ChlorKing NEXGEN80 User manual

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NEXGEN80 and 80R
Installation, Operation, and
Maintenance Manual

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TABLE OF CONTENTS
1.0DESCRIPTION 3
1.1 General Information 3
1.2 Principals of Operation 4
1.3 Specifications, Certifications, and Sizing Guidelines 5
2.0INSTALLATION 8
2.1 Unpacking 8
2.2Storage 8
2.3 Safety Considerations 8
2.4 Plan Ahead 10
2.5 Additional Parts Required for Installation 10
2.6 Power Supply Electrical Connections 11
2.7 Bonding 12
2.8 Plumbing Connections 13
2.9 Saturated Salt Feeder Installation 16
2.10 Plumbing the Overflow 17
2.11 Preparing the pH Neutral System 18
2.12 Plumbing the Hydrogen Vent 18
3.0OPERATION 19
3.1 Start-up Procedures and Checks 19
3.2 Adjusting Chlorine Output 19
3.3 Touch-screen Icon Explanations 20
3.4 Using the Touchscreen 21
4.0MAINTENANCE 28
4.1 Routine Maintenance 28
4.2 Cell Cleaning Procedure 28
5.0 WARRANTY INFORMATION 42
Note: This manual is subject to change at any time based on system improvements,
design changes, authorized modifications, or new information. Please consult
ChlorKing for the latest revision.
Manufacturer:
ChlorKing Inc
2935 Northeast Parkway
Atlanta, GA 30360
1-800-536-8180

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SECTION 1
DESCRIPTION
1.1 GENERAL INFORMATION
The NEXGEN system is an on-site sodium hypochlorite generator designed for
commercial swimming pool applications. The NEXGEN can produce up to 96 pounds of
equivalent chlorine per day. The system manufactures bleach continuously from a salt
concentration of 5000ppm to 7000ppm and uses the water from the pool as a raw
material. This unique feature eliminates issues with high TDS levels and requires less
salt as raw material than traditional methods. The NEXGEN is designed for commercial
service and can be run 24 hours a day or controlled by any pool controller. “R” models
are reverse polarity for reduced maintenance. The basic components of the NEXGEN
are outlined below.
Production
Tank
Dilution
Fan
Chemical
Metering
Power
Supply and
Control Box

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1.2 PRINCIPALS OF OPERATION
Production Tank Assembly
The production tank assembly consists of a polyethylene tank, four external electrolytic
cells, a circulation pump and heat exchanger. Pool water from the pool return line is fed
into the production tank. The circulation pump circulates water through the electrolytic
cells and heat exchanger. The water in the tank is maintained between 5000-ppm and
7000-ppm salt concentration. The electrolytic cells produce a 1666-ppm to 2500-ppm
sodium hypochlorite solution. The sodium hypochlorite flows to the pool at a flow rate of
4.4-gpm. The flow rate through the tank dictates the amount of sodium hypochlorite
produced. Sodium hypochlorite can be produced up to 96-gpd of equivalent chlorine.
The sodium hypochlorite flows to the pool for use in disinfection. The heat exchanger
has fresh pool water pumped through the coils to maintain tank temperatures of no more
than 10 degrees F above the pool water.
Dilution Fan
Electrochemical production of sodium hypochlorite produces hydrogen as a byproduct.
The dilution fan pumps fresh air into the production tank to dilute the hydrogen and force
it out the vent. The vent must be vented to outside atmosphere.
Saturated Salt Feeder
The saturated salt feeder supplies the production tank with a constant supply of salt to
produce sodium hypochlorite. Salt is used at the rate of 2 pounds per pound of equivalent
chlorine produced or 3 pounds per pound of equivalent chlorine produced depending on
production quantity selected. The saturated salt feeder is filled manually. Salt is pumped
using standard peristaltic chemical feed pumps.
Chemical Metering
Chemical metering is accomplished using a venturi. The flow through the venturi is
adjusted to provide the flow rate necessary to deliver the rated production of chlorine to
the pool.
Power Supply and Control Box
The power supply provides the current to the electrolytic cells to produce the rated amount
of sodium hypochlorite. The power supply houses all the safety features to prevent
system operation in the event of a malfunction.

