Startup & Commissioning

6.1  Pre-Commissioning

6.1.1 Equipment Check-Up  Perform the following check up on the equipment installed:

• Power to Hydroxypure system is OFF
• Electrical connections;
  • Circulation pump
  • Ozone unit
  • Chemical control unit
• Hard plumbing, joints, and equipment unions
• Flow switch connection (if installed)
• Ozone connection to DVI
• Dual probe connections
• Chemical supply tubes and peristaltic pumps
• Level sensor connections from either;
  • Standard systems
  • Optional suction lances
• De-Gas Chamber and Auto De-Gas Valve drains (if installed)
• Chemical supply

6.1.2 Main Circulation System

I. Set the DVI to the OPEN position (no draw of ozone)

II. Check all valves are in the correct position

III. Turn the main circulation pump ON

IV. Check flow in the main circulation system

V. Check for any leaks and rectify before proceeding

6.1.3 Static Hydraulic Test

The static hydraulic test ensures there are no leaks in the DVI system and that backflow of water does not pass check valves when the system is shut down.

I. Turn the main circulation system OFF

II. Check the DVI assembly for leaks around the body or ozone injector nipples

III. Check that water does not backflow through the ozone connection tubes towards the ozone units beyond the first inline check valve

IV. This test should be completed every three months or during anytime a service technician is on site.

6.1.4  Power Up

I. Turn mains power ON and set up the TIMER (refer to 7-Days dual GPO timer manual for setup and operation)

II. One (1) cycle ONLY per day;

Eight (8) hours per day in Summer 40kL to 60kL (10,600 – 15,900 US gal)

Four (4) hours per day in Winter 40kL to 60kL (10,600 – 15,900 US gal)

III. Turn the timer to manual if required to power the pool pump

IV. Turn the power ON to the pool pump

6.1.5 Dynamic Hydraulic Test

Perform a hydraulics test to check the integrity of plumbing and equipment

I. Check the system for water flow, seals, joints, injector points, and ensure the Multicyclone is function correctly and watertight

II. Backwash and rinse the filter

6.1.6 Setting the DVI

The DVI is operated by creating a pressure differential across the ozone injector. This occurs by directing flow using the valve on the front of the DVI assembly.

The DVI is provided with an indicator gauge which shows how by moving the valve, the level of ‘draw’ is adjusted.

The indicator is a guide only, not an accurate measurement of ozone injection.

I. Testing DVI (ozone) flow

If flow is not set correctly, the ozone system may suffer defects as a result of poor air flow. Poor flow through the ozone system will lead to overheating and subsequent failure of the ozone tubes.

II. Visual check

After setting the DVI valve, check that bubbles are clearly visible at the inlet of the MultiCyclone whilst the system is running.

III. Flow gauge (not include in kit)

Test each ozone nipple using the flow gauge provided. The optimal flow rate of ozone through each injector nipple is 3 litres per minute. Ensure each injection nipple is tested if your system has multiple injection points.

6.1.7 Power On

I. Turn the GPO on for the Hydroxzone unit and Chemical Dosing unit

II. The pre-set code for Chemical Dosing unit is ‘0000’. Do not adjust this code without reading the Chemical Dosing unit manual

III. DO NOT alter controller settings at this stage’

NOTE: The first 24 – 48 hours will provide varied readings as the probe settles in

6.1.8 Probe Settling

The Dual Probe in the Hydroxypure system will take up to 24 hours of operation to complete self-calibration.

Fluctuations in the display of pH and ORP, generally cycling up and down will be experienced.

If water preparation procedures have been followed, there will be sufficient Hydrogen Peroxide residual in the pool.

• Observe the ORP reading for approximately 30 minutes
• Note the highest ORP reading observed during this period
• This will be used as the initial ORP set point (described below)

 6.1.9  Initial Set Points

The Chemical Controller comes pre-configured to suit most domestic swimming pools.

Some settings may need to be adjusted, depending on the application. See ‘Operation’ section forfurther information on set points.

The Chemical Controller comes pre-configured to suit most domestic swimming pools.

For the purpose of commissioning only, use this procedure;

ORP

The factory setting is 280mV.

If the highest ORP reading is more than 300mV;

• adjust the ORP set point to 300mV

If the highest ORP reading is less than 250mV;

• adjust the ORP set point to 250mV

pH

The factory setting is 7.4.

This should not need to be adjusted.

See ‘Operation and Maintenance’ for further information if adjustments are required.

6.1.10 De-Gas System

Where an optional De-Gas System is installed, some installations may experience a very small amount of air discharged back to the pool.

Check that there are no suction leaks on any device downstream of the De-Gas Chamber.

If the bubbles are excessive, check the De-Gas Chamber has inlet and outlet connected to the correct ports.

If excessive water is discharged from the Auto De-Gas Valve, an additional rubber supplied in the Auto De-Gas Valve kit should be installed into the valve.

