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HYDROGUARD HG-302 - Blue I Water Technologies

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1. 6 4 1 Chlorine Calibration 1 Open the water sampling valve Let water flow while observing the colorimeter countdown timer in the LCD display 2 Fill the sampling container when the countdown timer reaches zero 0 Test the water sample for chlorine using a digital photometer 4 Press Scroll three 3 times until Cl Calibrated to appears in the LCD display The top line will display Cl Calibrated To and a number The number displayed is the last value someone entered for the calibration The bottom line will display Cl Sensor Was and a number This number is the sensor reading without any calibration at the time of the last calibration If there is a large discrepancy between these two numbers the sensor was calibrated improperly or the sensor needs to be replaced The value displayed normally on the main screen and the value the controller uses to determine dosing rates is the calibrated value 23 Cl calibrated Sensor value was Figure 21 Calibrating a Parameter Note Chlorine calibration should always be performed within 25 of the set point If the current chlorine level is 25 above or below the set point do not perform calibration until the chlorine level is closer to the set point 5 Press Enter 6 Enter the password Press the up arrow A or down arrow until the password is reached 7 Press Enter 8 Press Enter again The display will now show Calibrate Cl to on the to
2. Pressing the up arrow A once will change the display mode and cause the bottom row to alternate between the countdown Colorimeter timer and the alarm display If an alarm is issued and the flow measurement and or turbidity features are operating the bottom row alternates every several seconds between displaying the alarm the water turbidity level NTU and or flow rate and the Colorimeter countdown clock Pressing the up and down arrows amp Y together will display the Langelier index for approximately five 5 seconds and then returns to the previous display mode 6 3 2 Menus HYDROGUARD has two menu levels Operator and Technician The Operator menu includes settings that may be controlled by on site pool operators The Technician menu includes settings and calibrations that should be restricted to specially trained HYDROGUARD maintenance technicians Each menu has a separate password The technician level password may be used whenever a password is required however the operator password will only be accepted in the operator menu Table 3 displays the operator menu functions and their description and Table 4 displays the menu functions with the minimum and maximum values for each Table 3 Operator Menu and Variable Limits Name Description Shows most recent calibration and sensor value at calibration to aid in troubleshooting Cl interval max Maximum time between CI measurements pH set point Controls pH Relay 3 On Off
3. 2 Connect the turbidity module to the I O module using the supplied ribbon cable and any open connector the connectors on both boards operate in parallel Pass the sensor cable through an open glad on the bottom of the controller 4 Connect the wires from the sensor cable to the terminal block on the lower left corner of the Turbidity Module following the color order indicated on the module O Blue I Water Technologies Bue I Technologies NTU 70 120 6000 Ver 101 eoma 12 ENT cris 2 a OLT om 2 gt r EA a E a TEF a m wa pi z IFP 00 200 a o LA L PNNNENSENET Figure 35 Turbidity Electronics Module The sensor cable may be cut or extended up to a maximum distance of 650 feet 200m as needed If the turbidity relay is not going to be connected to any external equipment the installation is complete If the relay will be used to operate equipment based on the turbidity set point the following steps will need to be followed 8 5 5 Relay Wiring and Use Turn off all power supplies to the controller Wiring of the NTU turbidity relay is identical to wiring of all other relays and should be connected to a pump dependent interlocked power supply The line live wire of the pump dependent power source connects to the connection labeled Common on the NTU relay The line wire of the controlled external turbidity equipment is connected to the normally open N
4. OBluel HYDROGUARD HG 302 Swimming Pool Water Quality Analyzer and Controller User Manual 2015 Document ID HG302TM1 2 O Blue I Water Technologies No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or any computer language in any form or by any third party without the prior written permission of Blue Water Technologies Ltd Disclaimer Blue Water Technologies Ltd does not accept any responsibility for any damage caused to its products by unauthorized personnel Use of non Blue Water Technologies reagents and or replacement parts will void all warranties J Trademark Acknowledgements HYDROGUARDS is the registered trademark of Blue Water Technologies Ltd Copyright 2015 by Blue Water Technologies Ltd Table of Contents 1 General Safety Precautions 6 2 Preface 8 2 1 Intended Use 8 22 Safety Precautions 8 3 Overview of Chapters 9 4 Overview 2 4 1 Pool Chemistry Overview 2 4 2 The HYDROGUARD Solution 2 4 3 Features and Modules 2 4 4 Standard Modules 3 4 5 Optional Modules 3 4 5 1 Expert Pool 3 4 6 System Components 3 5 Installation 5 5 1 Working Environment 5 5 2 Selecting a Location 5 5 3 Recommended Installation Configuration 6 5 4 Site Requirements and Installation 6 5 4 1 Mechanical Installation Requirements 6 5 4 2 Mechanical Installation 6 5 5 Plumbing Require
5. 6 2 Installing Reagents The following procedure describes how to mix and install the reagent bottles Q 4 KJ Figure 13 Mixing Indicator Salt into Indicator Fluid 1 Open the HYDROGUARD Chlorine Indicator and Buffer kit The following items should be in the box A Chlorine indicator and buffer mixing instructions B 1 X 500 ml bottle of chlorine buffer with a white label C 1 X 500 ml bottle of chlorine indicator fluid with a blue label D 1X small bottle of chlorine indicator salt with a white label Remove the caps on both the indicator fluid and small indicator salt bottles Empty the contents of the indicator salt into the bottle of indicator fluid Place the cap on the bottle of chlorine indicator fluid and close tightly Turn the bottle upside down slowly and carefully so that no bubbles form in the fluid oo oa ee Repeat five 5 times until all the indicator salt is dissolved in the indicator fluid Warning Use protective gear as recommended in MSDS 7 Place the reagent bottles in position A Remove the cap from the reagent bottles Place the opening of the reagent bottle below the bottle siphons Lift the bottle up until the opening reaches the bottle siphon cap Push the lever above the siphon cover away from you and push the reagent bottle up mM Oo Push the bottom of the bottle into position 15 O Blue I Water Technologies Figure 14 Reagents Bottles in Position Caution D
6. alibration to aid in troubleshooting Alarm when Temp below this value urbidity setpoint 25 Total Alkalinity 27 25 26 otal Hardness Manually entered for Langelier Index D7 DS Manualy entered for Langelier Index 28 PAP Emergency Mode Allows ORP mode to be used if Cl measurement is a oroblem 23 Language Allows choice of language 30 System Reset Restarts controller safer than turning off and on 9 3 Technician Menu Table 20 Technician Menu Menu Name Description 52 Clpumpperiod h Pump cycle on off time for Cl Relay 1 58 bHpumpperiod 1 Pump cycle on off time for pH Relay 3 OH Overfeed ne Will open relay 3 if pH feeding continuously for this time ime 61 bH balance type To Select if Acid of Base is being added to adjust pH Will turn display of Flow rate on off only use if flow meter 2 Flow Sensor connected Choose between metric and US units 64 Celsius Farh Choose between metric and US units Value in degrees below set point which will close Temp Relay 6 66 urbidity Turns Turbidity Module ON OFF optional module 65 O Blue I Water Technologies NTU wiper a 67 i Interval for Turbidity Module Wiper to clean glass optional module interva Go Minutes ourer Time or baa tog bo or ounen Tmetor bata toger 73 Recording Interval Time interval between readings stored on the on board data logger Controller ID used with external communication 75 Software Version Curre
7. 2 Enter the operator or technician password and press Enter 3 Enter the turbidity set point value and press Enter With or without the NTU relay connected to external equipment 1 Press Scroll until Turbidity High Alarm appears on the display and press Enter 2 Enter the operator or technician password and press Enter 3 Enter the turbidity high alarm value and press Enter 8 5 6 2 Technical Menu Press up and down together to enter the technical menu Press Scroll until Turbidity ON OFF appears in the display and press Enter Enter the technician password and press Enter Press up to turn the turbidity sensor on and press Enter Press Scroll until Turbidity Wiper Interval appears in the display and press Enter Enter the technician password and press Enter DO ae eS eS Enter the wiper interval 2 minutes is recommended and press Enter The turbidity unit should now be active Confirm that the turbidity value appears on the LCD display If it is not active perform a system reset 8 5 7 Relay and External Equipment Operation The relay will operate in an ON OFF mode Whenever the measured turbidity is below the set point the relay will remain open no power to normally open connection Whenever the measured turbidity is above the turbidity set point the relay will close power will be supplied to the normally open connection If the measured turbidity is above the turbidity high alarm the alarm on the
8. Release the top union connecting the solenoid valve to the Colorimeter module Detach the cable from the solenoid valve ey Unscrew the solenoid valve intake tube a Unscrew and disconnect the sampled water supply pipe from the solenoid intake pipe at the bottom of the solenoid valve Colorimeter Top Union a Solenoid Valve Cable Solenoid Valve Bottom Union Solenoid Valve Sampling Cell Intake Pipe Sampled Water Supply Pipe Figure 29 Solenoid Valve with Colorimeter Module and Flow Cell 5 Disconnect the valve from the unions above and below 47 6 Connect the new solenoid valve a Connect the bottom of the new valve to the intake pipe b Insert a coin into the slot at the bottom of the intake pipe and turn until the intake tube is firmly connected to the new valve c Connect the top union to the valve and to the bottom of the Colorimeter unit and tighten d Connect the solenoid valve cable to the Colorimeter module 7 7 9 Replacing Control Panel Module Disconnect the power supply to the unit before opening the control unit 1 Disconnect the flat cable plug from the card 1 2 Unscrew the four 4 mounting screws 2 3 Putin the new card and tighten the four 4 mounting screws 2 4 Connect the flat cable plug to the card 3 Figure 30 Replacing All Types of Electronic Cards 7 7 10 Replacing 1 0 Module Disconnect the power supply to the unit be
9. The DPD 3 reagent bottle is installed the same as the DPD 1 and Buffer solution bottles and will be in a 600 ml bottle labeled as DPD 3 however priming is different Place the reagent bottle in position Remove the cap from the reagent bottles Place the opening of the reagent bottle below the bottle siphon on the right Lift the bottle up until the opening reaches the bottle siphon cap Push the lever above the siphon cover away from you and push the reagent bottle up PE a SY Push the bottom of the bottle into position Reagent Level Switch Figure 34 Reagent Bottles and Siphon Caps 7 Locate the Pump and Up button on the HYDROGUARD HG 302 control panel 8 Press the Pump and Up button together for ninety 90 seconds until the reagent drops are visible through the DPD 3 needle 8 2 3 New menus and settings The total chlorine monitoring requires a few additional menus and alarms and requires a few additional settings to be configured before operating the controller 53 Blue Water Technologies 8 2 3 1 Operator Menu The following table lists the parameters in HYDROGUARD s Operator menu Table 13 Operator Menu Menu Name Description E i alibration to aid in troubleshooting 6 linterval min Minimum time between CI measurements 8 Hsetpoint Controls pH Relay 3 OnOff or Proportional S alibration to aid in troubleshooting Alarm when pH below this value ee ee ie alibration to
10. act based on the last reading regardless of this setting 6 5 2 Configuring Settings in the Technician Menu Navigation within the Technician Menu is identical to the Operator Menu Y 1 To enter the Technician Menu press 1 Scroll to enter the Operator Menu and then press the up arrow and the down arrow together simultaneously Ay Vv until the menu display 29 O Blue I Water Technologies changes 2 Locate the desired parameter in the menu A Press Scroll until the desired parameter name appears in the LCD display B Press E Enter key Enter Password 100 appears in the LCD display ENTER PASSWORD Figure 23 Entering Technician Password 3 Enter the Technician Menu password Press the up arrow or down arrow until the password number is reached B Press Enter to accept the password C The parameter name and current setting appear in the LCD display The Technician Menu password is different from the Operator Menu password The default Note Technician Menu password is 456 and if lost can only be reset by replacing the chipset 4 Continue changing new parameter setting as described in the Operator Menu Press the up arrow A or down arrow until the desired value is reached 6 6 Calibration and Initial Operation Checklist Before leaving the site perform the procedure in this section and record the requested values Calibrate the following HYDROGUARD parameters and enter the in
11. active Confirm that the flow rate appears on the LCD display If it is not active perform a system reset 8 5 Turbidity 8 5 1 Overview The turbidity upgrade will provide a measurement of the turbidity in NTU Nephelometric Turbidity Units This provides a consistently objective evaluation of the overall water quality A body of water with high turbidity will appear dull or hazy What constitutes high will vary based on the specific body 59 O Blue I Water Technologies of water but in general water with turbidity above 0 5 NTU will appear hazy Deeper bodies of water will appear dull and hazy at a lower turbidity than shallow water High turbidity may be a result of poor filtration or unbalanced water chemistry The turbidity value will provide an indication that one of these conditions exists and action is required to improve the water quality In many cases the turbidity can be reduced by adding a flocculent to the filter which will improve filtration A turbidity relay is contained in the controller and will operate when the turbidity increases above set point This may be connected to a pump for flocculent or other equipment used to reduce turbidity providing an automatic response and maintaining clear water without requiring operating intervention Likewise if the turbidity ever exceeds a pre set limit the controller will set off an alarm indicating that attention is required 8 5 2 Installation Caution Prior t
