Pulse Instruments System 4 User manual

Pulse Instruments System 4 Manual
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Table of Contents
1. OVERVIEW..........................................................................................................3
1.1 INTRODUCTION................................................................................................................3
1.2 FEATURES ......................................................................................................................4
2. SYSTEM LAYOUT...............................................................................................5
3. SPECIFICATIONS ...............................................................................................9
3.1 SYSTEM COMPONENTS .................................................................................................10
3.2 PLC INPUTS AND OUTPUTS ...........................................................................................10
4. FUNCTION.........................................................................................................11
4.1 OPERATION ..................................................................................................................11
4.2 MONITORING.................................................................................................................12
4.3 CONTROL .....................................................................................................................12
4.3.1 pH / ORP...............................................................................................................................12
4.3.2 Proportional Control ..............................................................................................................12
4.3.3 Consent.................................................................................................................................13
4.3.4 Flow / Pressure Switch..........................................................................................................13
4.3.5 Manual Control......................................................................................................................13
4.4 SAFETY ALARM.............................................................................................................13
4.4.1 Alarm Contact........................................................................................................................13
4.4.2 30 Minutes Alarm / Pump On Too Long................................................................................14
4.4.3 Alarm Silence ........................................................................................................................14
4.4.4 Alarm Reset...........................................................................................................................14
4.4.5 Power ON Alarm Delay.........................................................................................................14
4.4.6 Water Fault............................................................................................................................14
5. INSTALLATION.................................................................................................15
5.1 CONTROL PANEL...........................................................................................................15
5.1.1 Mounting and Location..........................................................................................................15
5.1.2 Electrical and Power..............................................................................................................15
5.2 TERMINAL STRIP WIRING...............................................................................................15
5.3 SENSOR INPUT CONNECTION.........................................................................................16
5.4 TEMPERATURE CONTROLLER CONNECTION ...................................................................16
5.4.1 Connect J Thermocouple......................................................................................................16
5.4.2 Terminal Description .............................................................................................................16
5.5 FLOW SWITCH /PRESSURE SWITCH ..............................................................................17
5.5.1 Flow Switch ...........................................................................................................................17
5.5.2 Pressure Switch.....................................................................................................................17
5.6 FLOW CELL...................................................................................................................18
5.7 CHEMICAL METERING PUMPS........................................................................................18

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6. CONFIGURATION / SETUP ..............................................................................18
6.1 POWER UP...................................................................................................................18
6.2 SET POINTS..................................................................................................................19
6.3 TEMPERATURE..............................................................................................................20
6.3.1 Setup Temperature Sensor Type..........................................................................................20
6.3.2 Setup Temperature Unit........................................................................................................20
6.3.3 Setup Analog Output Mode...................................................................................................20
6.3.4 Setup Analog High and Low Range......................................................................................21
6.3.5 Change Offset .......................................................................................................................21
6.4 CHEMICAL METERING PUMP CONTROL ..........................................................................22
6.4.1 Priming ..................................................................................................................................22
6.4.2 Proportional Control ..............................................................................................................22
7. MAINTENANCE.................................................................................................24
7.1 ELECTRODE CLEANING..................................................................................................24
7.2 CALIBRATION ................................................................................................................24
7.2.1 pH Calibration........................................................................................................................24
7.2.2 ORP Calibration.....................................................................................................................25
7.3 ELECTRODE REPLACEMENT...........................................................................................26
7.4 CHEMICAL METERING PUMP..........................................................................................26
7.5 SURGE SUPPRESSOR....................................................................................................27
8. TROUBLESHOOTING GUIDES ........................................................................28
8.1 CONTROL SYSTEM FAILED .............................................................................................28
8.2 SENSOR FAILED............................................................................................................28
8.3 SENSOR CABLE IS DAMAGED.........................................................................................28
8.4 SENSORS NEED MAINTENANCE .....................................................................................28
8.5 CONTROLLER FAILED ....................................................................................................28
8.6 CONTROLLER ERROR MESSAGE....................................................................................29
8.7 CHEMICAL PUMP FAILED ...............................................................................................30
9CONTACT...............................................................................................................30

