Hanna Instruments BL121 User manual

BL121
SWIMMING POOL CONTROLLER

2
Table of
Contents
Dear
Customer
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 worldwide contact list for a Hanna representative near you at www.hannainst.com.
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
Pool Controller Contents...........................................................................................................................................................3
Safety Measures.....................................................................................................................................................................3
Description.............................................................................................................................................................................4
Controller Overview............................................................................................................................................................. 5-7
Product Diagram Front Panel............................................................................................................................................5
Rear Sub Panel...............................................................................................................................................................5
Connections, Alarm, Output and Power..............................................................................................................................6
Keypad Function.............................................................................................................................................................7
Setup/Installation............................................................................................................................................................. 7-21
General Installation Guidelines.........................................................................................................................................7
Pool Controller Install................................................................................................................................................ 8-11
Saddle Installation........................................................................................................................................................12
Probe Installation .........................................................................................................................................................13
Installing Aspiration Filters ............................................................................................................................................14
Installing Injectors ........................................................................................................................................................14
Flow-Cell Installation .............................................................................................................................................. 15-16
Controller Menu...................................................................................................................................................... 17-19
User Interface Map........................................................................................................................................................20
User Interface in Parameter Setup ..................................................................................................................................21
User Interface in General Setup......................................................................................................................................21
Operational Guide........................................................................................................................................................... 22-36
Measure................................................................................................................................................................. 22-23
pH Calibration ........................................................................................................................................................ 23-24
ORP Calibration ............................................................................................................................................................25
GLP Information............................................................................................................................................................25
Controller Modes...........................................................................................................................................................26
Control Mode.......................................................................................................................................................... 27-29
Security Feature............................................................................................................................................................29
Logging .......................................................................................................................................................................30
Log Recall.............................................................................................................................................................. 30-31
Analog Outputs.............................................................................................................................................................32
Events Management................................................................................................................................................ 33-35
Specifications................................................................................................................................................................. 36-37
Maintenance........................................................................................................................................................................38
Electrode Conditioning and Maintenance.........................................................................................................................38
Pump Tube Replacement ...............................................................................................................................................38
Accessories..................................................................................................................................................................... 39-41
Warranty .............................................................................................................................................................................42

3
This product is intended to maintain disinfectant and pH levels at a desired level in swimming pools. Remove the
instrument and accessories from the packaging and verify that no damage has occurred during shipping. Remove the
protective film from meter. Notify your nearest Hanna Customer Service Center if items are missing or damaged.
Two versions are available: In-line BL121-10 and Flow-cell BL121-20.
Each instrument is supplied with:
In-line BL121-10 Panel mounted Flow-cell BL121-20
• BL121 Swimming Pool Controller • BL121 Swimming Pool Controller
• HI1036-1802 Combined electrode (pH/ORP/
Temperature/Matching Pin) • Panel mounted flow-cell
• Saddle for electrode 50 mm 1 pc. • HI1036-1802 Combined electrode (pH/ ORP/
Temperature/Matching Pin)
• Fittings for electrode • Two valves for flow-cell connections with fittings and
tubing 10 m
• Injector 2 pcs. • Injector 2 pcs.
• Saddle for injectors 50 mm 2 pcs. • Saddle for injectors 50 mm 2 pcs.
• Peristaltic pump tubing 2 pcs. • Saddle for valves 50 mm 2 pcs
• Suction and injection tubing 10 m • Peristaltic pump tubing 2 pcs.
• Aspiration filter 2 pcs. • Suction and injection tubing 10 m
• Aspiration filter weight 2 pcs • Aspiration filter 2 pcs.
• pH 7.01 sachets 3 pcs. • Aspiration filter weight 2 pcs.
• pH 4.01 sachets 3 pcs. • pH 7.01 sachets 3 pcs.
• HI7022 ORP 470 mV solution 250mL • pH 4.01 sachets 3 pcs.
• Power cable • HI7022 ORP 470 mV solution 250mL
• User manual • Power cable
• User manual
Before using this product, make sure that it is entirely suitable for your specific application and for the
environment in which it is used.
Operation of this instrument may cause interference to other electronic equipment, requiring the operator to
take steps to correct interference. Any variation introduced by the user to the supplied equipment may degrade
the instrument’s EMC performance.
To avoid damages or burns, do not put the instrument in microwave ovens. For your and the instrument’s safety,
do not use or store the instrument in hazardous environments.
Note: Save all packing material until you are sure that the instrument works correctly. Any defective item must be
returned in its original packing.
Pool
Controller
Contents
Safety
Measures

