TPS PoolChem User manual

PoolChem
Date:15-Jan-2013
Version:4.1
TPS Pty Ltd
ABN 30 009 773 371
Phone: [phone]
International: 61 732058027
Email: [email protected]
Web: www.tps.com.au

Congratulations !
The poolCHEM is a high quality, precision ORP and pH controller and is designed for maximum
reliability to give you many years of reliable service.
Despite its impressive list of features, the poolCHEM is a breeze to operate. This manual has been
designed to help you get started, and also contains some handy application tips. If at any stage you
require assistance, please contact either your local TPS representative or the TPS factory in
Brisbane.
The manual is divided into the following sections:
Section 1 – Introduction
The introduction includes a diagram of the poolCHEM unit and its connectors. Brief descriptions
of the controls are provided. Please check the Unpacking Information section to ensure that you
have received all accessories and any options you may have ordered.
Sections 9 to 31 – Tech Mode
The main section of the handbook provides complete details of set-up and operation of the
poolCHEM. This section is provided for experienced users, such as the installer or pool
technician.
Section 32 – Troubleshooting
The detailed troubleshooting section provides many useful hints and tips in case there is a problem
with the poolCHEM. This section will help solve most problems without the need to return the
unit to the factory for repair.
Section 33 – Appendices
Appendices containing background information and notes are provided for those users who wish
to learn more about the poolCHEM.
Section 34 – Warranty
The TPS Warranty conditions are detailed in this section. Also included are details on the
procedure to follow in case the poolCHEM unit needs to be returned for service or repair.
2

Contents
Section 1 - Introduction
1. Introduction 6
1.1 poolCHEM Display and Controls 6
1.2 poolCHEM Connectors 6
1.3 Menu Key 7
1.4 Function Keys 7
1.5 Enter Key 7
1.6 Help Key 7
1.7 Shift Key 7
1.8 Arrow Keys 7
1.9 80 Character Display 7
1.10 Unpacking Information 8
2. poolCHEM Menu Structure 10
3. Installation 12
3.1 Mounting the poolCHEM 12
3.2 Install the Sensor and Injection Tee 12
4. Peristaltic Pumps 13
4.1 Commissioning the Peristaltic Pumps 13
4.2 Lubricating the Pump Tubing 14
4.3 PumpFault Error Message 14
4.4 Replacing the Pump Tubing 15
5. Control Outputs 17
5.1 Output Cable for poolCHEM 17
5.2 Output Cable for poolCHEM-1 17
6. Limits Set-up 18
6.1 Setting the Control Limits 18
6.2 Control Direction 18
6.3 Control Sensitivity 20
6.4 Control Limit Set-up examples 21
6.4.1 Setting the Alarm Margins 23
6.4.2 Setting the Alarm Delay Times 24
6.4.3 Enabling and Disabling the Alarm Function 24
6.4.4 Procedure in event of Alarm function being tripped 25
6.4.5 External Alarm Siren 25
6.4.6 Alarm Set-up Examples 26
7. Control Set-up 27
7.1 Setting up the ORP control function 28
7.2 Setting up the pH control function 28
7.3 Selecting Automatic Control or Standby Modes 29
8. Quick-Dose Function 30
9. NoFlo Indication 31
9.1 NoFlo Indication Troubleshooting 31
10. Temperature Calibration 33
3

10.1 Temperature Calibration Procedure 33
10.2 Temperature Calibration Notes 33
10.3 Temperature Calibration Messages 33
11. pH Calibration 34
11.1 pH Calibration Procedure 34
11.2 pH Calibration Notes 36
11.3 pH Calibration Messages 37
12. ORP Calibration 38
12.1 Calibration Procedure 38
12.2 ORP Calibration Notes 40
12.3 ORP Calibration Messages 40
12.4 Action in case of Failed ORP Calibration 40
13. Password Security 41
13.1 Enabling the Password Security function. 41
13.2 Using the Password Security function 41
13.3 Changing the Password 42
13.4 Disabling the Password Security function 42
14. Good Laboratory Practices (GLP) 43
14.1 Recalling Calibration information on the display 43
14.2 Printing Calibration information to the RS232 Port 44
14.3 Recalling System information on the display 44
14.4 Printing System information to the RS232 Port 48
14.5 Failed Calibration 49
14.6 Instrument Serial Number 49
14.7 Additional GLP Features 49
15. Datalogging Function 50
15.1 Recording readings manually 50
15.2 Recording readings automatically 50
15.3 Recalling Readings from the Notepad 51
15.4 Erasing Records from the Notepad 53
15.5 Printing Records from the Notepad to the RS232 Port 53
16. RS232 Port 54
16.1 Setting the Baud Rate 54
16.2 Sending Readings to the RS232 Port 54
16.3 RS232 Configuration 54
16.4 Communication and Statistical Software 54
16.5 Commands 55
16.6 Data Format 56
16.7 GLP Data Format 57
16.8 Importing Data into Microsoft Excel 58
17. Setting the Clock 61
18. Selecting Chlorine or Bromine 62
19. Selecting pH Resolution 62
20. Emergency ShutOFF timer 63
20.1 Procedure in event of ShutOFF timer being tripped 63
4

