Transcript
AQUA BALANCE Pure Comfort System Installation & Operation Manual
AQUA BALANCE PURE COMFORT SYSTEM Installation Manual
Table of Contents 1.0 System Introduction…………………………………..
1.0
1.1
Preface……………………………………..
1.1
1.2
System Features…………………………..
1.2
1.3
Pre-Installation…………………………….
1.3
1.4
Sodium Chloride Addition Chart…………
1.4
Specifications………………………………………….
2.1
Unit Specifications…………………………
2.1
3.0 Installation………………………………………………
3.1
2.0
2.1
3.1
Mounting Pure Comfort Backplate(110VAC) 3.1
3.2
Wiring for 110VAC………………………….
3.2
3.3
Mounting Disconnect Box (220VAC Only).
3.3
3.4
Mounting Pure Comfort Backplate(220VAC) 3.4
3.5
Wiring for 220VAC…………………………..
3.5
3.6
Mounting Pure Comfort Cell Housing…….
3.6
3.7
Assembling Pure Comfort Cell Housing …
3.7
3.8
Plumbing Configuration…………………….
3.8
3.9
Plumbing Pure Comfort Cell Housing ……
3.9
3.10
Plumbing Sample Cell & Rectifier…………
3.10
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1.0 System Introduction 1.1 Preface This manual presents the installation of the Aqua Balance Pure Comfort System. This manual applies in its entirety to current units. Guidelines are suggestions for assembling and installing the Aqua Balance Pure Comfort System. However, the actual physical environment will dictate how the installation is performed. Please refer to the Pre-Installation Checklist to assist you in preparing your new account for the Aqua Balance Pure Comfort System Warning: These instructions are for use by Ecolab Employees who have the Aqua Balance Pure Comfort System Certification ONLY. Local codes must be followed when installing Aqua Balance Pure Comfort System and all electrical work should be performed by a certified electrician at the expense of the customer.
1.2 System Features • •
•
•
Onsite chlorine generation A “Paddle” flow switch will be mounted at the bottom of the cell and wired to the neutral at the contactor in the main power supply box to interrupt power should flow stop. Aqua Balance Pure Comfort Systems have 0-100% chlorine production settings, using the potentiometer on the main power box. The Aqua Balance Pure Comfort System is equipped with a high voltage detection system that will shut the system down once the sodium chloride lever drops below 3,500 ppm.
Power Supply Box
Transformer
Rectifier
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1.3 Pre-Installation & Installation Checklists 7 to 10 Days in advance ___ Drain pool and or spa if Bromine was ever a sanitizer in the water ___ Install or confirm working phone line for AK2100 Controller – must be analog line and not digital ___ Recommend Sand Change for both pool and spa ___ Place Equipment Order – see faxed equipment order sheet received from Flat Fee Administrator or ABSS with completed survey for part numbers Order Customer Complete Test kit and Saline Kit Order TM Complete test kit, salinity tester and phosphate test kit ___ Schedule ECOLAB Service Manager if needed ___ Begin chemical balance or drain and refill pool & spa water ___ Test phosphate level in pool(s) and spa(s). Must be 125 ppb or less. ___ Confirm sodium chloride has been ordered ___ Locate pump room wall space that will accommodate board dimensions *Note: All units shipped for vertical installation unless specified horizontal Unit dimensions are 16” L x 42” H. *Note: Cell housing MUST be mounted within 4ft of rectifier box ___ Confirm account has scheduled an ELECTRICIAN for following requirements: *Note: 110VAC systems require dedicated “clean” GFI for install *Note: 110VAC systems come with standard 110VAC plug *Note: 220VAC systems require electrician to install Disconnect Box at customer’s expense *Note: 220VAC systems require UL listed water tight conduit *Note: 12 gauge wire required for 2.5 – 10 lb unit 10 gauge wires required for 15 lb unit 8 gauge wires required for 25 lb unit 24 to 48 hours in advance ___ Confirm electrical is installed and working ___ Confirm analog phone line is in working order ___ Confirm water is balanced *See Chemistry section for correct water parameters ___ Confirm sodium chloride is on-site and being added *See Pure Comfort I/O Manual or your Guidebook for sodium chloride chart ___ Inventory equipment to be installed for any ___ Call RMC with any installation questions at 888-271-7665 ___ Confirm tools needed to install * Appropriate wall anchors for your install should be included with installation kit
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See DAY OF INSTALL to confirm necessary tool Day of Install – You will need these items Telephone w/phone line to test controller’s phone line Tool Box - to include tape measure, level, utility knife, screw drivers, hammer, adjustable wrench or channel locks and side cutters Water tight conduit (for 220VAC units only) Cable ties Teflon Tape Drill Volt Meter Heat Gun ¼” NPT Tap 7/16” Tap 3/4” NPT Tap 29/32” Drill Bit Complete Test Kit for pool and spa water Salinity Test Kit or TRACER Digital Tester For 25 lb. units – PVC cable saw, sched. 40 or 80 PVC pipe and PVC primer and glue
Note: This manual is for all Aqua Balance Pure Comfort Systems. Aqua Balance Pure Comfort Systems 3.5, 7.5, and 10 lbs-25 lbs are a 220VAC system and may require a disconnect box. If local code allows for ‘line of sight’ to the circuit breaker panel a disconnect box may not be required. Aqua Balance Pure Comfort Systems less than 15 lbs require a dedicated 20amp circuit breaker, a 15 lb system requires a dedicated 30amp circuit breaker and 25 lb system requires dedicated 40amp circuit breaker.