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1.3SPECIFICATIONS, CERTIFICATIONS, AND SIZING GUIDELINES
Sodium hypochlorite production:
NEXGEN80 and NEXGEN80R - Up to 96 pounds per day at 7000ppm
Maximum pool return line pressure:
25 PSI including plumbing to and from the venturi injector
Electrical requirements:
NEXGEN80 - Rated 240 VAC, 87.12 A, 60 Hz
Requires a 240 volt single phase connection @ 100 amps minimum and 60Hz
120 volt connection to a chemical feed controller or 120 volt outlet @1 amp
NEXGEN80R - Rated 208/240 VAC, 87.12 A, 60 Hz
Requires a 208/240 volt single phase connection @ 100 amps minimum and 60Hz
120 volt connection to a chemical feed controller or 120 volt outlet @1 amp
Internal System Fusing
Power Supply NEXGEN80 and 80R – 2 x 60 amp RK5 class fuse
Circulation Pump – 10 amp internal circuit breaker
Chemical Metering / Control – 12 amp internal circuit breaker
Certifications
NEXGEN80 and NEXGEN80R are certified for indoor installation.
NSF Standard 50
UL Standard 1081
CSA Standard C22.2 #218.1
PRMA Reg. No. 33004
Sizing guidelines
Chlorinator sizing must comply with local codes. Please contact your local health
department for specific requirements or contact your local ChlorKing representative for
assistance.

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MINIMUM SPACE REQUIREMENTS FOR NEXGEN80:
18 24
31

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MINIMUM SPACE REQUIREMENTS FOR NEXGEN80R:

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SECTION 2
INSTALLATION
2.1 UNPACKING
Units are shipped from the factory. In the event of damages during shipping, it is the
responsibility of the customer to notify the carrier immediately and to file a damage claim.
Open the crate carefully and examine all material inside.
2.2 STORAGE
When storing units, use the original packaging and store under a shelter to protect the
contents from weather.
2.3 SAFETY CONSIDERATIONS
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
WHEN INSTALLING, OPERATING, AND MAINTAINING THIS EQUIPMENT, KEEP
SAFETY CONSIDERATIONS FOREMOST. USE PROPER TOOLS, PROTECTIVE
CLOTHING, AND EYE PROTECTION WHEN WORKING ON OR INSTALLING THE
EQUIPMENT. FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND TAKE ANY
ADDITIONAL SAFETY MEASURES APPROPRIATE. BE EXTREMELY CAREFUL IN
THE PRESENCE OF HAZARDOUS SUBSTANCES.
THE PERSONNEL RESPONSIBLE FOR INSTALLATION, OPERATION, AND
MAINTENANCE OF THIS EQUIPMENT MUST BE FULLY FAMILIAR WITH THE
CONTENTS OF THIS MANUAL.
ANY SERVICING OF THIS EQUIPMENT MUST BE DONE WITH THE UNIT FULLY OFF
AND DISCONNECTED FROM THE POWER SOURCE AND ALL PRESSURE BLED
FROM THE LIQUID LINES.
WARNING
CHLORKING® SYSTEMS ARE INTENDED TO BE INSTALLED ACCORDING
TO ALL LOCAL AND NATIONAL REGULATIONS.
CONNECT THE EQUIPMENT ASSEMBLY TO A CIRCUIT PROTECTED BY A
GROUND-FAULT CIRCUIT-INTERRUPTER.

