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Labor, shipping or incidental expenses are specifically excluded from this warranty. For warranty coverage, defective parts should be returned immediately to your CHEMTROL® Dealer or to our factory postpaid with a copy of your purchase receipt and a description of the malfunction.
MANUALPC-2012 IMPORTANT SAFETY INSTRUCTIONS Specified by ITS Testing Services for Swimming Pools and Spas READ AND FOLLOW ALL INSTRUCTIONS WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times. A wire connector is provided on this unit to connect a minimum No.
MANUALPC-2012 Page 1 CHAPTER I - INTRODUCTION Congratulations on your selection of a CHEMTROL® PC Programmable Controller for your water treatment. 1986 CALIFORNIA HEALTH CODE for Swimming Pools CHEMTROL® Automation uses advanced electronic sensing technology to monitor and control the most control critical...
Five different, yet very similar, CHEMTROL controller models or combinations of the above. are covered in this manual: PC2100, PC3000/PC5000, and PC6000/PC7000. The latter 4 models use similar hardware OPTIONS PC2100 PC3000 PC5000 PC6000 PC7000 and thus are referred to as PC3000 Product Line.
MANUALPC-2012 CHAPTER I – INTRODUCTION Page 3 Sanitizer Control CHEMTROL® PC controllers offer two choices for sanitizer control: Direct chlorine control using a membrane solid state sensor for Free Chlorine (standard on PC5000/PC7000 and available on PC2100/PC3000/PC6000) Oxidation-Reduction Potential control for chlorine or bromine using an ORP sensor with a platinum ring (available on all PC controllers).
Automatic feed mode (A) and running (>) protection. Line 2 shows a Sanitizer level of 1.5 ppm with the feed mode Please see Chapter V – Communications on the CHEMTROL® OFF (X) communication software CHEMCOM TM and how it works.
PROGRAM MENUS Initial Screens WELCOME TO CHEMTROL® 6000 When power is applied to the controller, CHEMTROL® PC Version 2.16 displays the Welcome Screen shown on the right. It includes the firmware version of the operating software installed on the controller and the factory’s Technical Support phone numbers.
PVC fittings. CONTROLLER CABINET The controller carton should include the following: CHEMTROL® PC controllers are contained in a rain proof and - Controller Cabinet, - Sensors as required for selected model, splash proof NEMA Type 3 cabinets.
Always verify that the switch is set to the correct voltage. Connecting the controller to higher voltage than its settings The CHEMTROL® PC is a dual-voltage controller with a may cause damage to the electronics that is not covered by voltage selector switch located inside the cabinet on the Power the manufacturer’s warranty.
MANUALPC-2010 CHAPTER II – INSTALLATION Page 9 Remote Alarm The temperature sensor has two leads, black and red. The The remote alarm is a 5A DPDT relay located on the upper combined conductivity/temperature sensor has four leads: right corner of the Power Board. The remote alarm relay can white, green, red and black.
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MANUALPC-2010 CHAPTER II – INSTALLATION Page 10 The brightness of the display can be adjusted with the potentiometer marked R-39 that is located in the center of the Mother Board (Error! Reference source not found.).
Phone Company may disconnect your service. Multiple Serial Connections (Option) Up to thirty (30) CHEMTROL® PC controllers can be multiplexed to a single phone line or a single computer line by using a network consisting of a host and several slaves. The connections are made through RS485 Serial Ports (Option RS485).
MANUALPC-2010 CHAPTER II – INSTALLATION Page 12 4-20 mA Converter Boards The 4-20 mA Converter Boards are two optional piggyback boards. They convert the digital outputs of the controller (sensor or control outputs) into analog signals that can be used by analog monitoring and control equipment.
Figure 10 - Flow cell Assembly For ease of installation and maintenance, the sensors should The CHEMTROL® PC controllers use up to nine different be mounted on the Flow Cell Assembly, as show above. It sensors for measurement of water chemistry, temperature,...
MANUALPC-2010 CHAPTER II – INSTALLATION Page 14 For even greater ease of installation and maintenance, the Paddle Wheel Rotary Flow Switch components of the bypass line assembly can be supplied in a pre-plumbed Sensor Cell Cabinet (also called Wet Box). The Flow Cell Assembly is mounted in a fiberglass cabinet The Rotary Flow Switch is a safety switch for the bypass line.
Excess air and electrolyte may escape through the hole below the rubber seal. Wipe any excess electrolyte with a soft tissue. Contact your CHEMTROL dealer if you need Figure 12 - PPM Sensor Flow Cell additional electrolyte.
MANUALPC-2010 CHAPTER II – INSTALLATION Page 16 ORP AND pH SENSORS Electrical Interference Properties CHEMTROL® controllers feature differential amplification of the sensor signals to reduce electrical The ORP and pH sensors are non-corroding sealed interference from stray currents in the water.