12. controller will be activated The NTU relay will remain closed power to the normally open connection even during an alarm 63 C Blue I Water Technologies 9 Relays Menus and Alarms This chapter lists HYDROGUARD s relays menu commands alarms and system technical data 9 1 Relays Table 18 List of Relays Relay Control Cl 1 Main chlorine system 2 Cl 2 Secondary chlorine system a OH Acid or base dosing a eric Turbidity Units Controls the injection of flocculants and coagulants Used only with the optional turbidity module See turbidity module documentation Alarm Activates an external third party alarm when certain alarm types are registered 5 6 Temperature Controls water temperature by activating the water heating system 9 2 0perator Menu Table 19 Operator Menu Menu Name Description alibration to aid in troubleshooting 6 Clintervalmin Minimum time between CI measurements 8 Hsetpoint Controls pH Relay 3 On Off or Proportional eee alibration to aid in troubleshooting Alarm when pH above this value 2 orP set Point ORP set point for emergency mode only ORP Calibrated to hows most recent calibration and sensor value at 2 3 _ Fr alibration to aid in troubleshooting 5 14 orp low alarm Alarm when ORP below this value 15 OPP High alarm Alarm when ORP above this value Open Cl relays 1 2 16 emp Set Point ontrols Temperature Relay 6
13. debris with your fingers B Replace the filter if any part of the filter fabric is torn 5 Wash the filter under running water A Point the high pressure water jet towards the filter at a right angle and spray until all debris has been dislodged B Spray the water jet into the filter casing until all debris in the casing has been dislodged Figure 27 Washing the Filter 6 Return the filter into place 1 Place the cleaned or new filter into the casing and verify the gaskets at each end are compressed 2 Verify the casing s O ring is in place and screw casing to filter base until the gasket is firmly compressed against the filter connector pipe 7 Open the water supply valve 37 O Blue I Water Technologies 7 4 Shut Down and Winterizing The HYDROGUARD controller is designed to keep the probes submerged even if there is no flow to the controller However if the controller is going to be offline for an extended period of time and or exposed to freezing temperatures it must be winterized to prevent damage to the controller and the probes l Remove each probe from the flow cell Fill the rubber caps that were on the new probes with tap water or preferably KCI potassium chloride solution and insert over the end of each probe Screw the plastic cap over the top of each probe to protect the connector Store in a safe location that will not drop below freezing preferably in the original probe bo
14. dry contact or 24V 1 Dosing will turn ON based on HG 302 decision to add chemicals pH Pump 2 Connect 24V wire between COM and N C The Chlorinator will receive 24V all the time OFF dousing time The voltage will disconnect from salt generation ON dosing time based on HG 302 decision to add chemicals Bw Cl Ext or pH Ext Line Common red aac pny maa Neutral blue _ _ 24V Power Supply Salt Chlorinator Ground green _ 5 6 5 Relays and the Dosing Systems They Control Table 1 Relays and the Dosing Systems They Control Relay Control Main chlorine system On Off or proportional Proportional controls pulse length or pulse frequency Secondary chlorine system On Off only no proportional control Acid or base dosing On Off or proportional Proportional controls pulse length or pulse frequency Nephelometric Turbidity Units Controls the injection of flocculants or coagulants Used only with the optional turbidity module Activates an external alarm when certain alarm types are registered and after the alarm delay time has expired Temperature Controls water temperature by activating the water heating system Caution Electrical connections in this section are ONLY recommendations All electrical connections should comply with National Electrical code NEC and all local regulations 6 First Time Operation and Calibration 6 1 Installing Sensors The following procedure
15. of the controlled dosing systems 4 Connect the line live wire to the connector marked Common of each active relay Caution Each relay connection is limited to 4 amps to prevent overheating The relays may show a higher rating but do not connect equipment exceeding 4 amps 5 6 3 Input Switches An input switch terminal block on the I O module allows for three input switches to be connected to the system as additional layers of security against accidental chemical additions If a connection is not detected at each input the controller will not activate any equipment or dose any chemicals Therefore if a safety switch flow level etc will not be installed a fixed connection jumper wire is required to allow the controller to operate The switch connections are Input Switch 1 between input 1 and 2 open connection with factory installed jumper Input Switch 2 between input 3 and 4 connected to rotating flow switch Figure 7 on the flow cell Input Switch 3 between input 5 and 6 external flow switch connection with factory installed jumper Caution An external flow switch is required between points 5 and 6 on the input switch terminal block The controller will not feed any chemicals if this connection is not present therefore the controller has a jumper wire pre installed to allow for initial set up and testing however Blue Technologies does not recommend operating the controller with this jumper installed unless
16. off to the controller Disconnect both pipes from the reagent pump Remove the four 4 mounting screws A a a DPA the colorimeter module Disconnect the Red and Blue wires from the Pumps connector on the colorimetric module Install the new pump and reconnect in this order the pipes the 4 screws and the wires to 6 Push the pump button until reagents are injected into the colorimeter cell approximately 90 Sec Note If only the motor is to be replaced the pump head will need to be removed and reattached See 5 5 1 Replacing Pump Head and Tubes 7 7 7 Replacing the Colorimeter Module The HYDROGUARD water quality controller has a self contained chlorine analyzing cell to determine the chlorine concentration in the pool water Follow the procedure below to replace the colorimetric module 1 Turn off the water inlet and outlet from the flow cell and turn off the controller power 2 Open the doors of both the analyzing module and the control module Colorimeter To Note There are no P i P Ca serviceable parts in the P colorimeter units Warning Colorimeter Unit 7 Attempting to open the colorimeter unit will void Solenoid Valve 220 the warranty C Figure 28 Colorimetric Unit 3 Locate the colorimetric cell unit in the analyzing sets Mounting Screws a Remove the top cap from the colorimetric unit Make sure not to touch the reagent injection needles in the cap b
17. or blockage in all he injection pipes from he chlorine tank to pump and rom pump to injection point 3 Check for chlorine in the ank If everything seems to be OK and the problem repeats onsider changing the overfeed time limit to a higher number oH pump has been active for more than a pre determined time limit No Dosing will and has shut off for reduce pH Safety reasons Perform a System Reset to turn back on 41 O Blue I Water Technologies Problem with Colorimeter Should use with care Reading ORP is now his method has ontrolling chlorine until Hisadvantages that Function may be enabled after no solution for alarms A3 4 5 6 7 problem is resolved up ill not reflect same o 3 5 days only results as normal operation Table 12 Troubleshooting Other Problems Problem Symptoms Potential Cause Solution Suggestion Connection between boards is loose hack all connections between boards pH and ORP wires reversed race pH and ORP wires from probe back to Display not functioning or is board displaying odd numbers Chipset is loose or pin bent heck that no pins on the chipset are bent and it is in completely and correctly ei a aoao heck and Replace fuse above main power Fuse is blown supply I O board has been damaged due to Check for burn marks on I O board Recheck improper electrical installation or proper wiring confirm all neutrals and grounds in contact are from t
18. sure that the control loop is within an acceptable range Recommended In systems equipped with the Expert Pool GPRS communicator this process can be performed remotely using BLUE internet remote access 10 5 First Time Chlorine Average Setting Table 24 Chlorine Settings Pool Volume CI Proportional Factor CI Pump Period m3 Thousand Gallons rsi too 20400 so O tonto 10 6 First Time pH Average Setting Table 25 pH Settings Pool Volume pH Proportional Factor pH Pump Period 0 1 5 0 30 51 100 200 400 10 30 0 30 1 00 101 200 400 800 14 40 1 00 1 30 201 500 800 2000 16 50 1 30 3 00 2000 18 70 3 00 4 00 73 11 Record Values Setting Before leaving the site perform the procedure in this section and record the requested values Calibrate the following HYDROGUARD parameters and enter the information into the table below Table 26 Record Values Setting Technician s Name Parameter Controller Reading External Device Reading Free Chlorine wo o S S w EE E O 75 Blue I Water Technologies 12 Technical specifications MECHANICAL DATA Dimensions controller WxHxD Dimensions mounting board 670 x 330 x 130mm 26 4 x 13 x 5 1 800 x 550 x 5 mm 31 5 x 21 7 x 0 2 Pg 9 Cable Glands 2 C to 55 C 35 6 F to 131 F 11 kg 24 Ibs Cable entries Max ambient temperature Weight approx ELECTRICAL CONNECTION Power supply 100 115 VAC 1A 200 230 VAC
19. the Phenol Red or Buffer 7 solution and wait for the reading to stabilize Note The reading will not stabilize if the temperature probe is not in the buffer solution also jo NN w sr 5 Press Scroll until pH Calibrated to appears in the LCD display 6 Enter the password Press the up arrow A or down arrow until the password is reached 7 Press Enter 8 Press Enter again 9 Press the up arrow A or down arrow until the value is the same as the value printed on the label of the Phenol Red or Buffer 7 Solution 10 Press Enter to save the new calibration or ES Esc to abort without saving 11 Press EEE Esc to return to the main display Note pH and Redox ORP sensors tend to be slightly erratic in the first 24 hours they operate If the above calibrations are performed immediately after these sensors are installed or replaced repeat the calibration procedure in approximately 24 hours The temperature probe provides grounding and stabilizes the pH and ORP readings 6 4 3 ORP Redox Calibration ORP is calibrated using an ORP Standard Solution A standard closest to the normal operating value should be used for calibration 1 Shut off the water inlet and outlet from the flow cell 2 Remove the ORP sensor and PT 100 temperature probe from the flow cell 3 Wipe the sensor probe with a dry cloth and submerge it and the temperature probe into a cup 25 O Blue I Water Technologies with the O
20. the supplied screws 2 Route the wires for the float switch through the conduit and to the electrical box by following the wires from the existing float switches 3 Loosen or remove the screws holding the conduit cover in place 4 Feed the wires through the conduit following the path of the existing float switches 5 Push the wires through an available opening in the rubber gasket make sure to push through near the final connection 6 Connect the wires to the Colorimeter board 7 Find the section labeled Reagent DPD Level 8 Connect the wires to the top two terminal connections it doesn t matter which red wire goes into which connector 8 2 2 5 Installing the New Integrated Chipsets 1 Turn OFF the power to the HYDROGUARD Controller 2 Locate the chip on the control panel 3 Carefully remove the existing chip as shown in Figure 33 4 Reinstall the chip labeled CP E TCL making sure to line up the direction marks as shown in Figure 33 5 Locate the chip on the Colorimeter Module 6 Carefully remove the existing chip 7 Reinstall the chip labeled COLCONT E TCL making sure to line up the direction marks as shown in Figure 2 Warning Installing the chip in the wrong direction will damage the system and can create an electrical fire 100 gt hazard C a j bf Directional Mark Figure 33 Installing the new chip 8 2 2 6 Installing DPD 3 Reagent
21. tube and solution is bypassing returning to reagent bottle Piston sticks once in a while Note Ver4 0 Zero or Low Reading than ill present Stack Piston Alarm Normal a heck Clean valve and spring Add alve malfunctioning grease Replace valve if necessary Needle will be black on outside DPD occasional does not drop properly b c not flowing through iew for a while and see if stacks Needle is cracked or tube split at needle Enter calibration enter password Calibrated at wrong level and press enter to accept reading rom colorimeter heck Clean valve and spring Add Chlorine Measurement alve malfunctioning j g Inconsistent grease Replace valve if necessary Needs Calibration near set point If 25 of set point re calibrate LED likely not selective or not LED colorimeter bad reading proper zero of 650 Check ith Tech Module and replace Reestablish proper flow to olorimeter and wait for next test heck to see if ORP Emergency mode is indicated Determine oroblem with colorimeter check onnections clean cell etc Colorimeter disconnected Reduce Inlet flow and or pressure a oo much water to the Inlet i regulator may be required Sample Cell or Colorimeter Redirect Outlet so constant Outlet blocked or not downward sloping downward slope and no sharp bends in the tube P Reduce flow pressure of water to ater is flowing too high in colorimeter olorimeter replace the needles N
22. 0 Setting Proportional Control 10 1 Proportional Control Overview The many variables that control pool chemical balance make each pool unique These variables include e Pool size e Capacity of dosing and filtration systems e Type of chemical used e Controller reaction time The above variables affect two primary control characteristics e Delay time between chemical dosing and when the controller senses these chemicals e How strong a response a dose of chemicals produces in the controller Older pool water chemical controllers worked in basic on off modes The controller supplied chemicals at a constant rate until it sensed that it reached the chemical balance set point This type of operation caused major fluctuations in water chemical levels which wasted chemicals and caused chemical levels to cross the desired high and low thresholds maneka Set Point eee Chemical Level Figure 36 Chemical levels with ON OFF Mode Controllers HYDROGUARD controls dosing proportionally This method sets dosing rates in relation to how far current chemical levels are from the set point The dosing rates gradually decrease as chemical levels get closer to the set point lf water chemical levels are far below the set point HYDROGUARD will control the dosing systems to operate at full capacity 100 As the controller senses chemical levels rising and getting closer to the set point it will control the dosing systems to slow down to a lower
23. 0 5A 50Hz 60Hz Approx 60VA Power supply for RTC 3 6V lithium battery DATA SERIAL OUTPUT SIGNAL OUTPUT Power consumption RS 485 Standard half duplex 4 20mA optional Chlorine set point 1 250VAC DC 4A Max Chlorine set point 2 250VAC DC 4A Max pH 250VAC DC Max Turbidity control 250VAC DC 4A Max General alarm 250VAC DC 4A Max Temperature control 250VAC DC 4A Max DISPLAY Measured value displays Chlorine pH ORP Temperature Flow Total Chlorine Turbidity Conductivity Function indicator Auto off on mode for chlorine pH and dosing indication by Red and Green LEDs 2 line 24 character LCD with background light For secondary parameters program alarms and status 2x 7segment red display 3 digits CHLORINE MEASUREMENT Measurement For chlorine and pH Free and or Total chlorine Sensor Colorimetric multi spectrum sensor Cell cleaning Automatic self cleaning mechanism patent Mixing technology Inner solenoid activated active mixer patent Measurement range Oto 10ppm Measuring Interval 2 to 10 minutes using the adaptive measurement method 1 bar 14 5 psi 3 to 12 LPH 1bar 0 75 to 36 GPH 14 5 psi 1 C to 45 C 33 8 F to 113 F Max inlet operating pressure Flow rate colorimetric cell Working temperature REAGENTS Reagent type DPD1 DPD3 DPD4 Min 0 033 ml per sample Unmixed DPD1 amp DPD4 3 years DPD3 15 months Mixed Recommended 60 days Reagent consumption Shelf life pH MEASUREME
