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Vortex Aquatic Structures International – Splashpad Owner/Operator manual

Copyright © 2005 Vortex Aquatic Structures International

ALL STRUCTURES AND COMPONENTS LISTED IN THIS MANUAL

HAVE BEEN MANUFACTURED OR ASSEMBLED BY VORTEX

AQUATIC STRUCTURES INTERNATIONAL INC.

ALL PLANS, DESIGNS, DOCUMENTS AND TEXT

CONTAINED HEREIN SHALL REMAIN AT ALL TIMES THE

PROPERTY OF VORTEX AND MAY NOT BE REPRODUCED,

IN WHOLE OR IN PART, WITHOUT PRIOR WRITTEN

CONSENT FROM VORTEX AQUATIC STRUCTURES

INTERNATIONAL INC.

NOTICE

Vortex Aquatic Structures International – Splashpad Owner/Operator manual

Contents

Table of Contents

1. Introduction

About this manual

Splashpad overview

2. Prior to WQMS startup

Verifying contractor connections

Verifying water level

Cleaning the holding tank

Preparing the Splashpad play events

Connecting the chemical probes

Inspecting the sand filter

Inspecting the Y-strainer

Inspecting the chemical reservoirs

3. WQMS operator controls overview

Splashpad control system

The Activator

Distribution manifold

The Vortex Controller

Controller

Controller

Login

Operation Time-Clock

System Time

Day of the Week

Period 1-2 Start Time and Stop Time

Purge Start and Duration

Max Inactive Period

Operator Control

4. Control Settings

General

5. Touch Screen Operation Modes

Automatic

Overriding programmed operating hours

Manual operation

Overriding activator

Overriding Pumps

6. Splashpad Spray Sequences

Definitions

Operator Controls

7. Play Product Override

Introduction

Operator Controls

8. System Status

Display Definitions

Operator Controls

9. Alarms

10. Protection Breaker

11. Controller failsafe features

Emergency shut down

12. Strantrol Chemical controller

Accessing the program menu

Setting the pH alarm points

Setting the HRR alarm points

Setting the temperature alarm points

Resetting the failsafe alarm

Displaying the set points

Modifying the set points

Single point calibration

13. Chemtrol 250/255 Chemical Controllers

Water Chemistry

Feed Mode

ORP and pH Sensors

Sensor Calibration

Sensors Storage and Winterizing

PPM Sensors (Chemtrol 255 only)

Calibration procedure

Alarms

SETPOINT control

Overfeed Safety Timer

To reset the Overfeed Safety Alarm

To change the limits of the safety timer:

Proportional Feed

Controller Reset

Chemtrol Default Factory Parameters

Safety Flow Switch

Sensor Testing - The Acid Test

14. WQMS startup procedure

Power up procedure

Adjusting the flow in the filter line

Adjusting the flow in the feature line

Testing and adjusting water chemistry

Initial holding tank chemical pre-dosing

Verifying/adjusting water chemistry balance

Quick startup guide

15. WQMS winterization procedure

16. Periodic maintenance

Daily

Weekly

Monthly

Beginning of season

End of season

17. WQMS component maintenance

Basic supplies and tool requirements

Consumable supplies

Pump

Chemical pump

Y-strainer

Filter

Sand Filter

Flow switch

Flow meter

Solenoid valves

Activator

PLC controller

Chemical controller

Chemical probes

18. Water chemistry balance

Calcium hypochlorite

Sodium hypochlorite

Free chlorine

Total chlorine

Combined chlorine (chloramines)

Superchlorination

Preventing the formation of chloramines in the WQMS pH

Total alkalinity

Water hardness

Recommended levels for WQMS water chemistry balance

Chemical dosage tables

19. Troubleshooting guide

WQMS troubleshooting

Pump troubleshooting

List of possible causes for problems with the pump

Chemical controller troubleshooting

Troubleshooting Chemtrol 250/255

20. WQMS warranty

Effective date

Repairs & replacements

Normal use

Claims

21. Appendix

WQMS pre-startup checklist

WQMS winterization checklist

Chemical log sheet

PLC inputs list

WQMS installation drawing

Holding tank installation drawing Deck drain installation drawing

1. Introduction

About this manual

The WQMS user manual contains information and instructions necessary for the proper operation and maintenance of your Vortex Splashpad equipment. Before starting the

WQMS, it is recommended that you read this manual in its entirety.

Use the table of contents to find information and familiarize yourself with the organization of this manual.

Always observe the following symbols:

THE INFORMATION SYMBOL IN THE CIRCLE ALERTS YOU TO

IMPORTANT DETAILS ABOUT THE WQMS. i

CAUTION!

THE WHITE EXCLAMATION MARK IN THE BLACK TRIANGLE ALERTS YOU

TO HAZARDS THAT CAN RESULT IN DAMAGE TO THE WQMS. FOLLOW

THE ACCOMPANYING INSTRUCTIONS TO AVOID HAZARDS.

WARNING!

THE BLACK EXCLAMATION MARK IN THE LIGHT TRIANGLE ALERTS YOU

TO POTENTIAL HAZARDS THAT CAN RESULT IN PERSONAL INJURY.

FOLLOW THE ACCOMPANYING INSTRUCTIONS TO AVOID HAZARDS.

Splashpad overview

The Splashpad is a fully automated aquatic play environment designed for use in recreational areas.

The automated components of the Splashpad are the Activator, the Controller, the distribution manifold, and the Water Quality Management System (WQMS).

Activator

Located in the Splashpad play area, the activation bollard allows Splashpad users to initiate play events with a touch of a hand.

Controller & distribution manifold

The Controller responds to the Activator by opening and closing solenoid valves along the distribution manifold in accordance with one of several preprogrammed spray sequences. The Controller is equipped with a 7-day, 24 hour programmable time clock that controls Splashpad operation during the operating hours of the facility.

