The provided manual describes the Topline TEC4000 Amperometric Chemistry Control System, a device designed for managing water chemistry in swimming pools and spas.

Function Description

The TEC4000 is an integrated dosing equipment package that monitors and controls water chemistry parameters such as pH, free chlorine, and optionally, redox potential. Based on this information, it instructs chemical dosing devices (for chlorine/bromine, pH minus, and pH plus) to supply chemicals to the water stream as needed. The system also controls a flocculent pump and agitator motor on a pulsed timer. It features four types of external interfaces: volt-free alarm, BMS, RS485, and RS232, allowing communication with a wide range of external equipment.

A water sample is continuously drawn from the main circulation system (post-filtration, via a sample bowl strainer) to a sensor assembly containing the electrodes. The sample flow, ideally around 60 liters per hour, is maintained past the probes and indicated by a flow puck, which is adjusted via flow needle valves. A flow detection switch ensures that chemical feeders are shut down and an alarm is triggered if there is no circulation. A sample tap is provided for taking water samples to standardize/calibrate the sensors against chemical reagent tests.

The system is designed for ease of use, with data entry via a color touch screen panel. Access is restricted by a security code to prevent unauthorized changes. It logs alarms and user actions, and historical graphs for pH, free chlorine, and redox (option) values are stored for 42 days. The controller can be configured with the pool or spa's location, name, and number, and graph scales can be adjusted. It supports various chemical types for amperometric cell control, including chlorine, bromine, and peroxide, and can also control chemicals via a redox probe.

Important Technical Specifications

Dimensions: 365mm wide x 650mm tall x 110mm deep
Power Requirement: 240 VAC single phase 50 Hz.
Power Consumption: 20 watts (excluding feeders)
Operating Temperature: 0 - 50 degrees centigrade
Enclosure: Metal IP54
Front Control Panel: Touch Screen behind polyester membrane
Display: Graphic LCD ¼ VGA 120mm wide x 90mm high
Chlorine Sensor: Amperometric 3-electrode system, measuring range 0 - 40 mg/l
pH Sensor: Glass with internal reference, measuring range 0-14 pH
Redox: +/- 2v
Outputs:
- Chemical feeders: 3 x 240 VAC 2amps switched
- External Alarm: Voltage free no/nc
- USB port
- RS485 data port
- WIFI
- BMS output: 0-10v pH, chlorine, and redox
- Timed 240 VAC 2 amps electric agitator
- Timed 240 VAC 2 amps flocculent
- Energy control system
- Real time clock
Inputs:
- 3 analogue
- 2 digital flow sensor
- Touch Screen Display
- Programmable input
Fuses: F1-F6 (3.15amp for various components like drop solenoid, pumps, agitator)
Relays: RL1-RL7 (for alarm, drop valve, pumps, agitator motor)
BMS Scale: Chlorine 0-40.95ppm, pH 0-14, Redox -2047 to +2048

Usage Features

The TEC4000 offers several user-friendly features:

System Menu: Provides access to routine operations like resetting timeouts, standardizing sensors, changing time and date, overriding dosing pumps, and accessing maintenance.
Security Code: Prevents unauthorized access to system settings.
Timeout Reset: Allows operators to reset pump timeouts, enabling continued chemical dosing after a set point has not been reached within a specified time.
Sensor Standardization: Enables calibration of chlorine, pH, and redox sensors using DPD1 and phenol red tablet tests taken from the sample tap. Dilution tests are required for DPD1 readings above 2ppm.
Time and Date Adjustment: Allows setting the local time and date for accurate data logging.
Dosing Pump Override: Pumps can be enabled/disabled or placed in manual mode to run for a selected period, independent of chemical levels. Manual chemical additions can be initiated by entering the desired change in level, with the system calculating the run time based on pool size and chemical strength.
Option Code: A unique code generated from the serial number is required to activate controller outputs and dosing pumps, ensuring proper commissioning by competent engineers.
View Log (Events): Records alarms and user operations, including standardization events and the user code used.
View Log (Graphs): Stores historical pH, free chlorine, and redox (option) values for 42 days, with adjustable graph scales.

Maintenance Features

Routine maintenance is crucial for the system's correct function and warranty validity. All maintenance processes should be recorded with a "Risk and Method Statement."

Safety Precautions: Emphasizes turning off electricity, closing input/output sensor assembly valves, and wearing appropriate PPE when handling chemicals or system parts that have contacted chemicals.
Probe Cleaning: Probes should be cleaned no more than once every 4 weeks using Topline probe cleaner. This involves disconnecting, unscrewing, soaking in cleaner, rinsing, shaking to remove air, and reinserting. Recalibration and standardization are required after cleaning.
Stainless Steel Electrode Cleaning: Involves removing the chlorine probe, pouring cleaner into the sensor assembly, agitating with a brush, and leaving for 20 minutes before replacing the probe.
Needle Valve Flushing: Needle valves (LHS, Top, RHS) in the sensor assembly should be cleared every 2 weeks by fully opening them for 5 minutes, then adjusting to ensure the flow puck is adjacent to the flow sensor.
Sensor Assembly Blockage: Blockages can be accessed and cleared by removing the sensor assembly from the backboard.
Fine Mesh Strainers: If fitted, these small filter units (located to the left of the sensor assembly) should be checked and cleaned to prevent blockages.
Flow Switch Check: Verified by closing Inlet and Outlet isolation valves; the display should show "NO FLOW."
Dosing Pump Maintenance: Involves removing the pump, releasing pressure, cleaning with injector cleaner to remove scaling, and checking one-way valves. The feed pipe and injector pipe should also be checked and replaced if damaged (injector pipe every 2 years).
Day and Bund Tanks: Should be kept clean, leak-free, and correctly labeled. Spillages must be cleaned immediately.
Injector, Rodding, or Quill Unit: The injector allows chemical solution into the pool. It should be cleaned regularly to prevent scaling.
Electric Agitator: Components should be cleaned and maintained.
CO2 Injectors: Regular maintenance is necessary to prevent scaling and ensure proper CO2 delivery.
Restarting TEC4000: After maintenance, the system should be restarted, and probes recalibrated/standardized.
Winter Shut Down: Specific procedures are outlined for winterizing the system, including turning off power, isolating sensor assembly, emptying day tanks, and flushing dosing pumps.
Servicing Schedule: A detailed schedule is provided for tasks to be completed weekly, every 4 weeks, every 6 months, and every 24 months, including checks for water filter, sample cell components, pump diaphragms, 4-function valves, dosing lines, foot valves, and injectors.
Pool Audit and Plant PPM: Includes audit sheets for personal protective equipment, chemical spill kits, pool test kits, and general plant room conditions, ensuring comprehensive maintenance and safety compliance.

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