24. 1 oe a Fonte 0 ss s fromiAkainy 0 0 2 otal terness 0 Ca mw oo C bore emoon voae o m OO a w System Reset ma ma 6 3 3 Configuring Settings in the Operator Menu Each of the parameters in the operator menu is configured in the same way The following procedure describes how to configure a typical setting 1 Locate the desired parameter in the menu Press g Scroll until the desired parameter name appears in the LCD display Press Enter key 21 C Blue I Water Technologies Enter Password 100 appears in the LCD display ENTER PASSWORD 2 Enter the Operator password the technician password will also be accepted Press the up arrow A or down arrow Y until the password number is reached Note Holding the Scroll key while pressing up or down will advance the first digit Holding the Up or down keys for an extended period of time will proceed through the numbers more quickly The factory set operator password is 123 The operator password can only be changed by entering the current operator or technician password see 4 5 Technician Menu Setup Press Enter to accept the password The parameter name and current setting appear in the LCD display Press Enter The LCD display shows the parameter and the current setting 3 Enter the new parameter setting Press the up arrow A or down arrow until the desired value is reached The second row of the LCD displ
25. Disconnect the outlet tube from the colorimetric unit Unscrew the union between the solenoid valve and the Colorimeter d Unscrew the four 4 mounting screws that hold the Colorimeter to the HYDROGUARD housing e Open the control module door f Trace the wires from the Colorimeter to the control module connector A total of four wire pairs 2x4 are connected to the control module 4 connected to the MIXER terminal block and 4 to the SENSOR terminal block g Disconnect the Colorimeter s wires from the Colorimeter module 5 Connect a new Colorimeter unit a Hand tighten the union between Colorimeter and the solenoid valve until the Colorimeter is tightly connected to the valve Check that the O ring is still in place b Screw the Colorimeter to the HYDROGUARD analyzing module housing with the four mounting screws Place the top cap on the Colorimeter unit Re connect the outlet tube to the Colorimeter Pass the wires from the new colorimeter through the gasket into the control module Connect the wires to the MIXER and SENSOR terminal blocks as indicated on the colorimeter module nr 9 2 9 6 Recheck all connections 7 Close the HYDROGUARD analyzing module door 8 Turn on the power and restore flow to the flow cell 9 Confirm that the colorimeter is operating properly 7 7 8 Replacing Colorimeter Solenoid Valve Turn the water inlet and outlet to the flow cell and turn off the controller power
26. H and ORP readings will continue to rise for the first 24 48 hours If calibration is required it is best to wait until the readings have O Blue I Water Technologies stabilized or recalibrate when the readings have stabilized 6 5 Technician Menu Setup The Technician menu includes advanced parameter settings that are accessible separately from the Operator menu Anyone can view the settings but only someone with technician password can change This has been done to allow only those who are qualified to change the advanced controller settings These are also settings that should not require frequent changes after the initial installation and set up Table 5 Technician Menu Functions and Descriptions 2 N Menu Name Description 52 f C1 pump period _ 1 Pump cycle on off time for Cl Relay 1 Cl pump ued Cl pump max pulses Jit O for on off pou S ci Overoed Tine a E 55 CiAveraging Displays an average of the last4Clreadings 56 CI lt 0 1 Alarm If CI drops below this level Alarm indicated and Opens Cl Relay 1 2 pH p factor Proportional Factor for pH Relay 3 pH pump period 1 Pump cycle on off time for pH Relay 3 pH pump freq pH pump max pulses min O for on off pump pH Overfeed Time Will open relay 3 if pH feeding continuously for this time pH balance type To Select if Acid of Base is being added to adjust pH 62 Flow Sensor Will turn display of Flow rate on off only use if flow meter connect
27. NT Measurement Range 4to 10 Sensor Ceramic diaphragm and gel filling Input impedance 0 5 10 70 ORP REDOX MEASUREMENT Measurement range Oto 1000mv Sensor Ceramic diaphragm and gel filling Sensor PT 100 Measuring range 0 C to 50 C 32 F to 122 F MEASURING CELL Working temperature FLOW REQUIREMENTS Measuring cell flow rate 1 C to 45 C 33 8 F to 113 F 35L h 601 h 0 3 bar 4 4 psi to 1 bar 14 5 psi Up to 0 9 bar 13 psi Flow switch type Rotary switch FLOW MEASUREMENT Inlet pressure Outlet pressure closed cell Frequency input via I O card or 4 20mA input via NTU card Measurement range 0 1 000 m3 hour PRESSURE REQUIREMENTS Inlet Pressure 0 3 bar 4 4 psi to 1 bar 14 5 psi Up to 0 9 bar 13 psi Outlet pressure open cell Gravity pH VALUE CONTROL Control function Proportional or On Off Outlet pressure close cell Characteristics Normal Inverted Relay function Pulse length proportional controller Pulse frequency proportional controller Control function Proportional or On Off Proportional band Yes Relay function Pulse length proportional controller Pulse frequency proportional controller CHLORINE CONTROL 2 Control function On Off Proportional band No Integral action time No Memory 256 Kbit Lines 1000 Recording interval 1 360 min Event logger Yes Total relay on time Yes Operation password Yes Technician password Yes Optional Feature O Blue I Water Techn
28. RP Standard Solution and wait for the reading to stabilize Note The reading will not stabilize if the temperature probe is not in the buffer solution also 10 11 N aud Press Scroll until ORP Calibrated to appears in the LCD display Press Enter Enter the password Press the up arrow A or down arrow until the password is reached Press Enter Press Enter again Press the up arrow A or down arrow until the value is the same as the value printed on the label of the standard solution Press Enter to save the new calibration or ai Esc to abort without saving Press eal Esc to return to the main display 6 4 4 Temperature Calibration Take a sample of water from the flow cell 1 2 10 11 Insert a digital thermometer into the sample Wait for the thermometer reading to stabilize p D t Press Scroll until Temperature Calibrated to appears in the LCD display Press Enter Enter the password Press the up arrow A or down arrow until the password is reached D i Press Enter The value that appears is the last calibrated value Press Enter again Press the up arrow A or down arrow until the value is the same as the independent digital thermometer Press Enter to save the new calibration or es Esc to abort without saving Press eal Esc to return to the main display Note When the HYDROGUARD is initially turned on the p
29. These changes must be completed prior to wiring Caution Before making a connection to a power source confirm that both jumpers are located on the correct voltage and that the appropriate fuse is in place Verify that the power switch or circuit breaker to the non dependent power source is off Connect the line live wire to the electronic relay board connector marked Line Connect the neutral wire to the electronic relay board connector marked Neutral Connect the earth wire to the I O Module connector marked Ground Continue with the other electrical connections oe et LY Turn on electrical power only after all electrical connections have been completed 5 6 2 Connecting the Dependent Relay Power Source The line live wire of the pump dependent power source connects to the connection labeled Common on each relay The line wire of each controlled system is connected to the normally open No or normally closed Nc connection of each relay as appropriate Normally Open means that the relay will be open i e no power from the relay until the controller calls for power Normally Closed means that the relay will be closed i e power from the relay until the controller calls to stop power 1 Verify that the power switch or circuit breaker to the pump dependent power source is off 2 Connect the earth wire to the ground return wire from each of the controlled dosing systems 3 Connect the neutral wire to the return wire from each
30. a flow meter is used in place of the flow switch Figure 9 Rotating Flow Switch 5 6 4 Wiring to Dosing Systems HYDROGUARD controls chemical dosing systems using a series of electronic relays that start and stop the dosing pumps Each relay opens and closes a switch that activates a separate pump or piece of equipment 6 Ji E A Ja s 309 NC NOC NC N Nc nd C NC NOIG NC NOC NC NG 1 2 3 4 5 6 w ox spe 2 HS a2 PH NTU ALARM TEMP of eases z oZz02Z0222 DROGUARD WG302 VO MODULE L Q Q Q QO Q d ra 0 o 0 o bob bob b 100 230V S zZ ox a T 2 ge bo CONTROL OUTPUT INPUT SWITCH 2 O Q OO INPUT FLOW METER SMTCH 1 FREQUENCY INPUT Figure 10 Schematic of I O Board 11 Blue D Toma ow Ce Lee Toe De ee Ce Main Power Main Power Cl Pump Line Common red Neutral blue Grae wee n 5 6 4 1 Dosing Pump or Solenoid Valve 1 Dosing will turn ON based on HG 302 decision to add chemicals 2 Connect the Line live wire through COM and N O CI Ext or pH Ext Line Common red Neutral blue Cl or pH Pump Ground green _ Relay Power Supply 5 6 4 2 Salt Chlorinator 1 Dosing will turn ON based on HG 302 decision to add chemicals 2 Connect the Line live wire through COM and N O CI Ext or pH Ext Line Common red Relay Power gt gt gt eee Supply Salt Chlorinator Ground green _ 5 6 4 3 Salt Chlorinator
31. aid in troubleshooting 2 D alibration to aid in troubleshooting 1 fTurb High alarm JAlarm when Turbidity above this value optional module 22 Alarm Delay Time delay before Alarm Relay 5 closes 23 Flowlowimit Low flow limit for external flow meter 30 PRP Emergency Allows ORP mode to be used if CI measurement problem _ B4 Allows choice of language B2 System Reset Restarts controller safer than turning off and on 8 2 3 2 Alarms The table below lists and describes the HYDROGUARD alarms and the relays they activate Table 14 Table of Alarms 55 Alarm ne Alarm Description No flow Flow switch on flow cell is off Low flow External flow meter below minimum flow Fe heck CLRMTR Communication error between colorimeter onnect and colorimeter board tuck piston Piston is not moving properly A6 Unclear cell Glass in colorimeter is dirty A9 ko Fromme lt or fnomeuusuayow otal CI above high limit A24 bHoverieedtime bH dosing on for longer than max time ho Emergency Mo problem to alow ORP emergency mode O Blue I Water Technologies 8 2 3 3 Technician Menu The following table lists the parameters in HYDROGUARD s Technician menu Table 15 Technician Menu Menu Name Description P factor Proportional Factor for CI Relay 1 52 CI pump period Pump cycle on off time for CI Relay 1 58 Hpumpperiod Pump cycle on off time for pH Relay 3 60 pHOverfeed Time Will ope
32. als must be in a high enough concentrations to effectively kill water borne bacteria In overly high concentrations however these same chemicals may also be dangerous to swimmers who bathe in the pool Various methods have been developed over the years to monitor and control the concentration and balance of chemicals used in pool water 4 2 The HYDROGUARD Solution The older manual methods of monitoring chemical balance are neither objective nor effective HYDROGUARD measures free and optionally total chlorine levels with a digital photometer which has many advantages over other types of sensors as well offering and option to to present the combined chlorine Digital photometer testing is completely objective It is not dependent on lighting conditions or the operator s eyesight and is far more accurate It does not require frequent calibration and is compatible with all types of disinfectant systems HYDROGUARD performs colorimetric testing in a closed reading cell It is the only system that automatically and accurately measures free chlorine using small amounts of reagent Once installed and calibrated HYDROGUARD is fully automatic It controls dosing systems directly releasing the proper quantity of chemicals based on frequent automatic measurements HYDROGUARD is simple to use Its straight forward control panel and parameters menu make chemical balance control an easy task All basic information can be viewed at a glance and changing s
33. ay below the value that is being changed shows the current value as shown in Figure 15 4 Press Enter to save the new setting or E Esc to abort without saving the new setting D To change the settings of additional parameters press fm Scroll until the desired parameter appears in the LCD display and repeat steps 3 and 4 above to set the new parameter Note The parameter in the menu There is no scroll back option To view or change a previous parameter in the Scroll button displays the next parameter in the list so that the operator can check every menu you must exit the menu by pressing ESH Esc and start the above procedure from the beginning CL SET POINT 1 Figure 20 Changing a Parameter 6 4 Calibration Parameters must be calibrated with measurements taken with external testing devices Always use digital calibration devices not the less accurate visual test kits Alternatively standard solutions may be used Make sure the standard solution is not expired or contaminated prior to using Follow the procedures below EXACTLY as instructed Caution ALWAYS take water for calibration from the sampling valve NOT from pool The controller should always be calibrated with water from the same source Note Calibration is only required every 6 to 12 months Minor deviations will exist between all testing equipment These minor differences do not warrant the calibration of the colorimeter
34. bes some popular optional components that may Optional Features be installed on the controller or added at any time Chapter 8 Lists and describes HYDROGUARD s operational Rel Menus Alarm elays Menus Alarms components and Technical Data Chapter 9 Describes how HYDROGUARD implements proportional Setting Proportional monitoring and control and instructs how to configure it Control Chapter 10 Recording settings in various pool environments Provides a table for the technician to record parameter value settings in various pool environments A table of technical specifications for the HYDROGUARD HG 302 Chapter 11 Technical Specifications O Blue I Water Technologies 4 Overview The HYDROGUARD HG 302 Water Quality Controller continuously monitors and automatically controls chemical levels in pool water HY DROGUARD automates chlorine pH ORP Redox temperature and other water quality tests i e turbidity total chlorine etc administering pool chemicals as required according to the results of these tests 4 1 Pool Chemistry Overview Pool chemistry is the science of controlling the concentration of chemicals used to purify swimming pool water under changing conditions Chlorine is commonly used to kill dangerous bacteria and other organisms that grow in pool water Acid or base chemicals maintain proper pH values for the comfort of bathers and to effectively disinfect the water These chemic
