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Stranco® Instruction ManualEzetrol® plus Analyser/Controller

W3T292576 / WT.050.425.001.GE.IM.0215

Suite 3, 2nd Floor, One 60 London Road, Sevenoaks, TN13 1BT

Tel.: +44 1732 771777 Fax: +44 1732 771800 www.evoqua.com

Important NoticeEvoqua Water Technologies Instruction Manuals are the safety documents for their products. The information provided therein is in accordance with the best practices known at the time of issue and, if fully implemented, should enable the user to operate the plant in the safest possible manner. It is therefore most important that instructions be read and understood prior to the installation, operation or maintenance of the plant.

Notes

Where necessary, special instructions are provided and are quoted under the following headings:

WARNING: A warning is given in instances where failure to observe the instruction could result in injury to personnel.

CAUTION: Cautions are given where failure to observe the instruction may result in equipment damage, or pollution to an allied system.

NOTE: Notes are provided to give additional emphasis to particular points of detail.

The following recommendations are made to ensure safe and efficient operation:-

1 Only suitably qualified personnel should install, operate and maintain the equipment.

2 Only Evoqua Water Technologies manufactured or approved parts should be used.

3 The equipment should not be used for any purpose other than that for which it was supplied.

4 If equipment being supplied is being put into storage or not being commissioned immediately, or if the plant is being de-commissioned, Evoqua Water Technologies urge that they be contacted for detailed advice.

In an effort to make progressive improvements to products, changes in design may be incorporated from time to time, which may not be reflected immediately in the instruction manual. If in doubt, contact Evoqua Water Technologies quoting the equipment serial number; serial numbers are essential for effective communication and proper equipment identification.

The equipment described in this manual may be used with substances that themselves may be hazardous to personnel safety. It is essential that persons employed in the vacinity of such substances be aware of the appropriate safety practices and the location of suitable safety equipment. Provision of safety cards and codes of practice concerning hazardous substance should be made by the supplier of the substance.

Warranty

The equipment supplied is guaranteed against mechanical defect notified to the Seller within a period of 1 year from the date of delivery. For such guarantee to be valid the purchaser must notify the seller in writing immediately such defect becomes apparent. If the Seller so requires, the Purchaser shall return the defective equipment (at the Purchaser’s expense) to the Seller. The Seller undertakes that it will, at its own option and its own expense, and by way of full discharge of its guarantee obligation hereunder, either repair, or supply a replacement for the defective equipment, or refund any purchase monies paid to it in respect of any such defective equipment, or portion thereof. If title to the defective equipment is at the time of such replacement or refund vested in the Purchaser, then title shall thereupon vest in the Seller. Replacement material situated outside the U.K. will be supplied F.O.B. U.K. Port. The guarantee given in this clause shall not be operative and enforceable if the equipment is not operated strictly in accordance with the sellers instruction, or in the respect of any defect arising from accident, deliberate act, misuse, neglect or from a breach from the terms of the following clause, or in respect of any defect arising through damage incurred while being transported after delivery of the equipment, or if the equipment has been altered or modified in any way by any person other than the seller, or in respect of any other cause whatsoever which lies beyond the Sellers control.

The Purchaser must comply with all user instructions and safety recommendations issued by the Seller, and must install, commission and maintain the equipment in accordance with good engineering practice, and under the supervision of suitably qualified personnel, and the Seller shall not be liable to the Purchaser for any loss suffered as a result of the Purchaser’s breach of the terms of this clause.

Subject to this guarantee all conditions, warranties and representations, whether expressed or implied (by statute or otherwise) relating to the equipment, are hereby excluded in so far as they can be excluded without such exclusion being void or unenforceable at law.

Wallace & Tiernan, Barrier, Chem-Ad, DEPOLOX, OSEC, and V10k are trademarks of Evoqua, its subsidiaries or affiliates.

The designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.All rights, especially those to duplication and distribution as well as translation, are reserved. No part of this document may be reproduced in any form (printing, photocopying, microfilm or any other method) or saved, processed, duplicated or distributed by the use of electronic systems without the express written consent of Evoqua Water Technologies.

International Contact Information

Area Phone email

Australia +61 (0) 3 8720 6597 [email protected]

Canada +1 905 944 2800 [email protected]

Germany +49 8221 9040 [email protected]

Singapore +65 8630 7100 [email protected]

U.S.A. +1 856 507 9000 [email protected]

U.K. +44 (0) 1732 771777 [email protected]

1W3T292576 / WT.050.425.001.GE.IM.0215

Ezetrol®plus ANALYSER/CONTROLLER

INTRODUCTION

The Ezetrol® plus controller has been specifically designed for all types of swimming pools, spas and water features that are dosed with chlorine. The Ezetrol® plus controller is flexible in its approach to input options, offering parameters of free chlorine, pH and temperature as standard. Other parameter combinations such as dual chlorine inputs and pH measurement or the measurement of free chlorine, pH and redox are available.

This manual has been produced to enable the user to obtain maximum service from the equipment and comprises installation, operation maintenance and spare parts information. Minor changes may be made to the equipment that are not immediately reflected in the manual - if such a change appears to have been made, contact Evoqua Water Technologies for information.

Our guarantee is conditional upon the equipment being used in accordance with the instructions herein and we therefore recommend that they be read and fully understood before the equipment is placed in service.

Evoqua Water Technologies

Contents

Target groups 1 Conventions 1.2

Safety 2 Intended use 2.1 General safety instructions 2.2 Safety instructions specific to the unit 2.3 Description 3 Chlorine measurement 3.1 Disinfection of water 3.1.1 Range of applications 3.1.2 Versions 3.2 Design 3.3 Overall design 3.3.1 Flow cell module 3.3.2 Electronic module 3.3.3 Functions 3.4 Overall Function 3.4.1 Flow cell module 3.4.2 Electronic module 3.4.3 Safety functions 3.4.4 Interfaces 3.4.5 Digital inputs 3.4.6

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Controller types 3.4.7 Control parameters 3.4.8 Alarms 3.4.9 Interfaces 3.4.10 Technical Data 3.5 Electronic module 3.5.1 Flow cell module 3.5.2 Sensors 3.5.3

Installation 4 Versions 4.1 Transport and storage 4.2 Transport 4.2.1 Storage 4.2.2 Installation 4.3 Unpacking 4.3.1 Location 4.3.2 Mounting 4.3.3 Sample water supply 4.3.4 Sensor connection 4.3.5 Electrical connection 4.3.6 Sample water drainage line 4.3.7 Commissioning 4.4 Starting up procedure 4.4.1 Filling cell grit 4.4.2 Insert the sensors and connect 4.4.3 Connecting the Sample Water 4.4.4 Connect the device to the power supply 4.5 Connecting a flocculant pump 4.5.1 Switch the unit on 4.5.2 System shut down 4.6 Auto tune 4.7 Settings overview 4.8

Operation 5 Display and operator controls 5.1 Code number 5.1.1 General notes on operation 5.1.2 Menu structure 5.1.3 Operating modes 5.1.4 Switching the Ezetrol®plus off 5.1.5 Switching the entire system off 5.1.6 Calibration 5.2 Chlorine calibration 5.2.1 pH calibration 5.2.2 Redox calibration 5.2.3 Temperature calibration 5.2.4

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Overfeed failsafe alarm 5.3 Errors and remedies 5.4

Maintenance 6 Routine maintenance 6.1 Daily 6.1.1 Weekly 6.1.2 Six monthly 6.1.3 Changing the fuse, battery, or MultiSensor 6.2 Replacing the fuse 6.2.1 Replacing the battery 6.2.2 Changing the MultiSensor 6.2.3

Spare parts 7

Flow cell module and sensors 7.1 Electronic module 7.2

Illustrations

Flow cell module (pressurised (AAC6100) Fig.1Backboard mounted unit (Drg. No. 50235) Fig.2Wiring diagrams (3 sheets Drg. No.50234) Fig.3Typical installation (Drg.No.PSK518) Fig.4

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1 TARGET GROUPS

This instruction manual provides the information for installation, operating and maintenance personnel. It contains important information for safe, reliable, trouble-free and economical operation of the unit. Observation of this information helps to prevent dangerous incidents, lowers repair costs, reduces down-times, and also increases the reliability and service life of the unit. The chapter “Installation” is intended for trained and qualified service personnel only. It contains important information on installation, configuration and commissioning of the unit.

All persons working with the unit must have read and understood the instruction manual, particularly the safety instructions it contains.