Description4
The Swimming Pool Controller is an automatic system to measure and control levels of pH and free chlorine in a
swimming pool or a spa. The chlorine level is measured based on the ORP of REDOX principle. An increase of the ORP
value correlates with an increase of the level of free chlorine. pH and disinfectant testing are made together for more
efficient disinfection and control. The efficacy of sanitizers, such as chlorine, are dependent on a controlled pH value. The
ORP value is the most consistent indicator of the sanitizing effectiveness of the pool/spa or water treatment. Typically 650-
750 mV at 7.2 pH indicates proper water treatment (all harmful bacteria are killed in less than 1 s). pH and disinfectant
testing are made using the HI1036-1802 combined electrode installed in-line or in flow-cell. To prevent the ground loop
effects from causing erratic readings and damage to the system the electrode has a matching pin considered the “earth
ground“ connection. The HI1036-1802 uses a Ag/AgCl reference with 3.5 M KCl. It was specially designed to detect the
broken electrode based on a shiffted ISO potential value. The ORP values are referenced to it.
It is the responsibility of the user/installer to determine an ideal setpoint for pH (e.g. 7,4) and ORP (e.g. 760 mv). The
Swimming Pool Controller will dose acid in case the pH of the water is above the pH setpoint and it will dose chlorine in
case the ORP value is lower than the ORP setpoint.
Although the Swimming Pool Controller is an automatic system, the user/installer should check the Swimming Pool
Controller and verify the levels of pH and free chlorine (in mg/L or ppm) in the pool, using a portable meter for pH and
free chlorine.
All measurements and the main events are logged in the internal memory of the Pool Controller and can be viewed using
the plot/record log recall feature or exporting the data on a USB key for advanced data processing on a PC.
The Swimming Pool Controller should only be used in combination with liquid acid (e.g. sulfuric acid) and liquid chlorine
(e.g. Sodium hypochlorite).
Do not use chlorine tablets, granular chlorine or other non-liquid chlorine applications.
Do not use the Pool Controller on a pool utilizing electrolytic chlorine generation (salt electrolysis).
Do not add stabilizer (e.g. cyanuric acid) to the swimming pool or spa while using Pool Controller. To remove
stabilizer from the pool, the pool contents must be removed and the pool cleaned.
The main operating modes of Swimming Pool Controller are measurement, dosing, setup and logging. Follow this general
outline of steps to get you started. The following topics are expanded in the sections of this manual.
Description

Controller Overview 5
Product
Diagram
Front Panel
Controller
Overview
1. Power Switch
2. Acid Dosing Pump
3. IN Acid
4. OUT Acid
5. Leakage holes
6. IN Chlorine
7. OUT Chlorine
8. Chlorine Dosing Pump
9. Cable Gland Seals
10. Probe Connector
11. Keyboard Area
12. USB port (host)
13. Liquid Crystal Display (LCD)
14. LED Area
15. LED Status
16. LED Service
17. Chlorine Pump Status LED
18. Acid Pump Status LED
Rear
Sub
Panel
Warning: Always disconnect power to instrument when making electrical connections.
Warning: Do not access larger rear panel. User Serviceable terminals are found in small sub panel only.

Controller Overview
6
Connections,
Alarm,
Output
and Power
Warning! Always disconnect power to the Pool Controller when making electrical connections.
Gland Seals for
Input/Output
wiring.
Sensor
Input
ANALOG
OUTPUTS
A01 +4 - 20 mA OUT
-
A02 +4 - 20 mA OUT
-
A03 +4 - 20 mA OUT
-
DIGITAL INPUTS
ALARM RELAY
POWER INPUT
N Neutral
Protective Earth
L Line
Power Cable.
Do not run other cables
with the Power Cable.