20.2 Disabling the Emergency ShutOFF Timer 64
20.3 External Alarm Siren 64
21. Selecting Buffers for Auto Buffer Recognition 65
22. Resetting the poolCHEM 66
22.1 Resetting the Calibration information only 66
22.2 Resetting the Full System information 66
22.3 Factory Default System Settings 67
23. Instrument firmware version number 67
24. Troubleshooting 68
24.1 General Errors 68
24.2 ORP Troubleshooting 68
24.3 pH Troubleshooting 69
24.4 Temperature Troubleshooting 69
24.5 Pump Troubleshooting 69
25. Appendices 71
25.1 pH Electrode Fundamentals 71
25.1.1 Asymmetry of a pH Electrode 71
25.1.2 Slope of a pH Electrode 71
25.1.3 Temperature Compensation 73
25.2 poolCHEM Specifications 74
26. Warranty 76
5

1. Introduction
1.1 poolCHEM Display and Controls
1.2 poolCHEM Connectors
6

1.3 Menu Key
●Press the key to access the user-friendly menu system.
●Press the key to quit without saving changes when entering data.
1.4 Function Keys
●Press the to function keys to select desired options within the menu system.
●These keys perform the following function directly in normal display mode…
: Press to record readings into the Notepad. See section 15.
: Press to transmit current reading plus date and time to the RS232 port. See section 16.2.
●Press the to function keys to enter a password when the security function is enabled.
See sections Error: Reference source not found and 13.
1.5 Enter Key
●Press the key to accept default values or save changes when entering data.
1.6 Help Key
●Press the key to obtain context-sensitive help messages.
●Press the key to obtain details of alarm conditions when unit is beeping and reading(s) are
flashing.
1.7 Shift Key
●Press and hold the key while scrolling data with the and keys to speed up the
scrolling rate.
1.8 Arrow Keys
●Press the and keys to scroll values up and down when entering or displaying data.
●Press the and keys to move the cursor left and right when setting the calendar clock.
See section 17.
1.9 80 Character Display
●80 character alphanumeric display with user-friendly menu and context-sensitive help system.
●Tech mode shows ORP and pH data in large digits. Limits, control status and Temperature are
displayed in standard characters. The current time is also displayed. For example…
7