Water Quality Management System (WQMS)

The main function of Vortex’s state-of-the-art Water Quality Management System

(WQMS) is to strictly monitor and control the quality of the Splashpad’s water via filtration, sanitization and recycling.

The WQMS is designed to operate in an unsupervised play environment at the highest standards of quality and reliability. In the event of water contamination, distribution of water to the Splashpad's play events is immediately halted until the quality of the water in the system has returned to acceptable levels. The WQMS employs an additional failsafe mechanism to ensure that there is always enough water in the system to support normal operation.

Splashpad safety

Designed in accordance with ASTM and CSA standards for playgrounds in public play areas, Vortex Splashpads are the safest and most reliable aquatic play environments available. They are built from the highest quality materials to ensure maximum structural integrity, durability, corrosion resistance, ongoing safety and an extended play life.

Always remember that child safety is priority number one!

CAUTION!

THE MAIN ELECTRICAL SERVICE MUST BE CONNECTED AND TESTED BY A

CERTIFIED ELECTRICIAN. IMPROPER HOOKUP CAN BE DANGEROUS AND

MAY CAUSE DAMAGE TO YOUR WQMS SYSTEM.

NOTICE

THOUGH THE ABOVE STEPS APPLY TO POST-INSTALLATION, OTHER

PROCESSES IN THIS SECTION SHOULD BE PERFORMED AT THE START OF

EACH SEASON (UNLESS YOUR SPLASHPAD OPERATES YEAR- ROUND).

i

2. Prior to WQMS startup

Verifying contractor connections

Electrical connections

The Vortex WQMS is designed to function on 208/230Vac, single or 3-phase.

Prior to startup, you should verify that all connections were made and tested by a certified electrician. You can refer to Vortex’s Installation Manual for more details on electrical installation.

Verifying the pump impeller rotation

If the pumps were not wired correctly on 3-phase electrical systems, the impeller may rotate in the wrong direction. This will negatively affect pump efficiency and may also damage the pump.

A pump rotation test should have been performed as part of the installation procedure.

Before starting the WQMS, confirm that this procedure was correctly executed and that the impeller is turning in same direction as the arrow on the volute of the pump.

If you have reason to believe that this test was not performed correctly, please refer to

Vortex’s Installation Manual for more details about the pump impeller rotation test.

WQMS startup procedure

Verifying water level

Prior to WQMS start up, you must ensure that the holding tank has been filled and that the float valve is functioning correctly and regulating the water level in the tank.

Cleaning the holding tank

The holding tank must be clear of debris before starting the WQMS. Drain all water from the holding tank and remove all accumulated sediment. Once the tank is clean, refill it and ensure that the float valve is functioning correctly.

Check valves

The holding tank is equipped with two check valves that are located at each of the outlets leading to the pumps. The purpose of these check valves is to keep water in the suction pipe when the pumps are shut down. This allows the pumps to keep their prime. Accordingly, you must ensure that both check valves are clear of any debris that could prevent them from closing completely. If necessary, you should also close ball valves used during the winterization of the Splashpad.

To test the check valves, drain the holding tank beneath both check valves and fill both lines (filter pump line and feature pump line) by pouring water directly into the strainer of each pump. Open the butterfly valve located before the pump strainer. The water that you pour into the strainers should be retained in the pipes and there should be no leaks at the check valves.

If leaking occurs, look for any foreign object that may be obstructing the valves.

Remove the obstruction and then repeat the testing procedure.

Preparing the Splashpad play events

At the start of each season you must remove the winter caps from the Splashpad's play events and attach the appropriate spray nozzles to each play product.

Before attaching spray nozzles to play products, you should clean all threads to prevent stripping and crossing.

Store the winter caps for future use.

PROBES MUST NEVER DRY OUT. WHEN NOT IN USE, STORE PROBES AT

ROOM TEMPERATURE WITH THE SENSOR CAP IN PLACE OR WITH PROBE

TIPS IMMERSED IN A SEALED CONTAINER OF WATER TO KEEP THEM WET.

Connecting the chemical probes

Before starting the WQMS, you must connect the chemical probes to the chemical controller.

1. Clean the tips of the probes using liquid dish or laundry detergent and a toothbrush.

2. Put Teflon® sealing tape on the threads and then install the sensors.

3. Connect both sensors to their appropriate BNC connection on the chemical controller (for more details see section 17 WQMS component maintenance -

Chemical controller).

4. Once the filtration pump is running, open the valves on the chemical bypass and let the sensors rinse in the sample stream water for 10 to 15 minutes before making any adjustments.

Inspecting the sand filter

Ensure that the sand filter is filled with the proper type and quantity of sand. (For more details on sand replacement, see section 17 WQMS component maintenance – Sand filter).

Inspecting the Y-strainer

Ensure that the Y-strainer is clean and installed securely. (For more details, see section

17 WQMS component maintenance – Y-Strainer).

Inspecting the chemical reservoirs

The chemical reservoirs and associated tubing must be clear of debris before starting the WQMS. Remove any accumulated sediment and rinse the reservoir and tubing thoroughly with fresh water.

3. WQMS operator controls overview

Splashpad control system The Splashpad control system consists of a Vortex Controller, a water distribution manifold, and one to three activators. The Vortex Controller responds to the Activator by opening and closing solenoid valves along the distribution manifold in accordance with several pre-programmed spray sequences. The spray sequences are factory programmed to respect the hydraulic requirements of your Splashpad while creating high levels of anticipation, surprise and entertainment for Splashpad users. A typical sequence follows a set order and will run between 4 to 16 minutes. These sequences determine the number of play events activated at any given time, promoting moderate water consumption as well as greatly enhancing the Splashpad’s overall play value.

The Activator Located in the Splashpad play area, the activation bollard allows Splashpad users to initiate play events with a touch of a hand.

The Activator will have no effect on a running sequence until the sequence is complete.