Setup/Installation 7
Controller Overview
1. MENU Key - Access to manual pump control, pH/ORP/Temperature options and General setup
2. p/qKey - In menu mode scroll the menu items / adjust the settings.
In measurement mode changes the screen: three parameter screen (pH, ORP, and Temperature),
single parameter screen and plot display.
3. HELP Key - Enter/Exit Help Menu
4. Virtual Function Keys - Contextual functionality
Keypad
Function
The following tasks require mechanical, plumbing and electrical skills. These should be made by qualified personnel. Two
configurations are available:
In line configuration: - the probe is placed in saddle, mounted on pipe after the pool filter.
Flow-cell configuration: - the probe is mounted in the flow-cell close to the controller. The water flow is assured by
tubes. In flow-cell configuration the water circulation can be maintained while maintenance or calibration procedures are
performed.
- When making selection for controller location, shield the controller from direct sunlight, dripping water and excess
vibrations.
- Select locations for saddles
- The probe saddle should be located after the pool filter for the In-line installation. This must be within 2 m distance
from the Pool controller.
Caution: Use gloves, protective clothing and eye protection goggles when working with Injectors and Tubing
- Determine if a Flow detector, or alarm relays or analog outputs will be used before mounting Flow-cell panel
or Pool Controller, as access to rear sub panel is needed.
Setup/
Installation
General
Installation
Guidelines

Setup/Installation8
Pool
Controller
Install

Setup/Installation 9
Pool
Controller
Install
1. Connection for flow detector is optional.
2. Connection for low level sensor for acid tank is optional.
3. Connection for low level sensor for chlorine tank is optional.
4. Probe connector.

Setup/Installation10
With a Phillips head screwdriver remove the screw, after opening lift
the back cover and remove it.
To insert in place, attach the bottom part of the cover to the
controller and push to close. Tight the screw with the screwdriver.
Pool
Controller
Install

Setup/Installation 11
• Check the tanks level.
• Mount the probe saddle (only for in line configuration).
• Mount the injector saddle (see procedure).
• Connect the aspiration tubes between tanks and pumps input.
• Connect the dispensing tubing between pumps and injectors.
• Check the low level sensors functionality if enabled.
• Check the functionality of hold input.
• For accurate measurements calibrate the probe before use in the system.
Pool
Controller
Install
Installation Guidelines
- Shield the controller from direct sunlight, dripping water and excess vibrations.
- Keep flow rate as constant as possible for optimum sensor operation.
- The sample analyzed should be representative of entire pool.

Setup/Installation12
Saddle
Installation
Using a 29 mm (1.14173”) drill, make a hole on the desired location on the available pipe, where the saddle will be
mounted (50 mm; 63 mm; 75 mm available).
1. The saddle will be mounted above the hole in the following order:
- Put the upper saddle (5) part with seal (4) mounted around the
hole.
- Put the lower part (2) of the saddle, together with inserted nuts
(1) into location.
- Insert a screw (7) through the hole with washer (6) mounted and
screw into the mounted nuts.
- Mount all the screws (7) by hand, then using a wrench screw
them carefully until tightened.
- Place the o-ring (8) provided , into the upper saddle.
Set saddle aside.
Saddles are used for the probe installation in an in-line installation, and for injector installations in both in-line and flow-
cell installations. Select pipe locations that are accessible with sensor cable length and tubing.
Saddle for Probe (in-line) Saddle threat size Drill size Min. - Max.
BL120-550 50 mm pipe 1 - ¼”thread 29 mm - 32 mm / 1.1417” - 1.2598”
BL120-563 63 mm pipe 1 - ¼”thread 29 mm - 32 mm / 1.1417” - 1.2598”
BL120-575 75 mm pipe 1 - ¼”thread 29 mm - 32 mm / 1.1417” - 1.2598”
Fittings for Valves for Flow-cell
connections
Saddle threat size Drill size Min. - Max.
BL120-450 50 mm pipe ½”thread 20 mm - 25.4 mm / 0.7874” - 1.0000”
BL120-463 63 mm pipe ½”thread 20 mm - 25.4 mm / 0.7874” - 1.0000”
BL120-475 75 mm pipe ½”thread 20 mm - 25.4 mm / 0.7874” - 1.0000”
Saddle for Injectors Saddle threat size Drill size Min. - Max.
BL120-250 50 mm pipe ½”thread 20 mm - 25.4 mm / 0.7874” - 1.0000”
BL120-263 63 mm pipe ½”thread 20 mm - 25.4 mm / 0.7874” - 1.0000”
BL120-275 75 mm pipe ½”thread 20 mm - 25.4 mm / 0.7874” - 1.0000”

