MAN255/04B

INSTRUCTION MANUAL

CHEMTROL

CHEMTROL

®

®

255 PPM/pH Controller

(v. 4.0 and up)

250 ORP/pH Controller

(v. 4.5 and up)

$ 10.00

TOLL FREE

PHONE

FAX

EMAIL

TECHNICAL SUPPORT

800-621-2279

805-683-8833

805-683-1893

[email protected]

A Division of SANTA BARBARA CONTROL SYSTEMS

5375 Overpass Road, Santa Barbara CA 93111

MAN255/04B

IMPORTANT SAFETY INSTRUCTIONS

Mandated by ITS Testing Laboratories, Inc

1. READ AND FOLLOW ALL INSTRUCTIONS

2. WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.

3. WARNING - Risk of Electric Shock. Connect only to a grounding type receptacle protected by a ground-fault circuit interrupter (GFCI). Contact a qualified electrician if you cannot verify that the receptacle is protected by a GFCI. (Only required for cord-connected units.)

4. Do not bury cord. Locate cord to minimize abuse from lawn mowers, hedge trimmers, and other equipment. (Only required for cord-connected units.)

5. WARNING - To reduce the risk of electric shock, replace damaged cord immediately. (Only required for cordconnected units.)

6. WARNING - To reduce the risk of electric shock, do not use extension cord to connect unit to electric supply; provide a properly located outlet. (Only required for cord-connected units.)

7. SAVE THESE INSTRUCTIONS.

WARRANTY

This CHEMTROL

®

Electronic Controller Model ________S/N _____________________________________ is warranted by SANTA

BARBARA CONTROL SYSTEMS (SBCS) to be free from defects in manufacturing and workmanship for a period of FIVE (5) YEARS from the date of purchase for the electronic module and ONE (1) YEAR for all other components. SBCS will repair or replace, at its option, any defective part during the warranty period. Labor, shipping or incidental expenses are specifically excluded from this warranty. For warranty coverage, defective parts should be returned immediately to your CHEMTROL



Dealer or to our factory postpaid with a copy of your purchase receipt and a detailed description of the malfunction.

TECHNICAL SUPPORT...........................................................1

WARRANTY.............................................................................2

TABLE OF CONTENTS ...........................................................2

INTRODUCTION......................................................................3

FREE CHLORINE ......................................................3

ORP CONTROL (Models 230/250) ............................3

PPM CONTROL (Models 235/255) ............................3

WATER CHEMISTRY ................................................3

INPUTS AND OUTPUTS ...........................................3

INSTALLATION........................................................................4

LOCATION.................................................................4

SENSOR INSTALLATION .........................................4

MAIN LINE INSTALLATION.......................................4

BYPASS LINE INSTALLATION .................................5

SENSOR CELL ..........................................................5

WATER FLOW...........................................................5

ELECTRICAL ...........................................................................6

VOLTAGE ..................................................................6

PPM BATTERY (Models 235/255) .............................6

REMOTE ALARM ......................................................6

FLOW SWITCH .........................................................6

SETUP MENU..........................................................................6

ACID/BASE FEED .....................................................6

SANITIZER/pH INTERLOCK .....................................6

SAFETY FLOW SWITCH...........................................6

TERMINAL BLOCK WIRING....................................................6

CHEMICAL FEEDERS .............................................................7

CHEMICAL FEED PUMPS ........................................7

EROSION FEEDER ...................................................7

OPERATION ............................................................................7

PPM SENSOR CONDITIONING (Models 235/255) ...7

SENSOR CALIBRATION ...........................................7

GAIN FACTOR (Models 235/255)..............................7

TABLE OF CONTENTS

CONTROL SETPOINTS............................................ 7

OVERFEED SAFETY TIMERS.................................. 7

OUT-OF-RANGE ALARMS ....................................... 8

FEED MODE ............................................................. 8

PROPORTIONAL FEED............................................ 8

CONTROLLER RESET ............................................. 8

STARTUP ................................................................................ 8

DEFAULT PARAMETERS......................................... 8

AUTOMATIC CONTROL ........................................... 8

MAINTENANCE ....................................................................... 9

GENERAL MAINTENANCE....................................... 9

EFFECT OF CYANURIC ACID.................................. 9

PPM SENSOR TESTING (Models 235/255).............. 9

PPM BATTERY (Models 235/255)............................. 9

NO PPM SENSOR CLEANING (Models 235/255)..... 9

ORP AND pH SENSOR TESTING ............................ 9

ORP AND pH SENSOR CLEANING.......................... 9

SENSOR REPLACEMENT........................................ 9

SENSOR STORAGE ................................................. 9

WINTERIZING ........................................................... 9

PORTABLE TESTER............................................................. 10

ORP SENSOR TESTING ........................................ 10 pH SENSOR TESTING ........................................... 10