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ONLY A CERTIFIED TECHNICIAN MAY INSTALL AND SERVICE THE
CHLORKING® NEXGEN SYSTEM.
MODIFYING THE CHLORKING® NEXGEN SYSTEM IN ANY WAY MAY CAUSE
BODILY INJURY AND WILL VOID THE WARRANTY.
DO NOT ALLOW CHILDREN OR ANYONE NOT CAPABLE TO OPERATE THE
CHLORKING® NEXGEN SYSTEM.
ONLY REPLACE COMPONENTS WITH THOSE SPECIFIED BY THE
MANUFACTURER.
WHEN INSTALLING THE SYSTEM, ENSURE THAT POWER IS LINKED TO
THE MAIN PUMP POWER SOURCE FOR THE POOL TO ENSURE THAT THE
CHLORKING® NEXGEN SYSTEM NEVER OPERATES WHEN THE PUMPS
ARE OFF.
ALL BOXES ON THE CHLORKING® NEXGEN SYSTEM CONTAIN HIGH
VOLTAGE COMPONENTS. NEVER OPEN ANY BOX WHILE THE POWER IS
ON.
THE SYSTEM HAS THE POTENTIAL TO RELEASE HIGH DOSES OF
CHORINE. USE CAUTION WHEN HANDLING, SERVICING, OR OPERATING
THE EQUIPMENT.
DO NOT ENERGIZE OR OPERATE THE SYSTEM IF THE CELL HOUSING IS
DAMAGED OR IMPROPERLY ASSEMBLED.
THE MOUNTING LOCATION OF THE UNIT MUST BE AT LEAST 1.5 METERS
FROM THE POOL.
CONSERVEZ CES INSTRUCTIONS
LORS DE L'INSTALLATION, DE FONCTIONNEMENT ET L'ENTRETIEN DE CET
ÉQUIPEMENT, GARDEZ LES CONSIDÉRATIONS SUR LA SÉCURITÉ AVANT
TOUT. UTILISER DES OUTILS APPROPRIÉS, DES VÊTEMENTS DE PROTECTION
ET LUNETTES DE PROTECTION LORSQU'ILS TRAVAILLENT SUR OU À
L'INSTALLATION. SUIVEZ LES INSTRUCTIONS DE CE MANUEL ET PREND LES
MESURES DE SÉCURITÉ SUPPLÉMENTAIRES APPROPRIÉES. SOYEZ
VIGILANTS EN PRÉSENCE DE SUBSTANCES DANGEREUSES.
LE PERSONNEL CHARGÉ DE L'INSTALLATION, DE FONCTIONNEMENT ET
D'ENTRETIEN DE CE MATÉRIEL DOIT ÊTRE PARFAITEMENT FAMILIARISÉ AVEC
LE CONTENU DE CE MANUEL.
AUCUNE OPÉRATION DE MAINTENANCE DE CET ÉQUIPEMENT DOIT ÊTRE
FAITE AVEC L'UNITÉ ENTIÈREMENT ÉTEINT ET DÉBRANCHÉE DE
L'ÉLECTRICITÉ ET TOUTE LA PRESSION SAIGNÉ À PARTIR DES LIGNES DE
LIQUIDES.
MISE EN GARDE

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CHLORKING ® SYSTEMES SONT DESTINES A ETRE INSTALLES SELON TOUS
LES REGLEMENTS LOCAUX ET NATIONAUX.
CONNECTER LE MONTAGE DE L'ÉQUIPEMENT SUR UN CIRCUIT
PROTÉGÉ PAR UN DISJONCTEUR DE FUITE À LA TERRE.
SEUL UN TECHNICIEN CERTIFIE PEUT INSTALLER ET ENTRETENIR LE
SYSTEME CHLORKING ® NEXGEN.
MODIFIANT LA CHLORKING ® NEXGEN SYSTEME EN QUELQUE SORTE
PEUT CAUSER DES LESIONS CORPORELLES ET LA GARANTIE
ANNULATION.
N'AUTORISENT PAS LES ENFANTS OU N'IMPORTE QUI PAS CAPABLE
D'ALIMENTER LE SYSTEME CHLORKING ® NEXGEN.
REMPLACEZ UNIQUEMENT LES COMPOSANTS AVEC CELLES
SPÉCIFIÉES PAR LE FABRICANT.
LORSQUE VOUS INSTALLEZ LE SYSTEME, S'ASSURER QUE LA
PUISSANCE EST LIEE A LA SOURCE D'ALIMENTATION DE POMPE A MAIN
POUR LA PISCINE POUR VOUS ASSURER QUE LE SYSTEME DE NEX-GEN
CHLORKING ® FONCTIONNE JAMAIS QUAND LES POMPES SONT HORS
SERVICE.
TOUTES LES CASES SUR LE SYSTEME CHLORKING ® NEXGEN
CONTIENNENT DES COMPOSANTS HAUTE TENSION. NE JAMAIS OUVRIR
N'IMPORTE QUELLE BOÎTE TANDIS QUE L'APPAREIL EST ALLUMÉ.
LE SYSTÈME A LA POSSIBILITÉ DE LIBÉRER DES DOSES ÉLEVÉES DE
CHLORE. SOYEZ PRUDENT LORS DE MANIPULATION, ENTRETIEN OU
FONCTIONNEMENT DE L'ÉQUIPEMENT.
NE PAS METTRE SOUS TENSION OU FAIRE FONCTIONNER LE SYSTÈME
SI LE BOÎTIER DE LA CELLULE EST ENDOMMAGÉ OU MAL ASSEMBLÉ.
L'EMPLACEMENT DE MONTAGE DE L'UNITÉ DOIT ÊTRE D'AU MOINS 1,5
MÈTRES DE LA PISCINE.
2.4 PLAN AHEAD
The NEXGEN is intended to be installed indoors. It is imperative to have prior knowledge
of the facility in which the unit is to be installed. Evaluate space requirements, electrical
requirements, and plumbing requirements. Determine what type of tools and hardware
will be needed to make the installation as problem free as possible.
2.5 ADDITIONAL PARTS REQUIRED FOR INSTALLATION
½ inch polypropylene or polyethylene tubing
¼ inch polypropylene or polyethylene tubing and a ¼ inch valve for tubing connection
PVC pipe in 3 inch or greater
PVC 90’s, 45’s, couplings and saddles or adapters for the return line size encountered
3 inch PVC pipe, 90’s, 45’s and couplings for the hydrogen vent
Anchors and mounting hardware
Container specified for muriatic acid solutions

