Pulse Instruments System 2 User manual

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User Manual
System 2
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www.pulseinstruments.net
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943 Flynn Rd. Camarillo, CA 93012 Phone: [phone] Fax: [phone]

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Table of Contents
1. OVERVIEW............................................................................................................................. 2
1.1 INTRODUCTION....................................................................................................2
1.2 FEATURES ..........................................................................................................2
2. SPECIFICATIONS..................................................................................................................3
3. FUNCTION ............................................................................................................................. 3
3.1 OPERATION.........................................................................................................3
3.2 MONITORING.......................................................................................................3
3.3 CONTROL............................................................................................................3
3.4 HANDS FREE.......................................................................................................3
4. SYSTEM COMPONENTS ...................................................................................................... 4
5. SYSTEM LAYOUT ................................................................................................................. 5
6. INSTALLATION...................................................................................................................... 6
6.1 INSTRUMENT CONTROL PANEL ............................................................................6
6.1.1 Mounting and Location............................................................................................... 6
6.1.2 Electrical and Power.................................................................................................. 6
6.2 PRESSURE SWITCH.............................................................................................7
6.3 FLOW CELL.........................................................................................................8
6.3.1 2PRS001.................................................................................................................... 8
6.3.2 FC04 .......................................................................................................................... 8
6.4 CHEMICAL METERING PUMPS ..............................................................................9
7. CONFIGURATION / SETUP................................................................................................. 10
7.1 POWER UP.......................................................................................................10
7.2 CONTROL SET POINTS ......................................................................................10
7.3 CONTROLLER CONNECTION...............................................................................10
7.4 CHEMICAL METERING PUMP CONTROL ..............................................................11
7.4.1 Priming..................................................................................................................... 11
8. MAINTENANCE ................................................................................................................... 12
8.1 ELECTRODE CLEANING......................................................................................12
8.2 CALIBRATION ....................................................................................................12
8.2.1 pH Calibration.......................................................................................................... 12
8.2.2 ORP Calibration....................................................................................................... 12
8.3 ELECTRODE REPLACEMENT...............................................................................12
8.4 CHEMICAL METERING PUMP..............................................................................12
9. TROUBLE SHOOTING GUIDELINES................................................................................. 13
9.1 SENSOR FAILED ................................................................................................13
9.2 SENSOR CABLE IS DAMAGED..............................................................................13
9.3 SENSORS NEED MAINTENANCE ..........................................................................13
9.4 CHEMICAL PUMP FAILED....................................................................................13

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1. Overview
1.1 Introduction
Fresh fruit and vegetable harvesting, post-harvest handling and cooling, packing and
processing activities that involve the use of water have a higher potential of
contamination by plant pathogens and microbes. Small errors in contamination
prevention and water disinfection procedures can have severe consequences due to the
ease of spread of microbes, particularly in re-circulated water systems.
Accurate monitoring and recording of disinfection procedures is an important component
of a sound post-harvest quality and safety program. Oxidation-Reduction Potential
(ORP), measured in millivolts (mV), has been introduced to fresh produce packers and
shippers as an easily standardized approach to water disinfection for harvest and post-
harvest handling. Operationally, much like a digital thermometer or pH probe, ORP
sensors allow for easy monitoring, tracking, and automated maintenance of critical
disinfectant levels in water systems.
The purpose of this manual is to provide users with instructions on how to operate the
water disinfection system and a brief overview of the application of ORP monitoring to
post-harvest sanitation processes.
1.2 Features
System 2, a pH and ORP control system, is housed in a NEMA 4X weatherproof
enclosure, which is an essential HACCP tool. This simple modular design offers
affordable continuous monitoring and control.
•Works with any oxidizer
•Sensors monitor pH and ORP
•Controller automatically turns chemical pump On or Off as needed
•Always maintains a tight chemical concentration range
•Injects chemical only as needed
•Self-cleaning sensors allow for low maintenance

