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Topline TEC4000 Manual

Amperometric chemistry control system
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TEC4000 Amperometric
Chemistry Control System
Manual

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Summary of Contents for Topline TEC4000

  • Page 1 TEC4000 Amperometric Chemistry Control System Manual...
  • Page 2 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.

  • Page 3: Table Of Contents

    Drawing 10148 REV 0 24-11-15 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 and Advisory Notes Section 7 Servicing / Extended Warranty Contracts and Retail Price List Section 8 Index...

  • Page 4: Section 1 Installation Instructions

    Drawing 10148 REV 0 24-11-15 SECTION 1 INSTALLATION INSTRUCTIONS...
  • Page 5 Installation Instructions for TEC Pool Dosing Equipment This equipment is only to be installed by a person qualified in electrical and chemical plumbing systems Technical Data TEC4000 Control System Dimensions 365mm wide x 650mm tall x 110mm deep Power Requirement 240 VAC single phase 50 Hz.
  • Page 6 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 A.Hunt Signature on behalf of Topline Electronics Ltd Date November 24 2015...
  • Page 7 POOL POOL Pool capacity >350M3 >200M3 >50M3 >10M3 >1M3 Controller Topline Topline Topline Topline Topline LMI Pumps only Na HSO4 (Dry acid 10%) Incoming calcium hardness and alkalinity are above 100 ppm Day tank size litres +110% bund Agitator Pump model...
  • Page 8 Drawing 10148 REV 0 24-11-15 Installation Instructions (Cont) Chemistry Control System Power Requirements Only qualified and competent electricians working to the 17th 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 suitable conduit terminated with suitable glands.
  • Page 9 Drawing 10148 REV 0 24-11-15 Installation Instructions (Cont.) Chemistry Control System Inter Wiring All the inter wiring is accessed by removing the lower cover. The connectors are push fit with screw terminals attached to the female connector. Connections accessed by removing lower panel 29-Agitator motor “E”...
  • Page 10 Drawing 10148 REV 0 24-11-15 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 pre filter, via a 3/8 inch PVC isolating valve and a ‘Bowl’ strainer. The sample line should be 3/8 inch BSP rigid PVC pipe.

  • Page 11: Section 2 Commissioning Handover Instructions

    Drawing 10148 REV 0 24-11-15 SECTION 2 COMMISSIONING HANDOVER INSTRUCTIONS...
  • Page 12 Drawing 9829 REV 101-12-06 Commissioning of the Pool Dosing Equipment REMOVE THIS AT COMMISSIONING Commissioning procedure It is important that the commissioning is comprehensive and complete and leaves 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.
  • Page 13 ACCEPTANCE of EQUIPMENT THE HANDOVER PROCEDURE, COMMISSIONING SHEET AND THIS SHEET ARE TO BE REMOVED AND RETURNED TO TOPLINE OR COMMISSIONING AGENT No person is to 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.
  • Page 14 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, are removed and how they are cleaned with Topline cleaning solution. The calibration procedure for the chlorine sensor, go through the operation of the controller, i.e.
  • Page 15 When acid and chlorine mix, chlorine gas is generated which is extremely dangerous. Only vapour take off CO2 bottles to be used with Topline CO2 systems. CO2 is an asphyxiate, warning systems should be installed in below ground level plant rooms.
  • Page 16 3 years. Terms are per 12 month guarantee. The offer of an extended warranty is only available within 4 months of the commissioning date. The costs are detailed in the Topline Electronics Ltd price list. Extended warranty must be paid for in advance.
  • Page 17 Drawing 10148 REV 0 24-11-15 SECTION 3 OPERATING INSTRUCTIONS...
  • Page 18 Drawing 10148 REV 0 24-11-15 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.
  • Page 19 Drawing 10148 REV 0 24-11-15 Risk and Method Statement...
  • Page 20 Drawing 10148 REV 0 24-11-15 Risk and Method Statement...