Upon completion of each sequence, the Splashpad user can re-activate the system by simply touching the activator.

Distribution manifold Located on the WQMS skid, the water distribution system consists of a stainless steel manifold, ball valves and solenoid valves with integrated flow control adjustment. You can use the flow control adjustment on the solenoid valves to adjust the spray zone of the play products. The ball valves effectively control the water supply to individual play products and are used to shut off the flow when solenoid valves require servicing.

The Vortex Controller Controller layout

Main Power

Switch

Door knob

Emergency Switch

Programmable

Logic Controller

(PLC)

Transformer

Touchpad

Interface

Controller

Switchboard (PCB)

Output Terminal Block Solenoid

Valves

Main Power Input Terminal Block

NEMA 4X Fiberglass Enclosure

Input Terminal

Block Activation and

Alarms

2Amps Power

Breaker

PLC upgrade port

RS-232

Communication Port

Controller

All Vortex Controllers are UL listed industrial control panels. They contain a programmable logic controller (PLC), a 120V/24V transformer, and an on/off power switch.

The Controller is programmed with spray sequences that are custom designed for each installation in accordance to the product selection and/or the client’s requirements.

Although there are many possibilities, a typical sequence will run for 4 minutes. During this time, the activator will not be able to interrupt or interfere with the sequence until it is complete. After which time, the participants can reactivate the next spray sequence. Please note that the sequences are not random; they follow a pre-designed pattern: from one to the next. The sequences determine the number of features activated at any given time, thus allowing the possibility to reduce water consumption.

Login The Vortex Controllers are password protected. Enter the password by pressing the star in the password screen, a keypad will be displayed. Once the numbers are entered, press the “Enter” button. Allow 5 seconds for the information to refresh before accessing the Main Menu screen.

Password: 1234

Note: this password cannot be changed.

Operation Time-Clock

Programming the operational hours

The operating hours of the facility can be easily programmed into the Operation Time Clock screen. Two opening and shut down times can be set and assigned to one or more days. To program the operational hours, simply enter the time in the “start time” and “stop time” fields, then click-on the desired day(s). Make sure that the actual date and time are entered.

System Time Pressing the appropriate field allows you to change the date and time settings. Moving from left to right - the 1st field represents: Month (1-12), Day (1-31), Year (0-99), Hour (0-23), and Minute (0-59). Select the appropriate field, enter the value using the number pad and press the ↵ symbol to enter the value.

Day of the Week Pressing the ‘day of week’ field allows you to select the day of the week (1=Sunday, 2=Monday, 3=Tuesday etc…).

Period 1-2 Start Time and Stop Time You can set the available Splashpad operational hours by entering the start and stop times. Then you can define which days those times should apply to by pressing the appropriate day fields. Note: If the second time period is not required set or leave the fields to 00:00.

Purge Start and Duration A Purge is draining all your Play Product Feature lines of stagnant water that could have been in the lines for a period of time. When Enabled the system starts the Play Product Pump and activates all the lines going to your Splashpad.

You can set the purge start time and duration by pressing the appropriate fields. The purge sequence will flush all water lines on the Splashpad at the given time and for the given duration.

Max Inactive Period Setting a value in this field will trigger a purge sequence after a certain number of Splashpad inactivity hours.

Help Menu At any time on any window you can press the HELP button to have a description of all the functions on this screen.

Operator Control

Rain Diverter to (If applicable) By pressing this button you select witch direction you select your Rain Diverter to bring back the water from the Splashpad (To Drain, To Holding Tank)

4. Control Settings

General

Auto is the default operating mode for all control settings. Pressing “MAN” will bypass the controller program and will manually activate the corresponding control setting. When both of the “AUTO” and “MAN” selections are in the raised position the resulting status will be “OFF”.

Emergency Button

Pressing the Emergency Button located on the top of the controller will shut down power to the complete system.

To resume Functionality of the Splashpad simply Pull up Red Button to its Operating Mode.

Program Version

All systems shipped in 2006 are equipped with Program version indicator.

When powering on the system, an LED will flash 3 times on the PLC.

Original Version: I0.0 will flash 3 times

Rev.1 Version: I0.1 will flash 3 times Rev.2 Version: I0.2 will flash 3 times

Activator 1-3

Setting the activator to “MAN” will bypass the controller program for the selected activator and set the Splashpad to a continuous operating mode until the operation time clock “Off” setting is triggered. When both of the “AUTO” and “MAN” selections are in the raised position, the resulting status will be “OFF” and the Splashpad will be disabled.

Operation Time Clock

The operation time clock is owner programmable and defines the Splashpad’s available hours of operation. Selecting the “MAN” position bypasses the programmed hours of operation and allows continuous Splashpad availability. Selecting the “OFF” position disables use of the

Splashpad.

Purge

Purge refers to a sequence that flushes the Splashpad’s system lines.

Selecting the “MAN” position triggers a purge sequence. Selecting the “OFF” position disables the daily programmed purge sequence.

PCB Board for Pumps (If applicable)

This PCB Board located in the top right section inside Controller is your Pump override. Each one of your Pumps (Filtration Pump and Play Product Pump) has a three position switch.

“AUTO” position: Normal Operation Mode. Controller can turn On or Off the pump and in AUTO the Controller will monitor the Flow switch and will shut

Off the Pumps if they detect that there is no flow in the Lines.

“MAN” position: Servicing Mode. This mode is ONLY used for servicing the system. It will bypass the controller program and run the Filtration Pump without monitoring the flow switch.

“OFF” position: Shut OFF mode. The Pumps are Off even if you have them running on the controller.

Filtration Pump (If applicable)

Setting the Filtration Pump to “MAN” will bypass the controller program and run the Filtration Pump without monitoring the flow switch. MAKE SURE

THERE IS SUFFICIENT WATER IN HOLDING TANK. IN “MAN” MODE PUMP

WILL RUN EVEN IF THERE IS NO WATER AND THERFORE DAMMAGE THE

PUMP.

