Prototype chemical batching system

1. CHEMITROL
Chemical Batching System
Users Manual
Revision 1.5
www.chemitrol.com
info@chemitrol.com

2. Table of Contents
1.0 Introduction............................................................................................................. 3
1.0 Introduction............................................................................................................. 3
1.1 Why use a batch tank or a day tank?................................................................... 3
1.2 Benefits of the Chemical Batching System ........................................................ 3
1.3 Theory of operation............................................................................................. 4
2.0 Specifications.......................................................................................................... 5
2.1 Electrical ............................................................................................................. 5
2.2 Mechanical.......................................................................................................... 5
2.3 Chemical Batching System Program Limits....................................................... 5
2.3a Water relay (1) ................................................................................................ 5
2.3b Pump relays (4) ............................................................................................... 5
3.0 Un-Packing & instillation of the ............................................................................. 6
3.1 Unpacking the unit.................................................................................................... 6
3.2 Mounting the controller ............................................................................................ 6
3.3 Electrical Installation ................................................................................................ 6
4.0 System Overview .................................................................................................... 9
4.1 Front Panel .............................................................................................................. 10
4.2 Display .............................................................................................................. 10
4.3 Key Pad............................................................................................................. 10
4.4 Led indictor lights ............................................................................................. 10
4.5 Start up Initial ................................................................................................... 11
4.6 Normal start up ................................................................................................. 11
4.7 Shutdown .......................................................................................................... 11
5.0 Operating Instructions........................................................................................... 11
8.0 Index ........................................................................................................................... 13
Table of Figures
Figure 1: Wiring configuration ........................................................................................... 7
Figure 2: The CBS controller within a typical system including pumps and day tank ...... 8
Figure 3: The CBS with the faceplate removed.................................................................. 9
Figure 4: The Features displayed on the CBS Faceplate .................................................. 10
CBS_Manual_R015 Page 2 of 13

3. 1.0 Introduction
Thank you for purchasing the Chemical Batching System. The Chemical Batching
System was designed to fill a large variety of liquid batch tank needs. The purpose
of the Chemical Batching System is to aid in the operation of a boiler water
treatment system. Currently boiler operators using day tanks must manually add
treatment chemicals by hand to the dilution water in their day tanks. As with any
manual operation errors can be made resulting in increased costs. Some of these
incurred costs would be due to overuse or underuse of treatment chemicals,
inconsistently mixed day tank batches and the potential hazards of hand mixing
hazardous chemicals. Potential savings would include reducing operator workload,
consistent chemistry in the boilers, resulting in lower maintenance costs.
1.1 Why use a batch tank or a day tank?
The reasons to use a batching tank or day tank in a boiler chemical treatment
program are many.
• A batch tank system is an alternative to using an “all in one”
chemical treatment product. These products may or may not meet
all the requirements of your system.
• This system dilutes concentrated chemical products, avoiding line
and nozzle plugging. Generally it is more cost effective in terms of
pounds of water treated per unit cost to purchase concentrated
chemicals from vendors rather than their water diluted counterparts.
Depending on the application, this could create line or nozzle
plugging problems. Diluting these concentrated products will reduce
plugging problems.
• It is advantageous to avoid concentrate chemical corrosion/erosion
within the boiler. Some water treatment chemicals have low
solubility in water and will not dilute without aggressive mixing.
Pre-mixing the chemicals in a day tank will dissolve and dilute these
chemicals before they enter the boiler system.
• Some boiler treatment chemicals are extremely corrosive in their
neet form. By diluting these chemicals in a day tank system you can
reduce neet chemical corrosion effects.
1.2 Benefits of the Chemical Batching System
The Chemical Batching System provides accurate, hands free, on demand
chemical blending of boiler treatment chemicals. The same concentration of
chemicals will be blended for each batch.
• Reduced operator involvement. Operators need only to replace
empty chemical containers and re-prime chemical pumps.
• No hand mixing of chemicals to make up batch tanks.
• Consistent blending of chemicals in every batch.
• Ability to program several chemical recipes for different operating
conditions. (Summer/Winter operations, weekend/weekday
operations, etc.)
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4. • Provides the ability to adjust chemical concentrations in the day
tank.
1.3 Theory of operation.
The chemical batching systems is essentially a sensor driven system. A day/batch tank is
set up with a high water level sensor and a low water level sensor. The tank feeds treated
water to the boiler. The level sensors control the cycles of the chemical batching
systems, which consists of five relays. Relays numbers 1 through 4 turn the chemical
delivery pumps on and off. Relay number 5 turns the water supply on and off.
1. The dilute boiler chemical solution is fed to the boiler from a batched tank.
2. The water level decreases below the actuation point of the low water level sensor
in the day tank.
3. An LED indicator appears lit on the control interface panel.
4. Upon actuation of the low level sensor the filling/treatment cycle begins.
5. The 4 timed relays begin their countdowns and the sensor relay actuates.
a. The 4 timed relays control up to 4 reagent pumps for adding up to 4 water
treatment chemicals.
b. Channels 1 through 4 are to be set with the Safety Timer Feature which
will not allow for the day tank to overflow, due to the relatively slow rate
of the pumps in use.
th
6. The 5 relay actuates a valve which fills the tank with city water.
7. The 5th relay terminates upon activation of the high water level sensor.
a. The volume of city water being added to the tank remains constant. This
allows the amount of reagent to be added also to remain constant. The
volume flow rate of the pumps is known; therefore to achieve the correct
addition of reagent, one can set the amount of time for each pump to run to
add the correct volume of reagent.
8. The dilute chemical solution is fed to the boiler
CBS_Manual_R015 Page 4 of 13