Setup/Installation 13
Probe
Installation
2.Remove protective cap and
verify if the o-ring is in
place.
5.Insert the prepared probe
with the adapter and
screw it carefully into
the saddle. You are now
ready for connecting the
probe to the Swimming
Pool Controller.
3.Insert the nut on the
probe.
4.Screw carefully the adapter
on the probe. Do not to
damage the o-ring.

Setup/Installation14
Installing
Aspiration
Filters
1. Cut required length of suction/injection tubing to reach between peristaltic pump and reagent tanks.
2. Place the aspiration filter weight and the compression fitting nut on the tubing.
3. Place the end of tubing on the filter.
4. The compression fitting has to be screwed until secured on the filter.
5. Slide the compression fitting from the peristaltic pump inlet (up arrow) onto the tubing.
6. Place the aspiration filter weight over the filter.
7. Slide the end of tubing over the fitting of the peristaltic pump tubing.
8. Slide compression fitting up over tubing.
9. Tighten on fitting.
10.Repeat for second aspiration filter.
11.Place into appropriate reagent tank.
2.
3.
1. Cut required length of suction/injection tubing to reach between saddle for injector and outlet of peristaltic pump.
2. Place the compression fitting nut on the tubing.
3. Place the end of tubing on the injector.
4. The compression fitting has to be screwed until secured on the injector.
5. Screw the injector in the saddle.
6. Slide compression fitting from peristaltic pump tubing onto tubing.
7. Slide the end of tubing over fitting of peristaltic pump tubing.
8. Verify correct pump is used.
9. Slide compression fitting over tubing.
10.Secure and tighten on fitting.
11.Repeat for second injector.
2. 3.
4.
5.
4.
Aspiration filters are used in the reagent
tanks to filter debris from entering the
tubing.
Installing
Injectors
6.

Setup/Installation 15
Flow-Cell
Installation
Prepare the aspiration and dispensing valve assemblies like in the above drawing following the next steps:
1. Insert two o-ring’s (2) on the nipple (1) from both side.
2. Screw the nipple in the saddle (3).
3. Screw the valve (4) in the open end on the nipple screwed in the saddle until is tight and oriented in front to be
operated.
4. Screw carefully the straight tube fitting (5) inside the valve taking care not to damage the o-ring.
5 Insert the tube (6) in the straight tube fitting (5).

Setup/Installation16
Flow-Cell
Installation
The flow cell will be mounted in the following order:
- Take one o-ring (4) and mount on the flow-cell cap (5). Insert these on
flow-cell tube (2) on the far end from lateral hole. Mount one flow-cell nut
(3) by screwing over the flow cell cap. Screw the straight tube fitting (6) in
the hole of flow cell cap.
- Take the second o-ring (4) and mount on the flow-cell adapter (1). Insert
these on flow-cell tube (2) on the near end from lateral hole. Mount the
second flow-cell nut (3) by screwing over the flow-cell adapter.
- Screw the elbow tube fitting (7) into the lateral hole of the flow-cell tube
(2).
- Place the o-ring (8) provided, into the flow-cell adapter (1).
Prepare the probe before inserting in the flow-cell.
- Remove protective cap and verify if the o-ring (10) is in place. Insert the
nut (13) on the probe. Screw the adapter carefully (12) on the probe. Do
not damage the o-ring.
- Mount the collar (15) on the panel with the provided screw.
- Insert the assembled flow-cell into the collar (15) and secure it by closing.
- Insert the prepared electrode (11) into the flow-cell, carefully, not
damaging the o-ring, until the adapter (12) mounted on the electrode is
inside the flow-cell.
- Screw the nut (11) until the electrode and flow-cell assembly is secured.
- Insert the tube (14a) from the aspiration valve already mounted on the
saddle.
- Insert the tube (14b) from the dispensing valve already mounted on the
saddle.
TEST MEASUREMENT
Rinse the electrode tip with distilled water. Immerse the tip (bottom
4 cm / 1½”) in the sample and stir gently for approx. 30 seconds. For
a faster response and to avoid cross contamination of the samples,
rinse the electrode tip with the solution to be tested before taking your
measurements.