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2.6 POWER SUPPLY ELECTRICAL CONNECTIONS
WARNING
DO NOT FORGET TO CONNECT THE EARTH TERMINALS AND THE EQUIPMENT
BONDING WIRE. THE ELECTRICAL SUPPLY MUST MATCH THE SYSTEM RATED
CURRENT. ENSURE THAT POWER IS LINKED TO THE MAIN PUMP POWER
SOURCE FOR THE POOL TO ENSURE THAT YOUR CHLORKING® NEXGEN
SYSTEM NEVER OPERATES WHEN THE POOL PUMPS ARE OFF.
For ease of service, it is recommended that a manual disconnect be installed
between the electrical service and the NEXGEN system.
Connect the electrical supply from the pool equipment room to the connections marked
240 VAC L1, L2 and ground. Ensure that the electrical service is protected by a circuit
interrupter and is rated for the model NEXGEN that is installed.
240 VAC
L1 and L2
240 VAC
L1 and L2
Ground

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Connect the blue control cord to a chemical feed controller or for manual operation, into
a 120V electrical outlet protected by a ground fault circuit interrupter.
2.7 BONDING
Connect a minimum 8awg bonding wire to the bonding lug on the bottom of the electrical
enclosure.
Blue
Controller
Cord
Bonding
Lugs

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2.8 PLUMBING CONNECTIONS
PLUMBING THE CHEMICAL METERING VENTURI
It is important that the Chemical Metering Venturi is plumbed correctly, or the
system will not function properly, and the warranty will be void.
The chemical metering venturi injector requires a pressure differential across the venturi
to achieve the rated chemical flow. A booster pump is needed to ensure the required
pressure differential is achieved. The NEXGEN will provide 100% of the rated output with
a maximum of 25 PSI at the venturi outlet. Install the booster pump in the supply line to
the venturi. Consult ChlorKing for booster pump sizing.
The booster pump is powered by the NEXGEN and must be installed within 10 feet
of the NEXGEN skid to ensure the electrical connection will reach the pump. The
pump wiring is located on the bottom side of the enclosure. Wire the booster pump
to the NEXGEN with the cable provided and to the pump according to the
instructions on the pump for 208/240 VAC connections. The NEXGEN ships with a
12amp breaker for a 1HP pump. Larger pumps will require changing the breaker.
Contact ChlorKing for breaker sizing.
Booster
Pump In
Return To Pool
ChlorKing
Nex-Gen
BY
Return To Pool Return To Pool
Nex-Gen 80 and 60R
Plumbing Layout
Field Installation
Hydrogen
Vent
18"
BLUE - Water
ORANGE- Acid
GREEN - Brine
Overflow
to
Drain Pump
pressure
switch.
Plumb
to pump
discharge
Acid
Tank
Filter Heat
Exchanger
Pump
Floor
Salt
Tank

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Plumb the inlet of the venturi to the booster pump which is connected to the return line of
the pool after all other pool components such as heaters etc. Use at least 3 inch PVC
pipe for this connection. It is recommended that a valve be installed at this connection
so that the system can be isolated from the pool.
Plumb the outlet of the venturi to the return line of the pool 18
inches after the inlet plumbing connection. Use at least 3 inch
PVC pipe for this connection. It is recommended that a valve
be installed at this connection so that the system can be
isolated from the pool.
Size Booster Pump based on return line
pressure
Return Line Pressure Pump Horsepower
5 PS! ½ HP
7 PSI 1 HP
12 PSI 2 HP
25 PSI 3 HP
PLUMBING THE PRESSURE SWITCH
Connect the pressure switch to the return line with ¼ tubing (not supplied) and the ¼
inch valve supplied. The pressure connection should provide a minimum of 5 psi when
the pool pump is on, and pressure should be less than 3 psi when the pool pumps are
off. Contact ChlorKing for installations that do not meet these specifications.
Inlet Outlet
Pressure
Switch
Connection

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2.9 SATURATED SALT FEEDER INSTALLATION
Place the Saturated Salt Feeder tank in an easy to access location. The tank will need
access for adding salt on a continuous basis.
Plumb the peristaltic pump suction lines to the salt outlets on the Saturated Salt Feeder
with 1/4 tubing supplied with the peristaltic pump. The salt outlets on the Saturated Salt
Feeder two small blue and white valves located at the bottom of the salt feeder. Plumb
the Saturated Salt Feeder water supply to the fitting on the chemical metering assembly
using ½ inch tubing.