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1.4 Sodium Chloride Addition Chart Pounds of Sodium Chloride Needed To Be Added To Achieve 5000 PPM Gallons of Pool or Spa Water 1000
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
24000
26000
28000
30000
0
42
83
167
250
333
417
500
583
666
750
833
916
1000
1083
1166
1250
200
40
80
160
240
320
400
480
560
640
720
800
880
960
1040
1120
1200
400
38
77
153
230
307
383
460
537
613
690
766
843
920
996
1073
1150
600
37
73
147
220
293
367
440
513
587
660
733
806
880
953
1026
1100
800
35
70
140
210
280
350
420
490
560
630
700
770
840
910
980
1050
Sodium Chloride PPM Level
1000
33
67
133
200
267
333
400
467
533
600
666
733
800
866
933
1000
1200
32
63
127
190
253
317
380
443
507
570
633
696
760
823
886
950
1400
30
60
120
180
240
300
360
420
480
540
600
660
720
780
840
900
1600
28
57
113
170
227
283
340
397
453
510
567
623
680
736
793
850
1800
27
53
107
160
213
267
320
373
427
480
533
587
640
693
746
800
2000
25
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
2200
23
47
93
140
187
233
280
327
373
420
467
513
560
606
653
700
2400
22
43
87
130
173
217
260
303
347
390
433
477
520
563
606
650
2600
20
40
80
120
160
200
240
280
320
360
400
440
480
520
560
600
2800
18
37
73
110
147
183
220
257
293
330
367
403
440
477
513
550
3000
17
33
67
100
133
167
200
233
267
300
333
367
400
433
467
500
3200
15
30
60
90
120
150
180
210
240
270
300
330
360
390
420
450
3400
13
27
53
80
107
133
160
187
213
240
267
293
320
347
373
400
3600
12
23
47
70
93
117
140
163
187
210
233
257
280
303
327
350
3800
10
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
4000
8
17
33
50
67
83
100
117
133
150
167
183
200
217
233
250
4200
7
13
27
40
53
67
80
93
107
120
133
147
160
173
187
200
4400
5
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
4600
3
7
13
20
27
33
40
47
53
60
67
73
80
87
93
100
4800
2
3
7
10
13
17
20
23
27
30
33
37
40
43
47
50
5000
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
FORMULA:
gallons X 8.331 X .005 = lbs. of sodium chloride
NOTE: .005 = 5,000 ppm so you can substitute desired change if not 5,000 ppm
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2.0 Specifications 2.1 Unit Specifications AQUA BALANCE PURE COMFORT SYSTEM TECHNICAL SPECIFICATIONS
Fuse Size
Typical output secondary DC Amps
Typical output secondary DC Volts
Max Equivalent Chlorine Production
Cell Stack
Cell Stack Housing
8.3 @ 110VAC
15 Amp Fuse
50
4.5
2.5 lbs/day
8X1
3IN
3.5
5.5 @ 220VAC
12 Amp Fuse
70
4.5
3.5 lbs/day
10X1
3IN
5.0
8.0 @ 110VAC
15 Amp Fuse
25
16
5.0 lbs/day
5X4
6IN
7.5
5.5 @ 220VAC
15 Amp Fuse
37.5
16
7.0 lbs/day
6X4
6IN
10.0
7.5 @ 220VAC
15 Amp Fuse
50
16
10.0 lbs/day
8X4
6IN
15.0
11.0 @ 220VAC
25 Amp Fuse
75
16
15.0 lbs/day
11X4
6IN
25.0
18.0 @ 220VAC
30 Amp Fuse
125
16
25.0 lbs/day
17X4
8IN
Model
Typical input Primary Amps
2.5
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3.0 Installation Note: Not every pool and spa pump room you encounter is the same. So, it is imperative that you become familiar with the pump room and plan out where the AK2100 Controller panel, Pure Comfort System Backplate and Pure Comfort System Cell Stack Housing will be mounted. As part of planning for the installation you will need to consider location of the unit, types of tools, wall anchors, and other hardware needed to ensure a problem free installation (see Installation Checklist).
3.1 Installation and Mounting of Pure Comfort System Backplate 110VAC Safety Note: Wear protective work gloves prior to handling the Aqua Balance Pure Comfort Back Plate. The Aqua Balance Pure Comfort System may have sharp edges.
Mounting Pure Comfort System Backplate for 110VAC Aqua Balance Pure Comfort System
1. Locate a space on the wall in the pump room that will accommodate the dimensions of 16L” X 42H” on the vertically mounted Pure Comfort System Backplate. A horizontal system is available but must be pre-ordered that way and will require space of 42L” X 16H”. The 15 lb. and 25 lb. Pure Comfort Systems are available as a horizontal system ONLY. In addition, the dimensions of the backplate are a little larger at 45L” X 20H”. Keep in mind that the cell housing must be mounted within 4 feet of the rectifier box on the AQUA BALANCE PURE COMFORT SYSTEM -Installation Manual
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Pure Comfort System Backplate to ensure that the power cables can easily reach the Pure Comfort System Cell Stack Housing. In addition, the Pure Comfort System Backplate must be mounted within 4 feet of the AK2100 controller panel to ensure that the cord can easily reach the chlorine electrical outlet on the panel. The Pure Comfort System Backplate and Pure Comfort System Cell Housing may be mounted on separate walls (i.e. corner of the pump room) but must remain within the specified 4 feet. (Contact the Remote Monitoring Center if the 4 foot restriction can not be met).