35. capacity 60 As chemical levels get even closer to the set point the dosing system will slow down even more 30 and so on until the chemical level gets to the set point With proportional only control it is difficult to reach the set point in larger or more heavily used pools O Blue I Water Technologies because the dosing rate slows too early Conversely in small pools or spas the set point may be exceeded because the dosing did not slow early enough The P factor allows the controller to be customized to the specific pool The percentage of the time on is explained by the following equation with chlorine as an example setpoint pan a Pes Mon E setpoint In this example the CI set point and measured values are If the P factor is changed the percentage of the pump cycle that will be on time on changes as follows Table 22 P factor The range for P factor for CI and pH are presented in the table below Table 23 P factor Range Cl p Factor 50 b n Off control o o o Very proportional and slow dosing pH p Factor 100 Ono control ft Nery proportional and slow dosing 10 2 Setting Proportional Factor Proportional control of chemical dosing requires configuration according to various factors The primary factors are the ratio between the pool size and the rate the chemical dosing systems can feed chemicals and the delay time between when the chemical level changes and when it is sensed by the
36. color order indicated on the module The sensor cable may be cut or extended up to a maximum distance of 15m 48 7 feet as needed 8 4 4 First Time Set up and General Operation Although the flow meter is connected it will not operate until it is set up in the controller menu 8 4 4 1 Operator Menu 1 Press Scroll until 23 Flow Low Limit appears on the display and press Enter 2 Enter the operator or technician password and press Enter 3 Enter the minimum flow rate and press Enter 4 The units of the flow rate can be set to GPM or m hr in the technician menu 5 If the flow rate drops below this value all relays will open except the alarm relay 6 Press Scroll again and 24 Flow K Factor appears on the display and press Enter 7 Enter the operator or technician password and press Enter 8 Using the table provided with the flow meter enter the k factor based on the pipe size fitting and units GPM or m hr 8 4 4 2 Technician Menu Press up and down together to enter the technical menu Press Scroll until 62 Flow Sensor ON OFF appears in the display and press Enter Enter the technician password and press Enter Select the appropriate units GPM or m hr and press Enter Press Scroll again and 63 Flow Rate appears in the display and press Enter ot a o Enter the technician password and press Enter 7 Select the appropriate units GPM or m hr and press Enter The flow meter should now be
37. controller In large pools changes in chemical levels occur slowly The dosing systems must 69 O Blue I Water Technologies feed large amounts of chemicals for a long period of time in order for a change to be noticed The chemicals also disperse slowly in larger pools Smaller pools on the other hand react much more quickly The length of time between the change and when the controller identifies the change also affects proportional control The controller can only identify water chemical levels after they have been distributed throughout the pool and have returned to the pump room for analysis by the automatic controller This may be a long time after the chemicals were released into the pool The controller therefore recognizes the chemical levels from dosing settings in the past The dosing systems continue feeding chemicals during this delay causing chemical levels to pass the set point resulting in fluctuations errr rere Set Point ms Chemical Level Figure 38 Feedback Delay Causes Chemical Levels to Pass the Set Point To prevent these fluctuations the controller must reduce chemical dosing rates as it senses that chemical levels are approaching the set point taking the delay into account The controller should also not overcompensate for the delay which would cause chemical levels to not reach the set point at all The proportional factor for chlorine and pH proportional control can be set on a scale of z
38. d Chorine Alarm Level using the up and down buttons eee OR eS NS 0 Press Enter 1 Press Esc to return to normal operation Troubleshooting Specific to Total Chlorine The troubleshooting of the HYDROGUARD controller with total chlorine will be the same as the troubleshooting of the standard HYDROGUARD controller However there are a few conditions that may exist with the total chlorine controller that do not occur with the standard unit The table below outlines these additional troubleshooting issues Table 16 Troubleshooting for Specific Alarms Chlorine Level is too high Dilute and test manually controller 20ppm and is bleaching ill operate fine once back in normal reagents level a Perform system reset and wait for FAC was calibrated but TC did not increase or TC is reading higher than FAC next TC reading upgrade to new software version decrease as expected 57 DPD3 is being trapped on Replace silicon piston with new FAC is reading high l piston ersion 8 4 Flow Meter Caution Prior to opening the controller or installing any electrical components turn off all power supplies to the controller 8 4 1 Selecting and Location The exact location of the flow meter will depend on the specific piping arrangement Several factors should be considered in order to provide maximum safety and accuracy Safety In order to prevent chemicals from being added when there
39. d before the reagents are depleted the testing and chlorine dosing will stop and a No Reagents alarm will be displayed therefore it is important to replace reagents before this occurs Filter Cleaning The HYDROGUARD unit has a filter installed in its water supply pipe which collects particles and impurities It should be cleaned or replaced periodically depending on water quality The filter cover is clear allowing for a quick visual inspection to determine if cleaning is required Shut down and Winterizing In areas where temperatures drop below freezing all water must be removed from the controller to prevent components from breaking and the probes must be removed and stored in a warm area and kept wet at all times The probes will last for several years if properly treated but will not read properly if exposed to freezing temperatures or stored in air Start up and Preventive Maintenance A preventative inspection and cleaning of components should be completed whenever the controller is restarted after a long gt 2 week downtime Likewise the controller has several mechanical components that will wear out over time To prevent future 33 O Blue I Water Technologies problems these components should be check and or replaced periodically This is most easily accomplished at initial start up prior to the beginning of the pool season Troubleshooting Occasionally problems will occur with the controller readings or chemical d
40. der to minimize the delay time between the pool water being sampled and HYDROGUARD testing the water and 7 O Blue I Water Technologies adjusting dosing levels The water inlet A flow is 60 80lit h pressure 03 1 bar 4 4 14 5psi should not exceed 1 bar 14 5 psi The outlet B pressure will range accordantly 0 0 9bar 0 13psi If your water inlet pressure exceed 1 bar 14 5 psi a pressure regulate Fig 4 should be installed Figure 5 Pressure Regulator Figure 6 Water Inlet and Outlet 5 5 2 Drainage Two drainage connections are required A gravity drainage connection is required for the water coming from the colorimeter A pressurized vacuum or gravity connection is required from the outlet of the flow cell The length of the colorimeter drain line should be as short as possible and must have a constant downward slope to prevent a backup of water The flow cell may be pressurized up to 14 5 psi 1 bar if the flow cell drain is connected to vacuum the inlet pressure must be at least 7 psi 0 5 bar greater than the drain vacuum A drain cap is located on the colorimeter outlet to prevent the backup of water into the colorimeter if the drain line is blocked A 1 2 NPT fitting is supplied for the colorimeter drain connection and a 1 4 FNPT fitting is supplied for the flow cell drain connection Figure 7 Colorimeter Drainage Note The HYDROGUARD colorimeter drains water at zero 0 pressure The d
41. describes how to install the Redox ORP and pH sensors in the HYDROGUARD unit The installation of all the sensors in the flow cell is similar expect for the connecting wires Caution Make sure the pH and Redox sensors have plastic or rubber plugs covering their ends Use another sensor if the plug of any sensor is missing or has fallen off Make sure to connect the appropriate wire to the appropriate sensors Labels are located on the wires near the probe connection and on the connection on the tube probe Module 1 Remove the sensor from its packing box 2 Remove the plastic cover or plug from the end of the sensor and drain the solution from the tube Keep the plastic cover in a safe place for winterizing or storage of probes 3 Hold the sensor by its metal connector with the glass tube pointing down 4 Insert the sensor into the top of the transparent flow cell and thread in securely DO NOT OVERTIGHTEN 5 Connect the appropriate sensor plug to the sensor s metal connector Make sure the proper plug is connected to the correct sensor 6 Switch the HYDROGUARD ON verify that pH reading appears on the red LED display and the ORP Redox reading appears in the LCD display Observe the pH and ORP Redox levels and wait several minutes until both readings stabilize If either one or both indicators do not display a proper reading or are not stable see Troubleshooting Figure 12 Installing Sensors in Sampling Cell
42. e chip carefully by prying up each end a little at a time with a thin screwdriver eN Ff Install the new chip in the same location Please note in the figure that the chip and the board each have a directional mark The chip must be positioned so that these directional marks are aligned Warning Installing the chip in the wrong is direction will damage the system and can create an electrical fire hazard Directional Mark Figure 31 Installing the New Chip 49 O Blue I Water Technologies 8 Optional Controller Features 8 1 Total Chlorine The Total Chlorine Controller measures both the Free Available Chlorine FAC and the Total Chlorine TC combined chlorine CC is calculated The free chlorine is the active chlorine in the water When chlorine is added to water hypochlorous acid HOCI is formed which is the active agent that actually disinfects the water However its reaction with nitrogen based compounds creates inorganic or organic chloramines also known as combined chlorine A high level of combined chlorine may cause excessive chlorine odor respiratory problems and eye skin irritation Likewise chloramines are relatively inactive and therefore do not aid in sanitizing The most common way to remove CC is to add a level of chlorine equivalent to 10 times the CC level Alternatively many complimentary sanitizing systems like UV will lower CC levels while providing additional water sani
43. ecifically designed for easy operation however some periodic maintenance is still required Basic guidelines are provided in Table 6 however the actual schedule may vary depending on the actual conditions and use Table 9 Periodic Maintenance Schedule Service Required Frequency Required Replacing Reagents Every 4 to 8 weeks Cleaning Pre Filter Check every 4 weeks clean when visible dirt and oil Calibration pH ORP Temp Cl Every 6 to 12 months Replacing Reagent Pump Head and Tubes Every 12 months Basic Operation involves setting the desired parameters and monitoring the system for alarms When operating normally HYDROGUARD demands very little operator involvement Calibration Sensor sensitivity and accuracy can degrade or drift over time For this reason HYDROGUARD settings must be periodically recalibrated and compared with measurements from other measuring devices such as electronic photometers pH sensors and thermometers or compared to standard solutions like pH buffers or ORP standards Reagent Replacement HYDROGUARD uses a very small amount 0 03 ml of chlorine reagents each time water is sampled The adaptive measurement interval will automatically vary the testing interval depending on water stability This allows the two 500 ml bottles to last approximately 4 to 8 weeks A Low Reagents alarm is issued when either one of the reagent bottles approaches depletion and should be replaced If the reagents are not replace
44. ed 66 Turbidity Turns Turbidity Module ON OFF optional module NTU wiper interval Interval for Turbidity Module Wiper to clean glass optional module 68 Minutes Current Time for Data Logger Current Time for Data Logger Current Time for Data Logger Current Time for Data Logger Current Time for Data Logger 73 Recording Interval Time interval between readings stored on the on board data logger Controller ID used with external communication Software Version Current software version 7 Operator Password Change operator password 7 Technical Password Change technician password O Blue I Water Technologies Table 6 Technician Menu and Variable Limits Max Menu Name Min Value Value nits CI pump period CI pump freq 0 on off pump Max pulses min o O o DN mn CIE 1 1 Ono ormer b coram b T pA pH pump eid bs 100 m m C 59 pHpumptreg P O on off pump fo pH Overfeed Time P 0 of peo p Flow Sensor ea S GPM O oN 20 T EE CE EE 20 Max pulses min ONE PM CR EE ON In In In In Turbidity OFF EE In In SE TS ER 7 VS CE SE VS 7 VS 1 5 0 0 off OFF OFF 5 0 0 off OFF 3 C 4 OFF Z e PE Z e PS DE CE I ha h OoOo rs operator Password f O e F7 frac Passno fe 6 5 1 Menu Feature Description There are several features of the controller that are not immediately obvious from the menus Adapti
45. edox and temperature probes Keyboard Panel mounted on the cover of the control module it functions as HY DROGUARD s user interface The control panel displays current measurements and indicates alarms All settings and adjustments are performed through the control panel I O Module Input Output Power Supply to the controller and relays The module contains the relays that control external dosing systems Colorimeter water outlet Regent Injection Frs ll View window oe Analyzing Unit CY ee A Solenoid valve Reagent Pumps DE x Colorimeter Drain QUE SN AN en Rotating Flow Switch Control Unit Reagent Siphon lt Caps Reagent Bottles SET Water Intake Filter y pH Redox Temperature Module I O Module Figure 1 HYDROGUARD Components 5 Installation Pump room installation involves several consecutive steps The installation process starts with the manual installation and connection of the unit to the system that it controls as described in this chapter Once physically installed sensors and reagents must be inserted into the unit and the control system must be started and calibrated as described in Chapter 5 First Time Operation and Calibration HY DROGUARD should operate for several days in order to be properly tuned to its specific pool environment Additional periodic tuning calibration and maintenance are required after HYDROGUARD has b
46. een operating on a regular basis This is described in Chapter 5 Continuous Operation and Maintenance 5 1 Working Environment Pollution Degree 2 Installation Category 2 Altitude 2 000 m Humidity 1 to 90 non condensing Electrical Supply 100 115Vac 1 0A or 200 230Vac 0 5A 50 60Hz Temperature 5 C to 45 C 5 2 Selecting a Location Take extra time in selecting a location since the installation location will determine the ease of the installation and future operation and maintenance The location where HY DROGUARD is installed is dependent on various considerations Convenient Access HYDROGUARD should be installed where it can easily be viewed and operated by pool personnel Dry Area HYDROGUARD handles electricity and includes electronic circuitry that is susceptible to short circuiting and or corrosion when exposed to water or high ambient moisture levels Pool Chemicals Pool chemicals can be corrosive to HY DROGUARD s electronic circuitry It is highly recommended that HYDROGUARD is not installed adjacent to the pool chemicals storage area or the dosing systems themselves Minimum Distance from Pump The water sampling line that is tapped into the main circulation pipe feeding HYDROGUARD should be as short as possible A long sample line from the main circulation pipe to HYDROGUARD creates an unnecessary delay between supply measurement analysis and chemical dosing Drainage The location should easily all