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2. Specifications
Condition Specifications
Monitoring Range pH: 0.00 to 14.00 pH
ORP: -1999 to 1999 mV
Control Range pH: 2.5 to 11.00 pH
ORP: 200 to 950 mV
Accuracy pH: ± 0.01 pH
ORP: ± 1 mV
Power 115 VAC; 10 Amps
Control Panel Weight 13 lbs
Control Panel
Dimension Height x Width x Depth: 10 in x 8 in x 6 in
3. Function
3.1 Operation
The System 2 provides complete automation of the water disinfection process and
chemical treatment. It utilizes unique capabilities for a “Hands Free” operation of water
treatment, allowing for true automation 24 hours a day. The System 2 works with any
oxidizer such as chlorine, chlorine dioxide, bromine, ozone, peroxide, and peroxyacetic
acid.
3.2 Monitoring
This system monitors pH in the range of 0 to 14 pH. This system monitors ORP in the
range of 0 to 1000 mV.
3.3 Control
Under normal conditions, pH is controlled by the system to the pH level set at the
controller. When the pH rises above the high set point value, the acid pump
automatically turns ON via a control relay and adds acid to the water until the pH lowers
down to the set point value, and then shuts off.
Under normal conditions, ORP is controlled by the control system to the ORP level set at
the controller. When the ORP value drops below the low set point value, the oxidizer
pump automatically turns ON via a control relay and adds oxidizer to the water until the
ORP value rises to the set point value, and then shuts off.
3.4 Hands Free
A flow switch interface only allows the operation to occur if there is flow in the process. If
this feature is being utilized, the logic works, so that if there is water flow through the
electrode flow cell, the chemical injection will start treating the water as needed. If no
flow is detected, the instrument control system will continue monitoring, but will not allow
any chemical injection. No water treatment will occur in the absence of flow.

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4. System Components
pH & ORP 7215S-01
pH Electrode PI0020-pH
ORP Electrode PI0020-ORP
Flow Cell 2PRS001
Flow Switch FS400PC
Two Chemical Pumps PBMA

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5. System Layout
Fig. 1 System Diagram

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6. Installation
The two primary components, Control Panel and Electrodes, should be preferably
mounted as close to one another as possible but no greater than 50 feet apart. (See the
system layout, Fig. 1).
6.1 Instrument Control Panel
6.1.1 Mounting and Location
Mount the control panel on a secure stand, bracket, or wall using the mounting feet
provided. Location of the instrument panel should be determined according to process
layout, keeping in mind that it is preferable to locate the control panel in a dry
environment whenever possible even though it is rated for wet environments at NEMA
4X.
The control panel should be accessible for routine maintenance, and easy viewing of the
front digital display. It should also be located with enough space underneath of at least
two feet for mounting the Injection Manifold, along with the switches and cables.
6.1.2 Electrical and Power
The control panel requirements are 115 VAC at 10 Amp. The panel is supplied with a
three prong grounded plug. Extra attached loads such as valves, mixers, and other such
devices should be accounted in the total electrical requirements.
WARNING: To reduce the risk of electrical shock, the control panel must be plugged
into a grounded outlet with ratings conforming to the requirements of the control panel,
and any other electrical loads connected to it. The panel should be connected to a good
ground. DO NOT USE ADAPTERS! All wiring must conform to local electrical codes.

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6.2 Pressure Switch
PS110
Pressure Switch inside the
Enclosure
PS110, pressure switch comes with NEMA 4X enclosure with 110VAC power receptacle
to plug in a device. The sensitivity of the pressure switch can be adjusted by turning the
dial inside of the receptacle (see picture above). For high pressure, reduce sensitivity
and loosen the dial. For low pressure, increase sensitivity and tighten the dial.
PS110 is easy to use and simple to install. Fittings, power cord, drop cord, along with a 5
feet tubing are provided in the package.
A pressure switch interface only allows the operation to occur if there is pressure in the
process. If this feature is being utilized, the logic works, so that if there is pressure in the
pipe, water flow through the electrode flow cell, the chemical injection will start treating
the water as needed. If no pressure is detected, PS110 will not supply power to the
control panel, therefore no operation.
Power coming
from the Outlet PS110 provide power
to control panel
PS110 Control Panel

