Goldline AQL-CHEM User manual

February 2008
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ORP & pH Sensing Kit
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Installation and Operation Manual
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AQL-CHEM
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GLINE
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T
ROLS

Introduction
When used with the Goldline Pro Logic control and AQL-CL chlorination kit, the
AQL-CHEM helps provide a fully integrated chemistry solution for your pool. The
Pro Logic senses the pool's ORP and pH levels and generates the correct amount of
chlorine to keep your pool properly sanitized. If a Goldline AQL-CHEM2 dispense
kit is also used, CO2 can be injected into the pool water when necessary, giving you
a complete automated system controlling both sanitization and pH balance.
What's Included
The AQL-CHEM comes with everything needed to allow the Goldline Pro Logic to
sense ORP and pH levels. The following is a description of the included compo-
nents:
Professional Grade ORPprobe- Samples water from the pool filtration system and
sends signals to the Pro Logic indicating the oxidation-reduction potential (redox) of
the pool water. ORP is an actual measurement of sanitizer activity and bacteriologi-
cal water quality rather than an expression of chemical residual levels. ORP is not
fooled by the effects of pH, TDS (total dissolved solids) and other factors giving a
more accurate measurement of the effectiveness of chlorine and water quality.
Professional Grade pH probe- Samples water from the pool filtration system and
sends signals to the Pro Logic indicating the acidity of the water. When used with a
Goldline AQL-CHEM2 or other pH dispensing device, the Pro Logic can keep the
pool water's pH levels balanced.
Probe Cell: The Probe Cell is used to house the probes and provide a location for
water collection and testing. Two hoses are provided to connect the Probe Cell to the
supply and return sides of the pool filtration system. The Probe Cell can be mounted
directly to the Pro Logic or remote mounted in the vicinity of the Pro Logic (re-
stricted by the length of the probe wiring).
Additional Pro Logic Relay: An additional relay is provided for Pro Logic PL-PS-
4 and PL-P-4 models. This additional relay allows the user to add theAQL-CHEM2
or other pH dispensing device to these models. Install this relay only if you have a
PL-PS-4 or PL-P-4 model and intend to add pH control.
pH Dispense Pigtail: The pH Dispense Pigtail provides a plug-in receptacle for the
AQL-CHEM2 solenoid valve's linecord or other line voltage pH related dispensing
device (peristaltic pumps, solenoid valves, etc.) that use a typical 110 VAC male
plug.
Various Hardware: The AQL-CHEM includes the necessary tubing, tubing con-
nectors and mounting hardware to complete the installation.
Compatibility
This AQL-CHEM is compatible with all Goldline Pro Logic pool controls. For Pro
Logic controls using theAQL-CLchlorination kit, theAQL-CHEM offers automatic
chlorine generation based on the pool's ORP level.
The AQL-CHEM is not compatible with the Aqua Rite and Aqua Logic series of
controls. An upgrade kit (AQL-CHEM-UPG) is available for use with some older
Aqua Logic products using theAQL-CLchlorination kit. Contact your local Goldline
dealer for more information. 1