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1. Overview
1.1 Introduction
Wash Water Sanitation by ORP for Fruits and Vegetables
Introduction: In the ever-increasing need and awareness for food safety and HACCP, Water has become
a focus point for proper disinfection treatment as pathogens and harmful microorganisms can become a
danger for contamination of fresh fruits and vegetables during growing and post harvest contact. Water is
a critical control point of contact where proper treatment can greatly reduce these microbes, thereby
reducing the chances of food borne illness.
Typical water applications include:
1. Field and growing water including irrigation water
2. Post Harvest Pre-cooling operations: Hydrovac™, Ice Injection, and Hydro-cooling
3. Wash and Dip Tanks
4. Flume wash systems
5. Spray wash systems
Sanitizers: Many water treatment sanitizers have been introduced in the market such as Chlorine,
Bromine, Ozone, Peroxyacetic Acid, Hydrogen Peroxide, Ultraviolet light (UV), as well as many
derivatives of Chlorine. These derivatives are Chlorine gas, Sodium Hypochlorite, Calcium Hypochlorite,
Chlorine Dioxide, Dichlor, Trichlor, and Hypochlorous Acid.
The Problem: With so many chemical choices and food commodities, it becomes very difficult to
standardize upon an adequate treatment level. How much chemical (ppm) of each type to use for which
product under varying conditions of organic matter, dirt load, wash contact time, temperature, pH and
pressure or vacuum?
ORP the Solution: The objective of using any sanitizer is to disinfect the water and destroy pathogens. All
mentioned sanitizers except UV are oxidizers and they all create oxidation. The stronger the oxidation,
the faster the microbe is killed. By measuring this oxidation level, we can directly measure the rate at
which these microbes are killed. ORP (Oxidation Reduction Potential) is a measure of the oxidation level
in the water and is measured in mV (millivolts) and thereby measures the activity of the sanitizer rather
than its concentration levels (ppm). The choice of sanitizer may be left up to the user bearing in
consideration, their own process requirements.
Standard for Water Disinfection: Research has shown that at a level of 650 mV of ORP, bacteria such as
E. Coli are killed on contact or within a few seconds. Yeasts and molds may require typically 750 mV or
higher in order to be killed. Regardless of any type of oxidizer or any combination of sanitizer, and
regardless of other varying water conditions, if there is adequate ORP, there will be proper disinfection.
Balancing pH and keeping the organic and dirt load low helps in the strain and demand of the water,
therefore it is recommended that clean water quality be maintained as best possible which will also
reduce the amount of sanitizer needed to reach effective ORP.
Measurement of ORP: There are several types of ORP measurement meters that vary depending on the
process requirements and design. Regardless of their style and design they all have a sensor (electrode)
that measures the ORP made of Platinum, and an instrument that reads the ORP electrode value.
All ORP meters and electrodes need to be kept moist and require periodic cleaning and calibration check
with standards of known value to ensure reliability and accuracy. Measurement is made by simply
dipping the electrode in liquid and observing the display. A stable reading is normally reached within a
couple of minutes.

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Process Meters: Used in a fixed location for continuous monitoring of ORP and provides a highly reliable
up to date measurement as conditions continuously change in most process water applications. These
instruments may also be used as a source of reading only and manually dosing chemicals, however
continuous monitoring instruments are commonly used to automatically inject sanitizer on demand, and
provide a reliable method of process control as well as recording for automated record keeping.
Maintenance: All ORP and pH electrodes need periodic maintenance and cleaning. A simple cleaning
procedure is dipping the electrode tip in dilute (1:100) acidic solution for two minutes and rinsing with
clean water. Then dip in electrode checking solution to verify accurate readings. Many ORP meters allow
calibration adjustment and should be corrected weekly. Inaccurate ORP readings are usually a result of
electrode contamination, which may be corrected by cleaning, or depletion of useful life, which needs
electrode replacement. Some ORP meters allow slight slope offset adjustments (calibration) to correct for
these errors.
pH measurement that follows a logarithmic curve requires more calibration adjustments than ORP that
follows a linear relationship. Both pH and ORP instruments should be calibrated regularly for reliable
accurate measurements, and routine periodic electrode maintenance should be performed.
Conclusion: ORP has proven to be a reliable method of measuring water disinfection and provides the
operator with a single value of measurement regardless of which product, commodity, operation,
treatment or sanitizer is used, and regardless of varying field conditions or method by which chemical is
applied.
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.
The purpose of this manual is to provide users 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
This dual pH and ORP control system is housed in a NEMA 4X weatherproof enclosure, which is an
essential HACCP tool. It includes a programmable logic controller (PLC) unit that controls alarm and
safety shut down. The audio alarm outputs 80 decibel with beacon and horn, and the safety shut down
automatically turns off the chemical pumps to prevent any hazardous condition. This simple modular
design offers affordable continuous monitoring and control, which allows unique hands free operation and
future upgrade capability for recording.
•Works with any oxidizer
•Sensors monitor pH and ORP
•Controller automatically turns chemical pump On or Off as needed
•Always maintain a tight chemical concentration range
•Inject chemical only as needed
•Self maintains and adjusts to organic load
•Smart logic allows “Hands Free” Operation
•Self-cleaning sensors allow low maintenance