2. Mark and drill hole locations for the metal Z-bracket. a. DRYWALL INSTALLATION - Locate studs to sufficiently hold the weight of the Pure Comfort System BackPlate. At least one side of the board needs to be on the stud the other can be mounted with drywall anchors. DO NOT TRY TO MOUNT THE BOARD SOLELY USING DRYWALL ANCHORS DUE TO THE WEIGHT AQUA BALANCE PURE COMFORT b. CONCRETE INSTALLATION - Mark on the wall each location in which you will drill holes to insert concrete wall anchors. 3. Attach the metal Z-bracket to the wall. Be sure to use to level the metal Zbracket before final torque of mounting screws. a. For 2.5 -10 lb. systems use 4 mounting screws 4. Hang Aqua Balance Pure Comfort System on to the metal Z-bracket. Verify once again that the unit is level. 5. Locate and drill the bottom two holes that will secure the board to the wall. Be sure to use wall anchors on both concrete and drywall installations.
3.2 Wiring for 110VAC Systems 110-VAC SYSTEMS These units are pre-wired at the factory with a standard plug for 110VAC wall outlet. If not already there, account must have a certified electrician install a dedicated GFI outlet for the controller. These units come equipped with an 110VAC plug that powers the contactor coil and can be plugged into the Aqua Balance Controller chlorine electrical outlet. DO NOT CONNECT AQUA BALANCE PURE COMFORT POWER SUPPLY BOX TO THE CONTROLLER WITH AN EXTENSION CORD. DUE TO LOCAL CODE VIOLATIONS. The optional cords are available to order as follows: 20’ Power Cord w/Molded Plug (3-prong) Part Number # 83260060 50’ Power Cord w/Molded Plug (3-prong) Part Number # 83260083 Yellow Wire Nut 12-18 gauge – pkg. of 20 Part Number # 92631001 1. Plug Aqua Balance Pure Comfort System marked “main power” to the installed dedicated GFI outlet 2. Plug second cord labeled “ORP Controller” into the chlorine feed on the Aqua Balance Controller. AQUA BALANCE PURE COMFORT SYSTEM -Installation Manual
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3.3 Installation and Mounting of Pure Comfort Backplate 220VAC MOUNTING POWER SUPPLY AND DISCONNECT BOX
1. Locate a space on the wall in the pump room that will accommodate the dimensions of 16L” X 42H” for the vertically mounted Pure Comfort System Back Plate. A horizontal system is available but must be pre-ordered and will require space of 42L” X 16H”. The 15 lb. and 25 lb. Pure Comfort Systems are available as a horizontal system ONLY. In addition, the dimensions of the backplate are a little larger at 45L” X 20H”. Keep in mind that the cell housing must be mounted within 4 feet of the rectifier box on the Pure Comfort System Backplate to ensure that the power cables can easily reach the cell. In addition, the Pure Comfort system power must be mounted within 4 feet of the AK2100 controller panel to ensure that the cord can easily reach the chlorine electrical outlet on the panel. The Pure Comfort System Backplate and Cell Housing may be mounted on separate walls (i.e. corner of the pump room) but must remain within the specified 4 feet. 2. Mark and drill hole locations for the metal Z-bracket. a. DRYWALL INSTALLATION-Locate studs to sufficiently hold the weight of the Pure Comfort System Backplate. At least one side of the board needs to be on the stud the other can be mounted with drywall anchors. DO NOT TRY TO MOUNT THE BOARD SOLELY USING DRYWALL ANCHORS DUE TO THE WEIGHT AQUA BALANCE PURE COMFORT SYSTEM. b. CONCRETE INSTALLATION-Mark on the wall each location in which you will drill holes to insert concrete wall anchors. 3. Attach the sheet metal Z-bracket to the wall. Be sure to use to level the sheet metal Z-bracket before final torque of mounting screws. a. For 15 & 25 lb. systems use 5 mounting screws 4. Hang Aqua Balance Pure Comfort System on to the metal Z-bracket. Verify once again that the unit is level. 5. Locate and drill the bottom two holes that will secure the board to the wall. Be sure to use wall anchors on both concrete and drywall installations
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3.4 Mounting Disconnect Box (220VAC Only) 1. You will need to locate wall space near the Pure Comfort System Backplate hang disconnect box. This box will be wired to the Aqua Balance Pure Comfort System Backplate to allow for the power to be turned off allowing during troubleshooting and repairs. Follow all local codes on distant for in which the box needs to be located, if breaker panel is within ‘line of sight’ disconnect box may not be required by local code.
Note: When using 220VAC Aqua Balance Pure Comfort System it must be wired to a dedicated circuit breaker. Failure to do so could result in damage to the Pure Comfort System. 220VAC Aqua Balance Pure Comfort Systems under 15 lb unit require a dedicated 20amp circuit breaker, 15 lb units require a dedicated 30amp circuit breaker and 25 lb units require a dedicated 40amp circuit breaker.
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3.5 WIRING PURE COMFORT SYSTEM BACKPLATE(220VAC)
220VAC SYSTEMS: Aqua Balance Pure Comfort System 3.5lb, 7.5lb and 10lb-25lb require all wiring encased in watertight conduit must be UL listed. Run a red, black and green wire from the disconnect box to the power supply board (see table below for correct gauge of wire). Check with local code for power pump to breaker requirements. Wire Gauge Sizing For 220VAC Systems Wire Model Voltage Gauge 3.5,7.5,10 220VAC 12
1. 2. 3. 4. 5.
15
220VAC
10
25
220VAC
8
Note: Aqua Balance Pure Comfort System 3.5lb, 7.5lb and 10lb-25lb come equipped with an 110VAC 5 foot cord to connect to Aqua Balance Controller Chlorine feed electrical outlet. Connect the red and black wires to the top lugs of fuse the disconnect box. Connect the green wire to the grounding pole or use a wire nut. Connect a red and a black wire to the bottom leads in the disconnect box and run these to the Aqua Balance Pure Comfort System control box. Connect the red and black wires to the appropriate wire nuts at the top of the contactor. (Labeled lines with wire nuts are provided) Connect ground wire at wire nut provided.