This will increase resistance and reduce the amount of water escaping.

The same procedure can be followed to check if anything has lodged in the rubber which could make excessive water pass through the valve.

Other parameters and alarms should not need adjustment when commissioning

6.2 Water Preparation

IMPORTANT: The following steps must be followed to ensure the pool is correctly prepared. Measure the pool volume with reasonable accuracy

6.2.1 Balance The Pool Water

I. Ensure the pool water is balanced within the following parameters, and within these tolerances be balanced to the Langelier Saturation Index within a range of -0.2 to +0.2

II. Standard pool balancing chemicals may be initially used for Calcium Hardness,  Alkalinity and pH

III. Do not use copper or metal based algaecides or phosphate removers

Desire Water Balance

6.2.2 Shock Dose

Provide the pool an initial shock dose of ‘Perox’ to gain a maximum Hydrogen Peroxide level of 150ppm. in consideration of current water clarity to maintain a base residual of 100ppm.  Follow the manufacturer’s instructions to calculate the correct dose.

Allow the pool to circulate for 1 hour before completing the next step.

6.3 Chemical Dosing Unit Setting

The Chemical Dosing unit is pre-calibrated and pre-set with parameters that suit a pool from 40kL to 60kL (10,600 -15,900 US gal). In most cases, adjustment will be required to the pre-set parameters. If Hydroxypure is being installed on a smaller or larger pool, or the minimum Perox (hydrogen peroxide) level or pH levels are either too high or too low, the following steps should be followed. Readings will vary from region to region depending on conditions. Some adjustment may be required.

Refer to the Chemical Dosing unit operations manual below for further information.

6.3.1 MV (Perox Settings)

NOTE: The lower set point is reading which correlates to the desired Perox (hydrogen peroxide) level in the pool

The ‘range’ is the distance between the lower and upper set points. The ‘proportion’ is the number of seconds per 100 seconds that the unit will dose. Always ensure that the proportional mode is on and the proportional setting at the lower range number is ‘00%’. Adjust the proportion (%) corresponding to the upper range number. Pre-set parameters for 40kL to 60kL (10,600 -15,900 US gal);

NOTE: The lower set point is the reading which correlates to the desired set point in the pool, and should NOT be altered unless as in 9.1.1 or 9.1.2 below.

I. Increase Perox

To achieve an increase in Perox (hydrogen peroxide) reading in the pool, LOWER the upper AND lower mV range settings by 5mV, maintaining the same range. This should provide a Perox (hydrogen peroxide) increase of around 10-15ppm. Then let the pool circulate for  48 hours before testing and comparing readings again.

II. Reduce Perox

To achieve a reduction in Perox (hydrogen peroxide) reading in the pool, INCREASE the upper AND lower mV range settings by 5mV, maintaining the same range. This should provide a Perox (hydrogen peroxide) decrease of around 10-15ppm. Then let the pool circulate for 48 hours before testing and comparing readings again.

III. Smaller or Larger Pools

To set the Chemical Dosing unit for larger or smaller pools, use the following guide.

Table 6-1 mV settings guide for smaller or larger pools

Table 6-2 pH settings guide for smaller or larger pools

Note any changes to the settings:

DATE:_____________________            TIME:_________________

New settings:

mV lower: ____________ 

mV upper: ____________                     mV proportion: _________%

pH lower: ____________

pH upper: ____________                    pH proportion:  _________%

6.3.2 After 1 Week

Observe the mV and pH readings.

Take a water test of the Perox and pH levels and note them down

DATE: _______________                     TIME: _______________

Readings on controller    

                                                               mV: ________________  

                                                               pH: _________________

Water test:                                           (hydrogen peroxide): ____________ppm 

                                                               pH: ________________

Make any fine tuning adjustments to the controller settings as required. Refer to the Chemical Dosing unit operations manual below.

NOTE: Do not make adjustments to the mV settings any greater than 5mV at a time.

6.4 Handover

To ensure effective and consistent operation of the system, the installer will provide instruction to the client on the following;

6.4.1 Overview Of Hydroxypure System

i. Key components and functions ii. Multicyclone cleaning

6.4.2 Chemicals

i. Only use chemicals recommended in this manual

ii. Safety when handling and storing chemicals required for the Hydroxypure system

iii. Where to obtain Hydroxypure chemicals locally

6.4.3 Timer

i. Timer operation and use of the manual override

ii. Recommended running times

iii. Adjusting minimum running time from summer to winter

6.4.4 Dynamic Venturi Injector Assembly

i. When to adjust the Dynamic Venturi Injector Valve

ii. How to adjust the Dynamic Venturi Injector Valve

6.4.5 Chemical Dosing Unit

i. Current settings

ii. Current water test results

iii. mV adjustments –  refer to manual or qualified service technician

6.4.6 Installation Checklist

Installation checklist to be left with the client as a record of correct installation and initiation procedures