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2. System Layout
Fig. 1 Automation of Wash Water Sanitation System Diagram

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Fig. 2 Operator Interface
Fig. 3 Side of the Control Panel

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Fig. 4 Bottom of the Control Panel
Fig. 5 Back of the Front Plate inside of the Control Panel
BNC Connector
ORP Meter
pH Meter
Temperature Meter
Temperature Input
Communication
Cable to PLC
pH and ORP probes
go through these cord
grips
Connect pump to the
corresponding drop
cord

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Fig. 6 Temperature Meter
Fig. 7 Manifold
Normal Temperature
Temperature
High Alarm
Temperature
Low Alarm
Sampling Port
Sensor Port Sensor Port
Pressure Switch Port
Extra Sensor Port

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3. Specifications
Control Panel
Range pH: 0.00 to 14.00 pH
ORP: 0 to 1000 mV
Temperature: -58 ºF to 1832 ºF
Resolution pH: 0.01 pH ORP: 1 mV
Temperature: 0.1 ºF
Accuracy pH: ± 0.02 pH
ORP: ± 1 mV
Temperature: ± 0.2% of FS
Power 110 VAC; 15 Amps
Control Panel Weight 56 lbs
Control Panel Dimension Height x Width x Depth: 20 in x 16 in x 13 in
Enclosure Rating NEMA 4X
Manifold
Ports 6 Ports: 1 Inlet, 1 Outlet, 3 Electrodes, 1 Sampling
Inlet / Outlet Ports ¾” NPT
Electrode Ports ¾” NPT or ½” NPT (depending on the sensors)
Material PVC
Pressure Switch
Pressure 100 psi Max
Adjustable Range 1.5 to 15 psi
Tubing Length 5 feet
Fitting ¼” NPT
Power 110 VAC
Chemical Pump
Capacity Variable, See Pump Manual
Pressure Variable, See Pump Manual
Strokes per Minute 360 Max

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Turndown Ratio 1800:1
Stroke Length Adjustment 20% to 100%
Material Variable, See Pump Manual
IP Rating IP 65 / IP67
Power 115 VAC
3.1 System Components
Control Panel PI1701-V1.1
pH 170E-pH
ORP 170E-ORP
pH Electrode PI0020-PH
ORP Electrode PI0020-ORP
Flow Cell ETA-2PRS001 / FC04
Flow / Pressure Switch FS400PC / PS111
Two Chemical Pumps EW, EK, EHE Series
Temperature FD5112-13
Thermocouple Type J
3.2 PLC Inputs and Outputs
Pins Descriptions
X0 Consent Input
X1 --
X2 --
X3 --
X4 --
X5 Flow Switch Input
X6 --
X7 --
Y0 pH Acid Pump Output
Y1 ORP Oxidation Pump Output
Y2 Visual Alarm
Y3 --
Y4 Audio Alarm
Y5 --

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HH
H
LL
High alarm
pH
Acid Pump
Normal
Operation
Low alarm
High alarm
1000 ORP
Normal
Operation
Oxid. Pump
Low alarm
HH
L
LL
0 0
14
4. Function
4.1 Operation
The system 4 provides complete automation of the water disinfection process and chemical
treatment with unique capabilities for a “Hands Free” operation, allowing for true automation 24
hours a day. It works with any oxidizer such as Chlorine, Chlorine Dioxide, Bromine, Ozone,
Peroxide, or Peroxyacetic Acid. It also controls the pH with any process compatible acid such as
Citric, Phosphoric, Muratic or Sulfuric Acid.
Fig. 8 pH and ORP Control Concept
pH has three set points: low alarm, acid chemical injection control, and high alarm. ORP also has
three set points: low alarm, oxidizer injection control, and high alarm.
pH
High alarm: turns on above HH
Acid pump: turns on above H
Low alarm: turns on below LL
ORP
High alarm: turns on above HH
Oxidation pump: turns on below L
Low alarm: turns on below LL