1.10 Unpacking Information
Standard poolCHEM Kit… Part No
1. poolCHEM Pool/Spa Controller 111113
2. Gel-filled Submersible pH Sensor, 2m cable 111230
3. ORP/Temperature Sensor, 2m Cable 111263
4. Inductive Pump Sensor 130102
5. pH4.00 Buffer, 200mL 121381
6. pH7.00 Buffer, 200mL 121387
7. ZoBell's ORP Calibration Solution, 200mL each of Part A and Part B 121309
8. Pool Injection Tee, for 2 sensors with 2 non-return valve injection points 117904
9. Dual Control Output Cable 130054
10. 24V DC Plug-Pack Power Supply 130106
11. poolCHEM Handbook 130050
poolCHEM-1 Kit…
1. poolCHEM-1 Pool/Spa Controller with 1 in-built peristaltic dosing pump 111114
2. Gel-filled Submersible pH Sensor, 2m cable 111230
3. ORP/Temperature Sensor, 2m Cable 111263
4. Inductive Pump Sensor 130102
5. pH4.00 Buffer, 200mL 121381
6. pH7.00 Buffer, 200mL 121387
7. ZoBell's ORP Calibration Solution, 200mL each of Part A and Part B 121309
8. Pool Injection Tee, for 2 sensors with 2 non-return valve injection points 117904
9. Peristaltic Pump Input Tube, 2m (one length supplied) 116358
10. Peristaltic Pump Output Tube, 2m (one length supplied) 116360
11. Tube weight for chemical drum 116354
12. Single Control Output Cable 130053
13. 24V DC Plug-Pack Power Supply 130106
14. poolCHEM Handbook 130050
poolCHEM-2 Kit…
1. poolCHEM-2 Pool/Spa Controller with 2 in-built peristaltic dosing pumps 111115
2. Gel-filled Submersible pH Sensor, 2m cable 111230
3. ORP/Temperature Sensor, 2m Cable 111263
4. Inductive Pump Sensor 130102
5. pH4.00 Buffer, 200mL 121381
6. pH7.00 Buffer, 200mL 121387
7. ZoBell's ORP Calibration Solution, 200mL each of Part A and Part B 121309
8. Pool Injection Tee, for 2 sensors with 2 non-return valve injection points 117904
9. Peristaltic Pump Input Tube, 2m (two lengths supplied) 116358
10. Peristaltic Pump Output Tube, 2m (two lengths supplied) 116360
11. Tube weight for chemical drum (two supplied) 116354
12. 24V DC Plug-Pack Power Supply 130106
13. poolCHEM Handbook 130050
Options that may have been ordered with your poolCHEM…
1. RS232 Interface Cable 130041
2. WinTPS Communication software for Windows 95, 98 and ME 130086
3. Alarm Siren, for high volume indication of Alarm or ShutOFF conditions 130101
Other spares…
1. Peristaltic Pump tube replacement assembly 116352
8

2. Syringe of Lubricant for Peristaltic Pump Tubing 130103
9

Sections 9 to 31 – Tech Mode
2. poolCHEM Menu Structure
A detailed breakdown of the menu system of the poolCHEM is shown below. This diagram
provides a quick reference for the menu functions available for the poolCHEM.
→
F1:Calibrate
→
F1:pH
F2:Temperature
F3:ORP
→
F2:Control
→
F1:Auto
or:
F1:Standby
F2:Quick Dose
F3:ORP
F4:pH
→
F3:Limits
→
F1:Set Limits
F2:Direction
F3:Sensitivity
→
F1:Fine
F2:Medium
F3:Coarse
F4:Alarms
→
F1:Enable
F2:Set Alarm Margins
F3:Set Alarm Delay Times
→
F4:Logger
→
F1:Recall
F2:Erase
→
F1:Erase All
F2:Erase Last
F3:Print
F4:Program
F5:Enable
or:
F5:Disable
→
F5:System
→
F1:Password
→
F1:Change Code
F3:Enable Security & Enter Code
or:
F3:Disable Security
F2:GLP
→
F1:Recall Cal.
F2:Print Cal.
F3:Recall Sys.
F4:Print Sys.
F3:Clock
F4:Baud
→
F1:300
F2:9600
F3:19200
10

Sections 9 to 31 – Tech Mode
F5:Setup
→
F1:Chemical
→
F1:Chlorine
F2:Bromine
F2:Resolution
→
F1:Low
F2:High
F3:ShutOFF
F4:Buffer
→
Select pH buffers
F5:Reset
→
F1:Calibration only
F2:Full System
11

Sections 9 to 31 – Tech Mode
3. Installation
3.1 Mounting the poolCHEM
The poolCHEM unit is pre-installed onto a convenient mounting panel. 6mm diameter holes are
located in each corner for mounting the panel. Use fasteners that are suitable for material to which
the panel is being mounted. The fasteners should be rated to at least 0.5kg each.
3.2 Install the Sensor and Injection Tee
Install the Sensor and Injection Tee as per the diagrams below. Use a suitable PVC joining
compound. The Tee is installed in the return line to the pool, as the pressure is low and the sensors
will only be exposed to clean, filtered water.
12