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3.6 Mounting Pure Comfort Cell Stack & Housing
1. Install the wall mount bracket for the Aqua Balance Pure Comfort System Cell Stack Housing. The wall mount must be mounted directly into a wall stud, unless it is a concrete wall, to ensure that it is level. 2. Clamp the cell onto the mounting cell. Connect the Pure Comfort Cell Stock Housing flow switch to the Power Supply box. This will allow for the system to shut down and it will not produce chlorine in a low flow situation. Failure to wire the flow switch will cause the system not to produce chlorine. 3. Connect the red wire on the flow switch to the red wire in the Pure Comfort Power Supply Box. 4. Connect the black wire on the flow switch to the black wire in the Pure Comfort Power Supply Box. 5. Connect the power cables from the rectifier box to the lugs at the top of the cell stack housing.
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3.7 Pure Comfort Cell Stack Assembly For the ease of assembly, it is recommended that,you fully assemble all fittings to the Aqua Balance Pure Comfort Cell Stack Housing prior to fastening it onto the clamps.
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3.8 Pure Comfort Plumbing configuration
PRE-FILTER INSTALLATION
POST FILTER INSTALLATION
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3.9 Plumbing Pure Comfort Cell Housing 1. Drill 29/32” hole on the plumbing coming directly after the filter. This will supply water to the inlet side of the Aqua Balance Pure Comfort System Cell. NOTE: You should plumb the inlet post-filter if you have surveyed the filter to be in good operating condition with the proper flow rate for the system allowing the minimum of 3gpm flow through the Aqua Balance Pure Comfort Cell. This will allow less cleaning of the Aqua Balance Pure Comfort Cell inline strainer because you are taking filtered water through the Aqua Balance Pure Comfort System Cell. OPTION: You may plumb the inlet pre-filter (coming directly out of the top of the circulation pump on the pressure side of the system) if you are concerned about getting proper flow through the mineral cell because of the filter. Please note that because this is pre-filtered water, your customers must be instructed to clean the inline strainer filter located on the inlet side of the Aqua Balance Pure Comfort System Cell Stack after each filter backwash. Failure to clean this strainer will eventually result in low flow into the flow cell which may lead to low chlorine in the body of water. 2. Tap both inlet and outlet holes with 3/4” NPT. 3. Teflon tape and thread in ¾”NPT X 1” Hose Barb. 4. Measure and cut 1” tubing to go from the inlet (top of pump) to the bottom (inlet) of the Aqua Balance Pure Comfort System Cell. 5. Measure and cut 1” tubing to go from the outlet (after the heater and flow meter) to the top (outlet) of the Aqua Balance Pure Comfort System Cell. 6. Install 1” tubing to and from the Aqua Balance Pure Comfort System Cell (see diagram)
Note: The 25 lb. Pure Comfort System Cell requires rigid 1.5” PVC piping for the inlet and outlet lines (instead of the 1” flex tubing). Refer to local code on the correct PVC grade needed (i.e. Schedule 40 or Schedule 80). You should contact the RMC at 888-271-7665 to order the 1.5” flow switch and filter screen assembly for the 25 lb. Pure Comfort System Cell.
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3.10 Plumbing Sample Cell & Pure Comfort Rectifier We need flow through the sample cell for the probes to read ORP and pH levels. Also, with the Aqua Balance Pure Comfort System, we need flow through the rectifier to cool it. Steps 1-5 are for new installs. If you are converting an existing Aqua Balance account to the Aqua Balance Pure Comfort System proceed to step 6. 1. Drill a 7/16” hole on the post filter side. This will be used to get water to the inlet side of the sample cell. 2. Drill a second 7/16” hole on the suction side of the pump. This will be used to pull water from the outlet side of the sample cell. 3. Tap both 7/16” holes with a ¼” for the ¼”NPT to ½”compression fitting 4. Teflon tape and thread in the connector for both ¼” NPT tapped holes. 5. Install ball valves, Jaco Fittings and ¼” to ½” compression nipple on to the 90” street elbow. Be sure that all threaded connections have Teflon tape applied to prevent leaks. 6. Connect the hose in the follow manner. Connect 1/2” flexible tubing from the prefilter Jaco fitting to the inlet side of the Aqua Balance AK2100 Controller sample cell (the inlet is the side in which the Flow Switch Magnet and Filter Screen are Located).
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7. Connect second 1/2” flexible tubing from the outlet of the Aqua Balance AK2100 sample cell to the Jaco fitting on the suction of the pump. 8. Connect 3/8” flexible tubing from the tee on the inlet side of the Aqua Balance AK2100 sample cell to one of the rectifier cooling connectors on the bottom of the Pure Comfort Rectifier Box #3 (Flow direction is not critical through the rectifier). 9. Connect 3/8” flexible tubing from the tee on the outlet side of the Aqua Balance AK2100 sample cell to the other rectifier connector on the bottom of the Pure Comfort Rectifier Box.
Rectifier Cooling Line Connection Points
Completing install 1. Testing VoltageAfter installation is complete turn on power and test all voltage to the Aqua Balance Pure Comfort System unit. Also note Aqua Balance controller must be in a feed cycle in order for voltage to be going to contactor coil If no voltage can be detected refer to the Aqua Balance Pure Comfort System troubleshooting guide included with the system 2. Balancing flow through flow cellONCE CIRCULATION SYSTEM IS TURNED BACK ON OPEN THE BALL VALVE LOCATED AT THE BOTTOM OF THE FLOW CELL. IF WATER COMES OUT THERE IS CORRECT CIRCULATION THROUGH THE FLOW CELL. IF NO WATER COMES UP RESTRICT THE OUTLET OF THE FLOW CELL UNTIL WATER DOES COME OUT. FAILURE TO DO SO WILL RESULT IN WATER BALANCING ISSUES AND DAMAGE TO THE ORP AND pH PROBES. AQUA BALANCE PURE COMFORT SYSTEM -Installation Manual
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POOL & SPA (For AK2100-S and AK2100-D) Installation & Operation Manual
Retain this manual for installation, operation, and servicing information.