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2 SAFETY 2.1 Intended use

The Ezetrol® plus is intended exclusively for the control of the treatment of water in swimming pools spa's and water features that are dosed with chlorine. It may only be used indoors and under the operating conditions described in the technical data. The operational safety of the unit is only guaranteed if it is used in accordance with its intended application as defined in the order and under the operational conditions stated in the technical specifications.

Compliance with the intended use also includes reading this operating manual and observing all the instructions it contains. Furthermore, all inspection and maintenance work must be performed at the prescribed intervals. The operator bears full and sole responsibility if this unit is put to any use which does not comply strictly and exclusively with this intended use.

NOTE: The Ezetrol® plus is not suitable for use with bromine based systems.

2.2 Safety Instructions

Evoqua Water Technologies places great emphasis on safety when working on or with the unit. This has already been taken into account in the design of the system, by the integration of safety features. The safety instructions in this documentation must always be observed. These do not affect the validity of any additional national or company safety instructions.

All safety instructions attached to the unit itself must be observed. They must always be complete and easily legible. The unit has been constructed in accordance with state-of-the-art technology and the accepted safety regulations. However, if the unit is used by persons who have not been adequately instructed, risks to life and limb of such persons or third parties and damage to the unit itself or to other property cannot be ruled out. Work not described in this operating manual may only be performed by authorised personnel. The operator of the overall system must ensure that only authorised and qualified specialists are permitted to work with and on the unit within their defined scope of authority. “Authorised and specialised personnel” refers to trained technicians employed by the operator, Evoqua Water Technologies or, if applicable, the service partner. Only qualified electricians may perform work on electrical components.

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Trouble-free operation of the unit is only guaranteed if original spare parts and components are used in precisely the combination described in this instruction manual. Failure to observe this instruction may incur the risk of malfunction or damage to the unit.

Never attempt to perform any modifications, extensions or conversions to the unit that could have an adverse affect on safety without the written approval of the manufacturer.

During normal operation, the housing must remain closed.

Prior to installation, inspection, maintenance and repair work, always switch the unit off with the main switch on the outside of the unit and secure against reactivation. Connect all cables in accordance with the wiring diagram. Ensure safe and environmentally-friendly disposal of agents and replaced parts.

2.3 SafetyInstructionsSpecifictotheUnit

This instruction manual and the technical documentation of the installed components of the unit must always be available at the installation site.

Always observe any supplementary, generally valid legal regulations or other binding rules and ensure their compliance! These rules and regulations apply to:

• work safety • accident prevention • environmental protection • hygiene • first-aid All personnel charged with installation, commissioning, operation, maintenance and repair of the unit must read and understand this instruction manual, particularly the safety instructions.

Never attempt to perform any modifications, extensions or conversions on the unit which could have an adverse affect on safety without the written approval of the manufacturer.

Only use spare parts which have been approved by the manufacturer.

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The use of spare parts not manufactured or approved by Evoqua Water Technologies will invalidate the warranty

Always observe the intervals for regular maintenance or inspection work which are either prescribed or stated in the instruction manual.

The system must not be used with flammable liquids or dangerous or toxic gases.

Never use corrosive cleaning agents! Use only a damp cloth to clean the unit.

Always read the instruction manual, in particular the safety instructions, before you operate the unit for the first time. Never employ any working methods which could endanger safety!

Always comply with the prescribed values for sample water admission pressure, connection voltage as well as ambient and operating conditions.

Never deactivate any safety features. During operation of the unit, unexpected incorrect functions may occur that result from failure or errors in the control system. In the event of such safety-relevant changes in the operating performance of the device, switch it off immediately and remedy the fault or have it remedied immediately. Even when the unit is switched off, external voltage may still be applied.

Always eliminate or have eliminated any leakage on the flow block assembly immediately.

In the event of a fire, always switch the unit off with the main switch on the outside of the unit or with the external main circuit breaker or fuse.

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3 DESCRIPTION 3.1 ChlorineMeasurement3.1.1 Disinfection of water

Swimming pool water is generally disinfected by adding calcium hypochlorite or sodium hypochlorite. Accurate dosing of these chemicals is extremely important because the degree of disinfection may be insufficient if the concentration is too low. On the other hand, if their concentration is too high, there may be a noticeable change in the odour or even corrosive damage to the pool.

3.1.2Rangeofapplications

Continuous measurement

• of the concentration of chlorine disinfectant • of the pH value • of the redox voltage • control of dosing units to automatically regulate the amount of

disinfectant in the water and the pH value.

The Ezetrol® plus complies with the following standards:

• DIN 19643 “Treatment of water of swimming-pools and baths” and

• ÖNORM M 5872 Equipment of water treatment plants for swimming pools with measuring and control instruments.

and• PWTAG - Swimming Pool Water Treatment and Quality Standards

NOTE: We do not recommend that Ezetrol® plus is used to control Bromine

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3.2 Versions

The following versions of the Ezetrol® plus are available:

• With chlorine and pH measurement and control • With chlorine and pH measurement and control and redox

measurement • For 200–240 V AC • with three mA outputs • Pre-mounted on a uPVC board (Part NoAAA1791)

• With 2 x measurement and control, pH measurement and control for a common circuit board

3.3 Design 3.3.1 Overalldesign

The Ezetrol® plus is a modular system.

The two main components are the flow block assembly (A) and the electronics module (C).

Up to 3 sensors (B) can be installed in the flow block assembly.

A B C

A Flow cell module B Sensors C Electronic module

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3.3.2 Flowcellmodule

The flow cell module has a plastic housing (B) with a removable cover. All the components of the flow cell module are installed in this housing:

• Flow control valve (B) • The MultiSensor for monitoring temperature and flow rate (F) • The drain (D) • The sample water inlet with check valve and ball valve (E) • The sample water outlet (C) with ball valve

The top clips (H) for the sensor and the lower clips (G) to hold the buffer or calibration solution can be mounted on the outside of the housing.

Two seats are provided for the lower clips. The cell body can be equipped with a maximum of 3 sensors (I). The Ezetrol® plus - flow cell module is always pressurised.

I

H

A

G B

F

E C D

A Plastic housingB Flow control valveC Sample water outletD DrainE Ball valveF Multi sensorG Lower clipH Upper clipI Sensors

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A

B

C

D

EA Reference electrode REF)B KCl electrolyteC SaltD Counter electrode (CNT)E Working electrode WRK)

A Reference electrode system Ag/AgClB Reference electrolyte (polymer gel)C Ceramic diaphragmD Ball membrane

A

B

C

D

Chlorine SensorThe chlorine measuring cell consists of a 3-electrode system as a combination electrode. The working and counter electrodes are made of a platinum alloy; the reference electrode is a silver/silver chloride electrode. The electrolyte is a saturated KCl gel and it cannot be replenished.

The measuring cell is delivered with a protective cap over the electrodes and the membrane The protective cap contains KCl solution to ensure that the measuring electrode is ready for operation. The protective cap must be removed before the unit is used. If the electrode is not used for some time, fill the protective cap with water (not distilled) and replace it over the electrode.

The surface of the electrode is continuously hydromechanically cleaned with special grit to prevent fouling. This means that the electrode must be screwed in as far as possible.

The measuring cell is connected to the Ezetrol® plus. A potentiostatic control circuit maintains the adjustable voltage between the working and reference electrodes constant. The resulting measuring cell current is proportional to the concentration of the oxidising agent. This complex measuring device ensures an accurate and reproducible measured value and a zero point that is stable for a long time.

pH ElectrodeThe pH electrode has a ceramic membrane and a silver/silver chloride reference electrode. The saturated KCl gel electrolyte does not need to be replenished.

The electrode is supplied with a protective cap filled with KCl solution that keeps the electrode ready for operation at all times. If the electrode is not used for some time, fill the protective cap with water (not distilled) and place it over the electrode.

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Redox ElectrodeThe redox voltage is used to indicate the state of the water that contains active oxidising and reducing substances.

The following approximate values can be used for a quick and complete disinfection of the swimming pool water:

For fresh water: pH 6.5 – 7.3 UG>750 mV pH7.3 – 7.6 UG>770 mV

For sea water (brine): pH 6.5 – 7.3 UG>700 mV pH7.3 – 7.8 UG>720 mV

The redox electrode has a ceramic membrane and a silver/silver chloride reference electrode. The electrolyte is a saturated KCl gel that does not need to be replenished. The electrode is supplied with a protection cap over the platinum electrode and the membrane; this cap must be removed prior to use. It contains KCl solution so that the electrode is ready to operate at all times. If the electrode is not used for some time, fill the protection cap with water (not distilled) and replace it over the electrode.

Cable extension and impedance converter Refer to Section 7.1 “Flow cell module and sensors” for details on cable extensions for special installations with a max. cable length of up to 50 m.

