910 g (32 oz)
Casing Wall mounted, built-in pump, IP65 rated
4.3. pH & ORP PROBE SPECIFICATIONS
Specifications HI10053 (BL100) HI20083 (BL101)
Range 0 to 12 pH ±2000 mV
Reference Double junction Double junction
Junction Cloth Cloth
Temperature sensor Yes Yes
Temperature range -5 to 70 °C (23 to 158 °F) -5 to 70 °C (23 to 158 °F)
AmpHel®Yes Yes
Matching pin Yes Yes
Body PVDF (blue) PVDF (red)
Top thread " NPT " NPT
In-line mounting thread " NPT " NPT
Cable length 2 m 2 m
Connector Quick connect DIN connector Quick connect DIN connector
Maximum pressure @25 °C 3 bar (43.5 psi) 3 bar (43.5 psi)

10
DESCRIPTION
5. DESCRIPTION
5.1. GENERAL DESCRIPTION & INTENDED USE
BL100 & BL101 pump controllers are part of Hanna Instruments pool-line family and feature a single
peristaltic dosing pump and a process electrode.
The BL100 accepts HI10053 pH probes. The BL101 accepts HI20083 ORP probes. These probes are
manufactured by Hanna Instruments specifically for these controllers.
The probes are easily installed using " NPT threads for in-line or flow cell installation.
The electrodes have a matching pin that prevents ground loop effects from causing erratic readings
and damage to the system.
Main Features
• Built-in peristaltic pump with On/Off or Proportional control
• Manual control for pump priming
• Overfeed protection using overtime safety timer
• Resumes dosing on restart in case of power failure
• Easy to read LCD display with intuitive, color-coded backlight
• Level input to stop control without reagents
• Probe detection and recognition
• User selectable languages (English, Spanish, French, Portuguese, Dutch, German)
• Specially designed to detect a broken pH electrode, based on a shifted ISO potential value
• Easy to navigate menu to program and adjust settings
• Wall-mounted design
• IP65-rated casing
Main Benefits
• Reduced installation time and costs
• Accessible and easy to maintain feeding system

11
DESCRIPTION
The BL100 measures the pH of a pool and offers automatic pH level control by adjusting the
chemical dosing.
The BL101 measures the chlorine level of a pool and offers automatic ORP level control by adjusting
the chemical dosing.
BL100 and BL101 can work together, stabilizing first the pH value and later the ORP value in the pool.
Each controller type works with one parameter only. If a wrong probe is used (e.g. HI20083 for
BL100), the controller signals the error by displaying ”WRONG PROBE” message.
The chlorine level is measured based on the ORP or REDOX principle. An increase in the ORP value
correlates with an increase in the free-chlorine level.
pH and disinfectant testing are made together for efficient disinfection and control. The efficacy of sanitizers,
such as chlorine, is dependent on a controlled pH value. The ORP value is the most consistent indicator of
the sanitizing effectiveness of the pool. Typically, 650-750 mV at 7.2 pH indicates proper water treatment.
Based on individual requirements, users can define the ideal set point for pH (e.g. 7.2 pH for BL100)
and ORP (e.g. 700 mV for BL101).
The BL100 model doses acid if water pH is above the assigned pH set point; and the BL101 model
doses hypochlorite if the ORP value is lower than the ORP set point.
The pump controller is an automatic system but it’s advisable that users check the controller and verify
pH and free-chlorine levels (in mg/L or ppm) in the pool using a portable colorimeter.
The pump controller should only be used in combination with liquid acid (e.g. sulfuric acid) and liquid
chlorine (e.g. sodium hypochlorite).