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Contents 1.0 System Introduction………………………………………………………………1-1 1.1 Preface ...........................................................................................................................1-1 1.2 System Features ...........................................................................................................1-1 1.3 Safety .............................................................................................................................1-1 1.4 Principle of Operation ..................................................................................................1-2
2.0 Specifications………………………………………………………………...……2-1 2.1 Control Board Assembly - AK2100-D ........................................................................ 2-1 2.1.1 Dimensions .................................................................................................... 2-1 2.1.2 Controller ........................................................................................................ 2-1 2.1.3 Acid Pump ...................................................................................................... 2-2 2.1.4 Wet Cell............................................................................................................ 2-2 2.2 Utilities ...........................................................................................................................2-2 2.2.1 Electrical ......................................................................................................... 2-2 2.2.2 Phone line ....................................................................................................... 2-2 2.2.3 Water Supplies ............................................................................................... 2-2
3.0 Installation………………………………………………………………………….3-1 3.1 Preplanning the Installation ........................................................................................3-1 3.2 Controller Installation ................................................................................................. 3-1 3.3 Equipment Installation Instructions .......................................................................... 3-3 3.3.1 Plumbing ........................................................................................................ 3-3 3.3.2 Wet Cell ........................................................................................................... 3-3 3.4 Instructions………. .......................................................................................................... 3-4
4.0 Set-up and Operation ……………………………………………………………4-1 4.1 System Checks ............................................................................................................ 4-1 4.1.1 Probe Response ............................................................................................ 4-1 4.1.2 Checking Relays ............................................................................................ 4-1 4.2 Calibration and Setpoints ........................................................................................... 4-1 4.3 Clearing Controller Overfeeds ................................................................................... 4-2
5.0 Maintenance………………………………………………………………………..5-1 5.1 Replacing the Acid Pump Tubing ............................................................................. 5-1 5.2 Probe Calibration Procedures ................................................................................... 5-2 5.3 Probe Cleaning Procedures ...................................................................................... 5-2
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6.0 Troubleshooting…………………………………………………………………..5-1 6.1 AK2100-D/AK2100-S Troubleshooting Chart ............................................................. 6-1 6.3 Chlorine is high even though Pure Comfort hasn’t fed ............................................. 6-1 6.4 Pure Comfort feeds but ORP doesn’t increase .......................................................... 6-1 6.5 ORP and pH reading on controller don’t match test kit results of pool water ………..…6.1 6.6 High pH readings and low ORP readings and feeders aren’t feeding ………………….. 6-1 6.7 pH is high in water even though muriatic acid pump is operating . …………………... . 6-1 6.8 pH is high in water and peristaltic pump won’t run ............................................................6-1 6.9 Pure Comfort isn’t able to keep up with chlorine demand ..................................................6-1 6.10 ORP probe reads 0 ...................................................................................................... 6-1 6.11 pH level consistently falls below set point ................................................................ 6-1 6.12 pH probes reads 4.22 or 9.77 ...................................................................................... 6-2 6.13 ORP an pH readings on controller are erratic ........................................................... 6-2 6.14 Chlorine level in pool water is high even though the controller is reading correct values .............................................................................................6-2 6.15 pH an PPM readings at the wet cell don’t match pH and ORP readings on controller faceplate .................................................................... 6-2 6.16 Controller display is blank ...........................................................................................6-2 6.17 Controller is in alarm but the account hasn’t received a call from the Remote Monitoring Center ............................................................................... 6-2
7.0 Replacement Parts …………………………………………………………7-1
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1.0 System Introduct ion
1.1 Preface This manual has been written and illustrated to present the basic installation, operation, and servicing instructions of the control board and feeder assembly for the pool/spa program. This manual applies to current units. Guidelines will be suggested in reference to the preferred method of installation; however, the variety of equipment and the surrounding environment will dictate the actual installation of the pool and spa equipment. WARNING: These installation, operation, and servicing instructions are for use by qualified personnel only. The installation must be made in accordance with local plumbing and electrical codes.
