TEC750A Amperometric Chemistry Control System Manual

TEC750A Amperometric Chemistry Control System

Manual

2

3 Drawing 9848 Rev 0 08-06-04 Topline Electronics Ltd IntroductionTopline were established in 1986 to provide high quality equipment. Topline now provide integrated dosing equipment packages with a comprehensive service backup. We believe that our after sales service is an integral part of the company’s success, and wish to assure existing and new customers that we will continually review product and service performance with the aim of improving both. If you are experiencing any problems with your dosing system or general water quality, please do not hesitate to contact a Topline engineer on 01323-440760. Topline are always willing to develop new products and services with clients, so if you have an idea on how to improve any of Topline’s products or wish to develop a product for your own use, please contact Andrew Hunt on 01323 440760.

4 Drawing 9848 Rev 0 08-06-04

Contents Section 1 Installation instructions Section 2 Commissioning /Handover Instructions Section 3 Operating instructions Section 4 Trouble shooting Section 5 Maintenance instructions Section 6 Operating / Warranty conditions/ Advisory Notes Section 7 Servicing / Extended warranty contracts Section 8 Index

5 Drawing 9848 Rev 0 08-06-04

SECTION 1

INSTALLATION INSTRUCTIONS

6 Drawing 9848 Rev 0 08-06-04

Installation Instructions for TEC Pool Dosing EquipmentThis equipment is to be installed by a person qualified in electrical and chemical

plumbing systems Technical Data TEC750A Control SystemDimensions 365mm wide x 500mm tall x 100mm deep Power Requirement 240 VAC single phase 50 Hz. Power Consumption 15 watts (Excluding Feeders) Operating Temperature 0 - 50 degrees centigrade Enclosure Plastic IP54 Front control panel Polyester membrane Display 16 x 2 alphanumeric LCD Chlorine sensor Amperometric 3 electrode system Measuring range 0 - 10 mg/l pH sensor Glass with internal reference Measuring Range 6.5 - 9.0 pH Outputs Chemical feeders 2 x 240 VAC switched Inputs 2 analogue 1 digital flow sensor 3 button keypad for information input CE Certificate Declaration of conformance Manufacturer's Name Topline Electronics Ltd Manufacturer's Address Unit 7, Crown Close Hailsham, E.Sussex England, BN27 3JF Declares that the product TEC750a conforms to the following product specifications: Low Voltage Directive 72/73 EEC Electromagnetic Compatibility Directive 2004/108/EC Restriction of Hazardous Substances (RoSH) Directive 2002/96/EC Waste Electrical and Electronic Equipment (WEEE) Directive 2002/95/EC CE marking. I the undersigned, declare that the equipment above conforms to the above directives and carries the CE marking. Manufacturer Topline Electronics Ltd Signature on behalf of Topline Electronics Ltd A.Hunt Date Feb.10th 2007

7 Drawing 9848 Rev 0 08-06-04 Installation Instructions (Cont.) Position of chemistry Control System A wall space of at least 600mm high by 450mm wide is required. Mount the controller with the TOP of the assembly no more than 1700mm from ground level. The system and measuring cell are mounted on a backboard. The water sample inlet is on the left hand side ( as seen facing it ) with the return outlet on the right hand side of the unit. The control unit and chemical storage areas should be easily accessible to the operator. Protective clothing should be available for use and warning signs present. The injection points and storage (pH correction and chlorine donor) should not be less than 2 meters apart and should be easily accessible. The injection points should be situated after the control system sample line take off, not above head height, but above the top of the day tanks to avoid siphoning. They should not be placed above any equipment that could be damaged by any leakage. The dosing lines should be as short as possible and run in protective sleeving marked with red and white tape for acid and yellow and black for chlorine. Dosing pump foot valve assemblies should be supported in a rigid pipe held clear of agitators and 4cm clear of the day tank bottom. If CO2 is used to correct the pH and the plant room is a confined space or below ground level, then a CO2 leakage detection sensor must be provided. A water supply (mains, not pool water!) should be provided for making up chemical solutions. Equipment selection check list TYPE POOL POOL POOL SPA SPA Pool capacity >350M3 >200M3 >50M3 >10M3 >1M3 Controller TEC2000 TEC2000 TEC750 TEC2000 TEC750 LMI Pumps only Na HSO4 (Dry acid 10%) Incoming calcium hardness and alkalinity are above 100 ppm Day tank size litres +110% bund 300 200 100 50 50 Agitator Man Man Man Man Man Pump model +4 function valve B145 PO65 PO65 PO55 PO55 Injector type LMI LMI LMI LMI LMI Dosing hose size 1/2 3/8 3/8 3/8 3/8 Na OCl (Sodium Hypo 10-14%) Incoming calcium hardness and alkalinity are above 100 ppm Day tank size litres +110%bund 300 200 100 50 50 Agitator No No No No No Hand transfer pump Yes Yes Yes Yes Yes Pump model +4 function valve B145 PO65 PO65 PO55 PO55 Injector type LMI LMI LMI LMI LMI Dosing hose size 1/2 3/8 3/8 3/8 3/8 Ca OCL2 (Cal Hypo 3%) Incoming calcium hardness and alkalinity are below 100 ppm Day tank size litres +110%bund 500 300 200 100 100 Agitator Elec Elec Elec Elec Elec Pump model +4 function valve B145 B145 PO65 PO65 PO55 Injector type Rod Rod Rod Rod Rod Dosing hose size 1/2 1/2 3/8 3/8 3/8 CO2 (Carbon dioxide) Incoming calcium hardness and alkalinity are below 100 ppm CO2 detector to be used if plant room floor is below ground level CO2 correction system TLE TLE TLE TLE TLE

8 Drawing 9848 Rev 0 08-06-04 Installation Instructions (Cont.) Chemistry Control System Power Requirements Only qualified and competent electricians working to the 16th Edition of Electrical Regulations should install electrical equipment. The controller is powered by a 240 volt single phase supply. The supply should be taken from a ring main and must be run in conduit terminated with suitable glands. Cable entry should be made through the glands provided in the base of the TEC 750a. Conductor size used should be 1mm max. The incoming AC supply must be via a 6 amp fused isolator and a suitable earth current detecting device (RCCB). Chemistry Control System Chemical Feeder Power -(Dosing Pump Power) The controller supplies a 240 AC single phase supply to the chlorine or bromine feeder and the pH correction feeder via the terminals accessed by removing the lower cover on the controller (see below photo 1). Both of these feeders will normally be 240 VAC single phase, If the feeders are not 240 VAC single phase refer to your supplier. The feeder supply lines should have a conductor diameter of no more than 1mm and be run in suitable conduit terminated with the correct glands.

1-Titanium Electrode Grey 2-Cell Ground 1 White 3-Cell Ground 2 White 4-Flow switch Ground Blue 5-Flow Switch Signal Black 6-Flow Switch 12v Brown

9 Drawing 9848 Rev 0 08-06-04 Installation instructions (Cont.) Water sample supply for the cell assembly A water sample supply should be taken from the under side of the main circulation pipe, via a 3/8 inch PVCU isolating valve and a ‘Y’ strainer. The sample line should be 3/8 inch BSP rigid PVC pipe. The pipe work from the cell assembly is 3/8 inch, and this joint is made with a 3/8 inch PVC d union to allow for removal and servicing of the cell assembly if required. The sample return can either be run to waste, to the balance tank, or returned back into the suction side of the main circulation, via a 3/8 inch PVC isolating valve. It is essential that there is a positive flow through the probe assembly i.e. pressure on the sample input side and no pressure or vacuum on the return side. A flow detection switch is fitted, so if there is no circulation the chemical feeders will be shut down.

Inserting the Electrodes Before inserting the electrodes ensure that you shake them to remove air from the tip of the electrode. Only tighten the probes by hand ie do not use tools. Do not insert the electrodes unless you intend to leave water in the cell assembly. The electrodes must not be allowed to dry out.

FLOCULENTDAY TANK

FILTER

SWIMMING POOL OR SPA

CHEMICALCONTROLLER

10m

ALKALINEDAY TANK

CHLORINEDAY TANK

ACIDDAY TANK

2m 2m

HEAT

EXCHANGER

CIRCULATIONPUMP

ULTRA VIOLET

STRAINER

10 Drawing 9848 Rev 0 08-06-04

SECTION 2

COMMISSIONING HANDOVER

INSTRUCTIONS

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Commissioning of the Pool Dosing Equipment REMOVE THIS PAGE AT COMMISSIONING

Commissioning procedure It is important that the commissioning is comprehensive and complete leaving no grey areas of responsibility or accountability. Clarity of description and explanation of the equipment to the client is therefore vital. Before the chemical dosing plant is explained, complete the below check list. All the lines must be completed, no blank lines are to be left. If any item is not OK then an explanation must be given. Commissioning Check list 1.Pool 2.Positon of controller |__________|__________|__________|__________|__________| 3.Cell / pipework leaks |__________|__________|__________|__________|__________| 4.Cell assembly water flow |__________|__________|__________|__________|__________| 5.Electrical RCCB |__________|__________|__________|__________|__________| 6.Cl / pH day & bund tank |__________|__________|__________|__________|__________| 7.Cl / pH warning labels |__________|__________|__________|__________|__________| 8.Cl / pH pump fixing |__________|__________|__________|__________|__________| 9.Cl / pH chemical leaks |__________|__________|__________|__________|__________| 10.Cl / pH injector position |__________|__________|__________|__________|__________| 11.Electrical Cl / pH pump correct pool |__________|__________|__________|__________|__________| 12.Injection lines Cl / pH pump correct pool |__________|__________|__________|__________|__________| 13.Cl / pH agitator fixings |__________|__________|__________|__________|__________| Notes reference above numbers ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________