12
DESCRIPTION
5.2. FUNCTIONAL & DISPLAY DESCRIPTION
BL100 Front Panel
CAL
MENU
BL100
BL1
00
pp
pH Pump
C
o
n
tr
ll
oller
1. Keypad area
2. CAL key – Press calibration key to enter calibration mode.
3. MENU key – Press menu key to enter setup mode and move through the menu.
– A long press of this key is used to exit the menu and return to measurement.
4. Acid (or base) dosing pump
5. LCD display
6. Arrow keys – When in measurement mode, press the two arrow keys together to prime the pump.
– When in menu mode, adjust settings.
– When in menu mode, in Control screen, press the arrow keys together and a
10 seconds pump test will start.
BL100 Liquid Crystal Display (LCD)
1
2
3
4
5
6
7
8
1. Stability indicator
2. Mode tags
3. Dosing pump icon
4. Status indicators
5. Measurement unit
6. First LCD line, measurement line
7. Second LCD line, temperature and message area
8. Temperature units

13
DESCRIPTION
BL101 Front Panel
CAL
MENU
BL101
BL1
0
1
ORP Pump
C
on
t
r
ll
oller
1. Keypad area
2. CAL key – Press calibration key to enter calibration mode.
3. MENU key – Press menu key to enter setup mode and move through the menu.
– A long press of this key is used to exit the menu and return to measurement.
4. Chlorine dosing pump
5. LCD display
6. Arrow keys – When in measurement mode, press the two arrow keys together to prime the pump.
– When in menu mode, adjust settings.
– When in menu mode, in Control screen, press the arrow keys together and a
10 seconds pump test will start.
BL101 Liquid Crystal Display (LCD)
1
2
3
4
5
6
7
8
1. Stability indicator
2. Mode tags
3. Dosing pump icon
4. Status indicators
5. Measurement unit
6. First LCD line, measurement line
7. Second LCD line, temperature and message area
8. Temperature units

14
DESCRIPTION
Rear Panel & Internal View
LEVEL
SENSOR
L N
ALARM
NC
COM
NO PE
RELAY
No user serviceable
parts inside.
Warranty void if
cover is removed.
Hot
Surface.
Electrical hazard.
Disconect power supply
prior to cover removal.
Refer to qualied personel.
Electrical Rating:
100 - 240 VAC; 15 VA; 50 / 60 Hz
Use a Phillips head screwdriver and remove the four screws, pull back the cover and remove it.
To replace the rear panel, insert the four legs back in place and tighten the four screws that secure the
panel to the enclosure.

15
DESCRIPTION
Alarm Relay, Power & Level Input
LEVEL
SENSOR
L N
ALARM
NC
COM
NO PE
RELAY
No user serviceable
parts inside.
Warranty void if
cover is removed.
Hot
Surface.
ALARM RELAY OUTPUT
SPDT 2.5 A / 230 Vac
NO Normally Open
COM Common
NC Normally Closed
NO COM NC
Pump controller not powered
or
Alarm condition
NO COM NC
Working condition with no alarm
POWER INPUT
LLine – Hot connection
PE Protective Earth – Ground connection
NNeutral
LEVEL SENSOR
(Enabled in Setup)
OPEN
CONTACT
CLOSED
CONTACT
TANK
LEVEL

16
DESCRIPTION
4
5
6
7
1 Tubing fittings
2 Sensor input
3 Cable gland for level sensor
4 Drainage opening
5Cable gland for alarm cable
6Cable gland for power cable
7 Enclosure cap
Cabling safety measures. Qualified personnel should perform wiring only.
• A disconnect switch must be installed to break all current carrying conductors.
Turn off power before working on conductors.
• Always disconnect the pump controller from power when making electrical connections.
• Do not run other cables with the power cable through the cable gland.
• Always run all cables through cable glands to maintain IP65 rating.