47. el An authorized technician ay open the cover and heck the coils connection ry to push the piston from the op down No reading Low reading Alarm Free Chlorine level is High reading Alarm above alarm level High reading Alarm Low pH A13 I age even no Low reading Alarm alarm level N14 Acid base level is above alarm level A416 NTU level is above alarm level a Q gt mr C lean tube An authorized echnician may open the over and clean the sensor lamp Change olorimeter if repeating Resolder LED connection hange colorimeter assembly Message NOT an error Info indicating replacement is soon needed ompare to manual reading heck if unstable reading is due to grounding Check the orrect set point Recheck in 24H and recalibrate heck replace probe Check onnection to board Change orobe if necessary ompare to manual reading heck reagent flow from bottle o colorimeter Check clean solenoid valve including spring Check correct water low Verify piston movement mixing Check dosing system from relay to dosing oumps Replace reagents ompare to manual reading heck if Stable reading is due o grounding Check the orrect set point Check onnection to board Change orobe if necessary heck constant reading ompare to manual reading heck wiper movement Clean sensor window Change if OBluel Alarm Description Solution Suggestion heck sho
48. ero point one 0 1 to fifty 50 for total chlorine and zero point one 0 1 to one hundred 100 for pH A high proportional factor means that chemical levels rise and fall unimpeded until they cross the set point as displayed below Chemical Level Figure 39 Proportional Factor 50 A low proportional factor slows the chemical flow rate far from the set point and it will take a very long time for chemical levels to get near the set point Chemical Level Figure 41 Proportional Factor Too High The proportional factor must therefore be suited for the particular pool with its specific conditions Chemical Level Figure 42 Proportional Factor Too Low When setting the proportional factor in HYDROGUARD start with the recommended settings according to the size of the pool HYDROGUARD then learns how to correlate the fluctuations automatically The fluctuations eventually get smaller and chemical levels remain close to the set point Contact Blue Customer Support and Training for more information on setting the proper proportional factor for your pool environment 10 3 Setting Pump Period Pump period is a single cycle during which the dosing pump operates and then rests Proportional control divides the pump period into two distinct phases active and at rest In general it is recommended to operate in a short cycle i e 00 30 Sec For large pools or if you activate solenoid valves you may conside
49. ettings is as simple as scrolling through the menu and adjusting the current settings 4 3 Features and Modules The HYDROGUARD unit measures four basic parameters that indicate pool water quality Four optional modules may also be added Details about the optional components are not included in this manual Additional manual sections will accompany the optional features 4 4 Standard Modules e Free Chlorine e pH e ORP Redox e Temperature 4 5 Optional Modules e Total Chlorine e Combined Chlorine e Flow rate e Turbidity e Expert Pool Wireless Management Package 4 5 1 Expert Pool An advanced and unique HYDROGUARD option is the cellular communication package known as Expert Pool Expert Pool provides web based monitoring and control service of up to five controllers The cellular communicator accepts HY DROGUARD s alarms and readings and transmits them to a web based application server The server then sends these readings and alerts via SMS cellular Short Message Service email or Internet Instant Messaging to pool managers inspectors service technicians and other authorized pool maintenance personnel The communications between HYDROGUARD and pool maintenance personnel is bidirectional allowing settings and features to be managed remotely through the Internet or from a mobile telephone Caution Remote control of pool water chemistry is potentially dangerous to bathers The HYDROGUARD remote monitoring and contr
50. fore opening the control unit 1 Disconnect the flat cable plug from the card 1 2 Unscrew the four 4 mounting screws 2 3 Putin the new card and tighten the four 4 mounting screws 2 4 Connect the flat cable plug to the card 3 7 7 11 Replacing pH Redox and Temperature Module Disconnect the power supply to the unit before opening the control unit 1 Disconnect the flat cable plug from the card 1 2 Unscrew the four 4 mounting screws 2 3 Putin the new card and tighten the four 4 mounting screws 2 4 Connect the flat cable plug to the card 3 7 7 12 Replacing Colorimetric Module Disconnect the power supply to the unit before opening the control unit Before replacing this card first remove the pH Redox and Temperature card as described in section 5 5 9 Disconnect the flat cable plug from the colorimetric card 1 Unscrew the four 4 mounting screws 2 Put in the new colorimetric card and tighten the four 4 mounting screws 2 Connect the flat cable plug to the colorimetric card 3 g e 2 NY a Replace and reconnect the pH Redox and Temperature sensors card as described in section 5 5 9 7 7 13 Module Software Update Each electronic module has a microcontroller chip IC with its own unique software Whenever a module s software is updated its chip must be replaced by a new version with the new software Turn OFF the power to HYDROGUARD Locate the chip that needs to be replaced Remove th
51. formation into the table 1 below If pH and ORP are reading slightly low do not calibrate as they will continue to increase for the first 24 48 hours Table 7 Technician Calibration Table BEIG Site Technician s Name Parameter Controller Reading External Device or Standard Value Redox ORP Perform the following tests 2 Press the pH Mode button on the control panel to change the mode to On Check that the dosing system is adding acid or base chemicals to the pool water 3 Press the pH Mode button on the control panel to return the pH mode to Auto 4 Press the CI Mode button on the control panel to change mode to On Check that the dosing system is adding chlorine to pool water 5 Press the Cl Mode button on control panel to return chlorine mode to Auto 6 Turn off the main circulation pump Check that the dosing systems are not adding any chemicals to the pool water 7 Record the values in each menu Table 8 Parameters Values Record Operator Menu Value Technician Menu GIP factor pH set point LL pH p factor 31 Tarpon Aam Tempra Trwa sapon rwy ru high Rem NTU per mena arm Day rocodmgiena RTS address EE Crowa soma ven ro Akainy operator Total haraness from es C Blue Water Technologies 7 Routine Operation and Maintenance Once installed by a qualified technician HYDROGUARD can begin monitoring and controlling pool water quality HYDROGUARD is sp
52. he same power Controller won t power up ORP and pH wires are reversed race wires back to Control Board and or disconnected onfirm ORP or pH probe is bad Replace faulty probe Unstable ORP and pH Poor Grounding heck PT100 I O board ground ORP and Readings oH wire grounding Hit escape to exit out of menu return to auto mode i a Zeng Overfeed Safety Shut off Check for overfeed alarm system reset to restore adjust overfeed time if needed Prime for 90 seconds confirm pumps work Reagent Pumps not Primed or oroperly and droplets form and drop from broken each needle Chlorine too high 20ppm and Dilute and test manually controller will is bleaching reagents operate fine once back at normal level Solenoid not shutting completely onfirm that water stops flowing when reading starts timer gets to zero Unscrew solenoid and clean the tip check filter for ORP and pH readings are very far from normal value In menu change mode Chlorine Measurement is Zero or Low Using wrong or not original Make sure reagents are in good reagents or reagent expired date onditions replace if needed passed es pump and confirm that droplets forming Needles Blocked Damaged as expected Problem Symptoms Potential Cause Solution Suggestion heck by raising solenoid above oump and or turning off for an hour and then seeing if reagent comes out immediately when pumped Bad Pump
53. hnicians are authorized to install and maintain the controller Only properly trained and licensed electricians should attempt any change to the system s electrical components Only properly trained and licensed swimming pool operators should attempt to make any changes to chemical dosing levels Always follow local health and safety regulations when performing any service on the HYDROGUARD unit or changing chemical dosing settings Note During disassembly procedures be sure to retain all hardware for use during disassembly Upgrade and replacement kits may re use some original components Q BlueI 3 Overview of Chapters This document is functionally divided into chapters and appendices according to the various steps involved in installing and operating the HYDROGUARD system Chapter 1 Short Overview of manual layout and information Manual Overview Chapter 2 Overview of Chapters Chapter 3 General description of how water quality is maintained in Controller Overview swimming pools and how HYDROGUARD automatically monitors and controls Chapter 4 Instructs how to install HYDROGUARD and how to Installation integrate it with pool water quality systems Chapter 5 Instructs how to configure calibrate and operate the First Time Set up HYDROGUARD system immediately after it is installed Chapter 6 Instructs how to respond to alarms and troubleshooting Routine Operation amp issues Maintenance Chapter 7 Descri
54. is no flow to the pool the flow meter should be installed in the main return line after the filter Accuracy in order to ensure accuracy the flow meter should be installed in a straight run of pipe following the minimum requirements listed in Table 10 Table 17 Minimum Installation Distance from Pipe Fittings Likewise if the pipe is not completely full of water or air bubbles are present the flow meter should be installed in the side or bottom of the pipe to prevent interference Lastly the flow meter cable is 8m 26 4 ft and may be cut or extended up to 15m 48 7 feet as needed The distance to the controller must not exceed this maximum 8 4 2 Hardware and Plumbing Installation 1 Drill an appropriate size hole based on the saddle clamp and flow meter in the main return pipe from the filter based on the criteria listed in 0 2 Install the saddle clamp 3 Lubricate the sensor o ring with a silicone lubricant DO NOT use a petroleum based lubricant as this may deteriorate the o ring 4 Insert the flow meter into the saddle clamp aligning the tab on the flow meter with the notch on the saddle clamp 5 Hand tighten the flow meter cap DO NOT use tools or over tighten 8 4 3 Electrical Installation 6 Pass the flow sensor cable through an open glad on the bottom of the controller 7 Connect the three wires from the sensor cable to the last terminal block on the lower right corner of the I O Module following the
55. its glass tube or metal probe clears the hole 5 Prepare the new sensor to be installed a Open the replacement sensor s box and remove the sensor by the metal connector b Ifthe sensor has a rubber or plastic plug at the tip of the glass tube remove the plug and shake the sensor The protecting oil inside the glass tube may interfere with the sensor s readings 6 Install the new sensor a Hold the sensor by its metal connector with the glass tube pointing down and insert the glass tube into a hole in the flow cell b Screw the probe into place DO NOT OVERTIGHTEN c Screw the sensor wire onto the probe 7 7 2 Replacing the Temperature Probe 1 Turn off the inlet and outlet water to the flow cell and the power to the controller 2 Open the doors of both the analyzing module and the control module O Blue I Water Technologies 3 4 7 7 3 N 11 12 13 14 15 16 7 7 4 17 18 19 20 7 7 5 Remove the four 4 wires from the temperature probe in the control module Remove old sensor from the reading cell a Unscrew the compression fitting from the temperature probe b Pull the probe up until it clears the fitting Install the new sensor a Insert the temperature probe into the fitting b Screw the compression fitting around the probe Replacing the Flow Switch Turn off the inlet and outlet water to the flow cell and the power to the controller Open the doors of both the ana
56. l Installation The following procedure instructs how to install the HYDROGUARD unit in a pool pump room 1 HYDROGUARD is shipped pre mounted on a mounting panel along with a water filter The mounting panel includes four screw holes one in each corner A B C and D Determine the location of one hole A on the HYDROGUARD unit or on the mounting panel Mark the location of the screw hole and drill a hole for a screw anchor Screw one corner of the HYDROGUARD unit or mounting panel to the wall ae 2 Level the HYDROGUARD unit or mounting panel and mark the remaining three B C and D O Blue I Water Technologies screw holes 6 Drill the three 3 remaining holes insert anchors and screw the remaining corners to the wall using 5 16 8 mm screws Figure 3 Mounting HYDROGUARD on the Wall Note HG 302 must be leveled in order to achieve proper operation 5 5 Plumbing Requirements and Installation 5 5 1 Water Supply HYDROGUARD requires a pressurized water supply to the flow cell a zero pressure gravity water return from the colorimeter and a pressurized or gravity return from the flow cell An isolating valve must be installed in the main circulation pump line between the pump and the filter Figure 4 Water Filter Water taken after the filter will have different chemistry than water taken before specifically lower Cl levels The pipe or tube from the main pipe should be as short as possible in or
57. ly stopped when the solenoid shuts If not shutting properly it must be cleaned or replaced Inspect the pump tubes for cracks or signs of significant wear and replace if necessary see 5 5 1 Install new reagents and press the pump button for 90 seconds to prime the tubes Inspect the pump needles in the colorimeter cap to ensure that droplets are forming and falling properly Replace if necessary Replace probes in the flow cell close the sampling valve and turn on flow immediately to re wet the probes Recalibrate the controller Cl ORP pH ORP and pH will likely require 24 48 hours to re stabilize and will require re calibration at this time 7 5 1 Replacing Pump Head and Tubes If the pump head and or tubes are cracked appear significantly worn or are no longer functioning properly they should be replaced to ensure consistent operation and control Turn off the power to the HYDROGUARD controller 2 Remove the tubes from the pump head and the needles in the colorimeter cap by holding the top of each needle and pulling the tube genily 3 Remove the tubes from the reagent bottles and wipe off any excess reagent the DPD will stain so be careful Unscrew the two 2 screws on the face of the pump head Save the screws Remove the pump head by pulling gently and sliding the pump head off of the motor assembly Slide the new pump head onto the motor assembly ensuring that the slot in the pump head matches the notch in the m