  • Page 21: Section 3 Operating Instructions

    Operating Instructions for TEC Pool Dosing Equipment Overview Controller The TEC4000 Control System has been designed for ease of use. However it is important that this manual is studied before you begin to use the TEC4000 Control System, so that you understand the principles of operation of the TEC4000 Control System before you start to use the system.
  • Page 22 DPD1 and phenol red tablet tests taken from the sample tap (not the pool) entered into the TEC4000 i.e. the actual pH and chlorine level in the pool. When taking a DPD1 test a dilution test must be carried out if the first test is above 2ppm. Only standardise the unit when required, if you are standardising frequently contact Topline for advice.
  • Page 23 Alarm levels. The chlorine, pH and redox all have variable upper and lower alarm levels. When there is an alarm the TEC4000 flashes the type of alarm and activates the alarm relay to provide a remote signal if required. The output from the alarm relay is volts free and either normally open or normally closed.
  • Page 24 Energy Saving Inverter An inverter can be linked to a circulation pump to save energy and up to three inverters can be controlled by the TEC4000. The amount of time the inverters run at slow speed and therefore the energy saved is logged, the period can be reset if needed. The full speed and slow speed is entered into the TEC4000.
  • Page 25 Contact Topline on 01323 440760 for this option code. Only competent engineers should enter this code. It is not the responsibility of Topline to check on this competence, this should be carried out via a risk assessment and training conducted by the installer and operator of the equipment.

  • Page 26: Section 4 Trouble Shooting

    Drawing 10148 REV 0 24-11-15 SECTION 4 TROUBLE SHOOTING FLOW DIAGRAMS...
  • Page 27 Drawing 10148 REV 0 24-11-15 Trouble shooting...
  • Page 28 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 29 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 30 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 31 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 32 Drawing 10148 REV 0 24-11-15 Trouble Shooting Poor Water Balance can be caused by the wrong choice of chemicals. In soft water areas shown in the below map the ideal choice of chemicals would be calcium hypochlorite to increase the calcium hardness and CO2 which lowers pH and increases alkalinity.
  • Page 33 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 34 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 35 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 36 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 37 Drawing 10148 REV 0 24-11-15 Trouble Shooting...
  • Page 38 Drawing 10148 REV 0 24-11-15 Trouble Shooting IN THE EVENT OF A SUSPECTED OR CONFIRMED CHLORINE GAS OR CHEMICAL MIX THEN THE CLUB SHOULD BE EVACUATED AND THE FIRE BRIGADE CALLED...