ORP AND pH SIMULATION .................................... 10

TROUBLESHOOTING ........................................................... 11

TABLE OF FIGURES............................................................. 11

PARTS LIST .......................................................................... 12

OPTIONS............................................................................... 12

SPECIFICATIONS ................................................................. 12

MAN250/04

Page 3

INTRODUCTION

The CHEMTROL

®

250 Series Controllers are microprocessorbased digital controllers designed to monitor and control the sanitizer and pH levels in swimming pools, spas, cooling towers and industrial applications.

The controllers are available with three types of sensors for measurement of water acidity (pH) and of sanitizer level in either

PPM (parts per million or milligrams/liter) or ORP in millivolts.

This manual covers the new versions of five models:

•

•

•

•

CHEMTROL

CHEMTROL

CHEMTROL

CHEMTROL

®

®

®

®

255 PPM/pH Controller,

250 ORP/pH Controller,

240 pH Controller,

•

CHEMTROL

®

235 PPM Controller.

230 ORP Controller.

FREE CHLORINE

As shown on Figure 1, Free Chlorine in water is in equilibrium under two forms:

•

Molecular HOCl, a strong sanitizer and oxidizer,

•

Ionized OCl-, a weak sanitizer and oxidizer.

At a pH of 7.5, the two forms are in equal proportions of 50% each. At lower pH values, HOCl predominates. At higher pH values, OCl- is dominant.

ORP CONTROL (Models 230/250)

The ORP sensor shows the voltage (in mV) produced by oxidizers in water.

It responds to strong oxidizers, such as HOCl and its bromine equivalent HOBr. It also responds to other strong oxidizers that are used in water treatment, such as Ozone (O3) or Potassium

Monopersulfate (KSO3).

Because HOCl is the primary oxidizer, the signal of the ORP sensor decreases with increasing pH values.

It is not specific to chlorine or bromine and responds to other oxidizers.

The chlorine or bromine concentration required to generate a desired ORP value varies with pH and overall water quality, particularly Total Dissolved Solids (TDS) concentration, organic load and cyanuric stabilizer concentration.

The ORP setpoint default value on the controller is 700 mV, which is recommended to kill germs and bacteria and maintain good water quality.

PPM CONTROL (Models 235/255)

The PPM sensor is specific to Free Chlorine only.

The controller displays the concentration of Total Free Chlorine

(HOCl + OCl-) in PPM (parts per million or milligrams/liter). It does not respond to Bromine and/or oxidizers.

Figure 1 - Equilibrium of Free Chlorine

The Free Chlorine display does not vary up to a pH of 7.8.

The PPM setpoint default value on the controller is 1.0 ppm, which is recommended to kill germs and bacteria and maintain good water quality. It can be adjusted to meet local conditions and Health Department requirements.

WATER CHEMISTRY

Before starting automatic control, test the water chemistry to make sure that the pH, Cyanuric Acid and Total Dissolved Solids are within the ranges recommended by the National Spa and Pool

Institute (NSPI).

The pH should be adjusted manually within 7.4 to 7.6. If it is below 7.0 or above 8.0, the controller will show an alarm condition and prevent feeding (programmable option).

To stabilize chlorine against solar UV radiation, a cyanuric acid

level of 20 to 25 ppm is ideal. However, this level can be quickly exceeded with stabilized chlorine (dichlor or trichlor). Note that many Health Department codes do not allow stabilizer levels above 100 ppm. If above 100 ppm, this results in chlorine lock that shows as low ORP readings even with high chlorine levels.

The Total Dissolved Solid (TDS) level should be below 2,000

ppm. If higher, the water is full of organic and inorganic impurities and should be dumped and replaced partially or completely.

For effective pH control, the Total Alkalinity should be between

80 to 120 ppm. If too low, the pH will bounce and be hard to control. If too high, the pH will be hard to change.

INPUTS AND OUTPUTS

Depending on the model number, the inputs include one or two sensors:

• a PPM sensor to monitor free chlorine concentration,

• an ORP sensor to monitor ORP or Redox,

• a pH sensor and a safety flow switch (optional).

