Chemtrol Pool Controller: Difference between revisions
→Chemical Probes
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The Chemtrol Pool Controller is a model PC2100 unit (often referred to as the "Chemtrol unit" in the Wiki). It was manufactured by [https://sbcontrol.com/ Santa Barbara Control Systems]. | The Chemtrol Pool Controller is a model PC2100 unit (often referred to as the "Chemtrol unit" in the Wiki). It was manufactured by [https://sbcontrol.com/ Santa Barbara Control Systems]. | ||
In the configuration used at Fairway Farms, it samples ORP (oxidizing properties of a sanitizer, such as chlorine) and | In the configuration used at Fairway Farms, it samples ORP (oxidizing properties of a sanitizer, such as chlorine), pH and total dissolved solids (TDS). It adds calcium hypochlorite (via the "chlorinator") and/or hydrochloric (muriatic) acid (via the "acid pump") to the pool as part of a closed-loop system. | ||
== Operation == | == Operation == | ||
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=== Alarms === | === Alarms === | ||
An alarm has been configured to sound when a measurement parameter (pH, ORP, TDS or flow rate) is far out of normal operating bounds. | An alarm has been configured to sound when a measurement parameter (pH, ORP, TDS, or flow rate) is far out of normal operating bounds. | ||
The parameter that is responsible for the alarm will flash on the Chemtrol LCD display. Note that it is normal and expected for the unit to alarm when the main pump is stopped. | The parameter that is responsible for the alarm will flash on the Chemtrol LCD display. Note that it is normal and expected for the unit to alarm when the main pump is stopped. | ||
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When there is insufficient flow, the message "Bypass Line" is shown at the bottom of the display. This also triggers an alarm (if configured). | When there is insufficient flow, the message "Bypass Line" is shown at the bottom of the display. This also triggers an alarm (if configured). | ||
According to the manual, the flow should be about 2-3 GPM. This can be adjusted by turning the "out" knob (leave the "in" knob fully open). In our system, up to 5-6 GPM seems to be a better target (when the system flow is optimal), allowing some margin. It is critical that there is enough flow to fully submerge the probe tips at all times to avoid damage. | According to the manual, the flow should be about 2-3 GPM. This can be adjusted by turning the "out" knob (leave the "in" knob fully open). In our system, up to 5-6 GPM seems to be a better target (when the system flow is optimal), allowing some margin. It is critical that there is enough flow to fully submerge the probe tips at all times to avoid damage and ensure proper measurement. | ||
== Procedures == | == Procedures == | ||
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# Press the left arrow twice to return to the main screen. | # Press the left arrow twice to return to the main screen. | ||
On the main screen, an "A" to right of the ORP reading indicates that the chlorinator is enabled (automatic control), "X" indicates it is disabled. | On the main screen, an "A" to the right of the ORP reading indicates that the chlorinator is enabled (automatic control), "X" indicates it is disabled. | ||
=== Enabling or Disabling the Acid Pump === | === Enabling or Disabling the Acid Pump === | ||
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== Instrumentation == | == Instrumentation == | ||
[[File:Pool Controller Instrumentation.jpg|thumbnail|Instrumentation for the pool controller.]] | |||
=== Chemical Probes === | === Chemical Probes === | ||
The ORP and pH probes are said to be rated for a year of use. | The ORP and pH probes are said to be rated for a year of use. Recent experience suggests that they are useful for about two swim seasons. Probes must be replaced when readings do not reliably align with those from the chemical test kit (and cannot be corrected via calibration). | ||
The [http://www.sbcontrol.com Chemtrol] branded probes are | The "original" [http://www.sbcontrol.com Chemtrol] branded probes are expensive. We have had good results with probes from [https://sensorex.com/ Sensorex] (purchased in 2020 and 2022). The cost is about 75% less than those from Chemtrol. | ||