Play Product Pump (If applicable)

Setting the Play Product Pump to “MAN” will bypass the controller program and run the Filtration Pump without monitoring the flow switch. MAKE SURE

THERE IS SUFFICIENT WATER IN HOLDING TANK. IN “MAN” MODE PUMP

WILL RUN EVEN IF THERE IS NO WATER AND THERFORE DAMMAGE THE

PUMP.

Rain Diverter (If applicable)

Setting the Rain Diverter to “MAN” Mode will bypass the controller program and having the Rain Diverter to bring back water to Holding Tank at all time.

Setting the Rain Diverter to “AUTO” Mode will enable the controller program and having the Rain Diverter to bring back water to Holding Tank during operating hours of the Splashpad. After operating hours or after a period of time of non usage of the Splashpad that you can determine (In Hours), the

Rain Diverter will bring back water to Drain Storm .

Setting the Rain Diverter to “OFF” Mode will prevent the controller program to activate the Rain Diverter to bring back water to Holding Tank or to Drain Storm.

5. Touch Screen Operation Modes The controller offers operating modes witch are set in the Control Settings screen:

Automatic

The controller should almost always be set in this mode. During the operating hours programmed in the time switch, the spray sequences are stimulated by touching the activator on the Splashpad.

VORTEX CONTROL SETTINGS

ACTIVATOR

#1

AUTO MAN

OPERATION

TIME-CLOCK

AUTO MAN

ACTIVATOR

#2

AUTO MAN

FILTER

PUMP

AUTO MAN

ACTIVATOR

#3

AUTO MAN

PLAY

PRODUCT

PUMP

AUTO MAN

Overriding programmed operating hours

In this mode, the controller overrides the time switch settings allowing the facility to function in the automatic mode outside the programmed hours.

#1

AUTO MAN

OPERATION

TIME-CLOCK

AUTO MAN

ACTIVATOR

#2

AUTO MAN

FILTER

PUMP

AUTO MAN

ACTIVATOR

#3

AUTO MAN

PLAY

PRODUCT

Manual operation

This setting allows the valves to be opened and closed manually, and is commonly used for maintenance purposes;

#1

AUTO MAN

OPERATION

TIME-CLOCK

AUTO MAN

ACTIVATOR

#2

AUTO MAN

FILTER

PUMP

AUTO MAN

ACTIVATOR

#3

AUTO MAN

PLAY

PRODUCT

Then, in the Play Product screen, select the appropriate play product;

VORTEX PLAY PRODUCT OVERRIDE

1 PLAY PROD. 1 AUTO MAN

… PLAY PROD. … AUTO MAN

Overriding activator This mode is designed to send a continuous signal to the controller without using the activator. By placing the activator switch in the MAN position, the controller will continuously run through the spray sequences. This mode can be used if there is a problem with the activator.

#1

AUTO MAN

OPERATION

TIME-CLOCK

AUTO MAN

ACTIVATOR

#2

AUTO MAN

FILTER

PUMP

AUTO MAN

ACTIVATOR

#3

AUTO MAN

PLAY

PRODUCT

Overriding Pumps

This setting is used for maintenance purposes only.

#1

AUTO MAN

OPERATION

TIME-CLOCK

AUTO MAN

ACTIVATOR

#2

AUTO MAN

FILTER

PUMP

AUTO MAN

ACTIVATOR

#3

AUTO MAN

PLAY

PRODUCT

6. Splashpad Spray Sequences

Definitions

Group

Pressing the box next to “Group” selects which group of products is displayed on the screen. Use the Left & Right arrows to display the next or previous 4 play products. There could be up to 8 play product entries per group.

Block

Pressing the box next to “Block” selects which sequencing table is displayed on the screen. Use the Up & Down arrows to display the next or previous spray sequencing block. Each spray sequencing block consists of a 4 minute time frame.

Activator Used

Displays which activator has been programmed to initiate the sequence for this particular group.

Total Flow

Displays the expected amount of water that will flow through the play products during the duration of the sequence.

NOTE: This is not a measured value. It is an estimated value based on individual play product.

Operator Controls

Modifying the Splashpad Spray Sequence

The Splashpad spray sequences are programmed in 4 minute intervals. In addition there are 4 sequencing blocks that can be individually programmed.

During normal operation, once a user touches the activator, the system will run through the first sequencing “block” after which the system will stop the sequence. Once the system is reactivated the second sequencing “block” will start and so on.

Any modifications made to these sequences are done by accessing the Splashpad Spray Sequence screen. Use the arrow keys to display the desired “Block” and “Group” of products. By pressing the appropriate zone in the Time/Play Product table you will toggle between “On” and “Off” for each play product and each minute of operation. The Splashpad System Controller has been designed to minimize the possibility of creating a water hammer condition. However, it is important to create smooth transitions between time periods. Typically, a sequence should start and end low with a maximum change in total flow of 30-50% per increment. As stated previously, the sequences are not random; they follow a pre-designed pattern: from one to the next.

To test and verify the result of the modification(s), press the “TEST” button;

the displayed sequence will run once. The water consumption is displayed under each column for this particular given time of the sequence.

This sequence pattern is repeated for each zone available on the Splashpad.

The controller will not allow a flow lower than 60% and higher than 80% of the total water consumption of the Splashpad for each minute in every sequence.

7. Play Product Override

Operator Controls

Arrow Keys

The Arrow keys allow you to scroll through the list of play products.

Auto/Manual Mode

The default settings should be set to “Auto”. Setting the system to “Manual” creates an operating mode that bypasses the user Activator and sequencing program. Pressing “Manual” will turn on the specified play product. If you do not set the mode back to “Auto” the play product will continuously run during the owner selected hours of operation. When neither “Auto” nor “Manual” is selected the play product will be disabled.