58. lyzing module and the control module Locate the flow switch attached to the flow cell Disconnect the flow switch wires from the I O module Remove the inlet connection to the old flow switch Remove the flow switch from the flow cell Pull the flow switch wires gently to completely remove them from the controller Insert the new flow switch on the flow cell Insert the inlet connection on the flow switch Route the flow switch wires back to the connection on the I O module and connect the wires to points 3 and 4 on the input switch terminal block Close the controller doors and turn on the water and power and ensure proper operation Replacing Reagent Siphons Turn the power off to the controller Disconnect the two 2 red wires from the reagent level connector on the colorimetric module Remove the four 4 mounting screws Install the new reagent siphons a Attach the four 4 mounting screws b Connect the two 2 red wires to the colorimetric module Replacing the sensor Turn the power off to the controller Disconnect the two 2 red wires from the reagent level connector on the colorimetric module Unscrew the old sensor by hand and pull out the sensor along with its two 2 red wires Install the new sensor by first pushing the two 2 red wires into the sensor tube screw in the sensor by hand Reconnect the two 2 red wires to the colorimetric module 45 7 7 6 Replacing Reagent Pumps Turn the power
59. mentation lectrique est ou sont bien d connect e s avant d ouvrir l unit ou d entreprendre toute op ration de service technique et tout branchement des composants lectroniques Attention II y a lieu d agir avec une extr me prudence lors de l installation de la mise en uvre et de la maintenance de l HYDROGUARD Seuls des techniciens d ment form s cet effet sont autoris s effectuer l installation et la maintenance de l analyseur du contr leur Seuls des op rateurs qualifi s de piscine d ment form s cet effet sont habilit s modifier les dosages des produits chimiques utilis s Conformez vous sans exception aux consignes locales de sant et de s curit lorsque vous effectuez toute op ration technique sur l analyseur le contr leur ou lorsque vous modifiez les param tres de dosages chimiques L alimentation g n rale peut tre branch e sur 110 120 ou sur 220 240VAC 50 60Hz Pour basculer d une tension l autre il suffit de changer les deux 2 cavaliers situ s au dessus de la principale connexion lectrique gauche du transformateur Une tension 110 120VAC requiert un fusible de 1 Amp une tension 220 240VAC requiert un fusible de 0 5 Amp Ces modifications doivent tre accomplies avant le branchement lectrique Attention Avant de relier l appareil une quelconque alimentation lectrique v rifiez que les deux cavaliers sont situ s sur les valeurs correctes de ten
60. ments and Installation 7 5 5 1 Water Supply 7 5 5 2 Drainage 8 5 6 Electrical Requirements and Installation 9 5 6 1 Connecting the Main Electrical Power Source 9 5 6 2 Connecting the Dependent Relay Power Source 10 5 6 3 Input Switches 10 5 6 4 Wiring to Dosing Systems 11 5 6 4 1 Dosing Pump or Solenoid Valve 12 5 6 4 2 Salt Chlorinator 12 5 6 4 3 Salt Chlorinator dry contact or 24V 12 5 6 5 Relays and the Dosing Systems They Control 13 6 First Time Operation and Calibration 14 6 1 Installing Sensors 14 6 2 Installing Reagents 15 6 3 First Time Menu Setup 17 6 3 1 HYDROGUARD Control Panel 18 6 3 2 Menus 19 6 3 3 Configuring Settings in the Operator Menu 21 6 4 Calibration 23 6 4 1 Chlorine Calibration 23 6 4 2 pH Calibration 25 6 4 3 ORP Redox Calibration 25 6 4 4 Temperature Calibration 26 6 5 Technician Menu Setup 27 6 5 1 Menu Feature Description 28 6 5 2 Configuring Settings in the Technician Menu 29 6 6 Calibration and Initial Operation Checklist 30 7 Routine Operation and Maintenance 33 7 1 Monitoring HYDROGUARD Alarms 34 7 2 Replacing Reagents 35 7 3 Cleaning the Filter 36 7 4 Shut Down and Winterizing 38 73 Start up and Preventive Maintenance 38 PBA Replacing Pump Head and Tubes 38 7 6 Troubleshooting 39 7 7 Replacing Components 44 ile Replacing Sensors 44 721 2 Replacing the Temperature Probe 44 7 7 3 Replacing the Flow Switch 45 7 7 4 Replacing Reage
61. n relay 3 if pH feeding continuously for this time e Juboy fume Turidty Module ON OFF optona mou Go Jumies furent Time for Data toger o 69 Hou Current Time for Data Logger Month Current Time for Data Logger 8 3 Activate Total Chlorine Monitoring Enter the Technician Menu by pressing scroll and up and down together Scroll to Total Chlorine ON OFF Change to ON the default is OFF Locate the LCD displays in the HYDROGUARD control panel A number should appear in the display TCI 0 00 gt YS Setting Total Chlorine Ratio Testing Interval Press Scroll to enter the operator menu Press up and down together to go to the Technician Menu Scroll to Chlorine Ratio set the Chlorine Ratio according to how often you want to measure TC The ratio may be set between 1 and 30 oF ot a SS o Example If the ratio is 1 a TC measurement will be taken every time a FAC measurement is made i e every 4 minutes if the ratio is set to 10 a TC measurement will be taken after 10 FAC measurements are made i e every 40 minutes Setting High Combined and Total Chlorine Alarms Enter the Operator Menu by pressing Scroll scroll until Total Chlorine High Alarm is reached Press Enter Enter Password Select the High Total Chlorine Alarm Level using the up and down buttons Press Enter Press Scroll again Display should read Combined Chlorine High Alarm Press Enter Select the High Combine
62. nally until the reagents are expected to be completely depleted and the Cl analysis and control will stop The blue LED lights in the flow cell will flash continuously until the reagents are replaced or they are depleted resulting ina NO REAGENTS alarm and an opening of the chlorine relays preventing any additional chlorine from being added Prior to receiving the NO REAGENTS alarm replace the reagents 1 Open the HYDROGUARD analyzing unit door 2 Press the lever above the siphon cover on the chlorine indicator bottle and pull the bottom of the bottle until it drops down from the siphon Figure 24 Replacing Reagent Bottles 35 Wipe the siphons with a dry cloth Perform the procedure to mix and install new reagent bottles as instructed in section 4 2 Installing Reagents Caution Do NOT pour remaining reagent fluid from the old bottle to new bottle Mixing old and new reagent fluids destroys their effectiveness Repeat the steps above with the chlorine buffer bottle Close the analyzing unit door Locate the Pump button on HYDROGUARD s control panel 5 6 7 8 Press the Pump button for fifteen 15 seconds until the water visible through the viewing window has a red tint Locate the LCD detail readings window in the HYDROGUARD control panel 10 Check if the Low Reagent alarm message appears in the bottom row Locate the red LED CI and pH readings indicators in the HYDROGUARD control panel co A number should a
63. ngs The main power supply may be connected to either 110 120 or 220 240VAC 50 60Hz Switching between voltages is accomplished by changing two 2 jumpers located above the main power connection to the left of the transformer For 110 120VAC a amp fuse should be use for 220 240VAC a 0 5amp fuse should be used These changes must be completed prior to wiring Caution Before connecting to a power source confirm that both jumpers are located on the correct voltage and that the appropriate fuse is in place Remote control of pool water chemistry is potentially dangerous to bathers The HYDROGUARD remote monitoring and control service is set by default to monitoring and reporting only Each relay connection is limited to 4 amps to prevent overheating The relays may show a higher rating but do not connect equipment exceeding 4 amps This section presents important information intended to ensure safe and effective use of Read the following carefully before handling the product These warnings and cautions must be followed carefully to avoid injury to yourself or damage to equipment Attention Seuls des lectriciens qualifi s ayant re u la formation ad quate peuvent entreprendre le branchement l entretien ou la r paration des composants lectroniques de l analyseur du contr leur Il existe un risque de choc lectrique lors de l entretien de ce syst me Ayez soin de toujours v rifier que la ou les source s d ali
64. nt Siphons 45 7 7 5 Replacing the sensor 45 7 7 6 Replacing Reagent Pumps 46 delat Replacing the Colorimeter Module 46 7 7 8 Replacing Colorimeter Solenoid Valve 47 7 7 9 Replacing Control Panel Module 48 7 7 10 Replacing I O Module 48 7 7 11 Replacing pH Redox and Temperature Module 48 7 7 12 Replacing Colorimetric Module 49 7 7 13 Module Software Update 49 8 Optional Controller Features 50 8 1 Total Chlorine 50 8 2 Installation 50 8 2 1 Required Parts 50 8 2 2 Installation of Hardware 51 8 2 2 1 Installing new Colorimeter Cap 51 8 2 2 2 Installing the Peristaltic Pump 52 8 2 2 3 Installing the Pump Tubing 52 8 2 2 4 Installing Reagent Holder and Float Switch 52 8 2 2 5 Installing the New Integrated Chipsets 52 8 2 2 6 Installing DPD 3 Reagent 53 8 2 3 New menus and settings 53 8 2 3 1 Operator Menu 54 8 2 3 2 Alarms 55 8 2 3 3 Technician Menu 56 8 3 Activate Total Chlorine Monitoring 57 8 4 Flow Meter 58 8 4 1 8 4 2 8 4 3 8 4 4 8 4 4 1 8 4 4 2 Selecting and Location 58 Hardware and Plumbing Installation 58 Electrical Installation 59 First Time Set up and General Operation 59 Operator Menu 59 Technician Menu 59 8 5 Turbidity 59 8 5 1 8 5 2 8 5 3 8 5 4 8 5 5 8 5 6 8 5 6 1 8 5 6 2 8 5 7 9 Relays Overview 59 Installation 60 Hardware and Plumbing Installation 60 Electrical Installation 60 Relay Wiring and Use 61 First Time Set up and General Ope
65. nt software version Operator 76 Change operator password Password echnical ES 77 Change technician password Password 9 4 Alarms Table 21 Alarms Alarm Alarm Description Result Noflow Flow switch in flow cell is off No chemical dosing Lowflow External flow meter below minimum flow No chemical dosing no chlorine dosing optional Communication error between colorimeter ORP emergency and colorimeter board mode No chlorine dosing No reagents Reagents are empty optional ORP emergency mode No chlorine dosing Unclean cell Glass in colorimeter is dirty optional ORP emergency pans mode No chlorine dosing Replace light LED in colorimeter is not working optional ORP emergency mode hlorine lt 0 1 Chlorine unusually low No chlorine dosing High ORP ORP above high limit No chlorine dosing No chlorine dosing A5 tuck piston Piston is not moving properly optional ORP emergency mode Low chlorine Cl below low limit A11 pis how prosor ovim o ma pona r wovengrim ooo as LowonP peP veio iwim ooo pe onnru fui above hihi J oo me four foulorebvengnime i A22 i A23 A24 ao p2e Temp righalarm Temperature boverign mt has Ploverteedtime pl dosing on for longer than maxtime dosing stops uni reset A24 bHoverfeedtime ph dosing on for longer than max time fo emergeny Mo problem alow ORP emergency mode A1 emp low alarm emperature below low limit 67 O Blue I Water Technologies 1
66. o or normally closed Nc connection of each relay as appropriate Normally Open means that the relay will be open i e no power from the relay until the controller calls for power Normally Closed means that the relay will be closed i e power from the relay until the controller calls to stop power 1 Verify that the power switch or circuit breaker to the pump dependent power source is off 2 Connect the earth ground wire of the power supply to the ground return wire from the controlled external turbidity equipment 3 Connect the neutral wire of the power supply to the neutral wire from the controlled external turbidity equipment 61 O Blue I Water Technologies 4 Connect the line live wire of the power supply to the connector marked C common on the NTU terminal block 5 Connect the line live wire of the controlled external turbidity equipment to the normally open No or normally closed Nc connection on the NTU terminal block Caution Each relay connection is limited to 4 amps to prevent overheating The relays may show a higher rating but do not connect equipment exceeding 4 amps 8 5 6 First Time Set up and General Operation Although the turbidity unit is connected it will not operate until it is set up in the controller menu 8 5 6 1 Operator Menu If the NTU relay is connected to external equipment 1 Press Scroll until Turbidity Set Point appears on the display and press Enter
67. o not refill the reagent bottles Do not mix or add reagent from other bottles Do not use any non Blue Technologies reagents Reagent Level Switch Figure 15 Reagent Bottles and Siphon Caps Note The Chlorine indicator with the blue label should connect to the blue siphon Figure 16 Labels of Reagent Bottles 8 Locate the Pump button on the HYDROGUARD HG 302 control panel Press the Pump button for ninety 90 seconds until the water visible through the viewing window appears with a red tint Note The water will only have a visible red tint if it has a chlorine concentration above 0 2 PPM and below 10 PPM If outside of this range remove the colorimeter cap and confirm that reagents are being pumped 9 Locate the red LED CI and pH displays in the HYDROGUARD control panel Figure 17 Anumber should appear in both displays LCD Display CI Value Display Red alarm lights Pump Button Figure 17 HY DROGUARD Control Panel The pH value appears approximately ten 10 seconds after HYDROGUARD is turned on The Cl value appears one to four 1 4 minutes after HYDROGUARD is first operated depending on the configuration If Chlorine Averaging is ON the chlorine display is an average of the past four 4 readings Therefore the first number displayed will be 25 of the actual value but the controller will act on the last reading regardless of the displayed value 6 3 First Time Menu Setup This secti
68. o opening the controller or installing any electrical components turn off all power supplies to the controller There are five 5 wires contained in a single cord from the sensor that must be connected to the controller The standard wire length is 22 ft 7m and may be cut or extended up to 650 ft 200m as needed The turbidity flow cell and sensor must be securely mounted using appropriate hardware for the mounting location Unfiltered water will need to be supplied to the turbidity flow cell at a flow between 0 25 to 1 GPM and less than 30 psi 2 bar 8 5 3 Hardware and Plumbing Installation 1 Mount the Turbidity Flow Cell using the supplied bracket or other mounting hardware as appropriate such that the inlet and outlet ports are horizontal and the flow tube extends down 2 Insert the sensor into the opening of the flow tube ensuring that the notch in the top of the opening matches the rod on the sensor 3 Hand tighten the connector to secure the sensor and seal the turbidity flow cell 4 Connect the water supply to the turbidity flow cell Follow the flow indicated by the arrow on the flow cell The flow rate should be between 0 25 and 1 GPM 15 60 gal hr or 50 225 L hr and the pressure should not exceed 30psi 2 bar The inlet and outlet connections are FNPT 8 5 4 Electrical Installation 1 Install the Turbidity Module electronics card on the inside bottom of the control panel door using the supplied screws
69. o power Check the fuse Replace if needed O Blue I Water Technologies 7 7 Replacing Components The following procedures describe how to replace certain HYDROGUARD components Caution The following procedures should only be performed by properly qualified and trained HYDROGUARD controller technicians Warning Disconnect all power supplies to the HYDROGUARD controller before opening the control unit door Replacing any parts of HYDROGUARD without the expressed written authorization of Blue Technologies Ltd or the qualified representative who supplied the product may void the warranty Blue Technologies Ltd takes no responsibility written or implied for installation or maintenance of HYDROGUARD that is not performed by a properly trained and certified HYDROGUARD technician 7 7 1 Replacing Sensors Replacing the pH or ORP sensor Turn off the inlet and outlet water to the flow cell and the power to the controller 2 Open the doors of both the analyzing module and the control module 3 Locate the sensor in the flow cell that is to be replaced The specific sensor may be identified by the label on the wire or by tracing the wire from the control panel back to the sensor 4 Remove old sensor from the flow cell a Unplug the sensor s wires from the sensor by grabbing the connector at the top end of the sensor and unscrewing the connector b Unscrew the sensor from the flow cell c Pull the sensor up until