MANUALPC-2010 CHAPTER II – INSTALLATION Page 17 Storage and Winterizing CAUTION: STORING OR SHIPPING A SENSOR WITHOUT CAP OR WATER WILL VOID ITS WARRANTY. All ORP and pH sensors are shipped with a plastic cap on the tip to protect the tip from physical damage. This cap also contains water to prevent the sensor from drying out.
MANUALPC-2010 CHAPTER II – INSTALLATION Page 18 FLOW SENSOR Flow Sensor Location Always install the flow sensor as far away as possible from obstructions that can affect the flow profile around the sensor. Figure 17 shows manufacturer guidelines for minimum lengths of straight pipe before and after the sensor.
CHAPTER II – INSTALLATION Page 19 PRESSURE TRANSDUCERS The pressure sensors are CHEMTROL® Series 1200 transducers (Figure 22) with a 1/4-18 NPT thread connection rated at -15 to 45 psi (-1 to 3 bar). For differential pressure monitoring, a transducer should be installed on the intake (influent) side of the filter or bank of filters and another one on the return (effluent) side.
CHEMICAL FEEDERS WARNING: Tank Sizing Install the pumps as shown in Figure 5, following the electrical The CHEMTROL® PC controller includes many safeguards to code and the pump manufacturer's instructions. prevent overfeeding of chemicals. However, there is always a risk of physical failure of the electronics or feed equipment that Carbonic Acid (CO2) Valve could cause overfeeding of chemicals.
MANUALPC-2010 CHAPTER II – INSTALLATION Page 21 FILTER BACKWASH The Power Board (Error! Reference source not found.) of the CHEMTROL® PC7000 includes six (6) double-pole, double-throw (DPDT) relays automated filter backwash. They can be used to control solenoid valves, motorized valves, hydraulic valves or pneumatic valves.
MANUALPC-2010 CHAPTER III -STARTUP Page 22 CHAPTER III - STARTUP CONTROLLER STARTUP After calibration is completed, remember to set the Readings Initial Reset back to the default value of ten (10) seconds. CHEMICAL CONTROL Before powering up the controller, locate the Battery Jumper J1 on the Mother Board (Error! Reference source not found.).
- in case of equipment malfunction or operator error. This time The CHEMTROL® PC has two pH control relays, one for Acid limit varies with each installation, based on the size of the feed and one for Base feed.
>ORP SANITIZER 1 ppm On the right are shown screens for the standard version and for the two models: the PC7000 and the PC5000. The PC6000 >ACID and PC3000 are similar except that the Free Chlorine sensor is COND 2000 not included for sanitizer control.
Page 25 8.1 - INITIAL SETUP SUBMENU The Initial Setup Submenu is used to specify basic operating INITIAL SETUP conditions of the CHEMTROL® PC. It is accessed through the Language Configuration Menu on the last line of the Display Screen. Units 8.1.1 - Language...
MANUALPC-2010 CHAPTER IV - OPERATION Page 26 8.1.4 - Clock The clock/calendar is used for programming of daily and DATE/TIME weekly schedules. It keeps track of odd months and leap years. In case of power shutdown, the backup battery Date 08/10/96 maintains power to the board.
Temperature The standard flow switch provided with the CHEMTROL® PC Limits is a rotary flowmeter with a paddle wheel. The shutoff is set at Langelier Index 0.23 1 gpm (about 4 l/m). Condition The Bypass Line Protection option should always be set to YES, indicating that the alarm is active and will cause the Submenu 8.2.3...
8.2.5 - Backup Battery RESET The CHEMTROL® PC uses a 3 V lithium battery to maintain calibration, setup and test data in memory storage in case of Complete Reset power shutdown. The battery is designed to last for more than 200 days without any power being supplied to the unit.
- on-site downloading to a computer or laptop, the computer (COM1: or other) to the RS-232 serial outlet on the CHEMTROL® PC, using a null-modem connector, or an - remote downloading by modem to a computer using the CHEMCOM TM program.
MANUALPC-2010 CHAPTER IV - OPERATION Page 30 8.4 - COMMUNICATIONS SUBMENU The details of the communications features are discussed in PHONE NUMBERS the COMMUNICATIONS Chapter (page 51). 1: ______________ 2: ______________ The Communications Submenu is used to select the phone numbers to report alarm conditions and to enter the 3: ______________ identification number for voice telephone reporting.
MANUALPC-2010 CHAPTER IV - OPERATION Page 31 1 - ORP MENU AUTO Calibrate Operation Setpoint Alarm Low The ORP sensor is used to monitor and control an oxidizing sanitizer, like chlorine or bromine, or a true oxidizer like ozone. Alarm High Time Limit The ORP Menu screen is used to access all the ORP submenus for Control Mode, setpoint and alarm settings as...