12 Drawing 9848 Rev 0 08-06-04 ACCEPTANCE of EQUIPMENT THE HANDOVER PROCEDURE, COMMISSIONING SHEET AND THIS SHEET ARE TO BE REMOVED AND RETURNED TO TOPLINE OR COMMISSIONING AGENT No person should sign this commissioning sheet unless they are completely satisfied with the dosing equipment supplied. Signing of this commissioning sheet means that you accept the equipment and have understood POINTS 1 TO 19 in the hand over procedure, Health and Safety Warning, Risk Assessment and Operations Manual. The dosing system is now yours and you are responsible for its maintenance and operation. No person should operate the equipment unless they have attended the training session. Start time ................................. Finish time ............................. Site .................................................................. Address .................................................................. .................................................................. .................................................................. Client (site) representative .................................................................. Telephone .................................................................. Fax .................................................................. Commissioned by .................................................................. Date .................................................................. Pool? |__________|__________|__________|__________|__________| Size m3? |__________|__________|__________|__________|__________| Serial No? |__________|__________|__________|__________|__________| Model? |__________|__________|__________|__________|__________| pH Pump type? |__________|__________|__________|__________|__________| Cl Pump type? |__________|__________|__________|__________|__________| Rodding injector? |__________|__________|__________|__________|__________| pH agitator man/electric? |__________|__________|__________|__________|__________| Cl agitator man/electric? |__________|__________|__________|__________|__________| pH Chemical? |__________|__________|__________|__________|__________| Cl Chemical? |__________|__________|__________|__________|__________| Cl day tank size? |__________|__________|__________|__________|__________| pH day tank size? |__________|__________|__________|__________|__________| Cl Strainer basket? |__________|__________|__________|__________|__________| pH Strainer basket? |__________|__________|__________|__________|__________| Topline safety kit? |__________| Alkalinity incoming |__________| Calcium Hardness incoming |__________| People at training session

13 Drawing 9848 Rev 0 08-06-04 Hand over procedure Explain and or demonstrate: 1. Pool and spa water should be clear with no smell or foaming. 2. All areas close to pool to be kept clean, appropriate cleaning agents to be used that do not contain detergents. 3. The pH must to be maintained between 7.2 and 7.8 for the chlorine donor to be efficient. Combined chlorine will form quicker if these levels are not maintained together with an increase in associated smell and irritated skin and eyes. More acid or CO2 will be used at first on a new pool due to the grouting and that the controller may enter pH time-out at first due to this. Acid reduces pH level. 4. Break point chlorination is to be maintained i.e. that free chlorine is to be no less than 2/3

of total. If break point chlorination is lost 10 times as much chlorine will be used to re-achieve break point with the associated increase in chemical costs.

5. Under dosing of chlorine will mean that bacteria will multiply in the water. 6. Over dosing chlorine will bleach costumes (consider that fashion costumes are not suitable for chlorine pools), irritate skin and effect bleached hair. 7. Explain Correct use of DPD1, DPD3, phenol red, alkalinity & calcium hardness tablets

and that a record of tablet results must be maintained. 8. Balanced water is essential and achieved when, alkalinity is between 75mg/l and

150mg/l, calcium hardness is between 75mg/l and 500mg/l and TDS not above 1000mg/l above source water (not salt water pools).

9. Describe the general overview of the system to the staff, point out the sample line, the route the sample takes through the pipework to the sensors and the sequence of sample line isolating valves i.e. isolation valves operation. Explain the necessity of having a regular unchanging flow through the sensor assembly and the function of the flow valve. Explain the operation of the flow switch and how this de-activates the chemical feeders.

10. Explain that subjecting the electrodes to very high pressure or vacuum will damage the electrodes. Indicate the electrodes and show which is which. Explain how the sensors work, how to remove them and how they are cleaned with Topline cleaning solution

11. Explain the calibration procedure for the chlorine sensor, go through the operation of the controller, i.e. reading, set point (required level), standardisation (actual level) (point out that the water sample used for standardising the electrodes must be taken from the sample tap adjacent to the controller, not from the swimming pool). Explain time out and proportional feed set up, show how to set and change all the parameters as described in the operations manual

12. The dosing pumps. Show how to tighten up the set screws on dosing pump heads and state that this should be done every six weeks. Show 4 function valve operation, foot valve assembly and injector maintenance. Point out the dosing system supplier is not responsible for blocked injectors or any damage caused by them. 13. CO2 controller. Show how to change the CO2 flow. Change over bottles, pressure gauges,

that the first stage regulator is set to 1.5 bar and how to the clean CO2 diffuser.

14 Drawing 9848 Rev 0 08-06-04 Hand over procedure (cont.) Explain and or demonstrate: 14. Show Risk assessment and Health and Safety sheet to staff. 15. When mixing the chemicals and filling the day tanks the following guidelines are to be used: a. Staff should always wear personal protective equipment (PPE) when mixing chemicals

or handling system parts that have come in contact with chemicals. Warning signs are to be put up to this effect.

b. COSHH sheets should be kept on site of all chemicals kept on site. c. Calcium hypochlorite ratio is NO MORE than 3 kilograms per 100 litres of water. Agitate solution for half an hour before use. d. Sodium Hypochlorite should be transferred to the day tank from the delivery drum using a

manual hand transfer pump. The solution should never be poured from container to container directly. The hand transfer pump needs flushing with water after use. If not, the pump will be permanently damaged. The repair/replacement will be charged for.

e. Sodium bisulphate strength should be no more than 10 kilograms per 100 litres of water and agitation is required when mixing sodium bisulphate.

f. Chemical levels should never be allowed to fall below 25% of tank capacity. g. When acid and chlorine mix, chlorine gas is generated. This is extremely dangerous. h. With a CO2 system only vapour take off type bottles are to be used. CO2 is an asphyxiate

and warning systems should be installed if the plantroom is below ground level or is a confined space.

i. All chemical storage areas and chemical pumps must be kept clean. All spillage’s must be cleared up immediately, absorbed using an inert material and placed in suitable containers for correct disposal. Appropriate authorities must be informed of spillages.

16. Explain the de activation of chemical feeders during backwashing. 17. Explain that organic polymer flocculents and cyanuric acid based (STABILISED)

chlorine should not be used due to coating of electrodes and chlorine lock out problems. 18. Cover terms and conditions 19. Point out that service calls will be charged for if the responsibility for the fault lies with

the operator or the maintenance schedule has not been kept up to date. 20. Ask everyone if they have any questions and have understood all they have been told.

15 Drawing 9848 Rev 0 08-06-04

TWELVE MONTH GUARANTEE Product Valid from Purchased From Installed by-: Commissioned by-: Your new Topline Product carries a full 12 month guarantee against faulty materials and workmanship. In the unlikely event that you have cause to complain during this period you should contact Topline Electronics Ltd. Unit 7, Crown Close, Hailsham, East Sussex. BN7 3JF. Tel: 01323 440760. We will replace components or the equipment, without charge. Provided that:- • Approved agent carried out the Commissioning and that the commissioning sheet has been

returned to Topline. • The Operating Instructions (provided with Equipment) have been followed. • Operating conditions have been met per the TEC750a. • All routine maintenance as been carried out. • Service Components installed are approved by Topline Electronics Ltd. • The Product has not had a repair attempted by others. • The Product has not been damaged, abused or altered, • The Product is being used for the purpose it was intended for. We reserve the right to use substitute Components of similar or higher quality. This Guarantee does not affect your statutory rights. PRODUCT SUPPORT. Our Technical Helpline 01323 440760 can provide assistance during office hours.

16 Drawing 9848 Rev 0 08-06-04

This is to certify that the Commisioning Session was attended by

................................................................

.................................................................................................................................

Who has passed examination on the safe operationof Topline Electronics Ltd dosing equipment.

On

at

.........................................

Signed ....................

Unit 7 Crown Close, Hailsham, East Sussex, BN27 3JFTelephone 01323-440760

.........................................

17 Drawing 9848 Rev 0 08-06-04

SECTION 3

OPERATING

INSTRUCTIONS

18 Drawing 9848 Rev 0 08-06-04

Health and Safety Warning

You must have safety clothing available for use when you are mixing or using any chemicals. Always wear protective clothing when handling chemicals. It is imperative that eye protection is employed at all times. Details of which clothing must be worn is given on the COSHH health data sheets. You must have the safety data sheets for the chemicals you use on site, these are provided by your chemical supplier. We cannot be held responsible for any accidents. Trained personnel should be the only people allowed access to chemical dosing systems. Remember, if something is wrong with any of the swimming pool systems,

TAKE THE APPROPRIATE ACTION!

Do not just record a fault and walk away - bad pool management can affect bathers health.

19 Drawing 9848 Rev 0 08-06-04

Risk Assessment

If the equipment is not operated by persons who are proficient in the operation of swimming pool plant, then there is a risk of: 1. Overdosing disinfectant (chlorine or bromine) and/or pH correction (acid or CO2) into the swimming pool. If this occurs then users of the swimming pool may experience skin irritation, burns and respiratory problems. 2. Direct mixing of chlorine donor and acid in the plant, will liberate chlorine gas which can kill. 3. Not maintaining adequate disinfection of the pool. If this occurs then bacteriological counts could exceed recommended levels. 4. Not maintaining recommended pH levels in the pool. If this occurs then users may experience skin irritation, burns and respiratory problems. 5. Operation of the controller with covers removed may result in electrocution. 6. CO2 is an asphyxiant and if this product is used in a below ground level or confined plant room then a CO2 detector must be installed. 7. If personal protective equipment is not used then there is an increase in risk to the operator, as defined in the relevant chemical C.O.S.H.H. sheet

20 Drawing 9848 Rev 0 08-06-04

Operating Instructions for TEC Pool Dosing Equipment Overview Controller The TEC750A Control System has been designed to control domestic and light commercial pools. Topline control systems are renowned for being easy to use. However it is important that this manual is studied before you begin to use the TEC750A Control System, so that you understand the principles of operation of the TEC750A Control System before you start to use the system. System Overview The TEC750A Control System consists of five items, the control module which receives information on water chemistry, the sensor assembly which sends information on water chemistry, two dosing devices one for chlorine/bromine, one for pH correction and chemical storage tanks. A water sample is taken from the main circulation system, post filtration, via a sample strainer to the sensor assembly which contains the electrodes. The sample flow is either run to waste (preferred) or returned back into the main circulation. Isolating valves are placed at each end of the sample line. The pH and chlorine/bromine probes are the main elements of the sensor. A bypass arrangement diverts the water sample, and a flow of about 60 litres per hour is maintained past the probes. This flow is indicated by the flow puck on the flow indicator and is adjusted via the flow needle valve. The flow ball should be approximately in the middle of the window. A regular non changing flow is essential for correct operation of the system. A sample tap is present, from which a water sample should be taken to enable the sensors to be standardised or calibrated against chemical reagent tests. The probes monitor the water chemistry parameters (free chlorine / bromine and pH) and the signal is sent to the control module. The control module instructs the chemical dosing devices to supply chemicals to the water stream as required, and the control module displays operational information. Up / Down and Enter keys. The pushbuttons are used to cancel any time-outs and adjust the control parameters. The LCD panel is used to display the actual pH, chlorine/bromine and various system messages. All of the normal system messages are detailed on the following page.