* pH5000 Polycarbonate Swimming Pool pH Sensor ($ | * pH5000 Polycarbonate Swimming Pool pH Sensor ($62 as of May 2022) | ||
* ORP1000 Polycarbonate Laboratory ORP Sensor ($ | * ORP1000 Polycarbonate Laboratory ORP Sensor ($97 as of May 2022) | ||
NOTE: In the future, the pH1000 may be a better buy (only $54 versus $62, as of 2022). The only difference is the cable length (confirm that it will reach). | |||
=== Flow Meter === | === Flow Meter === | ||
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The flow meter is an absolute necessity for automated chemical control. Due to the large main re-circulation lines in the system (larger than 2 inches), a bypass line is used to provide an alternate path to the pH and ORP sensors. The flow meter verifies that sufficient flow is present in this bypass line (such that the measurements reflect the chemical levels in the main re-circulation line and pool). | The flow meter is an absolute necessity for automated chemical control. Due to the large main re-circulation lines in the system (larger than 2 inches), a bypass line is used to provide an alternate path to the pH and ORP sensors. The flow meter verifies that sufficient flow is present in this bypass line (such that the measurements reflect the chemical levels in the main re-circulation line and pool). | ||
The | The flowmeter for the bypass line can be disabled under certain circumstances. However, this must be used with extreme caution, as operating a chemical feed without sufficient monitoring could cause dangerous/damaging chemical reactions. | ||
Upon installing the newest unit (April 2021), the bypass flow rate read-out was adjusted. Per the datasheet for the 155481, the unit produces 225 Hz (pulses/second) for a 20 GPM flow rate. The Chemtrol requires a value in "pulses per unit volume". In this case, 225 Hz / 20 GPM = 11.25 Hz/GPM, or 11.25. Prior to April 2021, a default value of 1 was used, resulting in a typical (incorrect) readout of 0 to 1 GPM. | Upon installing the newest unit (April 2021), the bypass flow rate read-out was adjusted. Per the datasheet for the 155481, the unit produces 225 Hz (pulses/second) for a 20 GPM flow rate. The Chemtrol requires a value in "pulses per unit volume". In this case, 225 Hz / 20 GPM = 11.25 Hz/GPM, or 11.25. Prior to April 2021, a default value of 1 was used, resulting in a typical (incorrect) readout of 0 to 1 GPM. | ||
The wiring for the flow meter is shown in the "PC2100 Auxiliary" (page 43), as part of the [[Pool_Systems_Automation#Auxiliary|Pool Systems Automation Drawings - Auxiliary]] package. | The wiring for the flow meter is shown in the "PC2100 Auxiliary" (page 43), as part of the [[Pool_Systems_Automation#Auxiliary|Pool Systems Automation Drawings - Auxiliary]] package. | ||
== Drawings == | |||
Connections to the Chemtrol Pool Controller (PC2100) are shown in the drawing below. | |||
[[File:FFSC-003 Pg 1 - PC2100 Wiring.png|300px]] | |||
== Technical Information == | == Technical Information == | ||
* The left-hand connectors (on the generation of controller that we own) for TDS/Temp, PWFS ( | * The left-hand connectors (on the generation of controller that we own) for TDS/Temp, PWFS (paddlewheel flow sensor), Flow and PPM are Conxall/Switchcraft 4-position Mini-Con-X male pin connectors. The mating connectors are Conxall/Switchcraft 6282-4SG-311 and as of January 2021, they are stocked by multiple distributors (Digi-Key, etc). | ||
* The display is a Newhaven Display NHD-160128WG-BTMI-VZ#-1. If replacing, make note of the required backlight resistor modification. Hawk Electronics of Buffalo Grove, IL stocks this part for $63.30 (as of January 2021). Replacement (at your own risk!) is fairly straightforward for an experienced technician; it requires simply the de-soldering of a header. | * The display is a Newhaven Display NHD-160128WG-BTMI-VZ#-1. If replacing, make note of the required backlight resistor modification. Hawk Electronics of Buffalo Grove, IL stocks this part for $63.30 (as of January 2021). Replacement (at your own risk!) is fairly straightforward for an experienced technician; it requires simply the de-soldering of a header. | ||