In cases where the electrode cable is not long enough and an extension is used, an impedance converter (Part No. U-95607) needs to be screwed onto the pH and the redox electrodes. It converts the very high-resistance electrode signal into a low-resistance signal. The impedance converter is powered by a built-in battery with a service life of approx. 5 years. The impedance converter should be sent to Evoqua Water Technologies for the battery to be replaced.

MultiSensor for flow-rate monitoring and temperature measurementThe flow of sample water is kept at a constant rate of 33 l/h by means of a flow control valve. If the flow rate drops below a specific value, the flow rate monitor sends an alarm and switches off the controller function.

The flow-rate monitor must be connected to the digital input of the Ezetrol® plus. The temperature sensor consists of a PT1000 sensor. The temperature is shown on the display and is used for temperature compensation of the measured chlorine and pH values.

A Reference electrode system Ag/AgClB Gel-coated Reference electrolyteC Ceramic diaphragmD Platinum electrode

A

B

CD

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3.3.3 Electronicmodule

The electronic module has a plastic housing with a removable cover.

The following are integrated into the cover of the electronics module (A):

• The display (D) • The operator controls (E) • A green LED (B) to indicate that the power is on • Eight red LEDs (C) to indicate the operating mode

A

B C

D E

A Electronic moduleB Green LEDC Red LEDD DisplayE Operator controls

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The electronic module consists of:

• Motherboard with power unit, RS485 interface • Buffer battery for the clock (A) • Connection for the pH measuring cell (B) • Connections for the chlorine and redox measuring cells (C) • The relay and the terminal strip for the outputs (D) • The housing ducts for the sensor cable (E)

A Buffer battery for the clock B Connection for the pH measuring cell C Connections for the chlorine and redox measuring cells D Relay and terminal strips for outputs E Housing ducts for the sensor cable F RS232 interface G Cable glands

The following are incorporated into the base of the housing:

• The RS232 interface (F) • The cable terminal screws (G)

3.4 Functions 3.4.1 OverallFunction

Up to four measured values can be indicated by process-adjusted components:

• Free chlorine • pH value • Redox voltage (optional) • Temperature

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Numerical values of the measured data, limit values and setpoint values are shown on the display. All measured values can be displayed at the same time.


The flow block assembly guarantees a stable measurement signal on account of:

• robust sensors • constant flow rate of sample water with the aid of the flow control valve • hydrodynamic cleaning of the measuring electrodes of the chlorine

sensor with sand • optimum flow around all sensors

The multi-sensor integrated into the flow block assembly monitors the constant flow rate of sample water, registers the temperature of the sample water and ensures equipotential earthing over a large surface area (sample water earthing).

3.4.3 Electronicmodule

The electronic module is used for visualisation and subsequent processing of the measured data as well as process control. Positioners or various dosing pumps can be connected to the control outputs of the process control unit.

The following functions are possible:

• Dosing of disinfectant • Correction of the pH value • Addition of flocculant with locking of the circulation system

Up to two relay outputs can also be used as alarm contacts. They can be freely configured. Multiple allocation of events is possible. The adaption program automatically determines the control parameters for dosing chlorine during start-up.

3.4.4 Safety functions

The safety functions integrated into the control unit are:

• safety shutdown if there is no flow of sample water • safety shutdown if the circulation fails • safety shutdown if the supply container signals it is empty • monitoring of the dosing time • dosing delay

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• alarms and common alarms • Error message • Password protection

3.4.5 Interfaces

The Ezetrol®plus supports the following add-on:

• ChemWeb-Server: Archiving and display of measured values, remote diagnosis, remote access with standard browser with internet and e-mail capabilities

3.4.6Digitalinputs

WARNING: The digital inputs are designed for voltage-free external contacts. External voltages may damage electrical circuits. Digital input Dl1 The Dl1 contact for the flow switch on the flow cell allows the dosing to be stopped and the alarm enabled.

• Before the delay time has expired, sample water monitoring (0 to max. 10 min.): The dosing pump for chlorine and the dosing pump for the pH correction medium continue running at the same rate. The DI symbol in the display flashes. Display: DI *sample water?

• After expiry of the delay time of the sample water monitor: the dosing pump for chlorine dosing and the dosing relay for pH correction are switched off. Display: DI *sample water?

This controller shutdown function is only active in automatic mode.

Digital input Dl2 The Dl2 contact is normally used as the circulation pump interlock, allowing the controller to be stopped immediately when the circulation pumps are electrically isolated.

• The dosing pump for chlorine and the dosing pump for pH correction are switched off.

Display: DlI *ext. STOP? When the standby function is switched on, display: STANDBY.


Digital input Dlll

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• The Dlll contact is generally used to indicate that the chemical tank is empty.

The dosing pump for chlorine and the dosing pump for the pH correction are switched off.

Display: Dlll *Carboy?


NOTE: Once the contact has been re-established there may be a delay in restarting the controller due to the dosing delay. The digital inputs Dl2 and Dlll are deactivated on delivery (fitted with jumpers). To activate the function, remove the jumpers and connect one external contact to each input.

3.4.7Controllertypes

The following types of control are integrated in the Ezetrol® plus and are available for selection depending on the dosing device connected.

Controllerfor Type ParameterDesignation Action

Positioner without feedback

3-point Positioner Dosing Cl2pH correction

MotorDosing pump + solenoid valves (pulse duration controlled)

2-point Dosing pump 2P Dosing Cl2pH correction ä (acid)or pH ã(alkali)

2 Motor dosing pumps (pulse duration controlled)

3-point Dosing pump 3P pH correction ä (acid)or pH ã(alkali

Pulse pump(pulse frequency controlled)

2-point Solenoid pump 2P Dosing Cl2pH correction ä (acid)or pH ã(alkali

2 solenoid pumps(pulse frequency controlled)

3-point Solenoid pump 3P pH correction ä (acid)or pH ã(alkali

Dosing release(dosing contact)

2-point Dosing contact Dosing Cl2e.g for OSEC-A)

Positioner (without feedback)Using the integrated controller, it is possible to implement feed control in combination with a positioner as an actuator. Depending on the control deviation, the positioner can control the quantity of gas fed, e.g. using the V10k gas feeder.

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The control direction (control of the positioner) is indicated by the LED in the display field.

Dosing of chlorine gas is increased

Dosing of chlorine gas is decreased

Dosing of CO2 gas is increased

Dosing of CO2 gas is decreased

In 'Manual' mode ('Cl2 actuator' or 'pH actuator' menu) the positioner can be opened and closed by pressing the s and t keys

NOTE: In the event of a power failure any positioners connected to the Ezetrol®plus are no longer actuated and stop moving. This does not interrupt the gas feed. This may result in a dangerous over dosing of chlorine.

To ensure that any positioners connected automatically shut down to 0% connect an external phase to terminal 53 (for chlorine) or 47 (for pH). This ensures that if the power to the Ezetrol® plus fails, this external phase switches the relay so that the positioner closes until it reaches the end position at 0%.

Pulse duration controller for dosing pumps The dosing pump is switched on for the calculated time within an adjustable cycle period Tp (relay contact). The cycle period is mainly determined by the reaction time of the connected system and entered as the cycle period Tp. Example: cycle period Tp 100 s Output value Yout 30 % Duty cycle 30 s Off-duty cycle 70 s

Pulse-frequency controller for solenoid pumpsSolenoid pumps are controlled with 0 to 100 or 0 to 120 pulses per minute, depending on the specification of the connected pump.

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The duty cycle during each dose is 0.3s. The break time is calculated to be between 0.2 and 60s depending on the dosing rate.

Example:- For a pulse pump with 120 pulses/min.

Yout in% 100 84 72 56 50 33 25 10 5 1 0Pulses/min 120 96 85 75 60 40 30 12 6 1 0

Manual actuation of a dosing pump or a solenoid valve1 Press t to access the “Mode” menu. 2 Press 3 , “>Mode” is displayed.3 Press t until “Manual” is displayed. 4 Confirm by pressing 3. 5 Press t to access the “pH actuator” menu (or similarly to access

the “Cl2 actuator” menu). 6 Press 3, “>OFF”, “pH+” or “pH-” is displayed. To switch on the dosing pump: Press s. To switch off the dosing pump: Press t.

Cl2 dosing pump running

“Increase pH “ dosing pump running

“Decrease pH” dosing pump running 2-point pulse duration controller for dosing pump and 2-point pulse frequency controller for pulse pumpOne dosing pump is used to decrease the pH value (dosing of acid), the other dosing pump is used to increase the pH value (dosing of alkali).