21 Drawing 9848 Rev 0 08-06-04 System Overview normal system messages

© 2004 ToplineElectronics Ltd

Power up sign on message displayed for 45 seconds

1.5ppm 7.3pH

At setpoint not dosing chlorine or pH

1.5ppm 7.6pHpH dose

pH pump being turned on and off to correct pH level

0.5ppm 7.3pHChor dose

Chlorine / bromine pump being turned on and off to correct the chlorine level.

0.5ppm 7.7pHChor+pH dose

pH and Chlorine / bromine pumps being turned on and off to correct the pH and chlorine levels.

NO FLOW

Flow switch deactivated no chemicals being pumped

1.5ppm 7.6pHCl Timeout

Chlorine / bromine timeout no chlorine being pumped

1.5ppm 7.6pHpH Timeout

pH timeout no acid being pumped

1.5ppm 7.6pHCl + pH Timeout

Chlorine / bromine & pH timeout no chlorine or acid being pumped

If the controller is configured for bromine the display will show Br not Cl.

22 Drawing 9848 Rev 0 08-06-04 System Set-up During commissioning the TEC750A Control System will be set up and you will be shown how to operate the TEC750A Control System. The following pages show you how to change the control parameters. All the option screens and their sub screens that are available are shown below, they are examples only: In the event of bromine control the system will display Br not Cl. Set up mode Access set up mode by pressing the "Enter" key. The controller will display the message "Standardise". There are four set-up menus Standardise, Setpoint, Timeout, Pump and Calibrate. These are obtained by pressing the up or down keys. Select the required menu by pressing the enter key. To change any of the values use the "Enter" key to position the flashing cursor beneath the value you wish to change, and using the "up" or "down" key to increase or decrease the value. To return the unit to normal operation simply press the "Enter" key until the normal operation screen is displayed. If you make a mistake simply re-enter set-up mode. Set-up Mode Options Standardise. In operation all sensing systems for pool control need to be standardised. To Standardise is the process of entering the values obtained from the DPD1 / bromine and phenol red tablet tests on the water taken from the sample tap (not the pool) .i.e. the actual pH and chlorine / bromine level in the pool. When taking a DPD1 test a dilution test must be carried out if the first test is above 2ppm. Only standardise the unit when required, if you are standardising frequently contact Topline for advice.

standardise

pH standardise7.5pH

Chlor standardise1.5ppm

Standardise pH and Chlorine display

Set point. The TEC750A Control System controls the water chemistry to a set point, if the water chemistry moves either side of this set point then pH or Chlorine correction will begin or stop. Setpoint is the pH or chlorine / bromine level required.

setpoint pH setpoint7.3pH

Chlor setpoint1.5ppm

Setpoint pH and Chlorine display

23 Drawing 9848 Rev 0 08-06-04 System Set-up (Cont.) Time-out. The pH acid and chlorine/bromine pump both have a time-out value. This is the time given to re-achieve set point. This is used to prevent over dosing of chemicals and it is important that it is set to suit pump ‘on’ times and pump capacity. Incorrect setting of the time-out can result in over dosing. The pump time-out can be given a value of 0-255 minutes in 1 minute increments. Setting the time-out value to zero will disable the time-out function.

Timeout

pH Timeout100 minutes

Cl Timeout70 minutes

Reset Time-outs. To cancel a time-out press and hold up key for 4 seconds. Check cause of timeout before resetting. Pump on Times. The TEC750A Control System has full proportional control of the dosing pumps. This is so that pump times can be adjusted to prevent overdosing of chemicals. There are 2 parameters that control the pump on time, "Pump Range" and "Pump scale". The calculation for pump ‘on’ time is 120 seconds * (Distance from Setpoint / Pump range) * Pump Scale = Pump on Time. Note: Pumps will only be on when level correction is required for the time calculated by the proportional range i.e. not all the time.

pump

pH pump range0.4pH

chlor pump range0.5ppm

pH pump scale5.0*10%

Cl pump scale7.0*10%

Pump range & duty cycle pH and Chlorine display

24 Drawing 9848 Rev 0 08-06-04

System set up (Cont.)

Calibration. To maintain control of water quality the TEC750A Control System needs calibrating. Calibration adjusts the rate of probe response. The unit can only be calibrated when there is between 0.5 to 7.5 ppm of free chlorine / bromine in the water but it is best calibrated when the pool water is at or near to setpoint. Before calibrating check that the flow ball is approximately in the middle of the window. Always calibrate using DPD1 / Bromine & Phenol red tablet results taken from the sample tap. When taking a DPD1 test a dilution test must be carried out if the first test is above 2ppm. Select calibrate from the set-up menu and press the ‘enter key’. Enter the DPD1 / Bromine value press the ‘enter key’. The TEC750A will tell you to turn off the flow, to do this close the input and output valves either side of the measuring cell. The TEC750a will then count down from 60 seconds, display the message ‘zeroing’, tell you to turn the flow back on and then start a new count from 90 seconds. When the TEC750A finishes this countdown one of two messages will be displayed, ‘OK’, and ‘Failed’. The ‘OK’ message indicates that the controller has been successfully calibrated, the ‘Failed’ message that the unit needs recalibrating or the electrodes need cleaning now. If after calibration the unit displays 6.5pH or 9.0pH the pH probe needs replacing. The Cl / Br reading should be at least 1.5ppm higher than the value entered to calibrate the TEC750A. After calibrating close the input and output valves, to see if the chlorine / bromine reading drops by approximately the amount in the water (DROP TEST), if this does not happen refer to the trouble shooting section in this manual. Turn the input and output valves on and standardise after 20 seconds.

calibrate Enter DPD1 value1.7

Turn flow off65

Turn flow on50

ok10

Failed10

Calibrate display

25 Drawing 9848 Rev 0 08-06-04

SECTION 4

TROUBLE SHOOTING

26 Drawing 9848 Rev 0 08-06-04 Trouble shooting Before contacting Topline for technical advice, please ensure you make a note of the current chemical test results, what the problem is and the current controller readings and settings. SYMPTOM PROBLEM REMEDY 1 NO LIGHTS ON UNIT POWER FAILURE OR TURNED OFF CHECK SUPPLY / TURN ON UNIT KEEPS RESETTING POOR RESET TURN POWER OFF AFTER 2MIN TURN POWER ON 2 FLOW PUCK AT BOTTOM NO CIRCULATION CHECK CIRCULATION PUMPS SAMPLE LINE VALVE SHUT OPEN SAMPLE LINE VALVES BLOCKED SAMPLE CELL CLEAR SAMPLE CELL 3 NO Cl Br PROBE RESPONSE NEED RECALIBRATION RECALIBRATE UNSTABLE READINGS AIR BUBBLE IN Cl PROBE REMOVE AND SHAKE DOWN NO CIRCULATION CHECK CIRCULATION PUMP SAMPLE LINE VALVE SHUT OPEN SAMPLE LINE VALVES SAMPLE CELL BLOCKED CLEAR SAMPLE CELL BLOCKED Y STRAINER REMOVE & CLEAN PROBE DIRTY REMOVE & CLEAN S/S ELECTRODE DIRTY CLEAN EXCESSIVE FLOCULENT CONTACT TOPLINE EXCESSIVE CYANURIC ACID CONTACT TOPLINE PROBE FAULTY REPLACE PROBE SUBJECTED TO VACUUM REPLACE STANDARDISING FROM POOL TAKE TEST FROM SAMPLE TAP TEST RECALIBRATING FROM POOL TAKE TEST FROM SAMPLE TAP TEST 4 NO pH PROBE RESPONSE NO CIRCULATION CHECK CIRCULATION PUMP SAMPLE LINE VALVE SHUT OPEN SAMPLE LINE VALVES AIR BUBBLE IN pH PROBE REMOVE AND SHAKE DOWN SAMPLE CELL BLOCKED CLEAR SAMPLE CELL BLOCKED Y STRAINER REMOVE & CLEAN pH PROBE DIRTY REMOVE & CLEAN pH PROBE FAULTY REPLACE pH PROBE SUBJECTED TO VACUUM REPLACE STANDARDISING FROM POOL TAKE PHENOL RED TEST FROM SAMPLE TAP PHENOL RED TEST 5 UNDER DOSING ACID/CO2 EMPTY DAY TANK FILL NO FLOW SEE PUMP WINDOW TO SMALL INCREASE PUMP WINDOW PUMP RANGE TO LARGE DECREASE PUMP RANGE PUMP SCALE TO SMALL INCREASE PUMP SCALE ENTERS TIME-OUT INCREASE TIME-OUT SETPOINT TOO HIGH DECREASE SETPOINT HIGH ALKALINITY LOWER TO AT LEAST 150 DOSING PUMP LOST PRIME REPRIME DOSIMG PUMP TURNED OFF TURN ON DOSING PUMP TURNED DOWN TURN UP MIXTURE TOO WEAK TAKE CARE MIXING NEXT BATCH BLOCKED TANK FOOT ASSEMBLY REMOVE & CLEAN OR REPLACE BLOCKED FEED PIPE REPLACE DAMAGED FEED PIPE REPLACE BLOCKED INJECTOR PIPE REPLACE DAMAGED INJECTOR PIPE REPLACE ONE WAY VALVE REVERSED CHECK ALL ONE WAY VALVES DOSING PUMP DIAPHRAGM BLOCK REMOVE PUMP HEAD CLEAN OR REPLACE BLOCKED 4 FUNCTION VALVE REMOVE & CLEAN OR REPLACE BLOCKED INJECTOR REMOVE & CLEAN OR REPLACE FAULTY DOSING PUMP SERVICE OR REPLACE NO pH PROBE RESPONSE SEE SYMPTOM 4