MANUALPC-2010 CHAPTER IV - OPERATION Page 32 Selecting YES for FEED LOCKOUT will inhibit any chemical feed from occurring in case of alarm. Selecting NO will allow Total Feed Time feeding to continue. This may be used to continue feeding an Max (min) oxidizer or sanitizer even if the sensor reading is sometimes Actual (min)
Test Kit: Calculated PPM Readings 1.5 ppm For the PC6000 and PC3000 controllers, the PPM values are Submenu 2.1.1 calculated from ORP and pH readings - using a CHEMTROL® proprietary algorithm. The algorithm is most accurate for clean water.
MANUALPC-2010 CHAPTER IV - OPERATION Page 34 2.3 - Setpoint SETPOINT The SETPOINT determines the SANITIZER level that will be maintained automatically by the controller when placed in the Sanitizer AUTO control mode. De-sanitizer To change the setpoint, press the RIGHT ARROW key and Both enter the numerical value with the digital keypad.
MANUALPC-2010 CHAPTER IV - OPERATION Page 35 3 - pH MENU Operation The pH sensor monitors the concentration of acid or base in AUTO the water. Calibrate Setpoint The pH Menu screen is used to access all the pH submenus for Control Mode, sensor calibration, setpoint and alarm Alarm Low settings.
MANUALPC-2010 CHAPTER IV - OPERATION Page 36 3.4 - Low Alarm ALARM OPTIONS The ALARM LOW value is set to generate an alarm when the Feed lockout pH reading falls below the set value. To change the value, press the RIGHT ARROW key and enter the numerical value Alarm buzzer with the digital keypad (see ORP submenus).
MANUALPC-2010 CHAPTER IV - OPERATION Page 37 Menu 4 4 - CONDUCTIVITY MENU CONDUCTIVITY AUTO Conductivity and TDS Calibrate 1500 Setpoint 1500 The Conductivity sensor monitors the concentration of Total Dissolved Solids (TDS) in the water. The conductivity of the Alarm Low water - in microsiemens per centimeter (µS/cm) - is converted Alarm High...
MANUALPC-2010 CHAPTER IV - OPERATION Page 38 4.6 - Time Limit Total Feed Time The TIME LIMIT sets the maximum amount of time in minutes that is allowed for continuous dumping of water to correct a high conductivity or TDS reading. This acts as a safety feature Max (min) to prevent overdumping of water in case of a malfunction of the Actual (min)
MANUALPC-2010 CHAPTER IV - OPERATION Page 39 5 - TEMPERATURE MENU HEATER AUTO Operation Calibrate Setpoint The Temperature Menu, or Heater Menu, is used to control the Alarm Low operation of the heater with the temperature sensor. displays can be shown in either degrees Fahrenheit or Celsius. Alarm High Time Limit The Temperature Menu screen is used to access all the...
MANUALPC-2010 CHAPTER IV - OPERATION Page 40 6- PUMP MENU Operation PUMP AUTO The Pump Menu is used to monitor and control the operation P influent of the main recirculation pump, including pressure and flow P effluent rate. It is also used for programming of pump shutoff delay (fireman) that allows time for cooling off the heater.
The factory set default factors of 12.0 and 1.75 are valid for Submenu 6.2.1.1 CHEMTROL® pressure transducer Series 1200 in the pressure range of -15 to 45 psi. It should normally not require any adjustment.
MANUALPC-2010 CHAPTER IV - OPERATION Page 42 6.4 - Flow Rate FLOWMETER This line displays the flow rate through the main recirculation line using input from the square wave pulse sensor. Enter number of calibrate the flow sensor, press the RIGHT ARROW key to pulses per unit enter Submenu 6.4.
MANUALPC-2010 CHAPTER IV - OPERATION Page 43 6.6 - Heater Delay (Cooldown Safety) FIREMAN The cooldown safety (or Fireman) is a delay for heater Heater cooldown cooldown before shutoff of the main recirculation pump. It is used to protect the heater from overheating due to lack of before Pump Shutoff water circulation.
Filter Backwash BACKWASH AUTO Start Date 08/10/96 The Filter Menu for the CHEMTROL® PC7000 allows the Start Time 15:30 operator to set the parameters for automatic backwashing. It can be applied to one filter (Error! Reference source not Filter Time (min) found., Page 21) or to several filters (Figure 28, Page 21) with...
MANUALPC-2010 CHAPTER IV - OPERATION Page 45 7.1.1 - Time Interval TIME INTERVAL This option allows the operator to set a cycle schedule with a fixed interval days between successive backwash Days between operations. Pressure differential is not considered. If this option is selected, the program asks for the number of days Backwash Cycles: between backwash cycles and then returns to the Backwash...