8. System Status

Display Definitions

Spray Sequence

Display spray sequence status (Idle = Stand by, Running = Sequence Running)

Rain Diverter (If applicable)

Display indicating where water drains (To Holding Tank, To Drain)

Activator State

Indicates user activator status

System Time

Display of date and time of day

Alarm

Displays the Nature of the alarm condition

Current Filtration flow rate (GPM) (If applicable)

Display of flow rate on Filtration Line

NOTE: This flow rate is used to determine backwash state. It may be 10%- 15% offset from float flow meter reading.

Minimum required Filtration Rate (GPM) (If applicable)

Display of minimum flow rate on Filtration Line before getting a “Backwash required” Alarm

Operator Controls

Reset Alarm

After resolving an alarm, press “Reset Alarm” to clear the status and re-start the pumps (if applicable)

Set Baseline (If applicable)

After doing a Backwash, pressing “set baseline” will reset minimum required flow rate. The controller will then give an alarm “Backwash required” once

GPM goes underneath this minimum required flow rate.

9. Alarms Alarms are displayed in the System Status screen. To reset an alarm, find and fix the cause of the problem, then, access the System Status screen and press the “Reset” button.

10. Protection Breaker The Controller is equipped with a breaker to protect the system from high voltage. The breaker may trip as a result of electrical surges and will need to be reset. It is located on the left side of the PLC.

Keep Enclosure Door Closed

The front door to the controller must remain closed during normal operation to protect internal equipment from humidity, water and dust.

11. Controller failsafe features

The Vortex WQMS is designed to constantly monitor water quality and flow in the system. In the event of contamination, the chemical controller generates a chemical alarm and sends an electronic signal to the programmable logic controller (PLC) in the

Vortex Controller. This signal triggers initiation of the failsafe process.

The failsafe process closes all solenoid valves to stop the flow of water to the Splashpad and prevent children from being exposed to contaminated water. During the chemical alarm period, both pumps will remain operational in order to mix the water for the chemical rebalancing process. Once chlorine and pH levels are restored to their proper range, the sequencing is re-enabled to allow water to flow to the Splashpad.

Other failsafe features ensure that there is always enough water in the system. For example, if the water level in the subterranean holding tank is too low, a mechanical flow sensor will send a signal to the PLC to inform the Controller of the low level. The

PLC will automatically send a signal to disable both pumps in order to prevent mechanical damage.

The low water level failsafe has no automatic re-enabling system. If the pumps are stopped due to a shortage of water in the system, someone will need to correct the water level issue on-site before manually restarting both pumps.

The following page provides a process chart illustrating the monitoring process for both failsafe features.

Emergency shut down

Depressing the emergency switch will shut down the entire Controller system.

Normal Operation Sequencing in progress

Chemical alarm signal sent from chemical controller to PLC?

Stop Sequencing (Solenoid Valves closed)

Both Circulation pump remain ON To mix water and rebalance water chemistry.

Water balanced?

No

Yes

No

Yes

Normal Operation

Sequencing in progress

PLC Check for flow in filter loop and feature loop

Flow present?

PLC Shut both pumps OFF

No

Yes

Find reason of low water level and fix it

Manually restart both pumps

Chemical Alarm

Monitoring Flow Monitoring

Both circulation pumps remain ON to mix water and rebalance water chemistry

PLC shuts OFF both pumps

Find reason for

Stop sequencing and close solenoid valves

PLC checks for flow in filter loop and feature loop

Normal operation sequencing in progress

Normal operation sequencing in progress

12. Strantrol Chemical controller

Accessing the program menu

To access the System3 program menu:

1. Press and hold both the CAL and � keys for 3 seconds until the LCD screen clears.

2. Release the keys and the word PROGRAM will appear on the display.

3. Press the � key to enter each menu and press the � key to exit.

4. Use the � and � arrows to scroll to the setting that you wish to modify.

5. Press the CAL key to select the setting and use the � and � keys to change the value.

6. Press the CAL key again to enter the new value and return to the menu.

7. To exit the program menu, scroll to EXIT MENU and press the CAL key. Note that a time-out feature will automatically exit the program menu after 2 minutes of inactivity.

Changing the language setting

Though the default language of the System3 is

English, the unit can also be programmed to display information in Spanish and French. To change the language setting:

3. Press the � key to enter the language menu. The screen will read ENG, indicating that the current language setting is English.

4. To select another language, press the CAL key.

ProgramProgramProgramProgram

CCCCaaaallll �

Language ENGLanguage ENGLanguage ENGLanguage ENG

5. Use the � and � keys to alternate between languages. A question mark will appear before each language.

6. Press the CAL key to select the desired language and return to the program menu.

7. To exit the program menu, scroll to EXIT MENU and press the CAL key. Note

Setting the pH alarm points

To set a pH high alarm point:

3. Press the � key until the display shows the pH high setting followed by the current pH high alarm point.

4. Press the CAL key and then use the � and � keys to input the desired value.

5. Press the CAL key to set the new pH high alarm point at the displayed value and return to the program menu.

6. To exit the program menu, scroll to EXIT MENU and press the CAL key. Note pH High 8.0pH High 8.0pH High 8.0pH High 8.0

To set a pH low alarm point:

3. Press the � key until the display shows the pH low setting followed by the current pH low alarm point.

5. Press the CAL key to set the new pH low alarm point at the displayed value and return to the program menu.

Setting the HRR alarm points

To set the HRR high alarm point:

3. Press the � key until the display shows the HRR high setting followed by the current HRR high alarm point.

5. Press the CAL key to set the new HRR high alarm point at the displayed value and return to the program menu.

of inactivity.

pH Low 7.0pH Low 7.0pH Low 7.0pH Low 7.0

HRR High 900HRR High 900HRR High 900HRR High 900

To set the HRR low alarm point:

3. Press the � key until the display shows the HRR low setting followed by the current HRR low alarm point.

5. Press the CAL key to set the new HRR Low alarm point at the displayed value and return to the program menu.

Setting the temperature alarm points

To set the temperature high alarm point:

3. Press the � key until the display shows the Temp high setting followed by the current temperature high alarm point.

5. Press the CAL key to set the new temperature high alarm point at the displayed value and return to the program menu.

HRR Low 600HRR Low 600HRR Low 600HRR Low 600

TEMP High 120TEMP High 120TEMP High 120TEMP High 120

NOTE: If the temperature display is not needed set the Temp High Alarm to the same value as the Temp Low Alarm.

