Predictive Maintenance in IoT-Enabled Salt Chlorinator: A Phenomenal Water Treatment Solution 

Our client, a swimming pool installation company owner from Britain, had approached us with a simple need: To install controllers for their water treatment systems and monitor the quality of water round the clock. TerraConnect, being the pioneer in delivering world-class water treatment solutions, fell into a brown study. Farsighted in sensing possible challenges, we came up with a long-standing solution: a comprehensive bundle of technology as an ideal solution to tackle probable issues in the long run. We wanted our client to reach the pinnacle of their business goals. TerraConnect has built a legacy of trust among clients with our flawless IoT products assisting water treatment plants for the best results. Our clients come back to us because of our resolution in delivering only excellence. 

So, what golden solution did TerraConnect suggest? 

Terra S: The Salt Chlorinator with Predictive Maintenance Potential 

Back to our drawing table, we brainstormed over the possible difficulties pool owners could face in the long run.  

First things first. We suggested Terra S, our salt chlorination-based IoT water controller for its significant features  

• A single controller with auxiliary relays to control the pump, dosing system and the filter backwash. Hence, an all-in-one controller for salt electrolysis, chemical dosing, pump regulation and filter backwash features. 

• 3.5” SPI TFT LCD Resistive Touch Display for real time monitoring of data 

• Dual dosing system for enhanced pH maintenance 

• 32-bit processor architecture with Wi-Fi and Bluetooth capability 

• Wide spectrum of sensors for pH, ORP, TDS, temperature, and flow switch 

• SMPS supported efficient power management 

• Long lasting Titanium electrode to save you from intermittent maintenance issues 

Yes, the last feature made us think further.  Over time, the efficiency of the Titanium electrode might weaken due to the deposits of Calcium and Magnesium ions during the electrolysis of the pool water. It is inevitable to balance the hardness of water (or the Calcium and Magnesium content of the water) to the optimum level while using the salt chlorinator.  

Conventionally, the deposited ions are removed through the reverse polarization process. However, prolonged deposition of these alkaline earth metal ions leads to the corrosion of the Iridium and Ruthenium Oxides, coated on the Titanium cell. The consequence-inefficient electrolysis and the quantity of free Chlorine released for disinfection diminishes during the whole process. Uff! All efforts for our client should not be for a lost cause.  

TerraConnect perceives challenges as opportunities to leverage innovative technology into our IoT solution. Associating with our partner Nuventure, we designed a comprehensive solution with Machine Learning (ML) integration for Predictive Maintenance (PdM) capability! Yes, a self-cleaning electrolysis cell for the salt chlorinator. 

The science behind Predictive Maintenance? Spill the beans! 

Predictive Maintenance (PdM) is the use of AI and data analytics to detect operational defects and potential machinery anomalies for timely maintenance and fault detection, before major repairs. Predictive maintenance facilitates imminent component failure warnings for operators to schedule maintenance, saving the infrastructure from abrupt failure and the business from unexpected downtime. Terra S manifests Predictive Maintenance in the terms of the preset AI algorithm, for prompt error detection. The advanced monitoring capacity of Terra S consistently keeps a check on the Chlorine levels in the water, in real time. The applied ML algorithm monitors the free Chlorine content against the total current density applied for the electrolysis and compares the data with the theoretical model to assess if the data variation is drastic to raise alerts. The ML algorithm compares multiple cells of the same grade at a time to understand if there is an anomaly on any cell and notify the operators as alarms. The ML algorithm activates the power supply to reverse the flow of electricity after a programmed amount of time to dissolve the deposited scaling. Besides, the water chemical composition like hardness and water quality is under surveillance, as faster reverse polarization can also hamper free Chlorine production. Thus, ML algorithm can not only increase longevity of the cell but also prevent the cell from premature maintenance. Our client can now confirm the right quality of the electrode for ensuring better pool experience for their customers with minimal maintenance. 

Our commitment to providing a holistic solution impressed our client, who was in seventh heaven. Thanks to our expert team of engineers who strive to stay updated with evolving technology to serve our customers the best. 

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