This type of controller is used if only one pump is connected (acid or alkali). The control direction (pH+ or pH-) must be correctly selected.

If the current value > setpoint the pump is not If the current value < setpoint the pump is not actuated. actuated.

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The actuation status of the dosing pumps is indicated by the LEDs on the display:

'Increase pH' dosing pump running (pH+ / alkali)

'Decrease pH' dosing pump running (pH- / acid)

3-point pulse duration controller for dosing pump and 3-point pulse frequency controller for pulse pump One dosing pump is used to decrease the pH value (dosing of acid), the other dosing pump is used to increase the pH value (dosing of alkali).

If the setpoint = actual value, no pump is activated (neutral zone Xsh).

The control range is 0 to +100% and 0 to -100%.

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The control direction (control of the dosing pumps) is indicated by the LEDs in the display field:

'Increase' pH dosing pump running (pH+ / alkali)

'Decrease' pH dosing pump running (pH- / acid)

Dosing contact e.g. for OSEC-AA special controller is required for controlling electrolysis units to prevent excessive on/off switching (on account of the response times of the electrolysis unit).

This controller output, therefore, uses a minimum duty cycle as well as a switching hysteresis to minimise the switching cycles.

If the value falls below the specified Cl2 setpoint minus hysteresis (e.g. setpoint 0.50mg/l - hysteresis 0.05 = 0.45mg/l), the controller output switches on.

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The controller output remains active for at least the set minimum duty cycle. If the setpoint is exceeded and the minimum duty cycle has expired the contact switches off.

The minimum duty cycle is ignored in the manual mode.

3.4.8 Controlparameters

Control parameters are input variables that determine the control functions of a controller. Different parameters apply to each type of controller.

max. pulse/minThe max. pulses/min parameter only applies to pulse pumps. This parameter is used to set the maximum number of pulses per minute in accordance with the pump used.

Setting range:The pulses max./min parameter can be set to either 100 or 120 pulses.

SetpointThe specified value at which the control parameter (chlorine, pH) is to be maintained by the controller.

Setting range:In accordance with the corresponding measuring range.

Tn On the basis of the integral action time Tn, the dosing rate changes constantly until the setpoint is reached. The higher the value of Tn, the longer it takes until the controller increases the dosing rate.

Tn higher: Control response is slower Tn lower: Control response is faster

Setting range: The parameter Tn can be between 0 – 100 min (Tn = 0 means that the 'I-element' is deactivated, i.e. a pure P-control response applies). It may not be possible to reach the setpoint value.

If using a positioner controller it is impossible to set Tn to 0 (off).

TpThe parameter Tp only applies to dosing pumps. With the cycle period Tp a switching period is defined, which must be coordinated with the respective pump type.

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Setting range:The parameter Tp can be set to between 10 – 180 s.

Example: Fast dosing pumps correspond to a low Tp; slow dosing pumps correspond to a high Tp. The control parameter Tp must always be adjusted to suit the dosing pump employed:

Dosing pump up to 20 20–40 40– 80 80–125 125–200 strokes/min

Tp value 120 100 60 30 15

TsTime required to reach the end value of the measuring range with 100% dosing rate (for more information, please see “Adaption”).

Setting range:The parameter Ts can be set to between 0.1 – 480.0 min.

Tu Time required between start of dosing and clear recognition of the reaction.

Setting range: The parameter Tu can be set to between 1 – 3600 s.

NOTE: If the values Tu and Ts are manually modified, the control parameters Xp and Tn are re-calculated.

Ty The parameter Ty only applies to positioners. Ty is the time which the positioner requires to adjust from 0 % to 100 %.

Setting range:The parameter Ty can be set from 10 – 180 s.

Xp The control amplification is determined by means of the proportional factor. The lower the proportional factor Xp is selected in % , the greater the deviation from the setpoint is amplified, and the more quickly the controller attempts to control the deviation from the setpoint. The control amplification factor is calculated using the following equation:

Factor = (1/Xp) x 100 %

23W3T292576 / WT.050.425.001.GE.IM.0215


Setting range: The parameter Xp can be set to between 1 % (factor 100) – 1000 % (factor 0.1). HysteresisThe hysteresis parameter only applies to 3-point controllers and the dosing contact. There is no controller output in the neutral zone.

Setting range: 0.01 - 0.50 mg/l (Cl2) 0.01 - 0.50 pH (pH)

Control directionThe control direction can only set for 2-point controllers and positioners for pH correction.

Setting range: pH+ or pH-

min. ON time The parameter min. ON time only applies for dosing contact and defines the minimum duty cycle for dosing.

Setting range: 1 - 120 min 3.4.9 Alarms

The alarms are sent via two relay contacts and the red LED. Each alarm can be assigned the following functions:

• Limit value = min all measured values are individually selectable (Cl2, pH, mV)

• Limit value = min all measured values are individually selectable (Cl2, pH, mV)

• Digital inputs 1 – 3 can be selected individually

The type of alarm can be selected in the “Alarm relay 1 and 2” and “Relay function“ menus. There are three alarm types. The response of all alarm types can be influenced by entering a delay (td) (please refer to the diagrams in this section).

Unlatched alarm without acknowledgement option(N.O. unlatched N.C unlatched)

W3T292576 / WT.050.425.001.GE.IM.021524


The LED lights up in the event of an alarm and goes out automatically when the alarm conditions are eliminated. The same applies to the contact.

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Latched alarm with reset acknowledgement option(N.O. latched N.C latched)The LED flashes in the event of an alarm until the alarm is acknowledged. The LED goes out, also if the set alarm conditions still apply when the alarm is acknowledged.

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25W3T292576 / WT.050.425.001.GE.IM.0215


Latched alarm with confirmation (acknowledgement option)(N.O. latched acknowledge N.C. latched acknowledge)The LED flashes in the event of an alarm until the alarm is acknowledged.

• If the alarm condition is no longer present when the alarm is

acknowledged, the LED goes out.

• If the condition which caused the alarm still applies when the alarm is acknowledged, the LED changes from flashing to permanent lit. The LED stays on until the condition which caused the alarm is eliminated (auto-reset).

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3.4.10 Interfaces

Two interfaces are available for making external connections to the Ezetrol® plus.

RS232 The RS232 interface is used to connect a printer

Specification of the RS232 interface for printer operation:

• Data transfer 9600 baud • Parity straight • Length of word 8 bit

An operating log is printed for each day of operation (see below).

W3T292576 / WT.050.425.001.GE.IM.021526


Each daily log consists of a log header, trend graphs and the output of the daily min. and max. values.

The available measurements and the corresponding parameters, such as the setpoint, Xp and Tn, are printed in the log header. The date of the last calibration is also documented. This is followed by a printout of the trend graphs, including the measuring ranges and the current operating mode, as a bar graph. The trend graphs are recorded at one-minute intervals.

The calibration times for each measurement are printed at the end of the log.

Printer log

NOTE: The maximum cable length between the interface and the printer must not exceed 15 m.

To print logs, Evoqua Water Technologies offer a RS232 log printer (AAC5995) as well as a printer connecting cable, 3 m (AAC5887) or 15 m (AAC5914) long, as accessories. Setup instructions are provided with the printer (FAE1208). NOTE: Information on the RS485 interface can be requested separately from Evoqua Water Technologies.

If a RS485 log printer from Wallace & Tiernan (AAB9187) is already available (e.g. from a previous system), it can still be used with this system by connecting it to the RS485 interface.

27W3T292576 / WT.050.425.001.GE.IM.0215


3.5 TechnicalData3.5.1 Electronicmodule

Housing Dimensions (W x H x D): 320 x 310 x 175 mm Weight: approx. 5 kg Enclosure: IP 66

Platform Mains connection: • 200–240 V AC ± 10%, 50–60 Hz, 14 VA, Fuse 0.63 A (T, type: TR5 or • 100–120 V AC ± 10%, 50–60 Hz, 14 VA, Fuse 0.63A (T), type: TR5

Insulation • Overvoltage category 2 • Contamination level 2

Operating conditions • Ambient temperature 0 – 50 °C • Operating environment No direct sunlight • Atmospheric pressure 75 – 106 kPa • Storage temperature -20 to +70 °C • Noise emission

W3T292576 / WT.050.425.001.GE.IM.021528


mA outputs Option

3x outputs • Output 0/4 – 20 mA • Accuracy < 0.5% FS • Load max. 600 Ohm • Max. temperature drift 0.2 % / 10 °C • Load monitoring • Electrically isolated up to 50 V to earth

Interfaces 1xRS232 for direct printer control (not electrically isolated) 1x RS485 for connection to: • ChemWeb-Server not electrically isolated

Display and 1 x operating panel with 6 keys operating unit 8 x Red LEDs for indication of operating conditions

1 x Green LED for indication of the power supply 1x display: 2x 16 characters, luminous


Housing Dimensions (W x H x D): 215 x 375 x 155 mm Weight: approx. 1.5kg

Connections Sample water: 5/16" PVC hose or 5/16" PE hose Threaded connection ½"

Flow control valve Flow rate: approx. 33 l/h (controlled) Control range: 0.2 - 4.0 bar Back pressure: max. 1.5 bar (pressurised)

Sample water temperature: max. 50°C

29W3T292576 / WT.050.425.001.GE.IM.0215


Multi sensor Switching point: 21 l/h ±3 l/h

Switching hysteresis: 2 l/h

Temperature sensor: PT1000 3.5.3 Sensors

NOTE: All sensor measurement inputs are electrically isolated to 50 V to ground.