The outputs are two relays for sanitizer and pH feed - acid or base - plus a relay for an optional remote alarm or telephone dialer.

MAN250/04

INSTALLATION

Page 4

LOCATION

Mount the controller cabinet as shown in Figure 2 on a wall in a secure location:

•

more than 10' (3 m) away from the water edge to comply with electrical code requirements,

•

if possible, not more than 10' (3 m) of the main recirculation line or of the bypass line. The sensors come with standard 10-foot (3-m) cables. If needed, you can order 25 or 50-ft BNC extension cables from your dealer.

• not exposed to direct sunlight,

• easily accessible to maintenance personnel,

• if possible in a separate room, or in a well- ventilated room as far away as possible from corrosive chemicals and storage tanks,

•

at a safe distance from power transformers, pump motors or high voltage power lines

• safe from unauthorized access or vandalism.

SENSOR INSTALLATION

Figure 2 - Installation with Sensors on Main Line

MAIN LINE INSTALLATION

On smaller installations (2 “ pipe diameter), the sensors can be mounted directly on the main recirculation line (Figure 2).

Use only the 2x2x1/2 in. SST reducing tees without reducers

(Figure 3). Do not install the sensors near an elbow or a constriction where there might be excessive turbulence.

Install the tees after the pump and filter. Insert the sensor tip down so that the tip is about 1/4 inch (1 cm) in the water. The sensors should be readily accessible for servicing but not exposed to physical damage.

Tighten the compression fitting by hand only to avoid breaking the internal glass tube in the sensors. Do not use a wrench!

Save the sensor caps for storage or shipping of the sensors.

When in storage or shipping, add salt water in the cap to keep the sensors from drying out. During winter, store the sensors above freezing temperature.

The sensors can be mounted three different ways:

• directly on the main recirculation line (Figure 2) (2 in.

pipe only),

• on a 1/2 in. bypass line as shown Figure 3,

• even better, in a sensor cell mounted on the bypass line

(Figure 5).

Figure 3 - Sensor in PVC Tee

MAN250/04

Page 5

BYPASS LINE INSTALLATION

Figure 4 – Installation with Bypass Line Assembly

To facilitate installation of the sensors and to assure a smooth and steady flow of water by the sensors, it is recommended to install the optional Bypass Line Assembly (P/N BPL-0.5). As shown in Figure 4, it includes:

- two (2) compression gland fittings (1/2" MPT) for the sensors,

- two (2) PVC tees (1/2" SST),

- one (1) in-line Y-filter (3/4" MPT),

- one (1) in-line flowmeter (1/2" FPT),

- a rotary safety flow switch (1/2" FPT),

- two (2) ball valves (1/2" SxS) for flow adjustment and for isolating the bypass line during backwashing of the filter and other maintenance operations,

- one (1) labcock (1/2" SxS) for water sampling and testing.

The Bypass Line Assembly should be installed exactly as shown on Figure 4. In particular, make sure to install the flowmeter in a vertical position and to install the flow switch downstream of

(after) the sensors to assure a smooth flow of water near the sensors.

SENSOR CELL

For additional ease of installation and maintenance, it is also recommended to mount the sensors in the optional Flow Cell,

Assembly as shown in Figure 5. It includes:

• the sensor cell with air vent and clear cover,

• two (2) compression fittings for the sensors,

• one (1) water sampling tap

• two (2) ball valves for controlling the water flow in and out.

WATER FLOW

Proper flow of water past the sensors is essential to obtaining good readings.

To ensure proper water flow, make sure that the bypass line is properly connected. As shown in Figure 4, the intake side should be on the effluent side of the recirculation system, i.e. after the filter. The return side should be to a low-pressure area - such as the vacuum side before the recirculation pump, or downstream after the heater, or atmospheric pressure in the pit of a vacuum sand filter or balancing tank.

To check the water flow in the bypass line, start the main recirculation pump. Open both the intake and the return valves on the bypass line and read the flow rate on the flowmeter. It should be in the middle of the range, i.e. about 2-3 gpm (about 8 to 12 l/min). If the water flow is too high, you can turn down the valve on the RETURN SIDE of the bypass line. If there is no water flow, replumb the bypass line as shown on the schematic.

NOTE: Most common installation problems with bypass line

installations are caused by faulty hydraulics.

Figure 5 - Flow Cell Assembly

MAN250/04

Page 6

ELECTRICAL

Make sure to follow local electrical codes.

SEE TERMINAL BLOCK WIRING BELOW.