27 Drawing 9848 Rev 0 08-06-04 Trouble shooting (Cont.) SYMPTOM PROBLEM REMEDY 6 OVER DOSING ACID/CO2 SIPHONING REMOVE INJECTOR, CLEAN & SERVICE MIXTURE TOO STRONG TAKE CARE MIXING NEXT BATCH NO pH PROBE RESPONSE SEE SYMPTOM 4 PUMP RANGE TOO SMALL INCREASE PUMP RANGE PUMP SCALE TOO LARGE DECREASE PUMP SCALE SETPOINT TOO LOW INCREASE SETPOINT LOW ALKALINITY RAISE TO AT LEAST 75 NO pH PROBE RESPONSE SEE SYMPTOM 4 7 UNDER DOSING Cl / Br EMPTY DAY TANK FILL FLOW LED OUT SEE 2 PUMP WINDOW TO SMALL INCREASE PUMP WINDOW PUMP RANGE TO LARGE DECREASE PUMP RANGE PUMP SCALE TO SMALL INCREASE PUMP SCALE ENTERS TIME-OUT INCREASE TIME-OUT SETPOINT TOO LOW INCREASE SETPOINT DOSING PUMP LOST PRIME REPRIME DOSING PUMP TURNED OFF TURN ON DOSING PUMP TURNED DOWN TURN UP MIXTURE TOO WEAK TAKE CARE MIXING NEXT BATCH BLOCKED TANK FOOT ASSEMBLY REMOVE & CLEAN OR REPLACE BLOCKED FEED PIPE REPLACE DAMAGED FEED PIPE REPLACE BLOCKED INJECTOR PIPE REPLACE DAMAGED INJECTOR PIPE REPLACE ONE WAY VALVE REVERSED CHECK ALL ONE WAY VALVES DOSING PUMP DIAPHRAGM FAILED REMOVE PUMP HEAD CLEAN OR REPLACE BLOCKED 4 FUNCTION VALVE REMOVE & CLEAN OR REPLACE BLOCKED INJECTOR REMOVE & CLEAN OR REPLACE FAULTY DOSING PUMP SERVICE OR REPLACE NO PROBE RESPONSE SEE SYMPTOM 4 8 OVER DOSING Cl / Br SIPHONING REMOVE INJECTOR, CLEAN & SERVICE MIXTURE TOO STRONG TAKE CARE MIXING NEXT BATCH NO PROBE RESPONSE SEE SYMPTOM 3 PUMP RANGE TOO SMALL INCREASE PUMP RANGE PUMP SCALE TOO LARGE DECREASE PUMP SCALE NO PROBE RESPONSE SEE SYMPTOM 2 SETPOINT TO HIGH DECREASE SETPOINT 9 INACCURATE pH READINGS NO pH PROBE RESPONSE SEE SYMPTOM 4

UNIT OUT of STANDARD RESTANDARDISE INACCURATE TEST KIT READINGS REFER TO TEST KIT INSTRUCTIONS. CHECK TABLET DATE

10 INACCURATE Cl Br READINGS NO PROBE RESPONSE SEE SYMPTOM 3

UNIT OUT of STANDARD RESTANDARDISE INACCURATE TEST KIT READINGS REFER TO TEST KIT INSTR CTIONS. CHECK TABLET U DATE 11 pH PROBE RETURNS 6.5 OR FAULTY PROBE REPLACE 9.0 AFTER CALIBRATION

28 Drawing 9848 Rev 0 08-06-04 Trouble Shooting. pH and Cl Probe Function test For more detail on the below procedures refer to the appropriate page in the Operating Manual 1a Take DPD1/ Bromine Phenol red, test from sample tap and record results 2a Is green flow LED on? if not, rectify. 2b Is flow ball in middle of window? if not, rectify. 3a. Does TEC750 agree with tests 25% DPD1 and 0.2 pH? 3b. If yes take no more action. 3c. If no turn off chemical feeders. 3d Standardise and perform drop test. 3e If drop test is correct turn on chemical feeders and take no more action. 4a If cl reading does not drop by approximately the amount of free cl in water calibrate. 4b If after calibration failed message is displayed or pH level is 6.5 or 9.0 goto 5a 4c If after calibration OK message is displayed and displayed pH level on TEC750 is not 6.0 or 9.0 go to 3d. 5a If first calibration goto 3d, if unit has been calibrated twice, clean probes. 5b Clean pH and Cl probe for 3 minutes in Topline probe cleaner. 5c Replace pH and Cl probe, leave pool water flowing over the probes for 20 minutes. 6a Re calibrate if pH level is 6.5 or 9.0 contact Topline. 6b Standardise and perform drop test. 6c If drop test is correct turn on chemical feeders and take no more action. 6d If cl/Br reading does not drop by approximately the amount in water contact Topline

29 Drawing 9848 Rev 0 08-06-04 Chemical Level Trouble shooting

The below chemical additions are guide lines only. Topline are not responsible for any errors in the calculations. The pool operator must check the chemical volume calculations him/her self before adding any chemicals. All chemicals should be added slowly with the pool operator being aware that mass chemical additions can adversely effect water quality and bather SAFETY.

MASS CHEMICAL ADDITIONS SHOULD NOT BE MADE WITH BATHERS IN THE WATER.

ALWAYS WEAR PERSONAL PROTECTIVE EQUIPMENT WHEN HANDLING

CHEMICALS ACTION OR PROBLEM REMEDY SYMPTOM. 1 HIGH CHLORINE ABOVE 10PPM DECREASE CHLORINE TO 3.0 ADD 50 GRMS PER 50M3 of WATER STOP BATHING of SODIUM THIOSULPHATE TO LOWER Cl BY 1PPM 2 LOW CHLORINE BELOW 0.3PPM INCREASE CHLORINE TO 1.0 ADD 350mls PER 50M3 of WATER WATER CLOUDY STOP BATHING of SODIUM HYPOCHLORITE TO RAISE Cl BY 1PPM ADD 75GRMS PER 50M3 of WATER of CALCIUM HYPOCHLORITE TO RAISE Cl BY 1PPM 3 HIGH COMBINED CHLORINE INCREASE BACKWASHING MAX TWICE A WEEK PER FILTER INCREASE WATER LOSS 40 LITRES PER BATHER PER DAY DAMAGED FILTRATION INSPECT / SERVICE DETERGENT IN WATER REPLACE POOL WATER 4 HIGH PH ABOVE 8.2 LOWER pH TO 7.5 ADD 500GRMS PER 50M3 of WATER STOP BATHING of SODIUM BISULPHATE TO LOWER pH BY 0.1 5. LOW pH BELOW 6.8 RAISE pH TO 7.5 ADD 500GRMS PER 50M3 of WATER STOP BATHING of SODIUM CARBONATE TO RAISE pH BY 0.1 6. HIGH ALKALINITY ABOVE 150 LOWER ALKALINITY ADD 2.4KG PER 50M3 of WATER SLOW pH CHANGES TO BELOW 150 of SODIUM BI SULPHATE pH LOCK KEEP ABOVE 75 TO LOWER ALKALINITY BY 20mg/L 7. LOW ALKALINITY BELOW 75 RAISE ALKALINITY ADD 1.7KG PER 50M3 of WATER QUICK pH CHANGES TO ABOVE 75 of SODIUM BI CARBONATE pH BOUNCE KEEP BELOW 150 TO RAISE ALKALINITY BY 20mg/L 8. LOW CALCIUM HARDNESS RAISE CALCIUM ADD 1.5KG PER 50M3 of WATER TO ABOVE 250 of CALCIUM CHLORIDE KEEP BELOW 500mg/L TO RAISE CALCIUM HARDNESS BY 20mg/L 9. HIGH TDS (NOT KEEP ABOVE 400mg/L

SALT POOLS) LOWER TO BELOW 3000mg/L WASTE POOL WATER

30 Drawing 9848 Rev 0 08-06-04

SECTION 5

MAINTENANCE INSTRUCTIONS

31 Drawing 9848 Rev 0 08-06-04 Routine Maintenance of system See pictures at end of section for reference When carrying out any maintenance on the chemical dosing system, turn off the electricity supply to the TEC750a, close input/output sensor assembly valves and sample line input/output valves. When handling chemicals or parts of the chemical dosing system that have come into contact with chemicals WEAR SUITABLE PERSONAL PROTECTIVE EQUIPMENT. All parts of the dosing system should be kept clean and dry where possible. Sensor Assembly Maintenance Probe cleaning The probes should not be cleaned more than once every 4 weeks, if you are cleaning the probes more often, there is another cause, which needs investigation. Only probe cleaner supplied by Topline should be used. Chlorine / Bromine probe/pH probe cleaning and inserting of new probes Carefully disconnect the probe from the TEC750a, unscrew the probe from the sensor assembly, place the probe in the Topline probe cleaner plastic container for about 3 minutes, remove and rinse in fresh water, shake down to remove any air trapped in the probe tip, replace in sensor assembly. Only tighten the probes by hand ie do not use tools. Recalibrate and standardise after cleaning. Stainless electrode cleaning The titanium electrode is directly below the chlorine electrode. Open the sample tap and remove some of the water from the sensor assembly and then close the sample tap. Remove the chlorine probe and pour 10ml of Topline probe cleaner into the sensor assembly, agitate with a small brush and leave for 20 minutes, then carefully replace the chlorine probe.

32 Drawing 9848 Rev 0 08-06-04 Routine Maintenance of system sensor assembly(Cont.) Flushing the needle valve The needle valve in the sensor assembly is to be cleared every 2 weeks. Fully open the needle valve allowing the water to run through for 5 minutes. Adjust the needle valve so that the flow indicator puck is adjacent to the flow sensor. Sensor assembly blockage If the sensor assembly is blocked at another point then access can be gained by removing the sensor assembly from the backboard, and removing the screw that gives access to the blockage. Reassembly Reassemble using PTFE tape on all threads. Use only enough tape to achieve a seal. ‘Y’ Strainer Not all systems are fitted with a ‘Y’ strainer. The ‘Y’ strainer is a small filter which removes small bits of dirt/debris that might otherwise block the sensor assembly situated to the left of the sensor assembly. Flow Switch The Topline flow switch function is to be checked by closing the Inlet and outlet isolation valves to stop the flow. ‘No flow’ should be detected and indicated on the LCD display. The flow switch is to the left of the sensor assembly. There are no user service parts in the flow sensor.