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Hysteresis / dead-band eliminate output chatter at the switch point (See Fig. 9).
Fig. 9 Hysteresis / Dead-band
4.2 Monitoring
This system monitors pH, ORP, and Temperature. pH is in the range of 0 to 14. ORP is in the
range of 0 to 1000 mV and temperature is in the range of -58 ºF to 1832 ºF using a Type J
thermocouple.
The operator interface (See Fig. 2) panel allows user friendly messaging for ease of use and
operation. It displays the pH and ORP control and alarm set points, as well as messaging for
alarm conditions and water fault in case of flow failure. New set point values may be entered
here and executed for operation.
Three color-coded warning lights indicate alarm states and conditions of the system by either
steady or flashing lights and color-coding. Pushbuttons on the panel allow for alarm resetting,
alarm silence and menu function access and selection.
4.3 Control
4.3.1 pH / ORP
Under normal conditions, pH is controlled by the system to the desired pH value set through the
operator interface. When the pH rises above the high set point value, the acid pump will
automatically turn on via a control relay. Acid is added to the water until the pH drops down to
the set point value, and the acid pump shuts off. The corresponding status indicator light will turn
on to indicate the pump is ON.
Under normal conditions, the oxidation pump is controlled by the system to the ORP value set
through the operator interface. When the ORP value drops below the low set point value, the
oxidation pump automatically turns on via a control relay. The pump adds oxidizer to the water
until the ORP value rises to the set point value, and then shuts off. The corresponding indicator
light will turn ON to indicate the pump is ON.
4.3.2 Proportional Control
Proportional control has the ability to increase or decrease the speed of the pump in relation to
the set point value by using a 4-20 mA signal. In order to proportionally control the chemical
metering pumps for acid and oxidation injection, the chemical metering pumps must be
connected to the ON / OFF control outputs and to the 4-20 mA signals from the control panel.
The system is able to turn ON or turn OFF the chemical metering pumps to inject chemical at the
specified set point values. The 4-20 mA output signals span the pH and ORP scales, 0 – 14 pH
and 0 – 1000 mV, respectively. See Section 6.4.2 for configuration details.
SP = Setpoint
Hys = Hysteresis

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4.3.3 Consent The consent function is used to
prevent acid and oxidation pumps
from running at the same time,
which may result in the
production of harmful gases.
Consent also allows for optimized
use of chlorine and creates better
chemical balance in the water. If
the consent jumper is in place,
the acid pump takes priority over
the oxidation pump, whenever
the acid pump is on, the oxidation
pump will never be on, even if the
value of the ORP is under the set
point.
Acid and oxidation pump will run independently if the consent is off.
4.3.4 Flow / Pressure Switch
If a flow / pressure switch is connected and if there is flow / pressure in the recirculation loop, the
chemical injection will start treating the water as needed. If no flow / pressure is detected (Water
Fault), the control system will continue monitoring and recording, but will not allow for any
chemical injection or any alarms to occur. In the “Water Fault” condition, the alarm function is
disabled, and an indicator light on the operator interface flashes on / off. The flow switch /
pressure switch function allows for a 5 second confirmation (on / off) in order to ignore false
signaling or momentary contact.
4.3.5 Manual Control
Turn the power switch located on the side of the control panel to the “MAN” position (see Fig. 3).
The system will bypass the PLC (programmable logic control) module. The pH and ORP meters
(see Fig. 1) will be on to monitor the pH and ORP values and the acid and oxidation pumps will
be on continuously. Use the manual control function if the PLC failed.
4.4 Safety Alarm
An alarm condition occurs due to process failure when levels of the chemicals exceed the
specified alarm limits of alarm set points. Chemical pump is shut-off and an audio-visual alarm is
activated until reset by an operator.
4.4.1 Alarm Contact
If pH reaches the alarm set point, either High or Low, the pH Alarm light located on the operator
interface panel (See Fig. 2) will immediately turn on, but the chemical pumps will continue to feed
as needed. If the alarm contact is maintained for at least 2-minutes, the alarm light will start
flashing, the main alarm (beacon and horn) will turn on, and the chemical pumps for both acid
and oxidizer will turn off. If the alarm condition restores itself so that the alarm contact is no
longer active, then the main alarm will reset itself and normal chemical dosing will be restored.
If ORP reaches the Low or High alarm set point, the ORP Alarm light located on the operator
interface panel (See Fig. 2) will immediately turn on, but the chemical pumps will continue to feed
as needed. If the alarm contact is maintained for at least 2-minutes, the alarm light will start
flashing, main alarm (beacon and horn) will turn on, and the chemical pumps for both acid and
oxidizer will turn off. If the alarm condition restores itself so that the alarm contact is no longer
active, then the main alarm will reset itself and normal chemical dosing will be restored.