Always interlock the controller with the timer on the main

power supply (see Figure 2) to prevent injection of chemicals when the recirculation pump is not running.

To prevent electrical shock, make sure that the power is disconnected before opening the cabinet.

The Mother Board is mounted behind the front panel and the

Power Board (Figure 6) in the back of the controller.

VOLTAGE

The operating voltage is factory set for 110, 230 or 24 VAC.

Make sure to check the voltage before installation to avoid damage to the control board and void the warranty. 110 V units have a power cord with a 3-prong plug. 230 V units have bare wires. 24 V units do not have a transformer. You can also check

Jumpers JP5 on the Power Board (Figure 6).

Figure 6 – Power Board

SETUP MENU

All outputs are the same as the input voltage.

Upon startup, the Setup Menu is displayed. You can also recall it at any time by pressing both arrow keys simultaneously.

PPM BATTERY (Models 235/255)

ACID/BASE FEED

The PPM sensor is connected to the Mother Board with its own

9 V battery. Replace the battery if the voltage falls below 7.5 V.

The Setup Menu first displays PHF (pH Feed) and either AC for

Acid Feed (default value) or bA for Base Feed. Press either arrow to change the setting.

REMOTE ALARM

The remote alarm is connected through the terminal block as shown below. It can be used to activate a remote alarm such as a light, a buzzer, or a bell, or even an automatic telephone dialer with voice messaging capability.

Acid Feed is used for all basic (alkaline) sanitizers: liquid chlorine

(sodium hypochlorite NaOCl) or dry chlorine (calcium hypochlorite

Ca(OCl)

2 tablets).

). Base Feed is used only for acidic sanitizers (trichlor

The Alarm Jumpers JP6 (Figure 6) are normally set for a HOT

(powered) contact with two jumpers in the 1-2 and 3-4 positions.

For a dry (N.O.) contact, set one jumper only in position 2-3.

SANITIZER/pH INTERLOCK

The Setup Menu then displays IL for Interlock and either 0 for

OFF or 1 for ON (default value).

FLOW SWITCH

Note: with a bypass line, a Safety Flow Switch is

absolutely required to prevent accidental feeding of chemicals if the line is shut off or obstructed.

The Sanitizer/pH Interlock is a safety feature designed to deactivate the sanitizer feed when the pH is out of range. This is particularly important with liquid chlorine, a strong basic chemical that raises the pH of the water.

The rotary paddlewheel flow switch connects to the controller terminal block as shown below using the + 5V power input. DO

NOT CONNECT TO HIGH VOLTAGE.

SAFETY FLOW SWITCH

The Setup Menu then displays FLO for Flow Switch with either 0 for OFF or 1 for ON (default value).

A blade flow switch uses a dry contact that connects as shown below to interrupt the power output. Make sure to orient the flow switch in the direction of flow.

TERMINAL BLOCK WIRING

HOT CMN GND

+ 5V

Red

SIG

White

GND

Black

SIG GND HOT CMN GND HOT CMN GND HOT CMN GND

SANITIZER FEED PADDLE WHEEL

FLOW

SWITCH

POWER IN ALARM ACID/BASE FEED

MAN250/04

CHEMICAL FEEDERS

Make sure to inject all the chemicals downstream of the sensors to avoid false readings, and downstream of all equipment

(pump, filter, heater) to avoid corrosion.

CHEMICAL FEED PUMPS

Install the feed pumps for liquid chlorine, calcium hypochlorite or dichlor solutions as shown in Figure 2, according to the manufacturer’s instructions.

EROSION FEEDER

With an erosion feeder for bromine or chlorine tablets, install a solenoid valve on the intake side of the bypass line to the erosion feeder as shown in Figure 7.

OPERATION

PPM SENSOR CONDITIONING (Models 235/255)

IMPORTANT: DO NOT CONNECT THE PPM SENSOR before the conditioning procedure is completed. Warranty may be void

if sensor is powered without proper conditioning.

Before using the PPM sensor for the first time – or after long storage in air – it is important to hydrate the sensor. Remove the sensor cap and place the sensor for at least 30 minutes in water containing a small amount of chlorine without connecting it to the controller.

Please note that the sensor’s time response for accurate chlorine reading could take up to 30 minutes after first hydration and up to

15 minutes to stabilize after each water chemistry change.

SENSOR CALIBRATION

No calibration is required for the ORP sensor.