5. 2.0 Specifications
2.1 Electrical
• Input Power
Voltage: 100 – 250VAC
Frequency: 47-63Hz
Input Current: 10A Max @ 115VAC
20A Max @ 230VAC
• Output power
Max Switched Voltage: 250VAC
Max Switched Current: 5A
Max Switched Power: 1250VA, 150W
• Level indictors
On/Off dry contact type 5 VDC
• Agency Approvals
UL TBD
2.2 Mechanical
Enclosure Material Molded Polystyrene
NEMA Rating NEMA 12/13
Dimensions 10.25 X 12 X 5.25
Display LCD 16 X 2 Character backlit liquid crystal
Operating Temperature 32-120 deg F (0 to 50 deg C)
Level sensor(s) 2 Dry contact liquid level sensors
2.3 Chemical Batching System Program Limits
2.3a Water relay (1)
0 seconds to 99 minutes
Triggered by low liquid level sensor
Secured by high liquid level sensor or programmable time out
safety function (see section 5.5)
2.3b Pump relays (4)
0 seconds to 99 minutes
Triggered by low liquid level sensor
Secured by Program (see section 5.0)
CBS_Manual_R015 Page 5 of 13

6. 3.0 Un-Packing & instillation of the
3.1 Unpacking the unit
Inspect the unit and the contents of the package. Please notify the carrier
immediately if there are any signs of damage to unit. Contact your
distributor if there are any missing parts.
3.2 Mounting the controller
The Chemical Batching System should be mounted in close proximately to
the batching tank and the chemical storage location ideally the controller
will be mounted on a stable horizontal surface at eye level. The chemical
pumps are normally located 2 to 5 feet away to allow the chemical pumps
to be plugged it to the controller. Please consult chemical pump
manufacture for the proper suction and discharge line sizing and length.
The controller requires the following clearances:
Top: 4”
Bottom 10”
Left 4”
Right 4”
Front 24”
3.3 Electrical Installation
CAUTION! There are live circuits inside the controller when the
controller is energized. The front panel, or plug access panel must never
be opened before power is removed from the controller
CAUTION! The electrical installation of the controller must be done by a
trained personal only.
CBS_Manual_R015 Page 6 of 13

7. Figure 1: Electrical Layout
CBS_Manual_R015 Page 7 of 13

8. PDK Controller
AC Power In
110 Volts AC
High
Level
Y
Sensor
Strainer Solenoid
Water Valve
Supply
Water Fill line angled
is
eta ry an d to promote good
rd p ro p ro Low
in g is to b e co n side se s o n ly. It is th e mixing in Tank
T his dr a w in fo rm a tio n p ru po Level
r
in tend ed fo o f P D K , In c. Sensor
ty
so le pro p er Pumped to
Feed Water
Line or Boiler
Drum
PDK Chemical Batching System 1
Incorporated
(401) 294-0012 tech@pdkeng.com
Wiring Schematic
Figure 2: Typical system installation including pumps and day tank
CBS_Manual_R015 Page 8 of 13

9. 4.0 System Overview
Figure 3: The CBS with the faceplate removed
CBS_Manual_R015 Page 9 of 13