Sections 9 to 31 – Tech Mode
4. Peristaltic Pumps
This section is applicable to the poolCHEM-1 which is fitted with one peristaltic dosing pump, and
the poolCHEM-2 which is fitted with two peristaltic dosing pumps.
IMPORTANT INFORMATION REGARDING ACID
●Always use dilute Hydrochloric Acid.
●Add 5 Litres of Acid to 15 to 25 Litres of water.
●NEVER ADD WATER TO ACID
●Using concentrated acid may damage your equipment and void the warranty
4.1 Commissioning the Peristaltic Pumps
Commissioning is a simple 4 step process…
1. Connect the Input Tubing.
The input tubing is the semi-rigid tubing, part number 116358.
Connect this to the tube fitting on the LEFT side of the each pump.
The compression fitting makes it easy to connect the tubing
securely.
2. Connect the Chemical Drum Weight
The poolCHEM is supplied with a small plastic weight for each
pump. This weight is to be attached to the Chemical Drum end of the
suction tube, and ensures that the Input Tubing is always immersed in
solution.
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Sections 9 to 31 – Tech Mode
3. Connect the Output Tubing.
The output tubing is the softer flexible tubing, part number
116360. Connect this to the tube fitting on the RIGHT side of the
each pump. The compression fitting makes it easy to connect the
tubing securely.
Connect the other end of the output tubing to the injection
assembly, as discussed in section 3.2.
4. Test the pump operation.
Once the pumps have been connected and the tubing fitted, their operation should be checked.
TPS recommends that this be done by pumping from a container of fresh water in case any of
the fittings are leaking, avoiding the possibility of corrosive and/or dangerous chemical
spillage.
Use the Quick Dose function (see section 8) to test the pump operation. It only takes around 25
seconds to prime the pumps, so the Quick Dose time can be set to 1 minute.
4.2 Lubricating the Pump Tubing
The poolCHEM is shipped with the correct lubrication on the peristaltic pump tubing. This
lubrication should be re-applied every year. Suitable Silicon lubricant is available from TPS in a
3mL syringe (part no 130103).
To lubricate the pump tubing…
1. Remove the pump tubing, as per the details in section 4.4.
2. Smear a small quantity of Silicon grease all around the tube. A thin film is all that is required.
NOTE
DO NOT use petroleum based oil or lubricants, as these will cause the Santoprene rubber to perish.
Use only Silicon based lubricant.
4.3 PumpFault Error Message
The poolCHEM monitors the dosing pump current usage and will detect problems with the pump
before damage can occur. If excess current is detected the unit will beep and display PumpFault in
the status window for ORP or pH. No further dosing of the chemical will occur and steps should be
taken to eliminate the fault.
Turn the unit OFF and check the pump tubing for kinks and ensure that the output tube is not
obstructed. A worn / faulty gearbox and motor can cause high current usage and will require
replacement.
The error message will be reset by turning the unit off or by pressing the Menu key. The fault will
re-occur the next time dosing is required if the cause has not been eliminated.
14

Sections 9 to 31 – Tech Mode
4.4 Replacing the Pump Tubing
Replace the Pump Tubing if it gets worn, begins to leak, or pumping volume is reduced. The Pump
Tubing may be replaced every year as a precautionary measure.
To remove the old Pump Tube…
1
2
3
4
Disconnect the power
supply from the
poolCHEM unit.
Remove the Input and
Output tubing from the
compression fittings. This
is simply a reversal of the
procedure detailed in
section 4.1.
Remove the see-through
protector plate on the front
of the pump.
Turn the roller holder so
that the rollers are in a
horizontal line. Pull the left
hand side compression
fitting from its seat. Begin
turning the roller holder
clockwise, so that the roller
holder acts as a lever
which pulls the pump tube
out as it turns. After
approximately 3/4 of a
turn, the right hand side
compression fitting can be
pulled out.
The old pump tube has
now been removed.
To fit a new Pump Tube…
1
2
3
4
Turn the roller holder so
that the rollers are in a
horizontal line. Push the
left hand side compression
fitting into its seat, round
side facing in. Begin
turning the roller holder
clockwise, so that the roller
holder acts as a lever
which pulls the pump tube
in as it turns. After
approximately 3/4 of a
turn, the right hand side
compression fitting can be
pushed in, round facing in.
The new pump tube has
now been fitted.
Replace the see-through
protector plate on the front
of the pump. This is
essential to protect the
rollers and tube from dirt
and moisture.
Re-fit the Input and Output
tubing to the compression
fittings. See the procedure
detailed in section 4.1.
The poolCHEM unit’s
power supply can now be
re-connected.
15