To calibrate the PPM and pH sensors, test the water with a reliable, fresh test kit (DPD and Phenol Red). Note the values and compare to the display values. Re-calibrate if needed, as follows:

- press [CALIBRATION],

- press [PPM] or [pH]: the display flashes,

- use the [UP] and [DOWN] arrows to adjust the value,

- press [CALIBRATION] again to save the new value.

GAIN FACTOR (Models 235/255)

If the signal of the PPM sensor is too low due to excessive cyanuric acid or other contaminants, the gain of the amplifier can be increased in the Setup Menu.

Start the Setup Menu by pressing both arrows simultaneously.

When the display shows GF for Gain Factor, select 1, 2 or 4 depending on the cyanuric level.

CYANURIC ACID LEVEL

(ppm or mg/l)

0-20

20-60

60 +

GAIN FACTOR

GF

1x

2x

4x

Page 7

Figure 7 - Erosion Feeder Installation

CONTROL SETPOINTS

The PPM setpoint is factory set at 1.0 ppm.

The ORP setpoint is factory set at 700 mV, which is recommended to maintain water quality by killing germs and bacteria. There is no need for ORP calibration.

The pH setpoint is factory set at 7.5, which is recommended for pool and spa applications.

To change a control setpoint:

- press [SETPOINT],

- press [PPM], [ORP] or [pH] : the display flashes,

- use the [UP] and [DOWN] arrows to adjust the setpoint,

- press [SETPOINT] again to save the new value.

OVERFEED SAFETY TIMERS

The internal safety timers are designed to alert the operator in case of overfeeding of chemicals as a result of mechanical or electronic failure or empty containers.

The timers are factory set at 15 minutes for PPM or ORP and 5 minutes for pH. This is normally sufficient to reach the setpoint.

At that time feeding stops and the timer resets to zero. If the limit is reached however, the feeder is deactivated, the alarm turned on and the display flashes the overfeed time. The operator should then check the chemical feeders, feed lines and tanks. After correcting the problem, the safety timer is reset by switching the feed mode to OFF and then back to AUTO.

To change the limits of a safety timer:

- press [SAFETY TIMER],

- press [ORP], [PPM] or [pH] : the display flashes,

- use the [UP] and [DOWN] arrows to adjust the value,

- press [SAFETY TIMER] again to save the new value.

CAUTION: Increasing the limit on a safety timer may cause overfeeding of chemicals.

MAN250/04

OUT-OF-RANGE ALARMS

The out-of-range alarms are factory set at 650 to 900 mV for

ORP, 0.3 to 6.0 for PPM and 7.0 to 8.0 for pH. If the ORP or PPM readings are below the low limit, the red LED alarm flashes but

sanitizer feed continues.

If the pH limits are exceeded, the red LED alarm flashes and all

feeders (pH and sanitizer) are deactivated - unless the sanitizer/pH interlock is defeated (see below).

To change an alarm limit:

- press [LOW LIMIT] or [HIGH LIMIT],

- press [PPM], [ORP] or [pH]: the display flashes,

- use the [UP] and [DOWN] arrows to adjust the value,

- press [LOW LIMIT] or [HIGH LIMIT] again.

CAUTION: Increasing the out-of-range limits may cause overfeeding of chemicals.

FEED MODE

The feed mode for the sanitizer or pH can be set to OFF, Manual or Automatic. To select the desired feed mode, press [PPM],

[ORP] or [pH] until the corresponding LED indicator light is illuminated. There is a short delay before activation. (Note:

Holding the switch for more than 5 seconds resets the setpoint and calibration for [PPM], [ORP] or [pH] to original factory

.

values).

PROPORTIONAL FEED

There are two ways to control the feed rate.

In standard ON/OFF control (Figure 8), the feed rate remains constant until the setpoint is reached, whereupon it stops.

In the Proportional Zone, activation of the chemical feeder is based on 1-minute cycles with varying ratios of ON and OFF feed times. As the sensor reading approaches the setpoint value, the

ON portion of the cycle decreases progressively. During the OFF portion, the feed light flashes continuously to indicate that the controller is under proportional control.

In proportional control (Figure 9), the feed rate decreases progressively as it approaches the setpoint. Proportional control is particularly useful to avoid overfeeding of chemicals in small bodies of water.

CONTROLLER RESET

The CHEMTROL

®

controller saves all user-defined values as well as factory defaults in its internal non-volatile memory.

Therefore, user-modified setpoints and acid/base feed modes will not be lost in the event of power failure and the factory default values can be restored at any time.