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6.3 Flow Cell
Flow cell allows water to enter from one end of the flow port and exits the other, while the
electrodes take their measurement.
6.3.1 2PRS001
Specification:
Uses in clean water application
Holds pH and ORP electrodes
½” NPT Ports
Installation: install a straight pipe from one of the flow
cell to the other end.
6.3.2 FC04
Flow Cell Flow Cell Installation
The pipe is in a U shape to trap water, so that the electrodes
will stay wet. For some electrodes, it is essential that they
stay wet at all time.
Specification:
Uses in dirty water or water with some solids application
Holds pH and ORP electrodes (1/2” NPT)
Two large water flow ports (1 ¼” NPT)
Sampling port
Extra port

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6.4 Chemical Metering Pumps
Choose a location for the pump, which is clean, dry, close to an electrical outlet, and
allows convenient access to stroke length control, frequency control, and tubing
connections. Avoid areas where ambient temperature exceeds 122 ºF (50 ºC) or falls
below 32 ºF (0 ºC), or where the pump or tubing would be exposed to direct sunlight
(See the pump manual for details).
Flooded Suction Mounting
Recommended for liquids that out-gas Shelf Mount Maximum 5 feet suction lift Tank Mount Maximum 5 feet suction lift

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7. Configuration / Setup
7.1 Power Up
To set up a new unit, first check that the power supply connections are correct, the outlet
is 110VAC, and that the connection and power sources are free of any ground loops,
inductive loads or magnetic fields. Shared loads on the same circuit may cause
interference, and therefore a clean power circuit is recommended. Also, when using the
AC supply, ensure that a 3-way grounded main lead is used to connect the unit.
7.2 Control Set Points
Before we begin operations, we must first define the process parameters.
Factory Preset
pH High Acid 7.2 pH
ORP Low Oxidation 670 mV
1. Press the pH SET/READ push
button and the set point indicator
light will come on, which indicates
and displays the set point value on
the pH display.
2. While pressing the pH SET/READ
button, adjust the SET knob to the
desired pH set point.
3. Release the button after the set point
is adjusted.
4. Press the ORP SET/READ push
button and the set point indicator
light will come on, which indicates
and displays the set point value on
the ORP display.
5. While pressing the ORP SET/READ
button, adjust the SET knob to the
desired ORP set point.
6. Release the button after the set point
is adjusted.
7.3 Controller Connection
Fig 2: Bottom of the Panel Instrument (Controller)
The bottom of the panel instrument (controller) contains an electrical connection labeled
pH OUT and ORP OUT. For each of the pH OUT and ORP OUT connections, a feeder

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power cord is wired to L(Line) and N(Neutral). Devices such as pumps, solenoid valves,
ozonators, etc. may be plugged in to these receptacles that require 115 VAC.
When installing the system without flow, connect a jumper between the two pins of
CONTACT INPUT in order to simulate flow (See Fig 2). After the installation or when
there is flow, disconnect the jumper for normal monitor and control.
7.4 Chemical Metering Pump Control
EZ Series EW Series EK Series EH Series
7.4.1 Priming
With the pump turned on but not pumping, set stroke length at 100% and frequency to
360 strokes per minute (SPM). If the pump is equipped with an air vent valve, open the
knob half turn. Liquid should move up through the suction tubing and into the pump head.
When the liquid starts running through the vent side tubing, close the air vent knob and
continue with output adjustment (See pump manual for details).
If the pump has no air vent valve, disconnect the discharge tubing from the injection
valve. When liquid enters the discharge tubing at the pump head, stop the pump. Then
reconnect the discharge tubing to the injection valve.
If the pump does not self prime, remove the check valve housing on discharge and
suction sides to make sure cartridges and gaskets are in correct positions (See pump
manual for details).