Free chlorine Model (sensor) : 3 electrode sensor with additional electrolyte salt filling

Measuring principle: potentiostatic amperometry

Temperature compensation: 0 to 50 °C Max. temperature drift: 0.2 %/10 K

Measuring range: 0 – 3 mg/l

Sample water conductivity: 200 µS/cm – 200 mS/cm

Storage temperature: -10 to 30°C

pH value Temperature compensation: 0 to 50 °C

Max. temperature drift: 0.2 %/10 K

Measuring range: 4 – 9 pH

Sample water conductivity: 200 µS/cm – 200 mS/cm

Storage temperature: -5 to 30°C

Redox voltage Temperature compensation: 0 to 50 °C

Max. temperature drift: 0.2 %/10 K

Measuring range: 400 mV – 900 mV

Sample water conductivity: 200 µS/cm – 200 mS/cm Storage temperature: -5 to 30°C

W3T292576 / WT.050.425.001.GE.IM.021530


4. INSTALLATION 4.1 Versions

Completesystem

230V Cl2+pH

Completesystem AAC1791consisting ofElectronicmodule AAD8479Flowcellmodule AAE2503

Scope of supply Depending on the individual order, the scope of supply includes the following:

• Electronic module • Flow cell module, pressurized • Strips for labelling the LEDs • Accessory set, comprising: five cable terminal screws six blind terminal screws bushes for closing empty ducts for the sensor cables on the electronic module fine filter • Sensors with accessories (depending on the order): Free chlorine (Cl2 ) pH value redox • Generally pre-mounted on a uPVC backboard, the unit is supplied with sample installation kit, including: 30m of sample hose ½" x 5/16" strainer ½" x 5/16" push fit sample isolation valve

31W3T292576 / WT.050.425.001.GE.IM.0215


• The pre-mounted kit assembly includes: Mounting kit Sensor cleaning solution Operating manual

4.2 Transport and Storage 4.2.1 Transport

The unit is supplied in standard packaging. During transport the packaged unit must be handled carefully and should not be exposed to wet weather or moisture. Check that the transport packaging is undamaged.

In the event of damage, please inform the transport company immediately, as your rights to compensation will otherwise be lost.

If the unit is damaged, please contact the respective Wallace & Tiernan agency immediately.

Keep the packaging until the unit has been correctly installed and taken into operation.

4.2.2 Storage

Store the unit and the sensors in a dry condition without any residual water in a dry place that is not exposed to the weather. Storage temperature, see Section 3.5 “Technical Data”.

4.3 Installation.

Only those persons suitably qualified/trained should undertake the installation of an Ezetrol®plus. Only those persons qualified to carry out electrical installation works should undertake the installation of electrical wiring of an Ezetrol®plus.

4.3.1 Unpacking

The equipment should be unpacked in a clean, dry area, preferably in the place in which the unit will be installed. All parts should be checked against the enclosed packing note before the packing materials are discarded.Upon receipt, immediately check if package is free from damage and that the contents are complete. Report immediately any damage. Handle the sensors carefully when unpacking, as they can be broken if dropped on a hard surface.

W3T292576 / WT.050.425.001.GE.IM.021532


NOTE: Each sensor is shipped with its tip immersed in a small cap of fluid, to prevent it from drying out. Leave the cap in place on the tip until you are ready to install the sensor into a sample cell with a fully established water flow.

4.3.2 Location

There are a number of factors that should be considered as you select a location for the controller. These include, but are not limited to:

• A sound mounting surface to adequately support the board assembly.

• A location that is accessible, free from chemical fumes, excessive heat and dampness should be chosen as they can seriously damage the controller. Damage due to chemical fumes, including hydrochloric acid fumes, will invalidate the warranty.

• The controller should be easily accessible for taking display readings or making operating adjustments. Lighting should be adequate and clearance must be provided for service. Do not mount in direct sunlight.

• High voltage transformers and other energy-emitting electrical devices can affect the delicate sensing circuits of the controller. Locate the board assembly as far away as practical from sources of interference and be sure that it is electrically grounded as specified in the wiring diagrams.

• The Ezetrol®plus is designed to be permanently powered. The main power into the unit should NOT be interlocked with main circulation pumps. The controller has a secondary input (external stop), which is used to isolate the dosing pump outputs. This input is volt-free and must not be powered (or the controller will be damaged, invalidating the warranty).

• The main power feed should be provided from a ‘clean’ 10-amp switched and fused source.

• The position of the nearest drain should also be given consideration, as the standard Ezetrol®plus supply requires a drain that is open to atmosphere to which the sample water to runs. An optional return to filtration, post filer, pipework kit is available.

4.3.3 Mounting

The Ezetrol®plus should be positioned at an easily read and accessed height. Evoqua Water Technologies recommend that the centre of the display is at a height of 1650 mm.

33W3T292576 / WT.050.425.001.GE.IM.0215


Drill a 9mm hole, in a convenient position, in each corner of the backboard.The holes in each corner of the board should be used to pass an 8mm bolt through. The fixing should be passed through the mounting board and one of the spacers supplied, at each corner.

The board should NOT be fixed directly against the wall, as this would cause damage to the sensor leads that are passed through the back of the board. Spacers are provided to hold the board away from the wall.

4.3.4 Samplewatersupply

Required pressure at flow cell.Minimum 0.25 barMaximum 4.0 bar

A flow of approximately 30 l/hr is required for the accurate operation of the chlorine sensor; the flow regulator automatically limits the amount of water flowing through the cell. A flow in excess of 30 l/hr would be held within the sample water sample pipe work and will eventually pass through the flow cell. It is important to use the hose supplied and not to increase the bore of the water supply pipe to prevent undue lag-time between the water entering the sample hose and passing the sensor tips.

Water from the flow cell is normally fed to the drain. It is also possible to return the ‘waste’ water back to a post filter point in the pool water return, at a maximum back pressure of 1.5 bar. A return water installation kit of parts is available.

W3T292576 / WT.050.425.001.GE.IM.021534


If the flow cell sample supply water pressure is less than 0.25 bar, a sample water pump may be installed either from the pool or from the circulation system (preferred). The use of a booster pump must include a loop of pipe work with a sample tapping to draw of a proportion of the water to pass through the sample cell. This prevents the entire pump pressure from being put directly onto the flow regulator and also stops the creation of an artificial lag time.

The sample water supply point must be installed in the delivery pipework between the circulation pump(s) and the filters. However, the sample water point must be installed upstream of the flocculant dosing station an the pressure applied directly to the measuring cell must be at least 0.2 bar. The sample water point must be chosen to ensure that the water sample is representative with a constant, bubble-free flow. The sample supply hose is supplied with the kit of parts. The sample line should be as short as possible. If the sample line is to be longer than 30m refer to Evoqua Water Technologies.

A sample strainer must be fitted to ensure that the flow switch, flow regulator and sensors cannot be fouled or damaged by solids passing from the circulation pump supply.

Failure to use the strainer provided will allow debris such as ‘hair & lint’ to pass into the flow regulator and the flow cell. This will compromise the performance of the Ezetrol®plus and will invalidate the warranty.

For sample runs of 20m upwards, a loop from the circulation pump delivery pipework should be taken to a point below or adjacent to the board mount assembly and returned to the suction side of the circulation pump(s).

The sample loop should be run in ½” uPVC pipe, suitably supported throughout its entire length. A ½” tee adjacent to the flow cell should be fitted and a minimal length of 5/16" hose and connected to the adapter on the strainer inlet, out let and then on the to the flow switch mounted directly under the flow cell. The fittings from the tee to the flow cell are included the ½” uPVC pipe and fitting are to be supplied by others.