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1.2 System Features The control board features a multitasking controller capable of communicating with a personal computer (via a direct connection with a modem or serial cable), controlling various equipment including the Pure Comfort and acid pump, making measurements including pH, ORP, flow and more. The control board also contains a wet cell for housing the pH and ORP probes and flow sensor. It also has the acid pump used for pH control. The control board consists of the following components: • AK2100-D controller for two bodies of water or the AK2100-S controller for one body of water. • Wet Cell with flow sensor and plumbing components • Model D-10 peristaltic pump for liquid acid feed. • pH Probe • ORP Probe
1.3 Safety 1. The AK2100-D and AK2100-S are a Class 1 product for protection against electric shock and also a Type 1 product with regard to disconnection of the control circuits. 2. READ AND FOLLOW ALL INSTRUCTIONS i. WARNING – Do not permit anyone untrained or under the age of 18 to use this product. 4. WARNING – Unit must be properly connected to earth ground. 3. WARNING – Never service unit with power applied, always turn off main circuit breaker to unit and all equipment when servicing. 4. WARNING – NEVER APPLY POWER WHEN SAFETY SHEILD IS NOT IN PLACE. 5. WARNING – Risk of Electric Shock. Connect only to a grounding type receptacle protected by a ground fault circuit interrupter (GFCI). Contact a qualified electrician if you cannot verify that the receptacle is protected by a GFCI. 6. WARNING – To reduce the risk of electric shock, do not use extension cord to connect unit to electric supply; provide a properly located GFCI outlet. FCC REGISTRATION TYPE OF SERVICE: The AK2100-D and AK2100-S are designed to be used on standard device telephone lines. They connect to the telephone by means of a standard jack called the USOC RJ11C (or USON FJ45S). Connection to telephone company provided coin service is subject to state tariffs. Upon request of the telephone company, provide the FCC registration number and the ringer equivalence number (REN) of the equipment which is connected to your line; both of these items are listed on the equipment label. The sum of all REN’s on your telephone lines should be less than five in order to assure proper service from the telephone company. In some cases, a sum of five may not be usable on a given line. DANGER – DO NOT MIX CHEMICALS! AQUA BALANCE PURE COMFORT SYSTEM -Installation Manual
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1.4 Principle of Operation The theory of operation of the system involves the automated control of pool and spa water for the proper pH and chlorine (specifically HOCl) levels. In order for the pool or spa to have these proper levels, the pH of the water must be controlled between 7.4 – 7.7 and be constant. The HOCl can be controlled when the pH is constant. The HOCl concentration is measured by ORP (oxidation-reduction potential) and is a relative number depending upon the active HOCl concentration. The active HOCl concentration is dependent on pH. Essentially the disinfection process in a pool or spa can be controlled by controlling pH and the ORP of the body of water. The mv reading associated with the proper HOCl level is controlled between 650 mv – 800 mv; the set point being the ORP reading associated with the free available reading as measured by the chlorine titration test. When the controller calls for acid feed to lower pH, the peristaltic pump is activated and feeds dilute muriatic acid. When the pH of the pool or spa water is satisfied, the pump turns off. When the controller calls for feed chlorine, the contactor in the Pure Comfort Power Supply is actuated and the feed continues until the controller is satisfied. The pH of the pool/spa water must be stabilized before the HOCl control is meaningful.
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2.0 Specifications
2.1.1 D imensions
• • •
Height Width Depth
Board 2’
Controller 8.5”
Pump 5”
3’ 3/8”
9.8” 5.3”
6.3” 7.9”
Wet Cell 12” 10” 5”
2.1.2 Contro ller This manual covers the AK2100-D and AK2100-S controllers. They are similar except that the AK2100-D has the capacity to control two bodies of water and more equipment. Throughout this manual, AK2100 shall refer to all models unless otherwise specified. • 110 or 220 VAC selectable input voltage • 3 AMP maximum relay current • 24 AMP AC maximum combined relay current • 2 AMP AC maximum 24 VAC current combined • 0.1 AMP DC maximum 12 VDC current • 135°F maximum operating temperature AQUA BALANCE PURE COMFORT SYSTEM -Installation Manual
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2.2 Utilities 2.1.3 Acid Pump • Constant feed rate • 120/240 VAC electrical rating • Feed time controlled by AK2100 controller 2.2.1 Electrical • A 120 VAC constant power supply connected only to a grounding type receptacle protected by a ground fault circuit interrupter (GFCI) and should be a dedicated outlet. Contact a qualified electrician if you cannot verify that the receptacle is protected by a GFCI. 2.2.2 Water Supplies • The water supply is from connections on the pool return and suction lines.
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3.0 Installation
3.1 Preplanning the Installation NOTE: Before starting the installation, take inventory of equipment that was sent. Check all shipped material for any damage and missing items. Before installation of the control board, the pool maintenance room should be surveyed and a decision made for the best placement of the control board as well as the Pure Comfort System. Remember that the wet end on the control board must be piped with flexible tubing to the pool’s circulation system. Several minutes in planning may save an hour or more during the installation. Additionally, locate the facility engineer or maintenance personnel and ask for assistance to do the following: • Check to verify that a phone line has been installed to the pool utility room • Inspect power receptacle to be used for the controller panel to verify that it is GFI, 110 VAC; if not, request that it be changed. • Check pump baskets for any excess air or air bubbles that may be present. If found, determine source of air leak and correct the problem. • Locate power breakers for pump motors and heaters. Shut off pumps and heaters prior to installation. • Advise the facility engineer that when the installation is complete, he or she will be asked to make an inspection and have the manager sign off on the Ecolab completion form.
3.2 Controller Installation 1. Unpack the pH and ORP probes and immerse in a clean container filled with water from the pool or spa to saturate the probes. 2. Find a location for the control board. 3. The AK2100-D control board configuration is shown in Figure 3-1. The following will be pre-mounted to the control board for a pool and spa install: one (1) controller, two (2) 110-volt duplex receptacles and two (2) wet cells. 4. The following will be pre-mounted to the AK2100-S control board for a single pool install: one (1) controller, (1) 110-volt duplex receptacle and one (1) wet cell.
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5. If adequate wall space is available, mount the board directly to the wall. If not, order the stand-off control board mounting bracket. The bracket will allow the board to be positioned over existing vertical and horizontal pipes. The bracket will position the board a maximum of 3” from the wall. 6. Mount the two peristaltic acid pumps to the board as shown in Figure 3-1. 7. Plug the peristaltic pumps into the duplex 110-volt outlets as shown in Figure 3-1. 8. Do not plug the controller into a power source at this time.