Resetting the failsafe alarm

To reset the failsafe alarm, press and hold the � and � keys for two seconds.

Displaying the set points

To display the set points, press the set point key. The set points will be displayed for 3 seconds.

Modifying the set points

To modify the set points:

1. Press and hold the set point key for 3 seconds. The display will change to pH

SetPt setting followed by the current pH Set point.

2. Use the � and � keys to input the desired value.

3. Press the set point key to enter the new value.

7.5 750 SetPt7.5 750 SetPt7.5 750 SetPt7.5 750 SetPt

Set point

Set point

HRR SetPt 750HRR SetPt 750HRR SetPt 750HRR SetPt 750

Set point

Set point

Single point calibration

1. Press and hold the CAL key for 3 seconds to enter the calibration menu. After the display clears, release the CAL key.

2. The display should now read CAL PH followed by the current pH calibration value.

Use your test kit to determine the actual pH and use the � and � keys to adjust the displayed value to the actual value.

3. Press the CAL key and then use the � and � keys to input the desired value.

4. Press the CAL key to enter the new pH calibration value.

5. The display should now show CAL TEMP followed by the current Temp calibration value. Use the � and � keys to adjust this value to the actual value.

6. Press the CAL key to enter the new Temp calibration value.

7. The display should now read CAL PPM and the ppm LEDs will be flashing. Use your test kit to determine the actual ppm and then adjust the value shown on the LED bar graph using the � and � keys.

8. Press the CAL key to enter the new ppm calibration value.

Cal pH 7.5Cal pH 7.5Cal pH 7.5Cal pH 7.5

Cal Temp 85Cal Temp 85Cal Temp 85Cal Temp 85

CCCCal ppmal ppmal ppmal ppm

13. Chemtrol 250/255 Chemical Controllers

Water Chemistry Before starting automatic control, manually test the water chemistry, using Taylor test kit #2005 or equivalent, to make sure that pH, Total Alkalinity and Calcium Hardness are within ranges recommended by the National Spa and Pool Institute (NSPI). If required, refer to page 64 of Vortex User manual to get chemical dosage to re-equilibrate water chemistry

The pH should be adjusted manually within 7.4 and 7.6.

For effective pH control, the Total Alkalinity should be between 80 to 150 ppm.

Calcium Hardness should be between 250 to 600 ppm.

Feed Mode The feed mode for the sanitizer or PH can be set to OFF, Manual or Automatic.

To select the desired feed mode:

Press (PPM), (ORP) or (PH) until the corresponding LED indicator light is illuminated.

ORP and pH Sensors

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

To clean a sensor, carefully remove it from the compression fitting. Clean the tip of the sensor with a mild liquid detergent (Joy, etc.) solution. Rinse with fresh water and soak the sensor in a mild acid solution for five minutes. Rinse with fresh water and reinstall the sensor.

Sensor Calibration NOTE: No Calibration is required for the ORP sensor

To Calibrate the PH sensor, test the water with a reliable, fresh test kit. Note the values and compare to the display values. Re-calibrate if needed, as follow:

1. press (CALIBRATION)

2. Press (PH): the display flashes

3. Use the (UP) and (DOWN) arrows to adjust the value

4. Press (CALIBRATION) again to save the new value

Sensors Storage and Winterizing Extended exposure to atmospheric conditions will cause the sensor tips to dry out and get damaged.

Always remove and properly store the sensors with the original cap provided, making sure that each cap is filled with the original storage solution or clean water. If the storage containers have been misplaced, store the sensors individually in small glass or plastic containers with clean water covering the sensor tips. Watch out for water evaporation.

Keep sensors tips in water all the time.

PPM Sensors (Chemtrol 255 only)

Conditioning of the sensor Before you operate the PPM sensor for the first time or after long time storage in air, it is important to hydrate the sensor for at least 1 hour in tap water containing a small amount of chlorine WITHOUT CONNECTING THE SENSOR.

The sensor should not be left for a long period of time in solutions containing no chlorine at all. The time response of the sensor for chlorine when first hydrated is also longer typically half an hour.

Measurement The sensor has to be used in stirred solutions or in a flow through system. If the hydration time is not respected or if the sensor is connected when not in solutions, the calibration of the sensor can be altered.

WHEN CONNECTED, THE SENSOR SHOULD ALWAYS BE IN WATER.

PPM Sensor testing To test the PPM sensor, used a DC Voltmeter (Fluke Model 344 or equivalent) and connect it to the HOCL and

Ground terminals on the PPM Board, with the PPM sensor in chlorinated water. You should read 2.6Vdc or higher.

You should also test the 9Vdc battery on the PPM Board. Replace it if the voltage falls bellow 8.2Vdc.

IF THE POWER SUPPLY OF THE SENSOR IS LOWER THAN 5.2 Vdc, THE SENSOR WILL BE DESTROYED.

Storage of PPM Sensor.

If the PPM sensor is not to be used for several weeks, it is better to store it dry, away from dust, light and heat. Otherwise it can be stored in tap water solution containing a small amount of chlorine.

NO PPM Sensor Cleaning Do not clean the PPM Sensor. Cleaners will damage the membrane and void the warranty.