To reset the setpoint and calibration values to the original factory values, press and hold [PPM], [ORP] or [pH] for 5 seconds.

Figure 8 - ON/OFF Control

Page 8

Figure 9 - Proportional Control

STARTUP

DEFAULT PARAMETERS

Setpoint

High/Low Alarms

Overfeed Safety Alarm

Proportional Bandwidth

PPM

1.0 ppm

ORP

700 mV

pH

7.5

0.3/6 ppm 650/900 mV 7.0/8.0

15 min.

1%

15 min.

1%

5 min.

1%

AUTOMATIC CONTROL

1. Run the recirculationpump with both sensors in line at least 30 minutes to stabilize the sensor readings.

2. Turn the controller on. The displays will show: a. the software version number, b. [pHF] with [AC] for Acid feed or [bA] for Base feed, c. [IL] with 0 or 1 if the sanitizer/pH interlock is ON, d. [FLO] with 0 or 1 if the flow switch is ON.

d. [Gn] with 1, 2 or 3 for the PPM Sensor gain (Models 235 and 255 only), e. the sensor readings.

3. Press [ORP] or [PPM] until the feed control light is on AUTO.

4. Press [pH] until the feed control light is on AUTO.

5. After 30 minutes, test the pH of the water with a Phenol Red test kit. Adjust the pH calibration if needed.

6. Test the free chlorine or bromine ppm in the water with a DPD test kit. Adjust the PPM or ORP setpoint if required.

7. Test the water regularly as required by local health authorities.

MAN250/04

Page 9

MAINTENANCE

The CHEMTROL

®

controller is virtually maintenance free. The enclosure and front panel can be cleaned with a soft cloth moistened with a mild soap and water solution or a glass cleaner.

Do not use abrasives or harsh chemicals.

ORP AND pH SENSOR TESTING

To test the sensors on line, carefully add a small amount of white vinegar or dilute acid solution in the skimmer. After a few minutes:

GENERAL MAINTENANCE

For commercial and public pools, it is important to test and record the water chemistry readings in compliance with Health

Department requirements using a good quality manual test kit.

Adjust the pH, ORP or PPM calibration and setpoint as required.

- the pH reading should go DOWN.

- the ORP reading should go UP.

If you still get no response or a sluggish response, clean or replace the sensors as soon as possible.

It is important to note that changes in pH, cyanuric acid concentration, TDS (total dissolved solids), and use of additional or alternative sanitizers will all impact the primary sanitizer residual level in comparison to ORP. To maintain a consistent sanitizer residual in parts-per-million (ppm), adjust the ORP setpoint as required.

For additional testing, use the PORTA-PROBE II (Figure 10)

Portable Tester, as shown on the next page.

ORP AND pH SENSOR CLEANING

EFFECT OF CYANURIC ACID

Increasing cyanuric acid levels reduce the concentration of free chlorine HOCl in water. This affects the effectivity of the sanitizer, as shown by reduced readings for ORP (Model 250) or PPM

(Model 255).

The sensor tips must be kept clean and free from chemical deposits and contamination to function properly. After saturation in pool or spa water, the sensors may need to be cleaned on a weekly or monthly basis depending on the water quality and other facility-specific characteristics. Slow response and inconsistent readings are indications that the sensors are in need of cleaning.

The controller reacts by adding more chlorine to compensate for the reduced effectivity. The only remedy is to replace all or part of the water until the cyanuric acid level is reduced.

To clean a sensor, carefully remove it from the compression fitting. Clean the tip of the sensor with a mild liquid detergent

(Joy, etc.) solution. Rinse with fresh water and soak the sensor in a mild acid solution for five minutes. Rinse with fresh water and reinstall the sensor.

PPM SENSOR TESTING (Models 235/255)

SENSOR REPLACEMENT

To test the PPM sensor, use a DC Voltmeter and connect it to the

HOCl and Ground terminals on the Mother Board, with the PPM sensor in chlorinated water. You should read 2.6 V or higher.

PPM BATTERY (Models 235/255)

For optimum controller performance, always use genuine

CHEMTROL

®

replacement sensors. For preventive maintenance it is also recommended to replace the sensors on an annual basis or as performance diminishes.

You should test the 9 V battery on the Mother Board. Replace it if the voltage falls below 7.5 V.

SENSOR STORAGE

NO PPM SENSOR CLEANING (Models 235/255)

Do not clean the PPM sensor. Cleaners will damage the membrane and void the warranty.