Installation
Overview
Installing the AQL-CHEM requires the following steps:
•Mounting the Probe Cell
•Plumbing the Probe Cell
•Installing ORP and pH probes
•Wiring probes to Probe Cell communication box
•Wiring the Probe Cell to the Pro Logic
•Wiring the pH Dispense Pigtail
•Configuring the Pro Logic
•Validating Operation
•Establishing Maintenance Schedule
Materials Needed for Installation
•7/16” drill bit
•¼” NPT tap
•Two small adjustable wrenches if side mounting to PL
•3/16” drill bit if side mounting to PL
•Deburring tool or file if side mounting to PL
•Tape and scissors if side mounting to PL (for drill template)
•Mounting hardware if not mounting to PL
•Flex tubing cutter
•Water-tight strain relief for dispense pigtail
•Flathead screwdriver and mallet to remove knock-out and install strain relief
•120VAC Ground Fault Circuit Breaker (GFCB) for powering dispense pigtail
•Extra wire, wire strippers, and wire nuts could be helpful in some installations
•Any items that would be required for wiring and installation per local code
Before carrying out any part of the installation, be sure to shut off input power to the
Pro Logic. Turn off the pool filter pump, water features and any other related equip-
ment. Relieve pressure from the pool filtration system.
Mounting the Probe Cell
The Probe Cell can be mounted directly on the side of the Pro Logic or mounted up
to 15' away (limited by length of Probe Cell cable). The key to successful Probe Cell
installation is in the plumbing. A pressure differential is required to allow clean,
untreated water to pass through the cell and across the probes. Consider this when
looking for an ideal mounting location.
Side mounting AQL-CHEM to Pro Logic: Side mounting the AQL-CHEM will
require drilling 3 mounting holes through the Pro Logic enclosure. Adrill template
is included with the AQL-CHEM to assist with the positioning of the holes. After
drilling, be sure to remove any burrs and brush away any metal shavings. Route
Probe Cell cable through access hole at the bottom of the mounting bracket BE-
FORE screwing the
2

bracket in place. For easiest installation, fasten the nylon lock nut loosely, then slip
the bracket keyhole slots over the bolt head and tighten. After installation, coil
excess cable in theAQL-CHEM and/or Pro Logic enclosures. Refer to the diagram
below.
Remote surface mounting the AQL-CEM: The Probe Cell can be mounted up to
15' away from the Pro Logic (limited by length of cable). Use the four mounting
holes on the back of the bracket when surfacing mounting. Common wood screws
can be used for most applications.
3
Use remote
mounting holes
when surface mounting.
Route probe cell cable
through access hole
BEFORE mounting.
metal washer
rubber
washer
Pro Logic
enclosure wall
AQL-CHEM
bracket wall
Side Mounting
AQL-CHEM

4
Plumbing the Probe Cell to the pool plumbing
The Probe Cell requires connection to the pool plumbing using the supplied flex
tubing. Two ports on the Probe Cell, influent and effluent, are connected to the
supply and return sides of the pool plumbing. Refer to diagram below as well as the
following steps:
Drill and tap a 1/4" NPT hole using a 7/16" drill bit on the return side of the pool
plumbing at a location just downstream of the filter, but upstream from theAQL-CL
Electrolytic Cell. Use caution not to tap tapered threads too deeply. Using teflon
plumber's tape, install a tubing connector into the hole. Run flex tubing from the
tubing connector to the influent Probe Cell port. Push flex tubing in fully to seat.
rill and tap another 1/4" NPT hole on the supply side of the pool plumbing. Use
caution not to tap tapered threads too deeply. Using teflon plumber's tape, install the
remaining tubing connector and run flex tubing to the effluent Probe Cell port. Push
flex tubing in fully to seat.
Cut a 3" length of flex tubing and insert it into the sample stream port. This port can
be used to draw water samples if needed.
FROM
POOL
RETURN
TO POOL
POOL
Influent
Port Effluent
Port
Sample
Stream
Port

5
Installing ORP and pH probes to the Probe Cell
The ORP and pH probes are shipped "wet" in plastic storage caps. It's very impor-
tant that the probes remain wet at all times. If the probes are allowed to dry out, they
will fail and the AQL-CHEM will be ineffective. After installation, the Probe Cell
will ensure that the probes are constantly exposed to pool water. During periods
when the filter pump is off (even extended periods), there should be sufficient mois-
ture remaining in the Probe Cell to ensure that the probes are protected.
Remove the ORP and pH probes from their plastic storage caps and save the caps for
future use. To ensure that the probes continue to remain wet, fill the Probe Cell with
pool water before installing the probes. Apply a length of plumber's tape to the
probe threads. Hand-tighten the probes only. At startup, check for leaks. If probe
leaks, do not tighten more—instead remove and re-apply new Teflon tape.
Wiring the probes to the Probe Cell
Both probes must be wired to the communication box within the Probe Cell. The
probe cables use typical BNC connectors that attach to the designated connectors on
the communication box. Refer to the label on the communication box for the appro-
priate connections. Push the connectors in and turn clockwise until locked. After
connecting, route the wires in a manner where they will not interfere with the door of
the Probe Cell. Save BNC connector protective covers for future use.
pH
Probe
ORP
Probe
apply teflon
plumber's tape
to threads