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3.5 Post Installation Instructions 1. Review the completed installations to make sure that the final job is professional looking and that the job site is clean. Take special care that all tubing is routed properly and wrapped. Ensure there are no leaks. 2. Have the facility engineer/manager inspect both the pool and spa installations. Inspect the pumps again for any air. NOTE: It is very important that the air is out of the system and that there is no air seepage into the system. If air is allowed to seep into the system, the pump basket will fill with air and cause the pumps to run dry. The pumps will then overheat, burn out and require replacement. 3. Turn on the pool and spa heaters. If there is a special procedure for relighting of the gas heater, ask the on-site engineer. If they are electric, turn the breakers on. 4. After the facility engineer is satisfied, have him or her sign off on the installation.
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4.0 Set-up and Operation
4.1 System Checks 4.1.1 Probe Response • Note pH and ORP readings on controller faceplate • Remove Pure Comfort power cord from Aqua Balance board and plug directly into 110v. outlet for 10 seconds. • When chlorine spike reaches the wet cell, the pH and ORP will both temporarily rise, indicating that your probes are functioning. •
Replace power cord into outlet on Aqua Balance Board.
4.1.2 Checking Relays • It is possible to activate the feed relays for testing purposes. • Press the decimal “.” key to display the main menu. • Scroll down using the down arrow key to “Service”. • Press Enter to enter the service menu. • Press Enter to select the “Manual” (first entry). • Scroll down using the down arrow key to select the MPS for the relay that you want; e.g. MPS 1 tests relay 1. • Press Enter to activate the relay. NOTE: Following the MPS number is an indicator in column 8. If this indicator is set to 1, the MPS and its relay are ON; if set to 0, the MPS and its relay are OFF. The relay stays activated for a default period of time (usually 2 minutes) unless Enter is pressed again. To return to the Service menus, press Decimal once. To return to the main menu, press Decimal twice. If all MPS selections have turned off and the screen has changed to the default, a single Decimal key press returns to the main menu.
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4.2 Calibration and Setpoints • Initial calibration is covered in section 4.2.4. • Subsequent calibrations are covered in section 5.3. • pH setpoint is 7.4, with 7.4-7.6 being acceptable. • ORP setpoint is 700, which corresponds to 2 ppm of Free Available Chlorine NOTE: pH and ORP are interdependent, that is the ORP value will change if the pH fluctuates. Therefore, it is crucial that the pH be calibrated first, and that it be in the 7.4-7.6 range! Once this is satisfied, the ORP can be calibrated using the assumption that a 700 reading corresponds to 2 ppm Free Available Chlorine. 4.3 Clearing Controller Overfeeds • There are times when it is necessary to clear an overfeed condition when displayed on the controller face plate. This is indicated by an “X” in the string of eight “0”s in the lower right corner of the display. This screen is the default which is normally on the display; it can also be reached by selecting the Display menu, Readings. • An over feed can occur for a variety of reasons including: (1.) sodium chloride level is low, (2.) closed inlet or outlet valve to the Pure Comfort Cell Assembly, (3.) Empty Muriatic Acid Container, (5.) Muriatic Acid Pump switch turned off, etc. In order to activate the “Clear Overfeeds” feature: 1. Press the Dot (“.”) key to reach the main menu. 2. Select “Config” and press Enter or Right Arrow. 3. Select “Reset” (currently the fifth entry) and press Enter or Right Arrow. 4. Select “RST Overfeed Time” and press Enter or Right Arrow. 5. Press Enter to clear the overfeed condition or Dot to leave it set. 6. Press Dot or Left Arrow twice to return to the main menu. In order to return to the “Display pH/ORP” screen: 7. Select “Display” and press Enter or Right Arrow. 8. Select “Readings” and press Enter or Right Arrow. 9. The controller will display all “zeroes” in the lower right hand side of the controller face plate.
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5.0 Maintenance 5.1 Replacing the Acid Pump Tubing NOTE: Special UV resistant black tubing should be installed if exposed to the sun. Inspect the peristaltic pump tubing frequently and replace when deterioration becomes apparent. Peristaltic pump tubing will eventually wear and break if neglected. This occurrence will cause chemical spillage and potential for personal injury or damage to equipment. Always wear protective clothing and safety glasses when working near chemical feed systems. Use the following instructions to replace the pump head squeeze tubing: Wear protective gloves, goggles, and other adequate protection for the chemical hazard. Before replacing the pump head remove chemical from tubing as follows: Remove strainer from chemical tank, then run pump until all chemical is removed from the tubing. 1. Remove the hose clamps from the tubing at the pump head (twist clamp to disengage teeth). 2. Pull the suction and discharge tubing from the pump squeeze tube. 3. Rotate the pump head counterclockwise to disengage from the latch studs on the feeder cover. 4. Grasp the tabs on the back cover of the pump head and pull straight out to remove. 5. Remove the old squeeze tube and retaining collars from the pump head. 6. Insert the collars in the pump housing with the open end facing out. Then position the spider to insert the squeeze tube on one side of the pump housing. 7. While rotating the spider counterclockwise, push the squeeze tube into the housing to center over the rollers and lock into the collars. 8. Replace the back cover on the pump head. Be sure it fits tightly against and flush with the housing. 9. Slide the pump head onto the motor drive shaft and turn it clockwise to lock onto the two latch studs. Retighten the latch screws to secure the pump head. 10. Push the suction and discharge tubing into the squeeze tube. Do not push past the retaining collars. Install a hose clamp to hold the tubing together and prevent leakage.