Please note that if 50% duty circulation pumps are employed, running only one pump only will reduce the sample rate of flow to the flow cell. Attention should be given to the amount of flow during this period and, if adjusted, the subsequent flow when the second pump flow is restored.

Should the ‘waste’ water be returned to the post filter circulation pipe work remove the ‘tundish’ from the board and the threaded insert, plus the spare threaded insert, used to support an isolation valve.

35W3T292576 / WT.050.425.001.GE.IM.0215


4.3.5 Sensor connection

Remove protective caps from the pH and chlorine sensors. Screw sensors into the flow cell. The chlorine sensor has an integral lead that can not be removed from the sensor. The back nut/thread on the sensor may be screwed into the flow cell without rotating the sensor or ‘knotting’ the lead.

There should be no air bubbles in the tip of the pH sensor, if there are, remove them by gently shaking the sensor (similar to shaking a clinical thermometer).

After start-up, all sensors require a settling-down period of approximately two - four hours. Calibration and other adjustments should only be made after this period and automatic feed control should be switched off. The Ezetrol®plus should not be left in automatic feed mode overnight for 24 hours after first fitting the sensors.

Do not use stabilised chlorine products, as the Ezetrol®plus will not function correctly.

Sensor warranty will be void if the above is not complied with.

4.3.6 Electricalconnections

Only those persons qualified to carry out electrical installation works should undertake the installation of electrical wiring of an Ezetrol®plus.

The electrical supply to the board assembly should be wired via a double pole isolation switch. The supply should be fused at 10 amp max and the location of the fuse clearly identified.

Please refer to wiring diagrams at the rear of this manual for identification of all the terminals to enable cable connection.

The Ezetrol®plus is not provided with internal dosing relay fuses. To ensure the relays and PCB are protected external fuses must be fitted.

WARNING: The Ezetrol®plus is designed to be permanently powered. The main power into the unit should NOT be interlocked with main circulation pumps. The controller has a secondary input (external stop), which is used to isolate the dosing pump outputs. This input is volt-free and must not be powered (or the controller will be damaged).

Power requirement: 230V AC, 1PH, 50 Hz.

W3T292576 / WT.050.425.001.GE.IM.021536


4.3.7 Samplewaterdrainageline

The sample water usually drains away through an unpressurised line. However, a pressurised line with max. 1.5 bar overpressure can be used as a return line. There is a ball valve installed in the sample water return line for this. It can be used to isolate the flow-through adapter, e.g. during calibration. The sample water admission pressure must always be at least 0.2 bar higher than the back-pressure on the cell outlet. Pressure losses in the return line must also be taken into consideration.

Hose Connectors - AAC1632 ½" Female x ¼" Hose Push Fit Adaptor

4.4 Commissioning

WARNING: Electrical hazard. Only authorised and qualified electricians are permitted to install the device and open the housing. The unit may only be put into operation when the housing is closed, and must be connected to protection earth. Modifications to the unit that go beyond those described in this manual are not permissible.

4.4.1 Start-up procedure

The unit can be taken into operation after it has been installed.

The following table contains the individual commissioning steps in their correct sequence. More detailed information is contained in the sections listed in the “Reference” column.

Completion of each task can be confirmed in the “Completed” column.

NOTE: If this installation sequence cannot be complied with, please contact the following service address: Evoqua Water Technologies LtdSuite 3, 2nd Floor, One 60 London Road, Sevenoaks, TN13 1BT, UKPhone +44 (0)1732 771777 Fax +44 (0)1732 771800 e-mail: [email protected]

37W3T292576 / WT.050.425.001.GE.IM.0215


Ser. No. Task Reference Completed

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

ForpHmeasurement:Set control output for pH, if necessary, set positioner running time 'Ty', 'Xsh' or 'max. pulses/min'

Set the control direction

Check setpoint for pH control, adjust if necessary

Adapt the values for 'Xp' and 'Tn' to the control loop

If a dosing pump is used, check the 'Tp' parameter and adapt to the pump, if necessary

Check limit values for pH ('min' and 'max'), adjust if necessary

ForRedoxmeasurement:Check limit values for redox ('min' and 'max'), adjust if necessary

Subsequentprocedures:Configure the alarms as required

Configure the analog outputs as required

Configure the RS232 printer interface

Configure the RS487 interface as required

Using menu 'actuator Cl2/actuator pH', check that all connected actuators are functioning correctly

Calibrate the fitted sensors after approx. 1hour running-in time

Switch to the 'auto' operating mode

Repeat calibration after 24 hours running time

pH Parameters

pH Parameters

Display menu

pH Parameters

pH Parameters

Limit values

Limit values

Alarm relay 1/2

Setup mA

Setup

Setup

Display menu

See Section 5.2

Display menu

See Section 5.2

W3T292576 / WT.050.425.001.GE.IM.021538


4.4.1 Fillingcellgrit

WARNING: If using pressurised versions: Before opening the cover, always shut off the supply line and the drainage line and then release the pressure in the cell body with the drain screw.

1 Unscrew the cover from the cell body

2 Fill half a screw cap of white cell grit for measuring cells (U¬93275) into the cell body. See Section 6 Maintenance.

3 Refit the cover onto the cell body. 4.4.2 Insertthesensorsandconnect

Arrangement of the sensors

A

B

C

A Cl2 B pH C mV

1 Remove the protection caps from the sensors.

2 Fit the sensors into the cover of the cell body, as shown above. The sensors are marked as follows:

A: Cl2: sensor for free chlorine, labelled “DES” B: pH: pH sensor, labelled “pH” C: mV: sensor for redox voltage, labelled “mV”

NOTE: Keep the sensor protective caps for subsequent use.

39W3T292576 / WT.050.425.001.GE.IM.0215


Arrangement of the cables

Connecting the sensor cables1 Place the sensor cables with the attached bushes into the cable ducts

of the housing and connect to the electronic module, see electrical wiring diagrams. The cable of the pH sensor is soldered on.

2 Depending on the sensor design, either plug or plug and screw the cable into place.

3 Mount the multi-sensor with the temperature measuring cable to the flow control valve. Place the temperature measuring cable through a duct and connect to the electronic module - refer to the wiring diagrams. Note that the shield of the four-core temperature measuring cable must also be connected.

4 Insert the supplied bushes into ducts that are not in use in order to seal the housing.

4.4.3 Connectingthesamplewater

CAUTION: The sample water supply point must be located upstream of the flocculant dosing station. Otherwise, it could influence the measurements.

Sample water inlet connection1 Do not use any copper pipe.

W3T292576 / WT.050.425.001.GE.IM.021540


A B C2 The pressure in the sample water inlet must always be within a

range of min. 0.2 to max. 4 bar. At the same time the pressure in the sample water inlet must generally be 0.2 bar higher than in the sample water outlet.

3 To prevent long process times, ensure that the lines in the sample water inlet are as short as possible.

4 An external strainer must be provided for the sample water inlet (Part No. UXA92304) with a mesh size of 0.5 mm.

4.5 Connectthedevicetothepowersupply

Refer to the electrical wiring diagrams at the back of this manual. WARNING: Only authorised and qualified electricians are permitted to install the device and open the housing. The unit may only be put into operation when the housing is closed, and must be connected to protection earth. Modifications to the unit that go beyond those described in this manual are not permissible. The device is not equipped with a mains switch and is in operation as soon as the supply voltage is applied. An external switch or circuit breaker is therefore necessary. The conductor cross-section of the mains cable must be at least 0.75 mm²; a mains fuse of 6 A must be provided by the customer. When connecting system components (e.g. devices, motors, pumps) and when entering operating data, the system components must be switched off in order to prevent uncontrolled activation or any incorrect function.

41W3T292576 / WT.050.425.001.GE.IM.0215


CAUTION: To ensure safe and correct commissioning, knowledge of the operation, connected electrical load, measurement signals, cable assignment and fuse protection of the connected devices and machines and the relevant safety regulations is required. Commissioning of the unit may therefore only be performed by qualified and authorised electricians.

Incorrectly connected devices can be damaged, possibly irreparably, or cause faults in other equipment when they are switched on or in operation. Ensure that the measuring and control cables are not confused or make contact with one another. Never connect or disconnect any cables to which voltage is applied. NOTE: The power supply line must have a 6 A switched fuse to provide an on/off facility.

Checking the mains voltage/connecting the unit1 Remove the 5 screws on the electronic module.

2 Carefully remove the cover. Unplug the cable between the cover and the housing.

3 Connect the mains supply inputs and outputs to the terminals (A) according to the circuit diagram (see also the following sections).