Extended exposure to atmospheric conditions will cause the ORP and pH sensor tips to dry out.

The PPM sensor should be stored dry and electrically disconnected.

Always remove and properly store the sensors if the pool or spa is to be winterized or inactive. Store the sensors with the original cap provided, making sure that each cap is filled with the original storage solution or salt water. If the storage containers have been misplaced, store the sensors individually in small glass or plastic containers with clean water covering the sensor tips.

WINTERIZING

The sensors should be prepared for storage as outlined above and protected from freezing. Although the controller is designed to withstand a broad temperature range, winter storage in a secure location at normal room temperature is recommended.

MAN250/04

PORTABLE TESTER

The PORTA-PROBE II (Figure 10) is a battery-operated portable tester/signal generator designed to test the ORP and pH sensors and to generate calibrated signals to test the controller. It is supplied with a 9V battery and a pair of shielded cables with BNC connectors.

The PORTA-PROBE II is not used to calibrate the sensors. This should be done with a chemical test kit, such as DPD for Free Chlorine and Phenol Red for pH.

It can also be used to test the TDS and Temperature sensors on the CHEMTROL

®

PC or CT controllers.

ORP SENSOR TESTING

Set the Mode Switch to TESTING. Connect the ORP sensor to the ORP BNC connector on the tester. Turn the Selector Knob to ORP.

Place the sensor in balanced water (pH = 7.5 / PPM = 1.0 Cl). You should get an

ORP reading within 650 to 750 mV.

Place the sensor in an acid solution. You should get a HIGH POSITIVE reading.

Place the sensor in a BLEACH (liquid chlorine) solution. You should get a LOW

POSITIVE reading.

pH SENSOR TESTING

The PORTA-PROBE II shows actual pH sensor readings in millivolts, as shown on the Table on the right.

Set the Mode Switch to TESTING. Connect the pH sensor to the pH BNC connector on the tester. Turn the Selector Knob to pH.

Place the pH sensor in nearly neutral water (pH = 7.5). You should get a pH reading of about -30 mV.

Place the sensor in an acid solution. You should get a HIGH POSITIVE reading.

Place the sensor in a BLEACH solution. You should get a HIGH NEGATIVE reading.

The linear scale on the right shows the conversion of millivolt readings into pH units.

ORP AND pH SIMULATION

Set the Mode Switch to SIMULATOR.

Use the two coaxial cables to connect the BNC connectors on the tester to the respective BNC connectors on the controller.

Set the Selector Knob to either pH or ORP Simulator. The readings on the controller should match the readings of the tester display (unless offset by calibration of the pH probe).

The outputs of the ORP and pH simulators can be adjusted with the two small knobs located below the digital display. The ORP range is 0 to 1,000 mV.. The pH range is -180 to + 180 mV (10 to 4 on the pH scale). These outputs can be used to test for proper operation of the feed and alarm features of the controller.

NOTE 1: Due to signal stabilization, the readings on the controller may take up to

10 seconds to reach full value.

NOTE 2: ORP and pH signals can be generated simultaneously but only one signal is displayed.

mV

pH Scale

pH

+420

+30

0

-6

-12

-18

-24

0

6.5

7.0

7.1

7.2

7.3

7.4

-30

-60

-90

-420

7.5

8.0

8.5

14.0

Page 10

Figure 10 - Portable Tester

MAN250/04

Page 11

TROUBLESHOOTING

No lights on.

Alarm lights and buzzer

on.

Illogical value displays.

No Chemical feed.

No Sanitizer feed.

No Acid/Base feed.

Chlorine or bromine residual too high or too

low.

pH requires frequent

calibration.

Inconsistent or slow

readings.

Chemical feeder runs

continuously.

pH or Sanitizer

overshoots setpoint.

pH or Sanitizer does not

reach setpoint.

1.

Check the circuit breaker and/or receptacle for proper operation. Connect to functional grounding-type GFCI protected power source.

2.

Check for a damaged power connector.

3.

Check internal fuse (1A slow blow) marked F7 on Power Board.

1.

Verify that the filtration system is functioning properly, water flow is adequate and water chemistry is in balance.

2.

Verify that sensor and power cables are properly connected to the respective connectors on the controller.

3.

Check the operation of the chemical feeders (pumps or erosion feeder).

4.

Verify that the (optional) flow sensor is properly installed.

1.

The sensor cable connections may be reversed. Verify that the sensor cables are properly connected to their respective BNC connectors on the controller unit.

2.