10. 4.1 Front Panel
Liquid Level Sensor
Indicators
LCD Display
Up Arrow
Back Arrow
Key Pad
Pump Status Indicators
Figure 4: The Features displayed on the CBS Faceplate
4.2 Display
The LCD is a 16x2 backlit module. If the characters are not readable, the
contrast can be adjusted using the potentiometer (R3) on the back of the
interface printed circuit board.
4.3 Key Pad
This is the user interface that is used to enter custom programs, change
settings, and review stored programs.
4.4 Led indictor lights
The led indicators display the status of the liquid level sensors and relays
1-5 (chemical pumps and dilution water fill solenoid).
CBS_Manual_R015 Page 10 of 13

11. 4.5 Start up Initial
After unit is installed plug it in and turn it on you will find pre installed
programs in the unit (listed below) you may use them as is, modify them
or delete them all
4.6 Normal start up
Once unit is programmed the parameters are stores in memory. Simply
verify water supply in on, the chemical pumps are primed and there is
sufficient chemical the unit will run normally
4.7 Shutdown
To secure the controller, turn off the power to the controller. For extended
shutdowns, the chemical lines should be flushed with water. Disconnect
water supply from the solenoid valve and remove chemicals. Store the
chemicals according to the instructions provided by your chemical
supplier. Pump lines should be flushed by placing chemical suction lines
in fresh water and starting the chemical pumps using the Prime mode on
the controller.
5.0 Operating Instructions
When you initialize the Chemical Batching System it will be running the last program
that was running before power down. In the case of factory default settings (ie. new unit)
Program 0 will be the default program running. To exit the current program into the
Main Menu press the back arrow key.
The up and back arrow keys are used to scroll through the Main Menu options. The
Main Menu choices are:
• Run
• Prime
• View Program
• Edit Program
• Safety Timer
• Program Delay
• Sensor Settings
• Factory Reset
CBS_Manual_R015 Page 11 of 13

12. 5.1 Run
Allows user to select a program to run. Options are Programs 0 to 9. Program 0
is not programmable; the default settings of program 0 are all relays are set to run
for 00:00 (mm:ss). Program 0 is useful for periods of boiler shut down times.
Programs 1-9 are programmable and are set at factory defaults of 0 mm:ss.
5.2 Prime
Allows user to run Relays 1-5 for 10 seconds per quarter second that the button is
held down. Used when adding or changing reagent containers. For example, if
the button is depressed for 1 second, the pump will run in manual for 40 seconds
total.
5.3 View Program
Allows user to view program settings. Options are to view programs 0-9. This
setting is useful for verifying controller settings.
5.4 Edit Program
Allows user to edit custom programs 1-9. User can program times for relays 1-4.
Relay 5 is strictly level sensor actuated and controls the water supply solenoid
valve.
5.5 Safety Timer
This is a safety feature intended to prevent overflow of your day tank in the event
of a high-level sensor failure. This function limits the amount of time that the
unit’s program can run. This time is user programmable and is generally set at
125% of the maximum time it takes to fill the tank to the high level sensor. Fill
times can vary depending on water supply line pressure. The factory default is 0
for this function.
5.6 Program Delay
This is an optional setting to add a delay between when the low level sensor
actuates, and the fill cycle program begins. The factory default time is set at 0.
The purpose of this option would be to allow the water supply valve to open
before the chemical pumps to begin pumping.
5.7 Sensor Settings
Allows the user to select the configuration of the liquid level sensors. The options
are either normally open (NO) or normally closed (NC) sensors. The purpose of
this function is to allow for the possibility of installing an alternative level sensor.
The factory default settings are normally open.
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13. 5.8 Factory Reset
Resets all programmable functions back to factory settings. All the custom
programs run times are set to 0, safety timer to 0, program delay to 0 and sensor
settings to normally open (NO).,
6.0 Index
batching tank................................... 3, 6 program 0 .......................................... 12
contrast............................................... 10 Program Delay ............................ 11, 12
Edit Program............................... 11, 12 programs.......................... 10, 11, 12, 13
Factory Reset............................... 11, 13 Run ..................................................... 11
liquid level sensor................................ 5 Safety Timer ............................ 4, 11, 12
liquid level sensors ...................... 10, 12 Sensor Settings ............................ 11, 12
Main Menu ........................................ 11 Start up Initial ................................... 11
missing parts.......................................... View Program.............................. 11, 12
................See 3.1 Unpacking the unit Wiring .............................................. 2, 7
Prime ............................................ 11, 12
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