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4.4.2 30 Minutes Alarm / Pump On Too Long
If the pH control point is active in the chemical feed mode for more than 30 minutes, the main
alarm will turn ON and will shut off both the acid and oxidation pumps.
If the ORP control point is active in the chemical feed mode for more than 30 minutes, the main
alarm will turn ON and will shut off both the acid and oxidation pumps.
4.4.3 Alarm Silence
If there is an alarm, press the Alarm Silence button on the operator interface panel (See Fig. 2) to
silence the alarm and a red indicator light on the button will be on. Don’t forget to turn off the
“Alarm Silence” button after the problem is fixed.
4.4.4 Alarm Reset
Alarm Reset button on the operator interface panel (See Fig. 2) will reset the main alarm to
normal mode, and restore the chemical pumps to normal operation for 30 minutes. If the alarm
condition continues to exist after 30 minutes, the alarm function will start again until the condition
is satisfied or reset.
4.4.5 Power ON Alarm Delay
This feature is activated when the control panel is supplied power (turned ON). A logic mode is
activated at power on so that for the first 30 minutes all alarms are ignored and chemical feed is
allowed to occur by the acid or oxidation pumps.
4.4.6 Water Fault
If there is a “Water Fault”, the pump and alarm functions are disabled, and a Water Fault light on
the operator interface (See Fig. 2) flashes on / off.

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5. Installation
Control Panel and Electrodes preferably should be mounted close to one another as possible and
no greater than 50 feet apart (See Fig. 1).
5.1 Control Panel
5.1.1 Mounting and Location
Mount the Instrument Control Panel on a secure stand, bracket, or wall by the mounting feet
provided. Location of the control 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, as well as the Visual Alarm, and in hearing range of the 80 db Audio Alarm (See
Fig. 3). 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.
5.1.2 Electrical and Power
The control panel requires 110VAC at 15 Amps. The panel is supplied with a 3-prong grounded
plug. Extra attached loads such as valves, mixers, and other such devices should be included 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 to 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.
5.2 Terminal Strip Wiring
From left to right
1. Acid Pump
2. Oxid. Pump
3. Neutral
4. Ground
5. Flow Switch
6. Flow Switch
7. (+) Temp Rcd
8. (-) Temp. Rcd
9. (+) 4-20mA pH Rcd
10. (-) 4-20mA pH Rcd
11. (+) 4-20mA ORP Rcd
12. (-) 4-20mA ORP Rcd
13. (+) 4-20mA pH Pump
14. (-) 4-20mA pH Pump
15. (+) 4-20mA ORP Pump
16. (-) 4-20mA ORP Pump
Terminal strip locations 1-4 are used to power the pumps. Terminal strip locations 5-6 are used
for flow / pressure switch. Terminal strip locations 7-12 are used for recording. (If not used for
recording, please do not remove the jumpers.) Terminal strip locations 13-16 are 4-20mA output
signals to control proportional pumps.

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5.3 Sensor Input Connection
Bring in the male BNC connectors of the pH and ORP probes through the two large cord grips at
the bottom of the control panel (see Fig. 4) and connect each to their appropriate female BNC
connectors on the pH and ORP monitors (see Fig. 5).
5.4 Temperature Controller Connection
5.4.1 Connect J Thermocouple
Connect the positive (White wire) of the J Thermocouple to terminal 1 and the negative (Red
wire) of the J Thermocouple to terminal 3 on the back of the temperature meter.
5.4.2 Terminal Description
No. Description
1 Positive terminal for thermocouple
2 --
3 Negative terminal for thermocouple
4 Power terminal (No polarity)
5 Power terminal (No polarity)
(6-13, not included with the default system)
6 Normally closed terminal for Low set point output
7 Common terminal for Low set point output
8 Normally open terminal for Low set point output
9 Common terminal for GO output
10 GO output terminal
11 Normally closed terminal for High set point output
12 Common terminal for High set point output
13 Normally open terminal for Low set point output
14 Common terminal for analog output
15 Current output terminal (4-20 mA)
16 Voltage output terminal (1-5 V, 0-1 V, and 0-10 V)
678910 11 12 13 14 15 16
1 2 3 4 5
(
6-13, not included
)