Sections 9 to 31 – Tech Mode
16

Sections 9 to 31 – Tech Mode
5. Control Outputs
This section is applicable to the poolCHEM (part number 111113), which is supplied with a
two-way control output cable (part number 130054) and the poolCHEM-1 (part number 111114),
which is supplied with a one-way control output cable (part number 130053).
5.1 Output Cable for poolCHEM
Plug the two-way Control Output cable (part number 130054) )into the Control Output socket.
The two-way control output cable connections for the poolCHEM are as follows…
Colour
Function
Black
ORP Common
Red
ORP Output
Blue
pH Common
White
pH Output
The control outputs on the poolCHEM are 24V DC at low current. They are provided to enable the
poolCHEM to switch external relays which in turn switch on the relevant pumps. Relays should be
selected according to the voltage and current loading requirements of the pumps to be used.
Any mains power wiring to the relays and pumps must be carried out by a qualified electrician.
5.2 Output Cable for poolCHEM-1
Plug the single Control Output cable (part number 130053) )into the Control Output socket. The
single control output cable connections for the poolCHEM-1 are as follows…
Colour
Function
Black
Output Common
Red
+24V DC Output
The control output on the poolCHEM-1 is 24V DC at low current. It is provided to enable the
poolCHEM-1 to switch an external relay which in turn switches on the relevant pump. A suitable
relays should be selected according to the voltage and current loading requirements of the pump to
be used.
Any mains power wiring to the relays and pumps must be carried out by a qualified electrician.
17

Sections 9 to 31 – Tech Mode
6. Limits Set-up
The limits must be set to the required values before attempting to use the poolCHEM for automatic
control.
6.1 Setting the Control Limits
1. Select the Limits menu ( →F3:Limits).
2. Select F1:Set limits from the menu. The current ORP limit is displayed. For example…
Enter ORP Limit : 720mV
Present ORP Reading = 750mV
Use the and keys to set the ORP limit. The allowable range is 0 to 999 mV.
Press to save the new value, or press to quit without saving the changes.
3. The current pH limit is now displayed. For example…
Enter pH Limit : 7.60pH
Present pH Reading = 7.80pH
Use the and keys to set the pH limit. The allowable range is 0.00 to 14.00 pH.
Press to save the new value, or press to quit without saving the changes.
4. The control limits are now set to the required values.
6.2 Control Direction
The poolCHEM is factory set to add sanitiser when the ORP reading is lower than the limit, and to
add acid when the pH reading is higher than the limit. To change these settings…
1. Select the Limits menu ( →F3:Limits).
2. Select F2:Direction from the menu. The following screen will now be displayed…
Select ORP Direction
→F1:Add when LOW F2:Add when HIGH
The arrow indicates the current selection.
Press to add sanitiser when the ORP reading is lower than the limit.
Press to add freshwater when the ORP reading is higher than the limit (not normally
applicable to swimming pool applications).
3. The poolCHEM confirms the selection and then goes on to select the pH direction…
Select pH Direction
F1:Add when LOW →F2:Add when HIGH
The arrow indicates the current selection.
Press to add alkali (eg. Soda Ash) when the pH reading is lower than the limit.
Press to add acid when the pH reading is higher than the limit.
18

Sections 9 to 31 – Tech Mode
4. The poolCHEM confirms the selection before going back to the Limits menu.
19

Sections 9 to 31 – Tech Mode
6.3 Control Sensitivity
To stop the pumps being rapidly switched on and off, the poolCHEM operates the pumps for a
preset band around the control limit. Examples to illustrate this are given at the end of this section.
To select the Control Sensitivity…
1. Select the Limits menu ( →F3:Limits).
2. Select F3:Sensitivity from the menu. The following screen will now be displayed…
Select ORP Sensitivity
F1:Fine →F2:Medium F3:Coarse
The arrow indicates the current selection.
Press to select Fine Sensitivity. The control band will be 10 mV.
Press to select Medium Sensitivity. The control band will be 20 mV.
Press to select Coarse Sensitivity. The control band will be 30 mV.
3. The poolCHEM confirms the selection and then goes on to select the pH Sensitivity…
Select pH Sensitivity
F1:Fine →F2:Medium F3:Coarse
The arrow indicates the current selection.
Press to select Fine Sensitivity. The control band will be 0.10 pH.
Press to select Medium Sensitivity. The control band will be 0.20 pH.
Press to select Coarse Sensitivity. The control band will be 0.30 pH.
4. The poolCHEM confirms the selection before going back to the Limits menu.
20