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5.2 Probe Calibration Procedures When calibrating the probes, it is very important that the pool filter is backwashed first in order to assure proper water flow through wet cell. After the filter has been backwashed, follow these steps: 1. Record the pH and ORP values on the controller display for the body of water you are calibrating. 2. Draw a water sample from the body of water you are calibrating directly from the wet cell. Compare the controller display readings with the actual pool water sample readings (see 4.2 Calibration and Setpoints). 3. If a calibration is necessary, press Dot to reach the main menu. 4. Scroll down using Down Arrow until you reach “Service”. 5. Press Enter or Right Arrow to enter the Service menu. 6. Scroll down using Down Arrow until you reach “Cal.”. 7. Press Enter or Right Arrow to enter the Calibration menu. 8. Scroll down using Down Arrow to the probe that needs calibration. It is labeled “pH 1”, or “ORP 1”, “PPM1”, “T1”, etc. 9. Press Down or Enter to select that probe. 10. Enter the correct calibration value using the number keys. You may need to overwrite a leading numeral with “0” or scroll left with Left Arrow. The decimal point cannot be edited and the cursor jumps over it. 11. Press Enter to save the calibration and exit the process. 12. Verify that the value has changed correctly on the calibration selection screen. 13. Press Dot or Left Arrow twice to return to the main menu. 14. Select Display using Up Arrow and Enter. 15. Select Readings using Enter. This will display the standard monitor screen. 5.4 Probe Cleaning Procedures Once a month check the ORP and pH Probes for evidence of dirt or oils by checking the Silver tip of the ORP Probe. If it is “tarnished” perform the following procedure. 1. Call Ecolab Remote Monitoring Center and inform them that you will cleaning the pool/spa probes. 2. Close the wet cell outlet valve. 3. Close the wet cell inlet valve. AQUA BALANCE PURE COMFORT SYSTEM -Installation Manual
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4. Ensure that an adequate amount of Probe’s cable is free to facilitate probe removal. 5. Unscrew the probe, ensuring care taken NOT to damage the sensing tip. 6. Immerse the probe in a mild detergent solution. 7. Gently swirl the probe in the detergent solution. 8. Rinse the probe tip in water. 9. Immerse the probe tip in a dilute solution of Muriatic Acid for two to three seconds. 10. Rinse the probe tip in water. 11. Reinstall the probe back into the wet cell ensuring care is taken NOT to over tighten the probe. 12. Repeat steps 4. through 9. for the remaining probe. 13. Open the wet cell inlet valve. 14. Open the wet cell outlet valve. 15. Call the Ecolab Remote Monitoring Center and inform them that the pool/spa probe cleaning is complete.
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mrg/mjl 02/21/05 6.0 Troubles hooting
6.1 AK2100-D/AK2100 -S Troubleshooting Chart Possible Cause Symptom 6.2 Pure Comfort System doesn’t feed although ORP reading is below set point
Action
a. Wait and observe next feed 1. Controller is between feed cycle. 2. cycles. Controller is in an “Overfeed” b. Reset Controller by clearing overfeeds. condition.
6.3 ORP is high even though Pure Comfort System 1. Someone at the account has a. Use a de-chlor product to added a hasn’t fed reduce high chlorine reading. 2. chlorine product that has b. Shock pool with chlorinated increased the ORP value. 6.4 Pure Comfort System High level of combined shock. chlorine in feeds but ORP pool water. doesn’t increase 6.5 ORP and pH reading on controller don’t match test 6.6 High pH readings and low ORP readings and feeders 6.7 pH is high in water even though muriatic acid pump is operating 6.8 pH is high in water and peristaltic pump won’t 6.9 run Pure Comfort System isn’t able to keep up with chlorine demand
a. Check to make sure that all valves to and from the wet cell are open. Acid pail is empty and safety a. Refill Muriatic Acid pail. b. Make sure pickup tubes in feed acid pail limit is activated. Worn Squeeze tube. a. Replace Squeeze tube. Improper Muriatic Acid mix. b. Instruct on how to mix acid properly c. using 4:1 ratio. Clogged check valve at Remove, clean or replace Muriatic Acid injection Point Rocker switch on acid pump a. Turn rocker switch to the “on” b. position. is in c. Increase feed time for the “off” position. chlorine. Unusually high bather load in pool. d. Increase feed time for chlorine. Controller has reached feed limit. e. Add Aqua Balance Pool Conditioner No Aqua Balance Conditioner to 40-60 PPM level. in water (outdoor pools only).
1. Inadequate flow though wet cell. 1.
1. 2. 3. 1. 2. 3. 4. 5.
a. Replace probe. 1. Defective probe. 6.10 ORP probe reads 0 6.11 pH level consistently falls 2. Muriatic Acid feed cycle is too b. Have Remote Monitoring Center long. below set point dj t M probe. i ti A id f d a. Replace 6.12 pH probes reads 4.22 or 1. Defective probe. AQUA BALANCE PURE COMFORT SYSTEM Installation Manual
mrg/mjl 02/21/05/05 6.13 ORP an pH readings on controller are erratic
1. Alkalinity in water is low. 2.
6.14 Chlorine level in pool is high even though the controller is reading correct 6.15 pH an PPM readings at wet cell don’t match pH ORP readings on controller 6.16 faceplate
1. 2. 1. 2.
a. Adjust alkalinity in water to 80120 b. PPM. Probe wires are loose. Tighten all probe wire Water to wet cell isn’t a. Check to make sure that all are open “in and out” of the wet cell Probes are out of calibration. b. backwash filter. Probes need to be cleaned. a. Clean probes. Probes need to be calibrated. b. Calibrate probes.
1. Power cord is unplugged outlet. 2. Controller motherboard was damaged by a power surge. 6.17 Controller is in alarm but 1. Phone line is disconnected at controller. account hasn’t received a 2. Phone line has been call from the Remote phone room. Monitoring Center 3. Phone system has changed dialing prefix. 4. Telephone switching been changed.
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a. Plug power cord into wall b. Call Remote Monitoring a replacement motherboard. a. Re-attach phone line or clean connections. b. Have engineering check connections. c. Have Remote Monitoring C change required dialing prefix. d. Have engineering check switching equipment.
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