33 Drawing 9848 Rev 0 08-06-04 Routine Maintenance of system Cont.) Auxiliary dosing equipment dosing pumps etc. The following instructions apply to Topline supplied products only Dosing pump maintenance General Dosing pumps The dosing pump is located on the day tank and pumps the chemical solution into the pool. By removing the dosing pump fixing screws, the pump can be lifted clear of the day tank. The dosing pump has a knob on the rear which adjusts the dosing rate, this knob should always be set at 90. The knob should never be rotated unless the pump is pumping, if the knob is rotated when the pump is off then the pump may be permanently damaged. Before removing or replacing any dosing pump part release the pressure via the 4 function valve. When reconnecting the dosing pipes ensure that the pipe is pushed fully into the recess and that the clamp ring and nut is secure. When dismantling any of the below assemblies, clean with an injector cleaner which you can obtain from your chemical supplier, taking care to remove any scaling as this scaling acts as a key to further scale build up. (Note: spraying with a silicone based lubricant after cleaning will help prevent scale build up). Re-assemble taking care to check that the one-way valves are positioned correctly the right way round and the feed and injector pipes are secure. Foot valve assembly The foot valve assembly filters the solution (chlorine, acid etc.) so that the dosing pump cannot be damaged by solids in the solution. It also prevents the solution from draining back into the day tank causing the dosing pump to losing prime. The foot valve assembly is located at the bottom of the chemical day tank linked to the bottom one way valve on the dosing pump via a feed pipe. The foot valve may need cleaning or replacing if the dosing pump will not work or prime. The feed pipe connects to the foot valve assembly with a plastic nut, the feed pipe is pushed fully into the recess on the foot valve and the nut tightened by hand only, see photo. Feed Pipe The feed pipe connects the foot valve assembly to the dosing pump. If this pipe is blocked replace with new pipe. Bottom one way valve on dosing pump The bottom one way valve stops the dosing pump from losing prime. The bottom one way valve is located below the dosing pump head connected to the foot valve assembly via the feed pipe and may need cleaning or replacing if the dosing pump will not work or prime. The feed pipe connects to the bottom one way valve in the same way as the foot valve assembly connects to the feed pipe but with the addition of a clamp ring . The feed pipe is pushed fully into the recess on the valve, the clamp ring is slid onto the feed pipe before the plastic and the nut tightened by hand only, see photo.

34 Drawing 9848 Rev 0 08-06-04 Routine Maintenance of system Cont.) Auxiliary dosing equipment dosing pumps etc. Set Screws The set screws secure the pump head to the pump body and need checking for tightness due to the force of the diaphragm hitting the pump head, loosening the screws. The set screws must be checked every 6 weeks. These are recessed into the pump head, see photo. If these screws are not tightened correctly the pump will start to leak and will be permanently damaged. Diaphragm The diaphragm moves forwards when the dosing pump is activated and forces the solution out of the dosing pump towards the 4 function valve. The force with which the diaphragm moves is controlled by the knob on the rear of the pump. The diaphragm is located behind the pump head and is accessed by undoing the set screws, this will need cleaning or replacing if the dosing pump does not work or prime. Before cleaning or replacing the diaphragm release the pressure via the 4 function valve. The diaphragm should be free of cuts with and splits. If you are in any doubt about its condition, replace it. The diaphragm is located on a thread and is removed by rotating anti clockwise. Reassemble ensuring that the set screws are tightened evenly. Four function valve and dosing pump priming The four function valve allows the pump to be primed, acts as a pressure relief valve in the event of the injector or injector pipe becoming blocked and stops the chemical solution from returning into the diaphragm area via a one way valve. The 4 function valve is located on the top of the pump head with the one way valve between the pump head and 4 function valve. The 4 function valve is may need cleaning or replacing if the dosing pump will not work or prime. To prime the dosing pump rotate the black knob on the 4 function valve 45 degrees and activate the dosing pump. The dosing pump is primed when there is no air visible through the pump head and the solution returns to the day tank via the 4 function valve return pipe. The 4 function valve is connected to the injector via the injector pipe and allows pressure to be removed from the injector pipe so it can be removed for servicing. To release the pressure in the injector pipe pull the yellow knob away from the black knob on the 4 function valve for 5 seconds. The injector pipe reconnects to the 4 function valve in the same way as the feed pipe connects to the bottom one way valve. Injector pipe The injector pipe connects the dosing pump via the 4 function valve and injector to the pool. The pipe connects to the 4 function valve and injector with a clamp ring/washer and locking nut. The pipe should be free of cuts and abrasions, if there is any doubt on the condition of the injector pipe then it should be replaced. Before removing or replacing the injector pipe release the pressure via the 4 function valve.

35 Drawing 9848 Rev 0 08-06-04 Routine Maintenance of system Cont.) Auxiliary dosing equipment dosing pumps etc. Injector LMI & Rodding unit The injector allows the chemical solution into the pool and prevents pool water from entering the injector pipe. The injector is either located directly or via a rodding unit into the pool pipe work and is connected to the dosing pump via the injector pipe. Rodding units do not negate the need to clean the LMI injector, they just increase the maintenance period. PTFE tape is used on the injector where it screws into the pool pipe work. The PTFE tape will need replacing when the injector is removed. The injector should only be hand tight. It will need cleaning or replacing if the dosing pump will not work or prime. Before removing or replacing the injector, release the pressure via the 4 function valve. The injector pipe connects to the injector in the same way as the feed pipe connects to the four function valve. If a rodding unit is fitted the rod should normally be fully withdrawn, and pushed in to clean the injector every day. The rodding unit rod is pushed in by loosening the cap a half turn, pushing the rod fully in, withdrawing fully and retightening the cap (Do not over tighten). If the rod is stiff then the rodding assembly should be removed and cleaned. Electric agitator The electric agitator contains no parts that can serviced by the operator. If an electric agitator is fitted, the chemical solution should not be allowed to fall below half way in the day tank. Hand Transfer Pump After using the hand transfer pump it is essential that the pump is flushed with fresh water. If the pump is not flushed with fresh water it will leak and be permanently damaged. CO2 injectors Maintenance The CO2 system (apart from an annual parts replacement) does not normally need any day to day maintenance, but in hard water areas it may be necessary to examine the CO2 diffuser for calcium salt blockage and if necessary removal of this with a de-scaling acid. Restarting the TEC750a after maintenance Open the sensor assembly sample line input/output valves and allow pool water to flow through the sensor assembly for 20 minutes. Turn the TEC750a electricity supply on, recalibrate, standardise and turn the dosing pump circuit breakers on. The TEC750a will need calibrating and standardising 24 hours later if the probes have been cleaned Winter shut down procedure If the pool that the TEC750a is controlling is to be closed for a long period, then the following procedure should be implemented on the TEC750a. 1. Turn off TEC750a. 2. Isolate sensor assembly using the input and output isolation valves. 3. Empty chemical day tanks. 4. Flush dosing pumps with fresh water.

36 Drawing 9848 Rev 0 08-06-04 Routine Maintenance of system (Cont.)

Routine Maintenance schedule use grid system for above

The below maintenance schedule must be maintained and a record kept or your warranty will be void. This record is to be kept with your operations manual. It is recommended that if you are not familiar with automatic chemical dosing equipment that you arrange for your supplier to carry out a quarterly visit. If no frequency is indicated then enter date work was completed

Min Frequency Date of Work Date of Work Date of Work Date of WorkDate of WorkTEC1000a 12 month

Cl Probe 3 monthpH Probe 3 month

S/S Electrode 3 monthFlow Tube 3 month

Sensor Assembly 3 monthY Strainer 1 week (tick) I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I I I I I

Flow Switch 1 week (tick) I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I I I I I

Dosing PumpFoot Assembly 3 month

Feed Pipe 3 monthBottom one way 3 month

Set screws 6 weeks I I I I Diaphram 3 month

Four function 3 monthInjector pipe 12 monthCl injector 1 month I I I I I I I IpH injector 3 month

Electric Agitator 12 monthHTP rinse After use(tick) I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I II I I I I I I I I I I

CO2 injector 12 month

37 Drawing 9848 REVISION 0 08-06-04 Maintenance pictures 1

38 Drawing 9848 REV 0 08-06-04 Maintenance pictures 2




42 Drawing 9848 REV 0 08-06-04 LMI Instructions

43 Drawing 9848 REV 0 08-06-04 LMI Instructions (Cont)

44 Drawing 08-06-04 LMI Instructions (Cont)
























68 Drawing 9848 REV 0 08-06-04 Electric Agitator Instructions

INSTRUCTION MANUAL

GENERAL REMARKS - General recommendations – Notes for safety

INSTALLATION AND START UP – Preliminary checks for the assembly - Installation - Start-up - Problems and countermeasures INSTRUCTION FOR MAINTENANCE - Periodical maintenance - Lubricants -Spare parts

69 Drawing 9848 REV 0 08-06-04 Electric Agitator Instructions (Cont)

GENERAL RECOMMENDATIONS Upon receipt of the materials make sure that no damage has occurred during the shipment. Notify the forwarding agent or the supplier, agreeing upon the actions to be taken. During the handling and transport up to the point of installation,use especially good judgement in the choice of the hooking points for the hoisting; in particular with regard to the specially covered shafts (with ebonite, rilsan, rubber, etc.) Besides causing breakage of the covering each small deformation or impact can modify the alignment of the shaft with consequent critical vibrations during the operation. Avoid hoisting the agitators from points of easy rupture such as the terminal hoards of the electric motors, hand wheels of adjustable speed motors, seal flow piping, etc. Possible slings must be passed under the gear box housing unit,, and not under the motors. When present always use the. hoisting eyebolts, initially checking the correct positioning and fastening.

NOTES FOR SAFETY

Each operation of handling, installation start-up and maintenance must be carried out, complying with the accident prevention laws in force and using every practical expedient for the purpose of safety of the work expressly mentioned in this text or in the enclosed documents of the subordinate suppliers, as well as effectuating all the procedures of sound execution of the work, commonly well-known by the qualified operators.