  • Page 39: Section 5 Maintenance Instructions

    Drawing 10148 REV 0 24-11-15 SECTION 5 MAINTENANCE INSTRUCTIONS...
  • Page 40 Carefully disconnect the probe from the TEC4000, unscrew the probe from the sensor assembly, place the probe in the Topline probe cleaner plastic container for about 3 minutes, remove and rinse in fresh water, shake down to remove any air trapped in the probe tip, replace in sensor assembly.
  • Page 41 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system Cont.) Auxiliary dosing equipment dosing pumps etc. The following instructions apply to Topline supplied products only Dosing pump maintenance (see www.topline.uk.net for downloads of pump manuals) General Dosing pumps The dosing pump is located on the day tank and pumps the chemical solution into the pool. By removing the dosing pump fixing screws, the pump can be lifted clear of the day tank.
  • Page 42 24 hours later if the probes have been cleaned Winter shut down procedure If the pool that the TEC4000 is controlling is to be closed for a long period, then the following procedure should be implemented on the TEC4000.
  • Page 43 Complete visual checks on bulk or bottle storage, Note: If any repairs to this Weekly equipment are required the liability usually lies with the chemical supplier not Topline Electronics Return to dosing control panel and check it has “settled” Complete full water balance check and record your findings Calibrate the control panel from your readings and ensure the controller is tracking the chemical levels by carrying out a “drop test”...
  • Page 44 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Pool Audit and Pool Plant PPM In addition to maintaining the dosing system it is essential that there is a planned audit procedure and routine processes are carried out on the general swimming pool plant, with associated Risk and Method Statements.
  • Page 45 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Pool Audit and Pool Plant PPM...
  • Page 46 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Pool Audit and Pool Plant PPM...
  • Page 47 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Pool Audit and Pool Plant PPM...
  • Page 48 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Pool Audit and Pool Plant PPM...
  • Page 49 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Pool Audit and Pool Plant PPM Routine Test Sheet It is a condition of the warranty that manual water tests are taken and recorded. Below is a sample sheet of the tests required and the frequency.
  • Page 50 Drawing 10148 REV 0 24-11-15 Routine Maintenance of system (Cont) Maintenance pictures sample cell...
  • Page 51 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions INSTRUCTION MANUAL MIXERS OPERATING INSTRUCTIONS AND MAINTENANCE...
  • Page 52 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions 5 HINTS AND WARNING 5.1 WARNING Please read the warning notices given in this section very carefully, because they provide important information regarding safety in installation, use and maintenance of the mixer. Keep this manual in a safe place, so that it will always be available for further consultation.
  • Page 53 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions 5.5 NOTES FOR SAFETY Each operation of handling, installation, start-up and maintenance must be carried out, complying with the accident prevention laws in force and using every practical expedient for the purpose of safety of the work expressly mentioned in this text or in the enclosed documents of the subordinate suppliers, as well as effecting all the procedures of sound execution of the work, commonly well-known by the qualified operators.
  • Page 54 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions 6.2 START-UP Before starting the agitator, it is advisable to carry out the following checks. On the motor Check the connections (bonds on the inside of the terminal board) are arranged in an exact way and so as to correspond with the supply voltage of the of the control line, which must always have the ground wire.
  • Page 55 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions On the seals Packing type: tighten the stuffing box before putting the tank under pressure. In case of lateral agitators, where the seal is under the level of the liquid, an initial dripping is considered normal, which then must be deleted by adjusting the tightening of the stuffing box.
  • Page 56 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions 8 INSTRUCTIONS FOR MAINTENANCE For a longer life of the equipment it is sensible to foresee an accurate maintenance of it, replacing, when necessary, the worn parts such as bearings, oil seal rings, rubber pegs of the flexible coupling, seals and packing.
  • Page 57 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions...
  • Page 58 Drawing 10148 REV 0 24-11-15 Electric Agitator Instructions Connections RUN WINDING CAPICITORS START WINDING THIS...
  • Page 59 May 2015 Revision Number 1 SECTION 1: IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING 1.1 Product Identifier Product Description: TOPLINE PROBE CLEANER HYDROCHLORIC ACID 5% Cat No. 124620000; 124620010; 124620011; 124620025; 124620026; 124620051; 124620100; 124620250 Synonyms Muriatic acid Molecular Formula HCl.H2O Reach Registration Number 01-2119484862-27 1.2 Relevant identified uses of the substance or mixture and uses advised against Recommended Use...
  • Page 60 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 For the full text of the R-phrases and H-Statements mentioned in this Section, see Section 16.