Verify that the filtration system is functioning properly, the water flow is adequate, and the water chemistry is in balance.

1. Check FLO setting in Setup Menu and safety flow switch on bypass line if applicable.

1.

Make sure the AUTO feed light is on.

2.

Check the setpoint.

3.

Check relay fuse (5A slow blow) marked F1 and F2 on Power Board.

1.

Check pHF setting in Setup Menu for Acid or Base feed.

2.

Make sure the AUTO feed light for pH is on.

3.

Check the pH setpoint.

4.

Check pH relay fuse (5A slow blow) marked F3 and F4 on Power Board.

1.

Remember that the pH, cyanuric acid concentration, total dissolved solids, and use of additional or alternative sanitizers will all impact the sanitizer residual level in comparison to ORP. Consider the impact of any chemicals recently added to the pool or spa.

2.

Check and adjust the setpoint.

1.

Clean or replace the sensor as outlined in the maintenance section.

1.

Verify that the sensor cables are properly connected to their respective BNC connectors on the controller unit.

2.

Clean the sensors as outlined in the maintenance section.

3.

Check to verify that all the electrical equipment in the facility pump room is properly grounded.

4.

Replace the sensors if needed.

1.

Make sure the AUTO feed mode is selected.

2.

Verify that the chemical feeders are properly connected to their respective connectors on the controller unit.

1.

Increase the width of the proportional zone.

2.

Check the dilution of sanitizer or acid/base solution.

1.

Decrease the width of the proportional zone.

2.

Increase the concentration of sanitizer or acid/base solution.

3.

Check chemical feeders for proper operation.

TABLE OF FIGURES

Figure 1 - Equilibrium of Free Chlorine.......................................................................................................................................................3

Figure 2 - Installation with Sensors on Main Line .......................................................................................................................................4

Figure 3 - Sensor in PVC Tee ....................................................................................................................................................................4

Figure 4 – Installation with Bypass Line Assembly .....................................................................................................................................5

Figure 5 - Flow Cell Assembly ....................................................................................................................................................................5

Figure 6 - PC Board....................................................................................................................................................................................6

Figure 7 - Erosion Feeder Installation.........................................................................................................................................................7

Figure 8 - ON/OFF Control .........................................................................................................................................................................8

Figure 9 - Proportional Control ...................................................................................................................................................................8

Figure 10 - Portable Tester....................................................................................................................................................................... 10

MAN250/04

MB250/255

PB250/255

PPM

ORP pH

PKT-2.0

PKT-1.5

BPL-0.5

PWFS

FCA

XC25

XC50

DIAL

Cabinet

PPM Display

ORP Display pH Display

PPM Setpoint

ORP Setpoint pH Setpoint

PPM Accuracy

ORP Accuracy pH Accuracy

Feed Controls pH Feed

Safety Systems

Control

PPM Output

ORP Output pH Output

Remote Alarm

Input Power

Page 12

PARTS LIST

Mother Board for CH250 or CH255 (specify voltage)

Power Board for CH250 or CH255 (specify voltage)

PPM sensor with 10-ft BNC cable

ORP sensor with 10-ft BNC cable.

pH sensor with 10-ft BNC cable.

Set of two (2) PVC tees and compression fittings for 2 in. (50 mm) line.

Set of two (2) PVC tees and compression fittings for 1 1/2 in. (37 mm) line.

OPTIONS

1/2 in. bypass line assembly with Y-filter, flowmeter, safety flow switch, two (2) shutoff valves and sampling tap.

Rotary paddle-wheel safety flow switch.

Machined transparent polycarbonate flow cell assembly for sensors.

Sensor cable extension with BNC connectors, 25-ft (8 m).

Sensor cable extension with BNC connectors, 50-ft (16 m).

Telephone dialer with voice messaging.

SPECIFICATIONS

Polystyrene (9.5x7.25" or 23.5x18 cm)

0 to 10 ppm

0 to 999 mV

0 to 14

0 to 10 ppm

250 to 950 mV

4.5 to 9.5

0.1 ppm

+/- 5.0 MV

+/- 0.1 pH

Off / Manual / Automatic / Proportional

Acid or Base Feed.

Visual and Remote Alarms

Comprehensive Diagnostic Self-Test

5 Amp/120 or 230 VAC

5 Amp/120 or 230 VAC

5 Amp/120 or 230 VAC

Dry contact for audio, visual or telephone dialer

0.25 A at 120 or 230 VAC (exclusive of pumps)