17
INSTALLATION
6. INSTALLATION
General Guidelines
• Select controller location so that it is shielded from direct sunlight, dripping water and excess
vibrations.
• Keep flow rate as constant as possible for optimum sensor operation.
• Install cable gland fittings and plugs, to properly seal the pump controller.
• The probes are easily installed using " NPT threads for in-line or flow cell installation.
• Ensure all tubing, cables, saddles and fittings are properly connected.
Note: BL100 and BL101 pump controllers are shipped with two types of tubing, for both flow
cell and in-line configurations:
- rigid tubing for outlet (dispensing) - connects the pump output to the injector
- flexible tubing for inlet (aspiration) - connects the filter to the pump inlet
Wiring Guidelines
Running cables through cable glands
• Unscrew the gland nut and remove the cap.
• Thread cable through outer opening of proper gland nut, through the seal, and into case.
• After connecting to terminal, reinsert seal and tighten nut on the threaded gland.
Connecting cables to the internal terminals
• Using a screwdriver, connect the cable leads to the appropriate terminal.
• Following the printed lead markings (L, PE, N for power supply; NO, COM, NC for relay; level sensor
if required) ensure the leads are wired to the correct position.
Installation Steps
1. Check the tank level.
2. Calibrate the probe before use in the system.
3. Mount the probe into saddle or into a flow cell.
4. Connect the aspiration tubing between the chemical tank and the pump’s inlet.
5. Connect the dispensing tubing between the pump and injector.
6. Check the level sensor’s functionality (if used).

18
INSTALLATION
Installation Schemes
We are proposing a few typical installation schemes: in-line and flow cell.
In-Line Installation, Overview & Parts Table
A detailed representation of an in-line installation with relevant components is found below.
The maximum pressure entering the flow cell system is 3 atm (44 psi).
TAN K
INJECTOR
FLOW FLOW
5
6
4
1
2
3
Note: Injectors prevent back flow into reagent tank.
1Flexible PVC tubing Ø 6.0 mm and Ø ¼
2 Aspiration filter
3 Saddle for Ø 50 (2") mm pipe, using " NPT thread
4 Injector, " NPT thread
5 Electrode
6 Rigid PE tubing Ø 6.0 mm and Ø ¼

19
INSTALLATION
Flow Cell Installation, Overview & Parts Table
Below is an illustrated reference of a generic flow-cell installation scheme with the relevant components.
The maximum pressure entering the flow cell system (P1) is 3 atm (44 psi) and decreases when it exits
the flow-cell (P2). The maximum pressure for the pump (P3) is 1 atm (14 psi).
INJECTOR
FLOW CELL
FLOW FLOW
FLOW
FLOW
TAN K
P1 P2 P3
2
1
12
3
4
5
6
7
8
11
9
10
1 Electrode
2 Mounting panel
3 Flexible PVC tubing Ø 6.0 mm and Ø ¼
4 Rigid PE tubing Ø 6.0 mm and Ø ¼
5 Aspiration filter
6 Nipple, " to "
7 Valve to control flow-cell flow
8Saddle for Ø 50 mm (2") pipe,
using " NPT thread
9 Injector, " NPT thread
10 Adapter for tubing
" to Ø 12 mm
11 Rigid PE tubing Ø 12 mm
12 Flow cell and adapter

20
INSTALLATION
Mounting Recommendations for Saddle
• Select required drill size. See table for dimension details.
Pipe
Drill
• Place the upper part of the saddle (3) on top of the
pipe (5) with the seal (4) placed over the hole.
• Take the lower part of the saddle (6), together with
inserted nuts (7) and align it under the upper part.
• Insert the screws (1) with washers (2) through the
holes and tighten by hand into the mounted nuts.
• Using a wrench, tighten all screws carefully.
Saddle for probe & injector Thread size Drill size
Ø 50 mm pipe ½” NPT thread 20 mm - 25.4 mm
Ø 63 mm pipe ½” NPT thread 20 mm - 25.4 mm
Ø 75 mm pipe ½” NPT thread 20 mm - 25.4 mm
Connecting the Probe to the Pump Controller (In-line Configuration)
The probe should be connected to the controller and calibrated before
installation.
To avoid twisting the cable, unplug probe from socket temporarily while
installing in saddle.
Insert the probe and screw it carefully into the saddle, taking care not to
damage the O-ring. Tighten the probe enough to ensure a tight seal.
1
2
3
4
5
6
7