INSTALLATION AND START-UP INSTALLATION - Follow the instructions possibly described on the assembly or installation drawing. -Check the space available for the assembly -Check that the supporting structure (beams, plates, flanges etc.) has keen correctly sized, taking the static and dynamic loads produced by the agitator into consideration -The anchor bolts must be suitable for the fastening holes (do not use undersized screws and must be assembled with plain washer and spring washer - Check the presence of baffles, when requested, in the cylindrical tanks. - In a vertical cylindrical tank, the most common arrangement that of assembling four baffles, spacing t(or 3 at 120’ in case of fast agitation).

hem 90’ from each other

- We advise spacing the baffles from the walls of the tank with approximately l/6 of the width of the baffle itself in order to eliminate the stagnant areas in the mixing of liquids with solids and of viscose liquids. The baffles shouldn’t be used if the viscosity of the products exceeds 20,000 cp. The approximate rule of thumb used is the following: Width of the baffle as % of the diameter of the tank 1/12 l/1S 1/24 1/40 Viscosity of the liquid in cp. as water 5,000 10,000 20,000

71 Drawing 9848 REV 0 08-06-04 Electric Agitator Instructions (Cont) - Check the possibility of inserting the impellers; disassemble and connect to the shaft in the vessel through the pre-arranged openings without forcing. In case of installation in the open it is necessary that at least the electric motor be protected by a canopy. The motor - gear box - bearing housing unit normally constitutes a single unit that is to be fastened to the support structure, observing the torque wrench settings of TAB.A and attending to the level in such a way as to guarantee a correct rotation of the shaft, free from oscillations that before long could damage the mechanical stability. Make sure that the impellers are assembled in accordance with the rotation direction and are fastened rigidly to the shaft. In case of two or more impellers, check the reciprocal distance along the shaft. The shaft must not be bent while it 1s inserted into the vessel and must not be rested so as to bear the weight of the drive unit. In case of a shaft and/or impellers carried out in various flanged parts, follow the connection of the parts pre-marked in the factory and tighten the connection bolts in accordance with the torque wrench settings of TAB.A Finally see to the assembly of all the possible additional elements supplied separately such as: - Bushing for steady bearing - Nut covers for covered shaft/impeller flanges - Pressure gauge for pressurisation tank, - Motor protection canopy. - Etc.


START UP Before starting the agitator, it is advisable to carry out the following checks.

ON THE MOTOR Check that, the connections (bonds on the inside of the terminal board) are arranged in an exact way and so as to correspond with the supply voltage of the control line, which must always have the ground wire. The entry of the cable into the terminal board must be well insulated and the cover must he screwed with care. We recommend the insertion between the feed line and the motor of a suitably calibrated overload cut out for the rated current in amperes indicated on the plate. Without the Overload cut out there is no guarantee for the damage of the winding. The rotation direction is generally clockwise, viewed from the motor side, and is in any event indicated by an arrow located on the motor itself: possible exceptions to this rule will be specified and the reversal of the rotation direction can be obtained by reversing two phases of the feed line among them. ON THE GEAR BOX Check the oi1 level before putting the agitator into operation. The larger gear boxes may be supplied without oil; in this case see to the filling with the issued oil until reaching the maximum level visible from the special indicator. Some types of gear boxes are supplied with un-drilled caps and are supplied with a vent plug, which must be replaced when installing at the place of the cap, situated in the highest position, in order to avoid leaks of lubricant caused by the variation of the general internal pressure during the operation. The gear boxes supplied with permanent lubricant with lifelong grease lack the load level and drain plugs. ON THE IMPELLER Do not start the agitator if the impeller is immersed in silt, unless this method of operation has been conditioned in the design hase. p

73 Drawing 9848 REV 0 08-06-04 Electric Agitator Instructions (Cont) ON THE ENTIRE UNIT Check the tightening of all the bolts and nuts in accordance with TAB. A. (Repeat the operation after two weeks of operation). After having carried out above-mentioned inspections you may proceed with starting the agitator with the Pre-arranged control devices. At the beginning of the operation, just as any machine running in, an agitator - caused by the greater friction’s - can lead to overheating and a higher absorption of current of the motor; these problems gradually disappear during the operation. When a gear box - cyclo converter - is installed, it is generally advisable in time to gradually increase the transmitted power, starting from the minimum values, or limiting it (50-70% of the maximum power) for the first hours of operation. Should an excessive unforeseen absorption occur, disconnect the motor from the power grid, check the perfect efficiency of the contact of the connections and check that the working conditions correspond to those established especially with regard to the density and viscosity of the liquid; in case the overload persists, contact our technical department. If there are vibrations, stop the agitator immediately and determine the causes that provoke it. All the agitators are suitable for the operation with a maximum and constant level; if not foreseen in the design phase, avoid the operation in tanks at variable or insufficient levels.

74 Drawing 9848 REV 0 08-06-04 Electric Agitator Instructions (Cont) ON THE SEALS Packing type: tighten the stuffing box before putting the tank under pressure. In case of lateral agitators, where the seal is under the level of the liquid, an initial dripping is considered normal, which then must be deleted by adjusting the tightening of the stuffing box. Single mechanical type: it is not necessary to carry out any preliminary operation since the seal is already ready for duty after the installation on the control unit of the agitator. Check if the seal model is suitable for rotating in one or both rotation directions. In case of lateral agitators where the seal is under the level of the liquid, make sure that it is always in contact with the liquid. Take care that in the operations of emptying fo11owing filling of the tank, zones of accumulated air (air bubbles) around the seal are not created. Even a few seconds of running dry can create localised overheating, which seriously damages the mechanical seal. The damages deriving from having run dry are easily recognizable the seal shows evident signs of burning and the counter face (if in aluminium) may be cracked due to thermal shock. The failures caused by running dry are never repaired under the guarantee. Double mechanical type must be used with a coolant; this liquid must circulate in the housing of the seals before starting the agitator. The liquid in circulation between the seals must generally be maintained at a pressure exceeding one atm of that in the vessel. If the pressure of the coolant does not exceed 2 atm, the external seal can be carried out with an oil seal ring.

75 Drawing 9848 REV 0 08-06-04 Electric Agitator Instructions (Cont) PROBLEMS AND COUNTERMEASURES a) The gear motor is noisy: check the oil level and replace it if necessary. b) The check the bearing and replace it if necessary check that no foreign matter is on the impeller.

shaft vibrates:

c) The gear motor strains at the start-up: check the bearing and replace it if necessary check that no foreign matter is on the impeller. d) The thermal protection trips frequently: check the bearing and replace it if necessary; check that no foreign matter is on the impe11er. check that the impeller is not blocked in the sediment e)The sea1 shows leaks: tighten the stuffing box in case of packing; replace the entire seal in case of mechanical seal. INSTRUCTIONS FOR MAINTENANCE Replace the oil in the gear box after the first 500 hours of operation, possibly seeing to an accurate internal cleaning. The gear boxes with synthetic grease do not require any maintenance. Check the level of the lubricant on the gear hot and in general, carry out the change of it at 4000 hours of operation, unless otherwise instructed by the manufacturer (see enclosed informative bulletins). For a longer life of the equipment it is sensible to foresee an accurate maintenance of it, replacing, when necessary, the worn parts such as bearings, oil seal rings, rubber pegs of the flexible couplings, seals and packing. The operations of disassembly and assembly of the mechanical seals must be carried out by skilled persons, with maximum precision and cleaning. Following, a number of instructions of a general nature are described regarding the operations to be carried out for the replacement of a mechanical seal in the case of an agitator ”from above1” and a ”lateral” agitator.

76 Drawing 9848 REV 0 08-06-04

Safety Data Sheet Probe Cleaner

Topline Electronics Ltd Unit 7, Crown Close Diplocks Way Industrial Estate East Sussex BN27 3JF Tel: +44 (0)1323 440 760 Fax: +44 (0)1323 844 508 Date: September 2005 1 IDENTIFICATION OF CHEMICAL Product Name: Probe Cleaner Chemical Name: Hydrochloric Acid 5% 2 COMPOSITION Ingredients Cas No. Einecs No. Phrases Hydrochloric Acid 5% 7647-01-1 231-595-7 R36/37/38 3 HAZARD IDENTIFICATION Irritant: Irritating to eyes, respiratory system and skin. 4 FIRST AID Skin Contact: Drench the affected area with plenty of water. Remove contaminated

clothing and wash before re-use. If large areas of the skin are damaged or if irritation persists seek medical attention.

Eye Contact: Irrigate thoroughly with water for at least 10 minutes. Obtain medical

attention. Ingestion: Wash out mouth with water. Do not induce vomiting. If patient is

conscious, give water to drink. Seek immediate medical attention. Inhalation: Remove from exposure, rest and keep warm, seek medical attention. 5 FIRE-FIGHTING MEASURES Non-Flammable Use extinguisher suitable to cause of fire. Hazardous combustion Products: Hydrogen Chloride Special Equipment: Self contained breathing apparatus and full

protective clothing.

77 Drawing 9848 REV 0 08-06-04 Apen 1 (Cont) 6 ACCIDENTAL RELEASE MEASURES Use appropriate personal protective equipment as detailed in section 8. Spillages and Leaks: Bund spill area, dilute with plenty of water and neutralise with lime slurry or sodium carbonate. Flush with plenty of water. Dispose of in accordance with appropriate local regulations. Do not allow undiluted material to enter drains, sewers or watercourses. 7 HANDLING AND STORAGE Handling: Wear suitable protective clothing. Avoid contact with skin and eyes. Storage: Keep in a cool, dry position, store in original container. Ventilation: Good general ventilation. Local exhaust ventilation is required. 8 EXPOSURE CONTROL/PERSONAL PROTECTION Exposure Limits 5 ppm (7mg/m3), STEL OES EH 40/94 PPE Respiratory: Type approved RPE for acidic vapours. Hand: PVC or rubber gloves Eye: Safety goggles. Skin: Rubber boots, PVC overalls. 9 PHYSICAL AND CHEMICAL PROPERTIES Appearance: Colourless to pale green liquid Odour: Pungent, Characteristic pH: Less than 1 Boiling Point/Range: 100 to 110 Melting Point/Range: 0 to -5 Solubility in Water: Completely miscible Vapour Density: 1.27 Vapour Pressure: Less than 5 at 15°C (measured in milli bars) 10 STABILITY AND REACTIVITY Known Hazardous Reactions: Attacks most common metals liberating hydrogen,

which can form explosive mixtures with air. Product can react violently with oxidising agents liberating chlorine.

Materials to Avoid: Alkalis, concentrated sulphuric acid, oxidising

agents, ammonia, amines.

78 Hazardous Decomposition Products: Hydrogen chloride.

79 Drawing 9848 REV 0 08-06-04 Apen 1 (Cont) 11 TOXICOLOGICAL INFORMATION Route of entry: Inhalation, skin contact and ingestion Inhalation: Inhalation of mists and vapour will cause irritation of the upper

respiratory tract, high concentrations may cause corrosion, pulmonary oedema may occur up to 48 hours after exposure.