Setup/Installation 17
The controller menu is grouped into five categories:
•Manual/Auto pump control
• pH Options (CAL, Setup, GLP)
•ORP Options (CAL, Setup, GLP)
•Temperature Options (Setup)
• General
Manual/Auto Pump Control
Each pump can be set to MANUAL control by selecting the On 10s/OFF options.
When On 10s is selected the pump runs continuously for 10 s. To increase the time up to 90 seconds press the Add 10s
button. The remaining time is displayed next to the selected pump in the menu. Pressing the OFF button will stop the
pump. To return to the automatic mode select AUTO for each pump.
In Auto mode the pumps will be activated when the measurement exceeds the set point value.
pH Options
Option Choices / Resolution Default Note
Dosing Type Acid/Base Acid Use the correct option according to the tank content.
Set Point 6.00 to 8.00 pH / 0.01pH 7.2 pH Use to set the expected pH level in pool. When the pH
pump is activated, the pump LED flashes.
Proportional band 0.1 to 2.0 pH / 0.1 pH 2.0 pH
pH regulated time proportional band. Proportions the
time off and time on within the band. The pump is on
continuously at the set point value with added band.
pH Flow rate 0.5 to 3.5 l/h / 0.1 l/h 2.2 L/h pH dosing pump flow rate
Overtime 1 to 120 min / 1min 30 min Maximum allowed dosing time in automatic mode
Alarm High (pH Low+0.1) to 14.0 pH
Acid / 0.1 pH 8.0 pH
Minimum pH value that triggers the alarm high event if it
persists more than 5 seconds*. Status and service LED will
activate and pH pump will be disabled.
Alarm High Enable
Disable Disable Enable/Disable the pH high alarms
Alarm Low 0.0 to (pH High-0.1) pH
Acid / 0.1 pH 6.0 pH
Maximum pH value that triggers the alarm low event if
it persists more than 5 seconds**. Status and service LED
will activate and pH pump will be disabled.
Alarm Low Enable
Disable Disable Enable/Disable the pH low alarms
Warnings and Errors Enable
Disable Disable Enable/Disable the warnings and errors related to pH
events
Alarm Activates
Relay
Enable
Disable Disable Enable/Disable the relay control for pH events (see
page 6).
Startup Dosing
Delay 1 to 180 min / 1 min 2 min The delay to start dosing at power-on
Analog Out Disabled, AO1, AO2, AO3 Disabled Assign an analog output to pH reading
Max. Analog Out 1 to 14 pH / 1 pH 14 pH High pH limit assigned to 20 mA
Min. Analog Out 0 to 13 pH / 1 pH 0 pH Low pH limit assigned to 4 mA
Acid Tank Input Enable
Disable Disable Enable/Disable the acid tank low level input
Controller
Menu
* The minimum adjustable value of alarm high is related to alarm low value if it’s enabled.
** The maximum adjustable value of alarm low is related to alarm high value if it’s enabled.