Calibration procedure For best accuracy, the calibration of the PPM sensor should be carried out at a pH for which the sensor measures 100 % HOCl. This can be achieved with the addition of dilute sulphuric acid to a tap water solution. The pH should never be lower than 5. For accurate calibration it is best not to use. Do not use pure deionized water for calibration. During field measurements, the sensor does not require further calibration.

Sensor Calibration To Calibrate the PPM sensor, test the water with a reliable, fresh test kit. Note the values and compare to the display values. Re-calibrate if needed, as follow:

1. press (CALIBRATION)

2. Press (PPM): the display flashes

3. Use the (UP) and (DOWN) arrows to adjust the value

4. Press (CALIBRATION) again to save the new value

Alarms To set a PH high alarm point:

1. Press (HIGH LIMIT)

3. Use the (UP) and (DOWN) arrows to adjust the Value

4. Press (HIGH LIMIT) again

To set a PH low alarm point:

1. Press (LOW LIMIT)

3. Use the (UP) and (DOWN) arrows to adjust the Value

4. Press (LOW LIMIT) again

Setting the ORP/PPM Alarm point

To set ORP/PPM high alarm point:

1. Press (HIGH LIMIT)

2. Press (PPM) or (ORP): the display flashes

3. Use the (UP) and (DOWN) arrows to adjust the Value

4. Press (HIGH LIMIT) again

To set ORP/PPM low alarm point:

Press (LOW LIMIT)

1. Press (PPM) or (ORP): the display flashes

2. Use the (UP) and (DOWN) arrows to adjust the Value

3. Press (LOW LIMIT) again

SETPOINT control To change a control SETPOINT:

1. Press (SETPOINT)

2. Press (PPM), (ORP) or (PH): the display flashes

3. Use the (UP) and (DOWN) arrows to adjust the Setpoint

4. Press (SETPOINT) again to save the new value

Overfeed Safety Timer

The timers are factory set at 15 minutes for ORP or PPM and 5 minutes for pH. If the ORP/PPM or pH Levels are not back within range before the Overfeed Safety Timer reaches the end of the delay, the chemical controller will automatically disable the feeder pump, trigger the Overfeed Safety Alarm and the display flashes the overfeed alarm time.

To reset the Overfeed Safety Alarm

The operator should check the chemical feeders, feed lines and tanks for any leak or chemical level. After correcting the problem, the safety timer is reset by switching the feed mode to OFF and then back to AUTO.

To change the limits of the safety timer:

1. Press (SAFETY TIMER)

2. Press (ORP/PPM) or (PH): the display flashes

3. Use the (UP) and (DOWN) arrows to adjust the value

4. Press (SAFETY TIMER) again to save the new value

Caution: Increasing the limit on a safety timer may cause overfeeding of chemicals which will cause the WQMS to stop sequences until chemical levels are back within ranges.

Proportional Feed

There are two ways to control the feed rate.

In standard ON/OFF control, the feed rate remains constant until the Setpoint is reached, whereupon it stops.

In Proportional Control, the feed rate decreases progressively as it approaches the Setpoint. Proportional Control is particularly useful to avoid overfeeding of the chemicals in small bodies of water.

Vortex recommend proportional feed for both chlorine and pH control.

Controller Reset

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

To reset all functions to the original factory values, press and hold (ORP or PPM) and pH for 5 seconds.

Chemtrol Default Factory Parameters PPM ORP pH

Setpoint 1.0ppm 700 mV 7.5 Low Alarm 0.3ppm 650 mV 7.0 High Alarm 6 ppm 900 mV 8.0

Overfeed Safety Alarm 15 min 15 min 5 min Proportional bandwidth 1% 1% 1%

Note: those default factory parameters are Chemtrol’s Parameters. They might differ from Vortex’s default parameters.

Safety Flow Switch

No flow switch is required with Chemtrol chemical controller. There is already one connected on the Vortex controller. Jumper JP19 should be on OFF position.

Sensor Testing - The Acid Test

A simple test can be used to verify that the ORP sensor is operating properly. It is called The Acid Test. Just carefully add a small amount of white vinegar or dilute muriatic acid in the strainer of the filtration pump and watch the ORP and pH readings.

Because of the increased activity of the sanitizer at low pH, the ORP reading should increase dramatically and the pH reading should go down. If there is no reaction, the faulty sensor should be replaced. For additional testing, use the PORTA-SENSOR II portable tester from Chemtrol (www.sbcontrol.com)

14. WQMS startup procedure

Power up procedure

• Clean out all sediment from the holding tank. The suction lines located in the holding tank have a winterizing valve (situated above the check valves) that must be set to the CLOSED position. Verify that the float valve moves freely and is free of debris. Locate and open the main water line to allow the tank to fill with fresh water. When the appropriate level is achieved, the float valve will shut off the fresh water feed. Remove the winter plugs and clean any debris from the Splashpad deck drains.

• Install the thumb-twist drain plugs or close associated ball valve on the filter and feature pumps. One by one, open the strainer on each pump (see Fig 1 in this section) and then slowly open the butterfly valve (see Fig 2 in this section) located on the suction end of the pump. If water floods into the strainer, close the butterfly valve and proceed to the next step. If no water pours into the strainer, open the butterfly valve completely and use a bucket of water or a hose to fill the strainer and the suction line connected to the holding tank. Replace the strainer cover, and leave the butterfly valves in the open position.

• Install the drain cap on the bottom of the sand filter. Open and inspect the sand filter, and ensure that it is filled with the proper amount and type of sand (refer to section 17 WQMS component maintenance – Sand filter). Set the multiport valve (the dial valve that is attached to the filter, see Fig 3 in this section) to the

FILTER setting.

• Open the bypass valves on the filter line and the feature line (see Fig 4 in this section).

• Open all the solenoid valves (see Fig 5 in this section) on the water distribution manifold and close the drain ball valve (see Fig 6 in this section).