4 Observe the following when connecting the external signals. Digital input 1: Flow rate monitor Digital input 2: Circulation pump interlock Digital input 3: Empty tank alarm

WARNING: Do not connect mains voltages to digital inputs:

W3T292576 / WT.050.425.001.GE.IM.021542


CAUTION: To avoid overchlorination or a malfunction of the pH controller, the control system must be connected to the circulation unit. To do this connect one enable contact of the circulating pump to digital input Dl2 (terminals 3 and 4) (see also Section 3.4.6 digital inputs).

Replacing the housing coverIf all cables are connected:-

1 Plug in the cable between the cover and the housing.

2 Replace the cover on the housing and tighten the 5 screws, making sure that the cable bushings are seated correctly and that none of the cables are trapped.

4.5.1 Connectingaflocculantpump

The flocculant pump is controlled via an unused alarm relay. The alarm relay is programmed so that the flocculant pump stops when the circulation unit is stopped. This requires an enable line to be connected from the circulation control unit to digital input Dl2.

Menu setting to activate the enable input of a pulse pump or dosing pump with the aid of alarm relay 1 (contact on terminals 46 and 47 open for circulation stop):

• Menu path 7 (alarm relay 1)

• Relay assignment: Dl2 (otherwise no selection is displayed)

• Relay function: N.O. unlatched

• Delay 0 min.

4.5.2 Switchingtheuniton

Requirements• Electrical connections are complete.

• Electrodes are inserted and connected.

• Cell grit has been added.

• Sample water supply line and drain line are connected having been tested for leaks and pressure, sample water flowing.

43W3T292576 / WT.050.425.001.GE.IM.0215


1 Switch on mains voltage. The programme version is briefly displayed e.g. EAC1069 V:3.01 22 OCT 2008

then the basic display appears. The unit is ready for operation.

2 Set the parameters for the positioner, the connected pump and the control direction in the menu path 'Parameters'.

3 Set the limit values and functions in the menu path 'Alarms'.

4 Vent the dosing pump, if necessary.

5 Calibrate the measuring signals after approx. 1 hour running-in time. Repeat calibration after 24 hours of operation.

6 Check the measured values by a manual measurement e.g. DPD.

7 Switch over to the automatic mode and check the function of the dosing and control systems.

8 Check the response to faults

Fault Display ResponseSample water 1 stop DI flashes

*sample water?Chlorine measurement:Immediately:Dosing pump continues to dose unchanged,or positioner no longer moves.

DI static*sample water?

After the delay has elapsed:The dosing pump switches off or the positioner closes

Circulation stop DII *ext. STOP?*(static)or STANDBY

The dosing pump switches off or the positioner closes

Empty dosing tank alarm

DIII *Carboy?(static)

The dosing pump switches off or the positioner closes

Air bubbles, that may hinder the rotation of the cleaning, grit disappear after an operating time of approx. 48 hours.

4.6 SystemShutDown

CAUTION: Risk of uncontrolled dosing of chlorine and pH-correction chemicals. Shut down the dosing system. If the installation site of the flow cell module could be affected by frost, the system must be shut down well in advance of any freezing conditions.

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1 Switch off the power supply.

2 Empty the sample water supply line and drainage line.

3 Empty the cell body.

4 Dismantle the filter housing and check the valve housing.

5 When the remaining water has drained from the flow control valve, refit the filter housing and check the valve housing.

6 Remove the sensors from the cell body cover and disconnect from the cable.

7 Apply a KCl solution to the protection caps of the CL2, pH and redox electrodes.

8 Store the sensors in a frost free place.

NOTE: The KCl reservoir (Part No. AAC4084) can be used instead of the protection cap.

A Sensor AB Sealing cap

C O-ring B CD Reservoir D

E Pedestal E

Recommissioning1 Prepare the sensors: Cl2, pH, redox electrodes Remove the protection cap and keep in a safe place.

2 Refit the sensors.

3 Turn the flow of sample water on again.

4 Check for leaks.

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4.7 Auto TuneOnly applies to free chlorine.

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ApplicationAdaption is used for the automatic assessment of the reaction times of the control loop (loop dead time Tu and loop rise time Ts) or the resulting control parameters Xp and Tn.

NOTE: The control parameters determined by the adaption must be considered as a recommendation for initial commissioning. The control parameters Xp and T can be manually optimised to ensure maximum control quality.

Requirements• Dosing pump set to automatic• Calibrated Cl2 measuring (zero point and DPD value)• Loop dead time

W3T292576 / WT.050.425.001.GE.IM.021546


Starting auto tune

1 Starting at the basic display, press F repeatedly until the 'Auto Tune' menu is reached. Press t until the 'Auto Tune' menu is reached.

2 Press 3. 'Start > adaption' is displayed.

3 Press 3 again.

Each adaption phase is then displayed with a status message:

Displaytext Explanation0: Init Initialisation1: Ym = 0% Pump off2: X = 20% Wait until current value is

47W3T292576 / WT.050.425.001.GE.IM.0215


Conclusion of auto tuning without errorsWhen the loop time (dead time Tu and rise time Ts) have been completed without error, calculation of the control parameters Xp and Tn commences. The calculated parameters are entered in the menus. When auto tuning has finished, the Ezetrol® plus uses the newly calculated control parameters and continues running in the selected mode (e.g. automatic).

To monitor the determined loop times they are entered into the Tu and Ts menus.

If any errors in the control loop do occur during adaption (e.g. filter backwash or changes in the circulation speed), this may lead to incorrect loop times, resulting in wrong control parameters being determined.

NOTE: Performing adaption does not affect the remaining control parameters.

Conclusion of auto tuning with errorsIf adaption is not successful, the error message 'Auto Tune?' is displayed.

If errors occur in the control loop during adaption (e.g. filter backwashing, changes in the circulation or widely fluctuating number of visitors to the pool) or if reaction times of the control loop are too long, adaption is interrupted.

Potential faultsInitial value not reached — When auto tuning has started and the dosing system has closed or the dosing pump has switched off, the measuring amplifier waits until the actual value has dropped below the initial value (0.2 x the measurement range value) this delay is indicated by 2: X = 20% being displayed and must not exceed 8 hours.

Loop dead time too long — The value determined by the time measurement between starting up dosing, switching on the dosing pumps and the rise of the actual value may only take a maximum of 1 hour. This measured time is displayed by 6: Tu!

Loop rise time too long — The time is determined by a measurement which the control loop requires at 100% dosing rate of the dosing system or the dosing pump, to increase the actual value to 50% of the measuring range. This measurement is indicated by 9: Ts! and may take a maximum of 4 hours.

If any of the error conditions described above occur, auto tune is interrupted. The measuring amplifier displays a fault message. The old parameters Xp and Tn are not changed.

W3T292576 / WT.050.425.001.GE.IM.021548


Determining the control parameters with known Tu and Ts values — If the loop time Tu and Ts are already known or if they cannot be determined automatically due to specific system conditions, the loop times can be entered into the Tu and Ts menus. When Tu or Ts are saved, the control parameters Xp and Tn are also calculated and entered in the menus.

4.8 Settings Overview

Display Factory setting CommissioningDISPLAY-MENU

Cl2 setpoint 0.35 mg/lsetpoint pH 7.00 pH

Mode ManualMenu Extended

CALIBRATIONoffset pH 0.00 pH

Man. temp. comp. 20°CPARAMETERCl2

Actuator Dosing pump 2PXp 10%Tn 20 minTy 90 sec.

max. pulse/min 120Tp 60 sec

Hysteresis 0.05 mg/lmin. ON time 1 min

PARAMETERpHActuator Dosing pump 3P

Xp 10%Tn 20 minTy (90 sec)

max. pulse/min 120Tp 60 sec

Hysteresis 0.05 pHControl direction pH-

LimitvaluesCl2 max 0.80 mg/lCl2 min 0.10 mg/lpH max 7.80 pHpH min 6.80 pH

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Display Factory setting CommissioningORP max 900 mVORP min 600 mV

ALARMRELAYS1Relay assign. --

Relay function N.O. unlatchedDelay 0 min

ALARMRELAY2Relay assign --

Relay function N.O. unlatchedDelay 0 min

SETUPsamp.water delay 0.0 min

Feed delay 3.0 minOverfeed delay 0.1h

Hold func. OffLanguage English

Standby function OffDisplay selection

[ ]Cl2pH

redoxTemperature °FTemperature °C

Interface AusBus addr. Cl2 00pH bus addr. 01

Bus addr. redox 02Code def 000

SETUPmAmA output 0...20 mA

mA1 assignment Cl2mA2 assignment pHmA3 assignment redox

Cl2 mA range 0 - mg/lAUTO TUNE

Tu 60 sTs 10.0 min

W3T292576 / WT.050.425.001.GE.IM.021550


5 OPERATION5.1 DisplayandOperatorControls

The display unit indicates important data. The Ezetrol® plus is operated using six keys. The exact depiction of the individual parameters on the display is described in the following sections.