70. oblem all chemical dosing all relays are open heck wiring between olorimeter sensor and No CI measurements olorimeter board Change olorimeter sensor case if oroblem continues tops colorimeter testing heck reagent level change and chlorine dosing No Reagents No reading bottle if needed Make sure Displays no CL he sensor is not stuck alue in control panel 39 No communication with he colorimeter ait for the 2nd measurement Piston is not moving properly within the 5 olorimeter a Impurities have accumulated in the olorimeter analyzing ell Stops chlorine eeding and activates relay external alarm he LED light in the olorimeter is not orking Insufficient onnection on board tarts when reagent level reaches 20 and notifies how many days are left until the reagents are depleted Redox ORP is above alarm level Opens Relay 1 and Relay 2 No Cl eed Used as a Safety measure to override the free chlorine measurement Unclean Cell gt gt gt NI A10 alarm level Redox ORP is below Free Chlorine level is below alarm level rmm re GE TS z TEE o gt D 3o O O eo D J D 2 D U U 7 ait on A11 High a otal Chlorine level is high above alarm level O o Z D O O ai and check visually Clean the olorimeter assembly Make sure the colorimeter No reading onnection is well connected o the mixer on control pan
71. ol service is set by default to monitoring and reporting only Remote control is available only upon special request 4 6 System Components HYDROGUARD has two primary units the analyzing unit and the control unit The analyzing unit performs the actual measurements It contains the following components Colorimetric Reading Cell measures free and optionally total chlorine levels in the water using DPD reagents and a closed cell digital photometer Flow Cell contains the sensors including the pH Redox ORP and temperature sensors Reagent Bottles contains the reagents used by the colorimeter to measure chlorine levels in the water Automatic Pumps and Solenoid Valve accurately controls the flow of water and reagents into the colorimeter making every measurement as accurate as possible The control units include all electronics and software that control the measurements performed in the analyzing unit and the chemical dosing by external dosing systems It includes the following componenis Control Panel calculates the measurement results and determines the required chemical dosing to maintain an appropriate chemical balance and provides data to external devices such as Expert Pool remote system Colorimeter Module controls the colorimeter and associated components such as the reagent pumps and solenoid valve It calculates the accurate chlorine level Tube Sensor Module receives the signal from the pH R
72. ologies Trademarks and Patents HYDROGUARD is the Registered trademark of Blue Water Technologies Ltd Patents issued and pending at the time of this printing Disclaimer Blue Water Technologies Ltd does not accept any responsibility for any damage caused to its products by unauthorized personnel Use of non Blue Water Technologies reagents and or replacement parts will void all warranties
73. on describes how to configure the settings set points alarms and calibrations through the HYDROGUARD control panel Caution HYDROGUARD s control board unit should not be opened except for initial installation and troubleshooting and should only be opened by a trained and approved technician 17 6 3 1 HYDROGUARD Control Panel The HYDROGUARD control panel Figure 18 is a simple intuitive interface for monitoring and controlling pool water quality and is divided into four distinct areas that are outlined in Table 2 ORP level Temperature ORP 840mV TEMP 28 0C Wait readinc CI 128 Time until next Cl Alarm or additional optional information Figure 18 LCD Display and Menu Buttons Table 2 HYDROGUARD Control Panel Overview LCD monitoring window amp menu controls At the top of the control panel is a long LCD display Scroll scrolls through the menu Ese ss Moves one level back in the menu without making changes Ente i Enters setting change mode and accepts setting change Changes value up or down Red LED lighted display shows pH level of pool water with the following buttons and lights Mode button Changes the control mode of the acid base dosing pump between automatic off and on Controls relay 3 Auto mode Automatic mode is when HYDROGUARD controls acid base light dosing adding chemicals as necessary Off mode light Relay is manually open No acid or base is added On mode light Rela
74. or Proportional 3 26 Clintervalmin Minimum time between CI measurements o e 19 O Blue I Water Technologies r l i r l l 2 3 4 5 7 pH Calibrated to pH low alarm pH high alarm OH set point OH Calibrated to interval min Shows most recent calibration and sensor value at calibration to aid in troubleshooting Alarm when pH below this value Alarm when pH above this value ORP set point for emergency mode only Shows most recent calibration and sensor value at calibration to aid in troubleshooting Alarm when ORP below this value Alarm when ORP above this value Open Cl Controls Temperature Relay 6 Shows most recent calibration and sensor value at calibration to aid in troubleshooting Alarm when Temp below this value Alarm when Temp above this value Controls Turbidity Relay 4 optional module Alarm when Turbidity above this value Time delay before Alarm Relay 5 closes Low flow limit for external flow meter K factor for external flow meter Manually entered for Langelier Index Manually entered for Langelier Index Manually entered for Langelier Index Allows ORP mode to be used if Cl Allows choice of language Restarts controller safer than turning off and on oH Sensor was 9 6 10 pHlowalamm ptt pHhighalamm ee pee o 13 S po po po po po mV mV mV mV mV 8 5 ES emp Set Point emp Calibrated to 17 a fu Hinata oa Wars de ti inom
75. osing These problems are most often simple to correct The troubleshooting section provides an outline to follow to help correct the problems easily 7 1 Monitoring HYDROGUARD Alarms HYDROGUARD issues alarms when it detects chemical levels that are above or below the allowed range Every alarm is automatically displayed in the LCD status display and logged in the data logger Most deviations in chemical levels however are automatically corrected Thus the internal alarms do not immediately activate an external alarm A delay mechanism prevents false alarms from minor deviations that were automatically corrected The external alarm is only activated after an internal alarm has been continuously active for a certain period of time as defined by the operator The Alarm Delay command in the Operator menu sets the number of seconds HYDROGUARD waits before closing Relay 5 the relay that operates the external alarm Only one alarm is shown at a time based on importance and the order in which it should be fixed For example if the pH is high and the ORP is low only the pH alarm will be indicated since lowering the pH will likely also correct the low ORP All of the alarms are presented in Table 10 Table 10 Alarms Description and Results Alarm Alarm Description Result A No flow Flow switch in flow cell is off No chemical dosing A2 Low flow external flow meter below minimum flow No chemical dosing Check CLRMTR Communication error bet
76. otor shaft DO NOT force the pump head onto the motor assembly it should easily slide into place 7 Rotate the pump head and slide the alignment pins into the motor assembly 8 Replace the two 2 screws to reattach the pump head 9 Attach the new pump tubes by pressing the tubes onto the connectors on the end of the pump head 10 Insert the pump tube leading to the bottom of the pump head into the appropriate reagent bottle 11 Attach the pump tube from the top of the pump head to the needle on the colorimeter cap by holding the needle and gently pressing the tube onto the connector _ oo 7 6 Troubleshooting The following procedures instruct how to locate evaluate and fix a problem when HYDROGUARD issues an alarm or indicates suspect chemical levels Table 11 outlines some controller problems that may generate a false alarm potential causes and solutions Table 12 outlines some possible problems associated that may occur but will not generate an alarm and their potential causes and solutions Table 11 Troubleshooting for Specific Alarms Description Symptom Solution Suggestion Not enough water is Increase flow and check flow reaching the controller Nig readin Switch wire connection on top all chemical dosing g board Check that the switch is all relays are open not stuck ater flow rate in main irculation pipe is lower oe heck the circulation pipes han the flow limit Stop No dosing not a controller pr
77. ow the outlet of the colorimeter to gravity drain without creating an obstacle i e pipe across walkway The flow cell may be pressurized to allow for return to the system under pressure 5 3 Recommended Installation Configuration UPS CHLORINE OR f CHLORINATOR EME y sco on ease i ATER a m o FILTER HEATER AT LIST 50 CM OR 20 INCH DISTANCE Figure 2 Recommended Installation Configuration 5 4 Site Requirements and Installation The HYDROGUARD assembly is wall mounted It should be located on a wall where pool operators and service technicians can easily access it for normal operation and maintenance It is also advisable to install it where the pool operator can easily view the readings and alarms Finally the complete unit with all connections weighs 18 lbs 8 kg so it must be mounted securely onto a stable wall The HYDROGUARD unit measures 26 3 x 13 1 66 8 cm x 33 2 cm The base of the complete HYDROGUARD assembly should be mounted at least 24 60 cm above the floor preferably at eye level 5 4 1 Mechanical Installation Requirements The HYDROGUARD unit and its mounting panel are not shipped with mounting screws or anchors The installer must provide screws and anchors that can hold the weight of the HY DROGUARD unit mounting panel intake filter and electrical outlets and junction boxes The screws and anchors must be compatible with the wall where it will be installed 5 4 2 Mechanica
78. p line and Sensor Reading on the bottom line The Sensor Reading is the current reading of the sensor with no calibration The Calibrate Cl to value is the new value which you want to set Calibrated Cl to 2 5 Sensor reading is 2 5 Figure 22 Sensor Reading After Calibration 9 Press the up arrow A or down arrow until the value is the same as the value given by the digital photometer Note The HYDROGUARD will not allow calibration above 0 5ppm from the un calibrated sensor reading If the value given by the digital photometer is more than 0 5ppm from the currently O Blue I Water Technologies calibrated value retest the water in the digital photometer If the value is still more than 0 5ppm above or below the calibrated value try testing the water with another device If there is still a deviation of more than 0 5ppm between the new digital photometer there may be a problem with the HYDROGUARD colorimeter which cannot be corrected by calibration alone 10 Press Enter to save the new calibration or Ec Esc to abort without saving 11 Press ies Esc to return to the main display 6 4 2 pH Calibration OH is calibrated using a Phenol Red or Buffer 7 solution Shut off the water inlet and outlet from the flow cell Remove the pH sensor and temperature probe from the flow cell ON gt Wipe the sensor probe with a dry cloth and submerge it and the PT 100 temperature probe into a cup with
79. ppear in both displays 7 3 Cleaning the Filter The HYDROGUARD unit is sent to the site mounted on a mounting panel Several other units are mounted on the panel alongside the controller One of the mounted components is a water filter which filters out sand rust course debris oil and other impurities in the sampled pool water These impurities may clog the HYDROGUARD s internal pipes contaminate the sensors or dirty the analyzing cell reducing its accuracy This filter must be cleaned regularly as it becomes clogged with debris and impurities The frequency at which the filter requires cleaning depends entirely on how much debris is in the pool water The following procedure describes how to remove clean inspect and if necessary replace HYDROGUARD s water filter 1 Locate the water filter mounted below the HYDROGUARD unit and the valve that is located on the water supply pipe Filter Connector Pipe S A Pipe to DN en HydroGuard lt td SER Te Valve A Water Intake Pipe Water Filter Casing Figure 25 HYDROGUARD Unit s Water Filter 2 Turn off water supply to HYDROGUARD by shutting the water intake valve 3 Remove the filter A Push the air relief valve 1 for the filter top to reduce the vacuum and unscrew the filter casing 2 B Remove the filter from the filter housing 3 ae On x SY PRO y aj O AL eA 4 Figure 26 Releasing Filter from Casing 4 Inspect the filter A Remove any loose
80. quez scrupuleusement toutes les consignes pertinentes Attention Le tableau de commandes de l HYDROGUARD ne doit en aucun cas tre ouvert si ce n est lors de l installation initiale et en cas de d pannage auquel cas son ouverture ne doit tre effectu e que par un technicien ayant re u la formation ad quate et d ment habilit O Blue I Water Technologies 2 Preface 2 1 Intended Use This manual is for qualified and trained pool service technicians who will install and service the HYDROGUARD HG 302 Water Quality Controller It provides instructions on how to install the HYDROGUARD system how to integrate it with external pool chemical dosing systems as well as how to calibrate operate and maintain the system This document includes some general information about how to monitor and maintain pool water quality but it does not teach how to operate swimming pools or administer chemicals 2 2 Safety Precautions Warning Caution Only properly trained and licensed electricians should attempt to wire or service the electronic components of the controller There is an Electrical Shock Hazard when servicing this system Always verify that all electrical power source s are off before opening the controller unit or attempting to service electronic components or wiring Extreme caution should be used when installing operating and maintaining the HYDROGUARD HG 302 Water Quality Controller Only properly trained tec
81. r longer pump periods 10 4 Step By Step Proportional Settings Finish the installation of all controllers electrical water feeding systems and electrodes 2 Calibrate the controller to the water chemical values at the sample point 3 Set the proportional factor and the pump period of the chlorine and the pH per the recommended setting in sections 7 5 and 7 6 71 4 Letthe controller operate the chlorinator and the pH correction devices and make sure that chemicals are injected into the water 5 Watch the chlorine and pH as they change We recommend that you record the values frequently so that the process is closely monitored 6 Ifthe values exceed the set point you need to decrease the proportional factor 7 If itt takes too long to get to the set point you need to increase the proportional factor Note In large pools the delay time between injection of the chemicals and receiving the change in the controller can be very long 80 minutes or more For this reason the process of getting a good control loop which can take 15 minutes in very small pools can be very time consuming in large pools up to a few hours Note It is possible to set up initial parameters per the recommendations in sections 7 5 and 7 6 and download the information after 24 hours to a PC making corrections according to the graph of the last 24 hours In any case after installation the technician should stay a sufficient amount of time to make