Skin & Eyes: Irritating to skin, eyes and mucous membranes. Ingestion: Ingestion may cause damage to the gastrointestinal tract.

Repeated exposure to low levels may cause erosion of the teeth and ulceration of the nasal septum and gums.

12 ECOLOGICAL INFORMATION Mobility: Liquid, soluble in water, predicted to have high mobility in soil. Degradability: Neutralised slowly by natural alkalinity. Bioaccumlative potential: Material does not bioaccumulate. Aquatic Toxicity: Fatal to fish and other aquatic life due to low pH. 13 DISPOSAL CONSIDERATIONS Substance: Via an authorised waste disposal contractor to an approved waste

disposal site, observing all local and national regulations. Container: As substance. 14. TRANSPORT INFORMATION UN No: 1789 Primary Hazard: Corrosive Packing Group: II Hazard ID No: 80 Class: 8 ADR/RID Item No: 5b

80 Drawing 9848 REV 0 08-06-04 Apen 1 (Cont) 15 REGULATORY INFORMATION Product Name: Probe Cleaner Label Name: Hydrochloric Acid 5% Hazard Symbol(s): Irritant Risk Phrases: R36/37/38 Irritating to eyes, respiratory system and skin Safety Phrases S1/2 Keep locked up and out of reach of children.

S26 In case of contact with eyes, rinse immediately with plenty of water and seek medical advice.

S45 In case of accident or if you feel unwell, seek medical advice immediately, show label where possible.

16 OTHER INFORMATION Recommended uses and restrictions: No further information Further information sources: No further information Sources of key data used to compile Safety Data Sheet. Approved carriage list, EH40. The data in this Safety Data Sheet has been supplied as required by the Chemicals (Hazard Identification and Packaging) Regulations 1997, as amended, for the purpose of protecting the health and safety of industrial users who are deemed capable of understanding and acting on the information provided. Please ensure that it is passed to the appropriate person(s) in your company who are capable of acting on the information. This data sheet does not constitute a users assessment of the workplace risk as required by the Health and Safety at Work Act, COSHH, Management of Health and Safety at Work or other health and safety legislation. Please ensure that this information is passed to the appropriate person(s) in your company, who are capable of acting on the information.

81 Drawing 9848 REV 0 08-06-04 Apen 2 Pool Test sheet

82 Drawing 9848 Rev 0 08-06-04

SECTION 6

OPERATING/WARRANTY CONDITIONS

AND ADVISORY NOTES

83 Drawing 9848 Rev 0 08-06-04

Operating Conditions affecting TEC parts and service warranty

A Only staff who have been trained by Topline Electronics Ltd. should operate the dosing system.. B Ensure that the maintenance schedule for the TEC750a has been kept to, and all actions

recorded. C Ensure DPD1, Phenol red, Alkalinity and calcium hardness results are recorded, balanced

water is maintained, free to combined ratio levels of chorine are within guide lines and pH is between 7.2 to 7.8.

D When taking a DPD1 test, dilution tests are carried out if the first reading is above 2.5ppm. E All tests to calibrate or standardise the TEC750a are to be taken from the sample tap beneath the TEC750A. Ensure tablet test readings are taken and recorded within 3 minutes. F Ensure that the Swimming Pool Water Treatment and Quality Standards are implemented

when possible G Plant backwashing should be carried out as per the installers instructions. During backwashing the chemical feeders must be turned off. H Ensure regular pathology testing is undertaken, we recommend once a month. I All poolside areas are to be kept clean, including the deck level grating and all scum lines,

only approved cleaning products to be used. J Use of flocculents. Aluminium sulphate solution (kibbled alum solution) is

used in a 5% solution. The rate for dosing aluminium sulphate is 0.05mg/l. Organic polymer based flocculents such as poly-aluminium chloride or equivalents can be used but rate of dose must be carefully controlled at 0.1ml/m3. The above rates are continuous. All flocculents can damage electrodes, if the above conditions are not met our electrode and service warranty is invalidated

K Only inorganic chlorine donors should be used. Before the use of cyanuric acid based (stabilised) chlorine refer to Topline Electronics Ltd. L Excessive use of de-foaming agent will stop the control system from working. Consult Topline Electronics Ltd. before using any de-foaming agent.

84 Drawing 9848 Rev 0 08-06-04 Advisory Notes Automatic water chemistry controllers are rapidly becoming the norm within water treatment circles. They can be an invaluable aid to swimming pool operators, they can help to minimise the length of downtime periods, and chemical costs, as well as maximising water quality achievements. However, it must be remembered that automatic chemistry controllers do NOT negate the need for common sense and the adherence to guidelines as defined in the Swimming Pool Water Treatment and Quality Standards issued by the Pool Water Treatment Advisory Group. The notes below are not intended to replace these guidelines, but are intended to show how the operator can achieve them using Topline dosing equipment and procedures. A. Staff Although all dosing systems work in a similar way, they all have there own particular way in achieving high quality water. It is therefore essential that the TEC750a dosing system is only used by staff who have been trained. B. Maintenance For the dosing system to function correctly, regular maintenance must be performed by qualified personnel. There are a number of swimming pool companies who profess to be experts in dosing systems. If the company has not been trained by Topline then it will not be able to look after your Topline dosing system. We would therefore recommend using your own trained staff, companies approved by Topline or Topline itself to look after your dosing system. Maintenance contracts, extended warranties and routine services are available from Topline. C/D Chemical balance is essential for smooth operation. You should have available a chemical test kit that measures free chlorine, combined chlorine, pH, alkalinity and calcium hardness. The below instruction are for Lovibond comparator balanced water kit AF129/CYS. If you use a photometer then great care must be taken with the equipment, the manufactures instructions must be strictly followed and dilution tests carried out when the reading for free chlorine is above 2.5ppm. You should also have available a thermometer and TDS meter. These are the minimum requirements for a commercial swimming pool. Free chlorine DPD1 test (guide between 1-4 PPM) 1. Fit the chlorine disc into the comparator. Rinse out 2 cells thoroughly with sample, leave

one filled to the 10ml mark and place it in the left-hand compartment to act as a “blank” behind the colour standards.

2. Leave a few drops of sample in the second cell and add a DPD1 tablet. Crush with a clean stirring rod. Make up to the 10ml mark with sample and mix. Note if the colour appears in the few drops, but disappears when volume is made up to 10ml mark, a high level of chlorine is present and the test should be repeated with the sample diluted with tap water.

3. Place in the right-hand compartment and match the colour against the disc immediately, reading the value from the bottom right hand corner. The result is free chlorine in mg/l. The dilution technique applies if the colour is deeper than the highest value on the disc.

Total and combined chlorine (guide combined chlorine no more than 1.5 times free i.e. breakpoint chlorination)

After the free chorine reading has been taken, add one DPD3 tablet to the cell containing the dissolved DPD1 tablet. Crush with clean stirring rod and mix. After 2 minutes match the colour against disc. The DPD1 and DPD3 test must be repeated using the dilution technique if the colour is deeper than the highest value on the disc. The reading is the total residual chlorine in mg/l. The difference between the free chlorine and total residual chlorine reading is the combined chlorine. After testing wash out the cells using clean water and the brush provided.

85 Drawing 9848 Rev 0 08-06-04 Advisory Notes (Cont.) C/D Chemical balance (Cont.) Chlorine in the water provides two functions: (1) To kill infection causing bacteria. (2) To degrade the pollutants introduced by bathers.

Remember, the water may be free of bacteria but this does not necessarily mean that the water is clean i.e. free of pollutants. Water will only be free of bacteria and organic pollutants if the filtration is adequate and break point Chlorination conditions are in place. Take water tests regularly to confirm these levels, otherwise operators run the risk of not achieving breakpoint Chlorination conditions, hence wasting chemicals and not ensuring optimum water quality, as regards smell and the ability of poor water quality to sting eyes.

Operators should be aware shock dosing can cause a rise in combined chlorine. Chlorine will not remove detergent from the water if there is detergent in the water then high levels of combined chorine can be expected.

pH Test (guide between 7.2 & 7.8) 1. Fit the pH disc into the comparator. Rinse out 2 cells thoroughly with sample, leave both

filled to the 10ml mark and place one in the left-hand compartment to act as a ‘blank’ behind the colour standards.

2. Add a phenol red tablet to the other cell and crush with a clean stirring rod. 3. Place in the right-hand compartment and match the colour against the disc immediately, reading the value from the bottom right hand corner. The result is the pH value. Adjustment of the pH value of pool water is essential because: (a) The bactericidal actions of most disinfectants depends on pH, it is therefore necessary to maintain pH value within an optimum effective range, lower limit 7.2 upper limit 8.0. (b) As the pH rises towards 8 bactericidal efficacy of chlorination decreases rapidly. (c) As the pH rises towards 8, the water as an increasing tendency to encourage precipitation of hardness salts. (d) As the pH falls below 7, the water becomes corrosive towards materials used in the construction of the pool. (e) If the pH value is too low or too high, the water can irritate the skin and eyes.

86 Drawing 9848 Rev 0 08-06-04 Advisory Notes (Cont.) C/D Chemical balance (Cont.) Total alkalinity test Place 50ml in shaker tube and add one Total alkalinity tablet. Shake well to disintegrate and continue adding these tablets one at a time until yellow changes to bright red. To calculate total alkalinity in mg/CaCO3 from formula - (No of tablets*40)-20 Wash out shaker tube after use. Maintaining the alkalinity of pool water is essential to avoid pH bounce and pH lock: The total alkalinity of water is a measure of the alkaline salts dissolved in it - bicarbonates and carbonates mainly. The higher the alkalinity the more resistant the water is to pH value changes: the alkalinity buffers the water. So “pH bounce” - large changes in pH value in response to changes in the dosage levels of disinfectant and pH correction chemical - is prevented, as long as total alkalinity is above 75mg/l as Ca CO3. Conversely alkalinity above 200mg/l can make any necessary pH adjustment difficult “pH lock” pH lock and pH bounce can be minimised by the correct choice of chemicals. Total alkalinity should be checked weekly, maintained between 75 and 100mg/l. Calcium hardness test Place 50ml in shaker tube and add one calcium hardness tablet. Shake well to disintegrate and continue adding these tablets one at a time until pink changes to violet. To calculate calcium hardness in mg/CaCO3 from formula - (No of tablets*40)-20 Wash out shaker tube after use. Maintaining the calcium hardness of pool water is essential to avoid corrosive water: The calcium hardness is the measure of calcium salts in the water. If calcium hardness is below about 40mg/l as Ca CO3, the water is likely to be corrosive to the fabric of the pool plant. By about 75mg/l a protective scale can start to form; so far as corrosion is concerned, there should be no need to boost hardness beyond that. Calcium hardness should be checked weekly and maintained between 75 and 500mg/l. Chemical choice The correct choice of chemicals can assist greatly in the control of alkalinity and calcium hardness i.e. Sodium hypo and dry acid in hard water areas and calcium hypo and CO2 in soft water areas. Totally Dissolved Solids TDS should not be allowed to rise above 1000 mg/l above source water. TDS is controlled by regular backwashing and the loss of water through permanent dilution. It is recommended that 30 litres of water per bather per day is replaced.