Example of basic display

A B C D

F EA Measured value of chlorineB Sample water temperature or digital input*)C Adaption runningD Manual or automatic modeE Measured redox valueF Measured pH value

Indicators

H Manual modeA Automatic mode[ ] Option - not selected[3] Option - selected

STANDBYStandby mode, see Section 5.1.3 Operating Modes.

*) When a digital input switches, the digital input is displayed instead of the temperature.

• Dl Digital input 1: flow switch• DlI Digital input 2: circulation pump interlock • DlII Digital input 3: empty dosing tank alarm

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Keys

Operating panel

Up• Move up one level• Display the previous option• Increase value

Down• Move down one level• Display the next option• Decrease value

Star• Delete alarm message, reset alarm relay• Acknowledge error message

Function

• Display next menu

Escape• Cancel input without saving new value• Move up one menu level• Display acknowledged error message again

Enter• Change to edit mode• Save changes

Operating indicatorsThe operating state is indicated by 9 LEDs. The meaning of these indicators is marked on the labelling strip to the right of the LEDs. When the LED is illuminated:

W3T292576 / WT.050.425.001.GE.IM.021552


Ezetrol® plus is switched on (POWER)

Chlorine dosing increased/chlorine dosing on

Chlorine dosing reduced

Dosing of pH correction medium increased/alkali dosing on

Dosing of pH correction medium decreased/acid dosing on

Magnetic switch 1 or alarm contact 1

Magnetic switch 2 or alarm contact 2

Fault message/Fault

Interface mode

5.1.1 Codenumber

The system should be protected against unauthorised access or unintentional incorrect operation by means of a freely selectable code number. In this case, the preset values can be displayed, but they cannot be altered. If this is nevertheless attempted 'Code???' is displayed, followed by the previous setting.

When switching on after a RESET or if the unit has been in operation for one hour without a key being pressed, the code number is reset to zero in the main menu and access is thus denied.

The values in the protected menus can only be altered after the correct code number has been entered in the main menu that identifies you as an authorised operator.

As an authorised operator, i.e. after entering the correct code number, you can change the code number if so desired. To do this , enter a new code number under 'CODEdef' in the 'SETUP' menu. If you then wish to block the unit against access by unauthorised operators, set the code to a different number in the main menu otherwise the code number is blocked after 1 hour if no key is pressed.

53W3T292576 / WT.050.425.001.GE.IM.0215


If you wish to allow general access, enter '000' in the 'CODEdef'. This means that all settings can be altered at any time without having to enter a code. In this case the CODE query is not displayed in the main menu. However, a different CODE number can be entered under CODEdef at any time to deny access to all operators who do not know the new number.

The default setting on delivery is CODEdef = 0, which means that the settings are not protected.

Information on how to proceed if you have forgotten the code number is given under RESET (menu path 11: DIAGNOSIS).

5.1.2 Generalnotesonoperation

• Starting from the basic display, the other menus are accessed by pressing the F key.

• Sub-menus are then accessed with the s and t keys.

• From any sub-menu press the ESC key once or twice to exit to the main menu and press it again to exit to the basic display.

• Select the menu item to be changed.

• Press the 3 key, an arrow appears in front of the value to be set.

• Use the arrow keys to increase or decrease the value or to skip to the next option.

• Store the correct value by pressing 3.

• If you have changed a value with the s and t but have not yet stored it with 3, you can restore the original setting by pressing ESC. Use the arrow keys to select the next sub-menu.

W3T292576 / WT.050.425.001.GE.IM.021554


During operation observe the following points:

• Check your entries and modifications before exiting the menu.

• Only press the keys with your fingers, never with hard or pointed objects such as pencils etc. This could damage the sealed keypad.

5.1.3 Menustructure

The Ezetrol®plus has 11 different menus.

• Display menu• Calibration• Cl2 parameter• pH parameter• Limit values• Alarm relay 1• Alarm relay 2• SETUP• SETUP mA• Adaption• Diagnosis

55W3T292576 / WT.050.425.001.GE.IM.0215


MenuView

Dia

gnos

is

cell

Cl2

pH e

lect

rode

Tem

pera

ture

Rel

ay

Yout

(Cl2

/pH

)

RS

485

Sof

twar

e re

leas

e

*RE

SE

T*

Aut

o Tu

ne

Tu Ts

Aut

o Tu

ne

Set

up m

A

mA

outp

ut

mA

outp

ut

mA

outp

ut

mA

outp

ut

Set

up

sam

p.w

ater

del

ay

feed

del

ay

over

feed

del

ay

Hol

d fu

nct

Tim

e

Dat

e

Lang

uage

Sta

ndby

func

tion

Dis

play

sel

ect

Inte

rface

code

defi

nitio

n.

Ala

rm R

elay

1/2

rela

y as

sign

.

rela

y fu

nctio

n

alar

m d

elay

Ala

rm Cl2

max

Cl2

min

pH m

ax

pH m

in

redo

x. m

ax

redo

x. m

in

tem

p. m

ax

tem

p. m

in

pH p

aram

eter

cont

rol o

utpu

t

prop

ort.

fact

or

Hys

tere

sis

duty

cyc

le

Cl2

par

amet

er

cont

rol o

utpu

t

prop

ort.

fact

or

inte

gr.a

ct.ti

me

duty

cyc

le

zero

Cl2

Cal

ibra

tion

DP

D C

l2

pH c

alib

ratio

n

calib

. tem

p.

man

. com

p.

tem

p.

pH o

ffset

cell

Cl2

pH e

lect

rode

tem

pera

ture

0.00

mg/

l 20

°C

7.00

pH

800

mV

actu

ator

Cl2

Set

poin

t Cl2

actu

ator

pH

pH s

etpo

int

man

. run

tim

e

Mod

e

Men

u

Cod

e

W3T292576 / WT.050.425.001.GE.IM.021556


Menupath1DisplayMenu

DisplayValuerange(defaults in bold)

Description

0.00mg/l20°C7.00pH800mV

Measuredvalues,unitsofmeasurement(basicdisplay)Display of all measured values (chlorine, pH, redox, tempera-ture), manual/automatic, digital inputs and adaption.

actuatorCl2 OPEN - OFF- SHUT

orOFF - ON

ManualadjustmentofpositionerorCl2dosingpump (not in 'AUTO' mode)(is not displayed if chlorine measurement is deactivated in SETUP).

setpointCl2 0.00mg/l3.00mg/l

(1.50mg/l)

Cl2concentrationsetpointcan only be set within the selected measuring range(is not displayed if chlorine measurement is deactivated in SETUP).

actuatorpH OPEN - OFF -SHUT or

pH- - OFF - pH+

ManualadjustmentofpositionerorpHdosingpump (not in 'AUTO' mode)(is not displayed if pH measurement is deactivated in SETUP).

pHsetpoint 4.00pH9.00pH

(7.20pH)

pHsetpointcan only be set within the selected measuring range(is not displayed if pH measurement is deactivated in SETUP).

feeddelay 05 min Displayscurrentfeeddelay(only in AUTO mode)

man.runtime 0.1h Period the pump runs for when the On button is pressed.(only in MANUAL mode)

Mode AutomaticManual

ModeThe selected mode is also shown in the basic display by means of the 'Auto' or 'Manual' symbols.

Menu ConciseExtended

MenulengthSelection of the menu length-Concise menu: Display and calibration menu only-Extended menu: All menus are displayed.

Code 000999

CodeEntry of code numberThe settings can only be changed if the number entered here agrees with the number in the Code def. menu.Otherwise, the error message 'code???' appears. The menu does not appear if the number '000' has been entered in the Code def. menu. If this is the case all of the settings can be changed.

57W3T292576 / WT.050.425.001.GE.IM.0215


MenuPath2Calibration

DisplayValuerange(defaults in bold)

Description

CALIBRATION CalibrationmenuThis menu path is used for all calibration settings. The controller output is held constant during calibration, the mA output is only held if the 'HOLD' function is on.

DPDCl2 1.00mg/l Cl2DPDcalibrationPress the 3 key. Enter the value measured by DPD 1 with the s and t keys. Press the 3 key to calibrate the display to this DPD 1 value

calibrationpH 7.5pH pHcalibrationPress the 3 key. Carry out a Phenol Red pH test. Set

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