6
Route cable
through
access hole
Route
though
knockout
Connect cable here
Wiring the Probe Cell to the Pro Logic
The Probe Cell is supplied with a 15' cable which connects to the Pro Logic control.
Route the cable through an available knockout and connect to the Pro Logic as shown
below. When side mounting the Probe Cell, route the cable through access hole at
the bottom of the mounting bracket BEFORE screwing the bracket in place.
Wiring the pH Dispense Pigtail
If pH dispensing is desired, the pH Dispense Pigtail must be installed. The Pigtail
provides a plug-in receptacle for theAQL-CHEM2 solenoid valve's linecord or other
line voltage pH related dispensing device (peristaltic pumps, solenoid valves, etc.)
that use a typical 110 VAC male plug. Wire the Pigtail according to the diagram on
page 7. Be sure that a Ground Fault type circuit breaker is used to provide power to
the Pigtail. Awatertight strain relief should be used to constrain the Pigtail where it
enters the Pro Logic enclosure.
The particular relay used for the Pigtail will depend on the Pro Logic model and the
auxiliary outputs that are already being used. An additional relay is included with
the AQL-CHEM for PL-PS-4 and PL-P-4 models (pH dispense devices can not be
controlled from the existing relays in these models). Refer to the following informa-
tion when determining which relay to use:
Pro Logic P-4 and PS-4 models: The relay included with theAQL-CHEM kit must
be installed and used to control the pH dispensing device on these models. Installa-
tion instructions for this relay can be found packaged with the relay. Once installed,
wire

7
the Pigtail directly to this relay in a similar fashion to the diagram on page 7. The Pro
Logic'sAux3 output will automatically be used to control this relay and the dispens-
ing device.
Pro Logic PS-8 and PS-16 models: Any available Aux or the Lights relay can be
used. Locate a relay that is not already in use and wire the Pigtail according to the
diagram below. The relay's corresponding Aux output will be used to control the
dispensing device.
to Line
on GFCB
to Neutral
on GFCB
Pigtail
to AQL-CHEM2
120 VAC Load
120 VAC
GFCB
pH dispense Pigtail
(included with AQL-CHEM)
use watertight
strain relief here
Configuring the Pro Logic
After the AQL-CHEM is mounted, plumbed and wired, the Pro Logic must be con-
figured using the Chemistry Config. Wizard found in the Configuration Menu. The
AQL-CHEM's pH probe must also be calibrated using the pH Calibration Wizard
found in the Maintenance Menu.
If a pH dispensing device is used, the relay that is used to control the device must be
configured. Refer to page 10 for detailed information.
Chemistry Config Wizard
If the AQL-CL chlorination kit will be used, be sure that it is enabled BEFORE
entering the Chemistry Config Wizard. The Chemistry Config Wizard will prompt
the user for information and automatically configure the Pro Logic to use the AQL-
CHEM sensing