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8. Maintenance
8.1 Electrode Cleaning
pH and ORP electrodes are both cleaned the same way. Take a 1:100 diluted solution of
acid to water in a cup, and place the electrode front tip in the solution at least two inches
deep, for minimum five to fifteen minutes. Rinse the tip and re-check the calibration.
8.2 Calibration
8.2.1 pH Calibration
1. Rinse the pH electrode with distilled or tap water and immerse in buffer 7.00. Ensure
that the pH set switch is in the read mode. Adjust the STANDARD knob until the
display reads 7.00.
2. Rinse the pH electrode with distilled or tap water and immerse in buffer 4.01. Adjust
the SLOPE knob until the display reads 4.01.
3. Repeat steps 1 and 2 as often as necessary until no further adjustment of the
STANDARD and SLOPE knobs is required.
8.2.2 ORP Calibration
ORP electrodes age in a similar fashion as pH electrodes do, but there is no specific
calibration procedure. An ORP 468 mV checking solution is included in the controller
package, which may be used to read and verify correct operation of the system. Note
that ORP is a linear relationship to oxidizer concentration, and therefore does not go out
of calibration. The solution is provided merely to diagnose any electrode contamination
or failure.
8.3 Electrode Replacement
Model PI0020-pH and PI0020-ORP are both high chlorine tolerance electrodes. To
replace the electrode, first disconnect the cable BNC connector by turning it a half turn
counterclockwise. DO NOT USE EXCESSIVE FORCE. Lift the BNC and disconnect it
from the electrode.
The electrode will easily slip out of the Electrode Flow Cell. Place the electrode tip in a
protective cap with some buffer solution or water.
Take the new electrode and remove the protective cap at the bottom of the electrode.
Calibrate the electrode using appropriate calibration standards. Place the electrode in
the Electrode Flow Cell and finger-tighten the compression nut. DO NOT USE
EXCESSIVE FORCE.
8.4 Chemical Metering Pump
Periodically check the chemical tank level to avoid the pump operating without liquid.
Check the pump operating condition at least every 6 months: pump head position,
screws, bolts, and seals. Check more frequently if using aggressive chemical. Also,
clean the hydraulic parts, such as valves and filters, as often as needed. (See PBMA
manual for details).

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9. Trouble Shooting Guidelines
9.1 Sensor failed
Unscrew the sensors from the threaded holder and place in known calibration standards.
pH in pH 7.00 and 4.00 solutions. ORP in 468 mV solution. The readings on the control
panel should match or should be close. Follow calibration procedure. If sensors are too
far off the standard readings, follow maintenance procedure as described in the next
section.
9.2 Sensor cable is damaged
Follow the sensor cable carefully along its length and check for any cuts, breaks, or tight
kinks. If the cable is damaged, replace sensor and send in old sensor to the factory for
cable repair.
9.3 Sensors need maintenance
If other parameters seem normal but the readings are abnormal in calibration standards,
service the sensors. Take a 1:100 diluted solution of acid to water in a cup and place the
sensor’s front tip in the solution at least 2 inches deep for a minimum five to fifteen
minutes. Rinse the tip and recheck calibration.
Calibration: Should be performed at least once per month.
Place the pH sensor in a cup of pH 7.00 solution immersed minimum two inches. The pH
controller should read 7.00 on the display. If not, adjust the Stand trim screw so that it
reads 7.00. Rinse the tip with tap water and place in pH 4.00. The display should match
the reading within 10 seconds. If the reading is not at 4.00, adjust the SLOPE trim to
match 4.00.
ORP sensor normally does not drift out of calibration, however a checking solution at 468
mV is supplied to serve as a check. Slight adjustment may be made on the ORP
controller using the CAL trip screw.
9.4 Chemical Pump failed
Reset on the control panel. If in the pump receptacle has 110VAC output but the pump is
not turning ON, check to make sure the pump is in the on position and at 50% stroke and
frequency. If the pump still does not turn ON, it means the pump has failed and needs
service.
Call the factory service center at
1-800-462-1926.