Topline TEC750A User manual

TEC750A Amperometric
Chemistry Control System
Manual

2

3
Drawing 9848 Rev 0
08-06-04
Topline Electronics Ltd Introduction
Topline 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 Equipment
This equipment is to be installed by a person qualified in electrical and chemical
plumbing systems
Technical Data TEC750A Control System
Dimensions 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.
FLOCULENT
DAY TANK
FILTER
SWIMMING POOL OR SPA
CHEMICAL
CONTROLLER
10m
ALKALINE
DAY TANK
CHLORINE
DAY TANK
ACID
DAY TANK
2m 2m
HEAT EXCHANGER
CIRCULATION
PUMP
ULTRA VIOLET
STRAINER

10
Drawing 9848 Rev 0
08-06-04
SECTION 2
COMMISSIONING
HANDOVER
INSTRUCTIONS

11
Drawing 9848 Rev 0
08-06-04 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 Validfrom
PurchasedFrom
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 operation
of Topline Electronics Ltd dosing equipment.
On
at
.........................................
Signed ....................
Unit 7 Crown Close, Hailsham, East Sussex, BN27 3JF
Telephone [phone]
.........................................

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.