• There are three flow switches (rotary) with ball valves that must be partially open. The first is located at the bypass line off of the manifold. The second is situated by the chemical injector, and the third is located near the flow cell assembly. Each of these flow meters (see Fig 7 in this section) has a small ball valve in line with it. Ensure that each ball valve is approximately half open.

• Insert the chemical probes (see Fig 8 in this section). Refer to section 17 WQMS component maintenance– Probes for installation details.

• Inspect the Y-strainer for any damage and clean or replace if required.

• Ensure that the chemical pump switch (connected to the chemical reservoir) is set to the OFF position. Remove and debris that may have entered the system and inspect all hoses for signs of wear or cracking. Please note that the pumps will be re-enabled after the holding tank has been pre-treated with sanitizing chemicals.

• Ensure that all feature selector switches, timer switches, and activator switches are in the OFF position. If your system is configured with a rain diverter set the switch to the AUTO position.

• Verify that all Splashpad play events have been prepared for operation. Refer to section 2.0 Prior to WQMS startup– Preparing the Splashpad play events for details.

• Ensure that the Emergency Shut Off switch, located on top of the operating control box is set to the DISENGAGE position. Switch the main breaker (not located on the WQMS skid) to the ON position and then set the main power switch of the Vortex Controller to the ON position. If power is not present, switch the main breaker to the OFF position and verify that all of the MSP fuses in the fuse block (see Fig 9 in this section) are properly installed, closed and in good condition. If necessary, check the fuses for continuity using a multimeter or continuity tester.

Butterfly valve

Multiport valve

Fig 2 Fig 3 Fig 5

Strainer

Fig 1

Fig 1-5: WQMS components

Fig 4

Feature line bypass valve

Solenoid valves

Flow cell with chemical probes

Fig 8 Fig 9 Fig 6

Fig 6-9: WQMS components

Fuse block Flow meter

Fig 7

Drain ball valve

STARTING THE FEATURE LINE WITH DEBRIS IN THE HOLDING TANK WILL

RESULT IN CLOGGING OF THE Y-STRAINER. BEFORE STARTING, RUN THE

FILTER LINE UNTIL THE WATER IN THE HOLDING TANK IS CLEAN.

Holding tank capacity

Minimum

Filter flow

Recommended flow

2000 gallons 67 GPM 95 GPM

2500 gallons 83 GPM 118 GPM

3000 gallons 100 GPM 141 GPM

4000 gallons 133 GPM 190 GPM

Adjusting the flow in the filter line

1. Ensure that all suction and holding tank return lines are open so that the water can flow freely to and from the holding tank.

2. Set the selector switch for the filter pump to the HAND setting.

3. With the pump running, slowly open the bleeder valve located on top of the sand filter and purge any air from the lines. Close the bleeder valve as soon as water begins to flow from the lines. After approximately one minute of operation, stop the pump and verify that the strainer still contains water. If there is no water remaining in the strainer, refill it and ensure that the gasket and strainer are properly seated. Close the pump lid, restart the pump and continue purging the air from the sand filter.

4. Once water is circulating, choke the butterfly valve to force a flow into the chemical line. Verify that the two flow switches (chemical injection and flow cell) are spinning. You should be able to see the wheel arms as they spin. If required, reduce the rotation speed of the flow switch by manipulating the small ball valve that is in line with the flow meter.

5. Set the filter line flow to the level recommended for your installation (see Filter line flow table below) by adjusting the ball valve situated after the filter pump.

Adjusting the flow in the feature line

Filter line flow table

WARNING!

WHEN HANDLING CHEMICALS. ALWAYS WEAR PROTECTIVE CLOTHING

SUCH AS SAFETY GOGGLES, RUBBER GLOVES AND A PLASTIC APRON.

Feature line bypass valve

1. Ensure that all suction and bypass return lines are open so that the water can flow freely to and from the holding tank.

2. Turn the selector switch for the feature pump to the HAND setting.

3. Once water is flowing, ensure that the flow switch (bypass line) is spinning and adjust the flow to approximately 45-50 GPM by choking the bypass valve. This will force water to flow into the flow switch. As the flow switch rotates, you should be able to see the wheel arms as they spin. If required, reduce the rotation speed of the flow switch by manipulating the small ball valve that is in line with the flow meter.

Purging/testing of the feature lines

You may test the feature lines once the pumps are running. To test the feature line, turn the selector switches on the interface panel to the HAND setting. This will open the solenoid valves and send water to the feature(s) on that line. Do this for each valve individually. Once purging/testing is complete, turn the switch back to the OFF setting.

If you are unable to shut off a solenoid valve, clean the diaphragm chamber of any debris. For details on cleaning procedures, refer to section 17 WQMS component maintenance – Solenoid valves.

Testing and adjusting water chemistry

Working with chemicals

A Splashpad with a Water Quality Management System requires the use of standard pool grade chemicals in order to maintain water quality. It is your responsibility to familiarize yourself with the proper handling and mixing of chemicals. You should also observe all warning labels and instructions provided by the chemical manufacturer.

Whenever a procedure requires the use of chemicals, remember and respect the following warnings:

THE PRE-DOSING PROCEDURE IS ONLY APPLICABLE TO INSTANCES WHERE

THE HOLDING TANK HAS BEEN COMPLETELY DRAINED AND RE-FILLED

WITH FRESH WATER.

DO NOT MIX CHLORINE AND MURIATIC ACID. THE COMBINATION MAY

CREATE A POTENTIALLY DANGEROUS CHLORINE GAS THAT CAN SEVERELY

IRRITATE AND DAMAGE YOUR EYES, NASAL PASSAGE AND LUNGS.

Chemical balance test kit

Though the WQMS uses a state-of-the-art chemical controller, a manual chemical test kit should be used periodically to ensure proper calibration of the chemical controller. At a minimum, this kit should be capable of testing levels of free chlorine, total chlorine, pH, total alkalinity and calcium hardness.

Vortex strongly…