82. rainage pipe should be as straight as possible and have a constant downward slope and should not have any bends where water flow can be restricted If the colorimeter drains to a bucket or basin the end of the drainage pipe should terminate above the bucket or basin rim Colorimeter Top Union Module Solenoid Valve Cable Solenoid Valve Bottom Union Solenoid Valve Sampling Cell Intake Pipe Sampled Water Supply Pipe Figure 8 Flow Cell and Colorimeter Components 5 6 Electrical Requirements and Installation HYDROGUARD requires a 110 120 or 220 240 VAC 50 60 Hz electrical power source ona separate 16A circuit in the plant room s electrical board The main HYDROGUARD power supply should be connected to a non dependent power supply so that the unit remains powered constantly The active relays should be connected to a pump dependent power supply interlocked power supply to provide an additional layer of protection against chemical addition and equipment operation when the main circulation pump is not operating 5 6 1 Connecting the Main Electrical Power Source The Main Power Supply may be connected to either 110 120 or 220 240VAC 50 60Hz Switching 9 O Blue I Water Technologies between voltages is accomplished by changing two 2 jumpers located above the main power connection to the left of the transformer For 110 120VAC a 1amp fuse should be use for 220 240VAC a0 5amp fuse should be used
83. ration 62 Operator Menu 62 Technical Menu 62 Relay and External Equipment Operation 62 Menus and Alarms 64 9 1 Relays 64 9 2 Operator Menu 64 9 3 Technician Menu 65 9 4 Alarms 66 10 Setting Proportional Control 68 10 1 Proportional Control Overview 68 10 2 Setting Proportional Factor 69 10 3 Setting Pump Period 71 10 4 Step By Step Proportional Settings 71 10 5 First Time Chlorine Average Setting 72 10 6 First Time pH Average Setting 72 11 Record Values Setting 74 12 Technical specifications 75 1 General Safety Precautions A A this product Warning Only properly trained and licensed electricians should attempt to wire or service the electronic components of the analyzer controller There is an Electrical Shock Hazard when servicing this system Always verify that all electrical power source s are off before opening the analyzer controller unit or attempting to service electronic components or wiring Caution Extreme caution should be used when installing operating and maintaining the HYDROGUARD Analyzer Only properly trained technicians are authorized to install and maintain the analyzer controller Only properly trained and licensed swimming pool operators should attempt to make any changes to chemical dosing levels Always follow local health and safety regulations when performing any service on the analyzer controller unit or when changing chemical dosing setti
84. rtcut with DVM Problem not coming Make connection on I O board rom Circulation ith flow sensor on system No external onnections 5 6 or wire to low sensor installed omplete circuit Change Board if necessary open Combine CL 19 ombine chlorine level is High reading Alarm high above alarm level No reagent in the nep ace A20 right bottle out of the Replace reagent DPD3 h ree Temp Low A21 E Low reading Alarm alarm level Probe connection failure Temp High A2 4 ils ous AROE High reading Alarm hlorine pump has been 2 Check for leakage or active for more than a blockage in all the injection pre determined time limit pipes from chlorine tank to 23 land has shut off for safety DELL ELLE LL pump and reduce sees reasons rom pump to Injection point Determine problem then 3 Check for chlorine in the do a System ank If everything seems to Reset be OK and the problem repeats onsider changing the overfeed time limit to a higher Flow Switch indicating no low Stop all chemical dosing all relays are i D ompare to manual reading heck reagent flow from bottle Eee La O colorimeter Check clean 0 1 PPM Opens Relay E solenoid valve including fend Relay 2 no Cl No chlorination spring Check correct water low Verify piston movement mixing Check dosing system from relay to dosing pumps Replace reagents Chlorine lt 0 1 a 1 Check set point for pH 2 Check for leakage
85. sion et que c est le bon fusible qui est en place Le contr le a distance des dosages chimiques de l eau de la piscine peut tre dangereux pour les baigneurs L option de surveillance et de contr le distance de l HYDROGUARD est param tr e par d faut seulement pour la surveillance et l mission de rapports Chaque connexion relais est limit e 4 Amp afin d viter toute surchauffe M me si les relais affichent ventuellement une valeur sup rieure ils ne se connecteront pas un l ment d passant 4 Amp All electrical connections should comply with National Electrical Code NEC and all local regulations Mixing reagents Caution Use protective gear as recommended in MSDS Caution Do not use chemicals that reduce the surface tension When using hydrochloric acid observe all safety regulations Caution HYDROGUARD s control board unit should not be opened except for initial installation and troubleshooting and should only be opened by a trained and approved technician Tous les branchements lectriques doivent tre conformes au Code Electrique National NEC National Electrical Code ainsi qu a toutes les consignes locales M langes r actifs Attention Utilisez l quipement de protection pr conis dans la fiche de donn es de s curit MSDS Attention N utilisez pas de produits chimiques susceptibles de r duire la tension superficielle Lors de l utilisation d acide chlorhydrique appli
86. tation Maintaining a low CC level will provide an overall cleaner and safer system with less noticeable chlorine odor Total Chlorine HYDROGUARD has an alarm for high combined chlorine This alerts the operator when treatment is required to lower the CC level 8 2 Installation lf the controller has been ordered as a total chlorine unit this section may be skipped This section is for upgrading an existing controller to include the Total Chlorine monitoring 8 2 1 Required Parts Starting with a complete HG 302 controller the following components are required to upgrade to Total Chlorine Control e Reagent Holder 1 e Float Switch 1 e Peristaltic Pump 1 e Pump Tubing 1 e Colorimeter Cap with 3 needles 1 e Integrated Chips 2 A diagram of a complete total chlorine controller is presented in Figure 32 below S WaterTechnologies Colorimeter water outlet Regent Injection s ON Cha View window iy L Analyzing E Unit Solenoid valve Reagent Pumps DER Colonmeter Drain LR TE A CO Dr D 4 A age ee Rotating Flow Switch Control Unit Bottles SET Water Intake Filter pH Redox Temperature Module vO Module 8 2 2 Installation of Hardware Warning Before installing any new hardware turn off all power supplies to the HYDROGUARD 8 2 2 1 Installing new Colorimeter Cap Remove the existing colorimeter cap by lifting up Remove the tubes from
87. tered When in ORP Emergency mode the ORP set point will be used to control Relay 1 primary Cl relay When the problem is corrected the controller will automatically resume operation in normal mode If not corrected after 3 5 days the controller will stop feeding Cl Cl lt 0 1 alarm option Whenever the Cl measurement is lt 0 1 ppm the controller will disable relay 1 and relay 2 This alarm is provided as an extra level of safety against over chlorination due to bleaching of reagents However it complicates the start up of the controller when the Cl level is very low Therefore this alarm feature may be turned off Blue Technologies highly recommends that this alarm remain in use except for start up Cl and pH Overfeed timers To prevent continued operation of equipment when a problem occurs these timers will disable the Cl or pH relays if the relay has been active for more than the selected time An alarm will be issued and the controller will need to be reset in order to restart the relay operation If 0 is entered the feature is off Chlorine Averaging This feature will only affect the displayed value not the action of the controller This feature is intended primarily to prevent operators from making constant changes due to minor normal fluctuations in the measured chlorine level Now there is an option to have the average of the last four readings displayed on the screen or simply the previous reading The controller will always
88. the DPD1 and buffer from the existing cap Insert the DPD1 and Buffer tubes into two of the needles on the new cap Press the new cap into place SY D D 51 8 2 2 2 Installing the Peristaltic Pump Attach the mounting plate of the pump to the mounting holes on the support board to the right of the other two pumps using the four supplied screws 2 Route the pump wires to the main electronics box by following the wires from the existing pumps 3 Loosen or remove the screws holding the top of the conduit cover in place 4 Push the wires into the conduit and feed through to the opening on the right 5 Push the wires through an available opening in the rubber gasket make sure to push through near the final connection 6 Connect the wires to the Colorimeter board 7 Find the section labeled Buffer DPD Pumps 8 Connect the red and blue wires at the top two terminal connections the connections are marked red and blue 8 2 2 3 Installing the Pump Tubing i Remove the screws on the cover plate to the peristaltic pump 2 Feed the pump tubing through the wheels on the pump starting at the bottom 3 Feed the bottom pump tube into the hole at the top of the reagent holder 4 Connect the end of the top tube to one of the needles on the colorimeter cap by pushing firmly 8 2 2 4 Installing Reagent Holder and Float Switch Attach the Reagent Holder on the mounting board to the right of the other reagent bottle caps using
89. ve Chlorine Measurement Interval The operator is able to select a minimum and maximum chlorine measurement interval The controller will automatically vary between these limits based on measurement stability An average measurement interval will be created between the minimum and maximum The controller uses an advanced algorithm to determine which of the three measurement intervals to use based on the stability of the readings In general if the readings are unstable or are O Blue I Water Technologies far below the set point the minimum interval will be used As readings become more stable it will use the average or maximum interval as appropriate Water Savings Mode To minimize the amount of water passing through the colorimeter the controller operates in a water savings mode The solenoid valve will open for 15 seconds to obtain a new fresh sample The valve will close and the sample sequence will start Once complete the valve will remain open for an additional 30 seconds to completely flush the sample cell ORP Emergency mode If a problem occurs with the colorimeter unclean cell stuck piston communication error or the customer runs out of reagents the controller may be temporarily operated in ORP Emergency Mode This mode must be started manually by scrolling to the ORP Emergency Mode Menu entering the password and switching the mode to ON If no colorimeter problem is present the controller will not allow this mode to be en
90. ween colorimeter no chlorine dosing Se onnect and colorimeter board optional ORP emergency mode No reagents Reagents are empty no chlorine dosing optional ORP emergency mode Stuck piston Piston is not moving properly no chlorine dosing optional ORP emergency mode Unclean cell glass in colorimeter is dirty no chlorine dosing optional ORP emergency mode m P in colorimeter is not working no chlorine dosing optional ORP emergency mode A9 Chlorine lt 0 1 Chlorine unusually low no chlorine dosing A10 High ORP ORP above high limit no chlorine dosing P O1 oO N O Blue I Water Technologies Low chlorine Cl below low limit A11 pi2Highetloine above ighimt Fo ms CT PE TT ooo pia honn brasoveni S ms fowo bre veow owim 1 me hornu ruway aboveighimt SSSSCSidCSSSSS A22 S Combine CI high Combined CI above high limit Replace DPD3 DPD3 low otal Cl testing stops emperature below low limit i A22 emp high alarm emperature above high limit a Cl overfeed time Cl dosing on for longer than max time dosing stops until reset OH overfeed time OH dosing on for longer than max time OH dosing stops until reset No Emergency No problem to allow ORP emergency mode OO 7 2 Replacing Reagents HYDROGUARD issues a LOW REAGENTS alarm when the float at the end of one of the reagent siphons detects that one or both of the reagents is approaching depletion After this time HYDROGUARD will count down inter
91. x for additional protection Drain the flow cell completely by opening the sampling valve on the bottom Leave the valve in the open position to allow air to completely dry the cell Remove the reagent bottles and flush each pump tube by inserting the pump tube in a container of fresh water and pressing the pump button for at least 90 seconds Remove the pump tubes from the water containers and press the pump button for an additional 90 seconds to remove any water With the solenoid valve in the open position turn off the power to the controller If the solenoid is in the closed position the unions at the top and bottom of the solenoid should be loosened to allow the colorimeter and solenoid to completely drain Check the security of the controller doors to ensure a weatherproof seal 7 5 Start up and Preventive Maintenance After the controller or flow has been off for a long period of time gt 2 weeks a few simple checks should be done during the initial start up Several components may need to be cleaned and some mechanical parts may be replaced as preventative maintenance 1 2 Remove the colorimeter cap and clean the quartz glass using a cotton swab Remove the solenoid and check the tip for corrosion this may occur if shut down improperly and check the plastic stop for deterioration The corrosion can usually be cleaned away and the solenoid will continue to work properly After start up confirm that the water is complete
92. y is manually closed Acid base chemical is added as long as this light is on For safety reasons this mode automatically changes to Auto after 30 to 240 seconds one pump period Red LED lighted display shows chlorine concentration in pool water in parts per million with the following buttons and lights Mode button Changes control mode of chlorine dosing pump between automatic Off and On Auto mode Automatic mode is when HYDROGUARD controls chlorine light dosing adding chemicals as necessary Off mode light Chlorine dosing is Off No chlorine is added On mode light Chlorine dosing is On Chlorine chemical is added as long as this light is on For safety reasons this mode automatically changes to Auto after 30 to 240 seconds Pump button Manually operates the reagent pump in the HYDROGUARD Alarm light Lights when HYDROGUARD issues an alarm O Blue The LCD display on the control panel displays current water conditions in two rows of data The top data row displays the measured ORP level and water temperature The bottom row alternates between various displays lf HYDROGUARD does not issue an alarm the bottom row displays a countdown timer to the next colorimetric chlorine test If no alarm is issued and the flow measurement and or turbidity features are operating the bottom row also displays turbidity level NTU and or water flow rate m hour or GPM When an alarm is issued the bottom row displays the alarm

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