Chlorinator: Difference between revisions
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== Pulsar System == | |||
== | {{Note|type=info|text=Further details to follow.}} | ||
=== Process Flow === | == Accu-Tab System == | ||
{{Note|type=info|text=The information in this section is preserved for historical reference.}} | |||
Prior to 2024, a PowerBase Model 3150 chlorinator (that utilized the "Accu-Tab" system) was responsible for chlorination. This system was removed prior to the 2024 swim season. | |||
=== Retrospective === | |||
Upon installing the new chlorinator prior to the 2024 swim season, we learned that the prior system should never have been sourced from "Unfiltered Water". This was likely a carry-over from an earlier system that passively relied upon a pressure differential to feed chlorine into the system. Many of our issues (that were addressed via the modifications described below) could have likely been avoided had the system been re-plumbed to tap into "Filtered Water". | |||
The inline Y-strainer was regularly bypassed, as once it captured debris, flow was reduced to the point that the chlorinator was starved of incoming water. This would often lead to malfunction as contamination would clog up the solenoid when large debris was present in the incoming water. | |||
=== Theory of Operation === | |||
==== Process Flow ==== | |||
Water flows to the chlorinator from a tap on the outlet side of the main pump, i.e., "Unfiltered Water". An inline strainer provides a limited amount of filtration (i.e., ASTM 30, 600 µm), preventing harmful particulates from entering the chlorinator. Evidence has shown that the chlorinator solenoid is subject to malfunction without sufficient inline filtering. | Water flows to the chlorinator from a tap on the outlet side of the main pump, i.e., "Unfiltered Water". An inline strainer provides a limited amount of filtration (i.e., ASTM 30, 600 µm), preventing harmful particulates from entering the chlorinator. Evidence has shown that the chlorinator solenoid is subject to malfunction without sufficient inline filtering. | ||
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Water is pumped from the solution tank to the pool via a check valve, preventing pressure on the pool return line from forcing water back into the solution tank. | Water is pumped from the solution tank to the pool via a check valve, preventing pressure on the pool return line from forcing water back into the solution tank. | ||
=== Programmable Logic Controller === | ==== Programmable Logic Controller ==== | ||
[[File:Chlorinator PLC.jpg|thumbnail|The chlorinator electrical controls, with a custom PLC modification.]] | [[File:Chlorinator PLC.jpg|thumbnail|The chlorinator electrical controls, with a custom PLC modification.]] | ||
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It should be noted that the float switch always controls the solenoid (via the PLC). If the water level is high, the solenoid is disabled to prevent overflow of the solution tank. Lacking a low-level switch, there is no means to prevent the pump from running dry. Outside controls (such as verification of bypass line flow in the chemical controller) are used to ensure sufficient water is supplied to the chlorinator to prevent this from happening. | It should be noted that the float switch always controls the solenoid (via the PLC). If the water level is high, the solenoid is disabled to prevent overflow of the solution tank. Lacking a low-level switch, there is no means to prevent the pump from running dry. Outside controls (such as verification of bypass line flow in the chemical controller) are used to ensure sufficient water is supplied to the chlorinator to prevent this from happening. | ||
== Maintenance == | === Maintenance === | ||
At some point, flow into the chlorinator is restricted by scale build-up on the sieve plate in the solid tablet tank. This may result in prolonged operation upon a call for chlorine, as the water flow rate through the tabs is reduced. When this occurs, cleaning is necessary. It is assumed that cleaning should be performed at least once per season. | At some point, flow into the chlorinator is restricted by scale build-up on the sieve plate in the solid tablet tank. This may result in prolonged operation upon a call for chlorine, as the water flow rate through the tabs is reduced. When this occurs, cleaning is necessary. It is assumed that cleaning should be performed at least once per season. | ||
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# Return the chlorinator to automatic (or off) mode and re-fill with chlorine tabs. | # Return the chlorinator to automatic (or off) mode and re-fill with chlorine tabs. | ||
== Troubleshooting == | === Troubleshooting === | ||
=== Overflow === | ==== Overflow ==== | ||
Overflow in the reservoir (mixing basin) is likely due to the failure of one of two valves: | Overflow in the reservoir (mixing basin) is likely due to the failure of one of two valves: | ||
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* Make-up water into the mixing basin is controlled by a mechanically-operated plunger valve, opened and closed by a float ball. This valve is a 1-inch Kerick PT100SS. This valve appears to make up the difference between outflow (via the chlorinator pump) and inflow that would otherwise only pass through the solid tablet tank. The valve may, over time, become damaged or blocked by debris. Inspect and clean as needed. The valve can be purchased individually from various sources. Alternatively, a rebuild kit (p/n 9500200) or the whole assembly (p/n 9501056) may be purchased from Aquatic Source or PurAqua Products. Assuming the rod and float ball are in good condition, replacing only the valve (re-using the rod and float ball) is a good balance of cost and ease of repair. | * Make-up water into the mixing basin is controlled by a mechanically-operated plunger valve, opened and closed by a float ball. This valve is a 1-inch Kerick PT100SS. This valve appears to make up the difference between outflow (via the chlorinator pump) and inflow that would otherwise only pass through the solid tablet tank. The valve may, over time, become damaged or blocked by debris. Inspect and clean as needed. The valve can be purchased individually from various sources. Alternatively, a rebuild kit (p/n 9500200) or the whole assembly (p/n 9501056) may be purchased from Aquatic Source or PurAqua Products. Assuming the rod and float ball are in good condition, replacing only the valve (re-using the rod and float ball) is a good balance of cost and ease of repair. | ||
=== Pump Leakage === | ==== Pump Leakage ==== | ||
The pump shaft seal may have failed | The pump shaft seal may have failed. | ||
== Drawings == | === Drawings === | ||
Chlorinator wiring, including the PLC, is shown in the drawing below. | Chlorinator wiring, including the PLC, is shown in the drawing below. | ||
{{Note|type=info|text=This drawing does not include the additional modifications made to include a shut-off valve with additional level sense switches.}} | |||
[[File:FFSC-004 Pg 1 - Chlorinator.png|300px]] | [[File:FFSC-004 Pg 1 - Chlorinator.png|300px]] | ||