Setup/Installation18
Controller
Menu
ORP Options
Option Choices / Resolution Default Note
Set Point 200 to 900 mV / 1 mV 700 mV Use to set the expected ORP level in pool.
Proportional band 10 to 200 mV / 1 mV 100 mV
ORP regulated time proportional band.
Proportions the time off and time on within the
band. The pump is on continuously at the set
point value with added band.
Cl2Flow rate 0.5 to 3.5 l/h / 0.1 L/h 2.2 L/h ORP dosing pump flow rate
Overtime 1 to 120 min / 1 min 30 min Maximum allowed dosing time in continuous
mode
Alarm High (Low+1) to 1000 mV / 1 mV 900 mV
Minimum ORP value that triggers the alarm
high event if it persists more than 5 seconds*.
Status and Service LED’s will activate and Cl2pump
will be disabled.
Alarm High Enable
Disable Disable Enable/Disable the ORP high alarms
Alarm Low 0 to (High-1) mV / 1 mV 200 mV
Maximum ORP value that triggers the alarm
low event if it persists more than 5 seconds**.
Status and Service LED’s will activate and Cl2pump
will be disabled.
Alarm Low Enable
Disable Disable Enable/Disable the ORP low alarms
Warnings and Errors Enable
Disable Disable
Enable/Disable the warnings and errors related
to ORP events
(see page 6).
Alarm Activates Relay Enable
Disable Disable Enable/Disable the relay control for ORP events
Startup Dosing Delay 1 to 180 min / 1 min 5 min The delay to start dosing at power-on
Analog Out Disabled, AO1, AO2, AO3 Disabled Assign an analog output to ORP reading
Max. Analog Out -1999 to 2000 mV / 1 mV 2000 mV High ORP limit assigned to 20 mA
Min. Analog Out -2000 to 1999 mV / 1 mV -2000 mV Low ORP limit assigned to 4 mA
Cl2Tank Input Enable
Disable Disable Enable/Disable the Cl2tank low level input
Temperature Options
Option Choices / Resolution Default Note
Alarm High (Low+0.1) to 100.0 °C / 0.1 °C
(Low+0.1)to 212.0 °F/ 0.1°F
50.0 °C
122.0 °F
Minimum Temperature value that triggers the
alarm high event if persist more than 5 seconds*
Alarm High Enable
Disable Disable Enable/Disable the temperature high alarms
Alarm Low 0.0 to (High-0.1) °C / 0.1 °C
32.0 to (High-0.1) °F / 0.1 °F
10.0 °C
49.9 °F
Maximum Temperature value that triggers the
alarm low event if persist more than 5 seconds**
Alarm Low Enable
Disable Disable Enable/Disable the temperature low alarms
Warnings and
Errors
Enable
Disable Disable Enable/Disable the warnings and errors related to
Temperature events

Setup/Installation 19
Option Choices / Resolution Default Note
Alarm Activates
Relay
Enable
Disable Disable Enable/Disable the relay control for Temperature
events
Unit °C / °F °C Temperature measurement unit
Analog Out Disabled, AO1, AO2, AO3 Disabled Assign an analog output to Temperature reading
Max. Analog Out -4.0 °C to 105.0 °C / 0.1 °C
24.8 to 221.0 °F / 0.1 °F
105.0 °C
221.0 °F High Temperature limit assigned to 20 mA
Min. Analog Out -5.0 °C to 104.0 °C / 0.1 °C
23.0 to 219.2 °F / 0.1 °F
-5.0 °C
23.0 °F Low Temperature limit assigned to 4 mA
* The minimum adjustable value of alarm high is related to alarm low value if it’s enabled.
** The maximum adjustable value of alarm low is related to alarm high value if it’s enabled.
General Options
Option Choices Default Note
Time Current set time. Option to change the current time
Time Format hh:mm:ss 24h
hh:mm:ss 12h hh:mm:ss 24h Option to change the current time format
Date Current set date. Option to change the current date
Date Format
yyyy-mm-dd,
dd-mm-yyyy,
mm-dd-yyyy,
yyyy/mm/dd,
dd/mm/yyyy,
mm/dd/yyyy
yyyy-mm-dd Option to change the current date format
Key Beep Enable
Disable Disable Enable/Disable the Audible tone for key
pressing
Alarms and Errors
Beep
Enable
Disable Enable When Enabled a Audible tone will be generated
when a new event is triggered.
Decimal Point / Comma Point Decimal separator selection
LCD Contrast 0 % to 100 % / 1 % 50 % Display contrast
LCD Backlight 0 % to 100 % / 1 % 50 % Display backlight contrast
Language English User interface language
Restore Factory
Settings All user interface settings will be restored to default.
Controller Info Controller Firmware version, Language, Serial Number
Probe Info Model, Firmware version, Serial Number, Factory Calibration Status
Controller Password Enable
Disable Disable When Enabled a lock icon is displayed
Controller ID 0 to 9999 / 1 1234 Setting used to identify the controller
Hold Input Enable
Disable Disable Enable/Disable the recirculation pump HOLD
input
Events Timeout 0 to 60 min / 1 min 0 min. The timeout value after an High/Low alarm
warning became alarm.
Controller
Menu

Setup/Installation20
User
Interface
Map