8
kit. The procedure to perform the Wizard is shown below. Detailed information
about specific screens relating to the configuration can be found on the following
pages. To enter the Chemistry Config Wizard:
1. Press "Menu" until Configuration Menu is displayed.
2. Hold both "<" and ">" for three seconds.
3. Press ">" repeatedly until "Chemistry Config. Wizard" is displayed.
4. Push "+" to start Wizard.
5. Advance through the Wizard using "<" and ">" buttons. Use "+" and "-" but-
tons to answer questions when prompted.
6. Continue until finished.
Sensing System
Select Enable to configure the AQL-CHEM.
pH Reduction Control
Select the desired option related to pH control.
Disabled pH control is turned off. Select this mode if no pH dispenser will be
connected to the Pro Logic.
Auto Sensing Use this mode when an AQL-CHEM2 kit or other type of auto-
matic pH reducer will be controlled by the Pro Logic. The Pro Logic
will dispense pH reducer (CO2or acid) when necessary to prevent
the pH level from rising.
Forced On pH reducer is added for 15 minutes regardless of pH level and then
automatically goes to Auto Sensing mode. This mode is helpful
when setting up and testing the AQL-CHEM2 or other automatic
dispenser.
Chlorine Feed (displayed only if the chlorinator is enabled)
Select the desired option related to chlorine generation.
ORP Auto The Pro Logic refers to the ORP level in the pool and automatically
Sensing adjusts chlorine output to maintain a desired level.
Timed (%) The chlorine output is based on the manual setting only. ORPlevel
is not used to control the chlorinator output.
Maintain pH Level
The Wizard prompts you to enter the desired pH level (7.5 default). The Pro Logic
will dispense CO2when necessary to maintain this level. The adjustable range is
from 7 to 8 in .1 increments. Enter the desired pH level.
pH Alarms
The Pro Logic will automatically set a high and low alarm for the pH level. The high
alarm point is 8.1 and the low alarm point is 6.9. If the pH level meets or exceeds
these points, a "Check System" message will display locally and on all remote con-
trols.
pH Feed Timeout
To protect the pool, the Pro Logic control will automatically shut down pH control
and display a "Check System" message if the AQL-CHEM2 or other pH dispensing
device runs continuously for more than the selected timeout value. This prevents a
situation
(15 min)

9
where the Pro Logic is constantly feeding CO2because of a probe error or external
problem with the pool and allows the pool owner to evaluate the pool chemistry
before continuing with pH control. Use the "+" and "-" buttons to select one of the
preset timeout values. If the Pro Logic exceeds this pH Feed Timeout, it can be reset
in the Check System Default Menu display.
Maintain ORP Level
The Wizard prompts you to enter the desired ORP level (650mV default). Note that
the Pro Logic will attempt to maintain this level but typically the pool's ORP level
will vary above this value during normal operation. The adjustable range is from
400mV to 900mV in 5mV increments.
ORPAlarms
The Pro Logic will automatically set a high and low alarm for the ORP level. The
high alarm point is 850mV and the low alarm point is 350mV. If the ORP level
meets or exceeds these points, an alarm message will display locally and on all re-
mote controls. Also, if the ORP level is too high, chlorine generation will shut down.
Chemistry Extend
When the Chlorine Feed selection is set to ORPAuto Sensing and/or the pH Reduc-
tion Control selection is set to Auto Sensing, the Pro Logic will keep the pool filter
pump on regardless of its timer settings until the sanitizer level and/or pH level are
within their programmed parameters. The pump will continue to run and either
chlorineand/or CO2willcontinue todispense until theprogrammed levelsare reached.
When both sanitizer level and the pH level are within the desired levels, the pump
will be allowed to go back to automatic control.
Sanitizer Feed Timeout
When the Chlorine Feed selection is set to ORPAuto Sensing, the Pro Logic control
will automatically shut down ORP control and display a "ORPTimeout" message if
the timeout value is exceeded (1-24 hours). This prevents a situation where the Pro
Logic is constantly generating chlorine because of a probe error or external problem
with the pool and allows the pool owner to evaluate the pool chemistry before con-
tinuing with ORP control. The Timeout can be reset in the Check System Default
Menu display.
pH Calibration Wizard
After installation, the pH probe must be calibrated using the pH Calibration Wizard
within the Maintenance Menu of the Pro Logic. Periodically, a pool water test
should be compared to the pH level reported in the Diagnostic Menu of the Pro
Logic. If there is a discrepancy between the two values, the pH Calibration Wizard
should be redone.
Run the pool pump for a minimum of 20 minutes before starting the pH Calibration
Wizard. The procedure to perform theWizard is shown below. Detailed information
about specific screens can also be found below.
1. Press "Menu" until Maintenance Menu is displayed.
2. Press ">" repeatedly until "pH Calibration Wizard" is displayed.
3. Push "+" to start Wizard.
4. Advance through the Wizard using "<" and ">" buttons. Use "+" and "-" but-
tons to answer questions when prompted.
5. Continue until finished.