  • Page 61 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 4: FIRST AID MEASURES 4.1. Description of first aid measures General Advice Immediate medical attention is required. Show this safety data sheet to the doctor in attendance.
  • Page 62 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 7: HANDLING AND STORAGE 7.1. Precautions for safe handling Wear personal protective equipment. Do not breathe vapors or spray mist. Do not get in eyes, on skin, or on clothing. Do not ingest.
  • Page 63 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 8.2. Exposure controls Engineering Measures Ensure that eyewash stations and safety showers are close to the workstation location. Wherever possible, engineering...
  • Page 64 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES 9.1. Information on basic physical and chemical properties Appearance...
  • Page 65 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 11: TOXICOLOGICAL INFORMATION 11.1. Information on toxicological effects product Information Product Information (a) acute toxicity;...
  • Page 66 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 12: ECOLOGICAL INFORMATION 12.1. Toxicity Eco toxicity effects Do not empty into drains. Component...
  • Page 67 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 14: TRANSPORT INFORMATION IMDG/IMO 14.1. UN number UN1789 14.2. UN proper shipping name Hydrochloric acid 14.3.
  • Page 68 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Number 1 SECTION 16: OTHER INFORMATION Full text of R-phrases referred to under sections 2 and 3...
  • Page 69 Drawing 10148 REV 0 24-11-15 Probe Cleaner MSDS SAFETY DATA SHEET TOPLINE PROBE CLEANER (6% HYDROCHLORIC ACID) Creation Date 22 May 2015 Revision Date Revision Summary. This safety data sheet complies with the requirements of Regulation (EC) No. 1907/2006 Disclaimer The information provided on this Safety Data Sheet is correct to the best of our knowledge, information and belief at the date of its publication.
  • Page 70 Drawing 10148 REV 0 24-11-15 SECTION 6 OPERATING/WARRANTY CONDITIONS ADVISORY NOTES...
  • Page 71 When taking a DPD1 test, dilution tests are carried out if the first reading is above 2.5ppm. That all tests to calibrate or standardise the TEC4000 are taken from the sample tap beneath the TEC4000. That TEC4000 readings tablet tests are taken and recorded within 3 minutes.
  • Page 72 There are a number of swimming pool companies who profess to be experts in dosing systems. If the company has not been trained by Topline then it will not be able to look after your Topline dosing system. We would therefore recommend using your own trained staff, companies approved by Topline or Topline itself to look after your dosing system.
  • Page 73 Drawing 10148 REV 0 24-11-15 Advisory Notes (cont) Maintaining the alkalinity of pool water is essential to avoid pH bounce and pH lock: The total alkalinity of water is a measure of the alkaline salts dissolved in it - bicarbonates and carbonates mainly.
  • Page 74 ) Tests to calibrate and standardise Topline dosing system DPD1 and phenol red tests used to standardise or calibrate the Topline dosing system must be taken from the sample tap beneath the sensor assembly. The Topline dosing system is measuring the free chlorine and pH value in the plant room not the pool.
  • Page 75 Cyanuric acid can be used with TEC4000 dosing system but levels should not exceed 50ppm. (L) De-foaming agent is used to reduce the amount of visible foam on a spa. The foaming is usually caused by detergent in the water, from bathers who do not shower before using the facilities.
  • Page 76 Drawing 10148 REV 0 24-11-15 SECTION 7 SERVICING, EXTENDED WARRANTY CONTRACT...
  • Page 77 To achieve the response time Topline Servicing is divided in to geographic areas covered by designated engineers. The time of a callout and estimated time of arrival will be logged by Topline on the service sheet for the callout. If required, a copy of the work sheet will be emailed to site.
  • Page 78 Providing a Complete Service Topline will quote for any additional work that we can carry out, not covered by warranty or a Service Agreement. Work carried out immediately without a quote will have a labour charge applied as detailed in the Price List.
  • Page 79 Drawing 10148 REV 0 24-11-15 ANNUAL SERVICE AGREEMENTS All Topline equipment is supplied with a one year parts and labour warranty. This warranty includes a commissioning visit with on-site training. A Service Agreement can be provided in the first years warranty at a 40% discount.
  • Page 80 Hailsham, East Sussex BN7 3JF Contract No -: Site No -: Order No. -: Start Date Valid for: Signed for Topline Electronics Ltd Signed for Client Print Print Date Date Position Position Service Agreement Contract to be carried out as detailed in the “Annual Service Agreement” and the “Service Method Statement”.
  • Page 81 Chemistry Control System Power Requirements Equipment selection check list Inserting the Electrodes Position of chemistry Control System Technical Data TEC2000 Control System Topline Electronics Ltd Introduction Water sample supply for the cell assembly Section 2 Commissioning Index Acceptance of equipment Commissioning Check list...
  • Page 82 Drawing 10148 REV 0 24-11-15 Section 5 Maintenance Index Bottom one way valve on dosing pump Chlorine probe/pH probe cleaning CO2 injector Maintenance Day and Bund Tanks Dosing pump maintenance Dosing pump manuals on line Electric agitator 42 & 51-58 Feed Pipe Fine Mesh Filter Flow Switch...
  • Page 83 Drawing 10148 REV 0 24-11-15 Section 7 Servicing, Extended Warranty Contract Annual Service Agreements Document list Service Contract Extended Warranty Service Method Statement...