MANUALPC-2010 CHAPTER IV - OPERATION Page 46 VOLUME OF WATER 7.1.6 – Volume of Water This option causes a backwash cycle to be initiated when the Backwash starts when volume of water accumulated since the last backwash exceeds Volume of water accumulated the set amount.
MANUALPC-2010 CHAPTER IV - OPERATION Page 47 CONTROL SUBMENUS CONTROL TYPE Features Manual The CONTROL Submenus are common to all the functions that require control of the operating variable at a fixed setpoint. Automatic This includes ORP, pH, Conductivity and Temperature. Timer For all functions, control can be made more effective and Submenu X.1...
MANUALPC-2010 CHAPTER IV - OPERATION Page 48 X.1.3 - Automatic Control AUTOMATIC CONTROL In the Automatic Control Type, the operator can choose ON/OFF among two different Control Modes: ON/OFF or, as shown on Submenu X.1.3. Proportional 4-20 mA X.1.3.1 ON/OFF Control In the ON/OFF Control mode, the controller activates the Submenu X.1.3 control outlet until the setpoint is reached, at which point it is...
MANUALPC-2010 CHAPTER IV - OPERATION Page 49 CALIBRATION SUBMENUS X.2 - Calibration Options CALIBRATION The CALIBRATION Submenu is common to all the functions 1 Point (zero) that require sensor calibration. This includes Sanitizer, pH, Conductivity and Temperature. It allows calibration for 1, 2 or 2 Point (slope) 3-point - depending on the degree of accuracy that is required.
MANUALPC-2010 CHAPTER IV - OPERATION Page 50 SHOCK AND SAVINGS SUBMENUS X.8 - Treatment Selection SHOCK AND SAVINGS Shock Treatment Submenu X.8 is used to select the shock treatment and Deshock savings program. Chemical Saver The Shock Treatment program is used to destroy harmful elements, such as chloramines, germs and algae, by raising Submenu X.8 the oxidizer or sanitizer level on a specified schedule.
MANUALPC-2010 CHAPTER V – COMMUNICATIONS Page 51 CHAPTER V - COMMUNICATIONS The CHEMTROL® PC controller features remote operation with PC-compatible computer using CHEMCOM ™ software program for Windows. The CHEMCOM ™ program is a proprietary program that allows true duplex operation. This means that any action on the remote computer is immediately implemented on the screen of the controller, and vice versa.
Using the phone extension cable, connect the jack on the CHEMTROL® PC to a telephone line. The phone line does not have to be a dedicated line and it can be used for other communications when not in use for the controller.
OK. This last line also gives access to the Configuration Menu. Data Collection Test data for operating parameters can be collected in two different ways: By data logging in the controller internal memory (available on all CHEMTROL® PC controllers), scanning with remote computer using CHEMCOM ™...
MANUALPC-2010 CHAPTER V - COMMUNICATIONS Page 54 Data Log Download Data logged in the controller can be downloaded by selecting Data log option as shown in Figure 38. This data can be displayed in the Recent Scans display as shown above. NOTE: The data log can also be accessed outside of the CHEMCOM...
PPM Sensor: Software Upgrade DO NOT CLEAN the PPM sensor. Cleaning the membrane. The software program in the CHEMTROL® PC controller can May cause irreparable damage. be upgraded by replacing the program and display chips that are located on the Mother Board.
Total Alkalinity (TA). If it is too much however, the CHEMTROL® controller will show the high (above 150 ppm), pH response is slow and requires more variations in HOCl - which are not shown by normal test kits. It acid or base feed.
A SHOCK treatment warning is displayed on the Display feed rate of the chemical feeder. In case of doubt, make sure Screen when activated. to consult a qualified CHEMTROL® representative or call the factory. C. The out-of-range alarms stay on as long as the oxidizer or NOTE 1: The chemical feeders should be properly sized for the sanitizer levels are above the high limits.
MANUALPC-2010 CHAPTER VI – MAINTENANCE Page 58 PORTABLE TESTER II (Error! Reference source not The PORTA-PROBE found.) is a battery-operated digital portable tester/signal generator. It is designed to test the ORP, pH, conductivity and temperature sensors and to generate calibrated signals to test the controller.
MANUALPC-2010 CHAPTER VI – MAINTENANCE Page 59 TROUBLESHOOTING PROBLEMS SOLUTIONS 1a. Check power to system. 1b. Check On/Off Switch on right side of cabinet. 1. NO DISPLAY. 1b. Check Voltage Selector Switch in upper section of Power Board. Verify proper input voltage 110V or 230V. 1d.
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MANUALPC-2010 Page 64 US units..................25 Water Level................43 UV systems ................56 Water level control ............19, 43 View Data Log ................28 Water level sensor ..............19 Voltage selector................8 Water Maintenance ..............1 Warranty Card ................6 Water recirculation ..............2 Water balance ................2 Water sampling ..............
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