87 Drawing 9848 Rev 0 08-06-04 Advisory Notes (Cont.) C/D Chemical balance (Cont.) Water Balance A balanced water is neither scale forming nor corrosive; that is, it shows no tendency to precipitate salts. It is important to maintain the water in balance, but for most pools the water will be balanced if the pH is maintained within recommended range. After pH value, the main factors which determine whether the water is balanced are alkalinity, hardness, dissolved solids and temperature. These factors are all interrelated but in a complex way. What is important is to make sure that chemicals used to disinfect and alter the pH are appropriate to the source water. The correct choice of chemicals will help control alkalinity and calcium hardness i.e. Sodium hypo and dry acid in hard water areas and calcium hypo and CO2 in soft water areas. To formally assess the water balance (Langelier Index) we use the following formula: Langelier Index = Temperature Factor(TF) + Calcium Factor(CF) +Alkalinity Factor(AF) + pH value -12.1 Temperature TF Calcium Hardness CF Alkalinity AF Degrees C 24 0.6 75 1.5 50 1.7 29 0.7 100 1.6 100 2 150 1.8 150 2.2 200 1.9 200 2.3 300 2.1 300 2.5 400 2.3 800 2.5 For example if the pool water was 29 degrees C, alkalinity was 150, calcium Hardness was 200 & pH value was 7.5 the Langelier index would be: (TF)0.7 + (AF)1.8 + (CF)2.3 + (pH)7.5 -12.1 = 0.2 (Langelier Index) A positive Langelier index indicates scale forming water a negative index indicates corrosive water. The Langelier index is only a guide, and is no substitute for understanding and the systematic maintenance of chemical levels. (E) Tests to calibrate and standardise Topline dosing system DPD1 and phenol red tests used to standardise or calibrate the Topline dosing system must be taken from the sample tap beneath the sensor assembly. The Topline dosing system is measuring the free chlorine and pH value in the plant room, not the pool. There can be significant differences between the pool and the plant room due to localised pollution introduced by bathers in the immediate area of where the water sample was taken from. The operator will not be aware of the localised pollution and any data entered into the Topline dosing system from samples taken in the pool can introduce serious chemical control problems.

88 Drawing 9848 Rev 0 08-06-04 Advisory Notes (Cont.) (F) The Swimming Pool Water Treatment and Quality Standards issued by the Pool Water Treatment Advisory Group, is the recommended source of data not supplied in this manual. However no document can replace training and common sense. PWTAG Tel Nos. 01379-783678. (G) Backwashing. If the pool/spa filters are not backwashed at the appropriate rate and routinely, then there will be an increase in combined chlorine and the amount of chlorine used to reach acceptable levels of free chlorine with the associated increase in running costs. Backwashing should not be used to control the TDS. TDS should be controlled by constant dilution i.e. 30 litres of water per bather per day. Backwashing to reduce TDS will reduce the life of the filtration media. (H) Pathology testing. The pools and spas should be tested at least once a month for E.Coli, Pseudonomas, Total viable counts, Staphaureus and coliforms. EWS on 01457-877755 can conduct these tests. (I) Pool Surround Cleaning Use protective clothing when handling all chemicals. Check the product COSHH regulations. A rigid cleaning regime is absolutely essential to pool surrounds and balance tank man-hole lid areas. Balance tank lids should be lifted every three months and the edges of both surfaces should be scrubbed with a HIPHOS and VANODINE and then the lid should be replaced. Deck level pool surround channels and scum channels build up a layer of fats. This fatty layer is best removed by scrubbing with a hot 15% solution of sodium bi-carbonate every three months. the rest of the pool surround areas (especially where people walk) Is cleaned with a strong safe cleaner, we recommend a two stage cleaning process using Hi-PHOS and Vanodine which is available from Evans Vanodine International 01772 322200. DETEGENT BASED PRODUCTS SHOULD NEVER BE USED POOLSIDE. The Hi-phos cleaner is mixed 1-25 with water and applied using a flat sponge type mop, leave to dry. Do not let the cleaner enter the pool. We suggest cleaning about 15 square meters at a time. This procedure is carried out every month. The Vanodine cleaner is mixed 1-200 with water and applied using a flat sponge type mop, leave to dry. Do not let the cleaner enter the pool. We suggest cleaning about 15 square meters at a time. This procedure is carried out every day. (J) Flocculents enhance the removal of dissolved , colloidal or suspended material by bringing it out of solution or suspension as solids, then clumping the solids together, which is more easily trapped in the filter. Flocculents also help filter the infective cysts of cyrptosporidium and Giardia which are resistant to chlorination. The pH must be maintained within recommended operating range or the flocculent will not be effective. Overdosing flocculent will adversely effect the TEC750a dosing system performance. (K) Cyanuric acid is a stabiliser added to pool water to reduce chlorine loss due to ultraviolet light from the sun and should therefore only be used in outdoor pools. Cyanuric acid can be used with TEC750a dosing system but levels should not exceed 30ppm. (L) Defoaming agent is used to reduce the amount of visible foam on a spa. The foaming is usually caused by detergent in the water, from bathers who do not shower before using the facilities. We therefore do not recommend the use of de-foaming agent which can adversely effect filtration media and dosing system performance.

89 Drawing 9848 Rev 0 08-06-04

SECTION 7 SUPPORT

90 Drawing 9848 Rev 0 08-06-04 Servicing including calls made under guarantee

SERVICE METHOD STATEMENT Telephone Contact 01323-440760. The number will be manned between 09.00hrs and 17.00hrs Monday to Friday excluding Bank Holidays (Answer phone at all other times redirecting to a mobile number) . First action will be to discuss the situation and to try and find a resolution over the telephone. If required a Topline Engineer will attend site as detailed below, in accordance with the Service Price List or Service Agreement, an estimated time of arrival will be given. Parts and equipment are supplied as detailed in the Price List, special Discounts may apply by prior arrangement. VAT is at the prevailing rate in addition to our charges. We aim to provide a fast and efficient Service, if the site is experiencing difficulties with Pools and Spa’s outside our remit we will make our resources available to help find a solution. Topline will review all statements and prices from time to time, we reserve the right to make changes when necessary.

WARRANTY

The TEC750 is supplied with a one year parts and labour return to Topline warranty.

91 Drawing 9848 Rev 0 08-06-04 Section 1 Installation Index CE Certificate Declaration of conformance Page 6 Chemistry Control System Chemical Feeder Power Page 8 Chemistry Control System Inter Wiring Page 8 Chemistry Control System Power Requirements Page 8 Equipment selection check list Page 7 Inserting the Electrodes Page 9 Position of chemistry Control System Page 7 Technical Data TEC750A Control System Page 6 Topline Electronics Ltd Introduction Page 3 Water sample supply for the cell assembly Page 9 Section 2 Commissioning Index Acceptance of equipment Page 12 Certificate of staff training Page 16 Commissioning Check list Page 11 Commissioning procedure Page 11 Guarantee 12 month Page 15 Hand over procedure Page 13 Product support Page 15 Section 3 Operating Instructions Index Health and Safety Warning Page 18 Risk Assessment Page 19 Calibrate Page 24 Pump on Times Page 23 System Overview Page 20 System Set-up Page 22 Set up mode Page 22 Set point Page 22 Standardise. Page 22 Timeout Page 23 Section 4 Trouble shooting Index Chemical Level Trouble Shooting Page 29 Probe Trouble Shooting Page 28 System Trouble Shooting Page 26

92 Drawing 9848 Rev 0 08-06-04 Section 5 Maintenance Index Apen 1 Probe Cleaner COSHH sheet Page 76 Apen 2 Pool water test sheet Page 81 Bottom one way valve on dosing pump Page 33 Chlorine probe/pH probe cleaning Page 31 CO2 injectors Maintenance Page 35 Diaphragm Page 34 Dosing pump maintenance Page 33 Dosing pump picture Page 38 Electric agitator Page 35 & 68 Feed Pipe Page 33 Flow Switch Page 32 LMI Data sheet Page 42 Needle Valve Page 32 Foot assembly Page 33 Foot assembly picture Page 41 Four function valve and dosing pump priming Page 34 Hand Transfer Pump Page 35 Injector LMI & Rodding Page 35 Injector LMI & Rodding Picture Page 41 Injector pipe Page 34 Maintenance schedule Page 36 Probe cleaning Page 31 Restarting the TEC750a after maintenance Page 35 Sensor assembly blockage Page 32 Sensor Assembly Maintenance Page 31 Sensor Assembly Picture Page 37 Sensor Reassembly Page 32 Set Screws Page 34 Titanium electrode cleaning Page 31 Winter shut down procedure Page 35 Y Strainer Page 32

93 Drawing 9848 Rev 0 08-06-04 Section 6 Operating/Warranty Conditions & Advisory Notes Index Advisory Notes Page 84 Backwashing. Page 88 Calcium hardness test Page 86 Chemical balance Page 84 Chemical choice Page 86 Cyanuric acid Page 88 Defoaming agent Page 88 Floculents Page 88 Free chlorine DPD1 test Page 84 Maintenance Page 84 Operating Conditions Page 83 Pathology testing Page 88 pH Bounce page 86 pH Lock Page 86 pH Test Page 85 Pool Surround Cleaning Page 88 Staff Training Page 84 Swimming Pool Water Treatment & Quality Standards Page 88 Tests to calibrate and standardise (source) Page 87 Total alkalinity test Page 86 Totally Dissolved Solids Page 86 Water Balance Page 87 Section 7 Servicing, Service Method Statement Page 90

Documents

TEC750A Amperometric Chemistry Control System Manual