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2.10 PLUMBING THE PRODUCTION TANK OVERFLOW
Install the overflow with the T provided in the installation kit. This T will remain open on
top to prevent syphoning in case of tank overflow. The bottom of the T receives a 1.5”
FPT low pressure connection with hose directed to a floor drain, drain tube is not
provided.

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2.11 PREPARING THE pH NEUTRAL SYSTEM
Before use, remove the pH probe from the top of the production tank and remove the
cover from the end of the pH probe. Re-install the probe.
Plumb the suction port of the peristaltic pump with the #1 hose to a container (not
supplied with the NEXGEN) specified for muriatic acid solutions.
Note: Sulfuric acid and dry acid (sodium bisulfate) are not recommended for pH
adjustment. Under some conditions the electrolytic cell can be damaged.
WARNING
Read all cautions and directions provided with the muriatic acid used. Always add acid
to water. Use only with adequate ventilation. If strong odor is noticed, STOP, ventilation
is inadequate. Leave area immediately. If the work area is not well ventilated, you MUST
use a properly fitted and maintained NIOSH approved respirator for acid fumes.
For best results fill the acid tank with a 1 to 1 water / muriatic acid solution.
2.12 PLUMBING THE HYDROGEN VENT
WARNING
EXOLOSION RISK. FAILURE TO PLUMB THE HYDROGEN VENT TO OUTSIDE
ATMOSPHERE MAY RESULT IN DAMAGE TO EQUIPMENT OR PERSONS.
ALWAYS VENT THE SYSTEM AWAY FROM SPARK OR FLAME
Hydrogen vent pipes must be rigid plastic (PVC) and installed in a continuous upward
gradient (1/8 inch per foot rise). The pipe must be vented to outside atmosphere. Use a
minimum of 3 inch pipe for the vent. The vent pipe should not be longer than 100 feet.
(Consult ChlorKing if longer runs are required). Keep the opening clear and protected
from water or debris with the use of a hood or bend. Do not use screens or louvres at the
vent outlet.
Hydrogen
Vent

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SECTION 3
OPERATION
3.1 START-UP PROCEDURES AND CHECKS
Check that all components are mounted securely. Check that all plumbing is secure and
tight. Check that all plumbing and electrical connections are connected in the proper
place.
Ensure that all system isolation valves installed during installation are open.
Fill the Saturated Salt Feeder with pure rock or pellet salt. Do Not Use Granular Salt.
Open both Saturated Salt Feeder valves.
Fill the muriatic acid container with a 50% water to 50% muriatic acid solution.
Turn on any breakers or disconnect boxes used for circuit protection.
Ensure the blue cord is connected to a chemical feed controller and the controller is calling
for feed, or that the blue cord is plugged into a live outlet.
The NEXGEN will go through a series of startup steps and automatically start generating
chlorine.
If the NEXGEN does not start automatically, see Troubleshooting in section 6.
3.2 ADJUSTING CHLORINE OUTPUT
Adjust the flow through the flow meter for the following
production rates:
4.4 GPM = 96 pounds of chlorine production per day
3.5 GPM = 78 pounds of chlorine production per day
2.9 GPM = 85 pounds of chlorine production per day
1.3 GPM = 73 Pounds of chlorine production per day
NOTE
The maximum production rate of 96 pounds is
achieved at 7000 ppm salt concentration and 4.4
GPM.
Adjustments in excess of 4.4 gallons per minute will
not produce more chlorine. Adjustments in excess of
4.4 gallons per minute will only consume excess salt.
Flow
Control
Flow Meter

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3.3 TOUCH SCREEN ICON EXPLANATIONS
This icon is displayed if the system is turned off.
This icon is displayed if the system is waiting for a signal from an external
controller.
This icon is displayed if cell cleaning mode has been selected. This icon
will be displayed until the cell cleaning process is complete.
This icon indicates a failure during the acid wash sequence for cell
maintenance.
Press this icon to clear the fault described above.
This icon indicates that acid is being pumped during the cell cleaning cycle.
Faults are accompanied by a beeping sound. If this icon is visible, pressing
it will stop the beeping sound.

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3.4 USING THE TOUCHSCREEN
Home Screen
Below is the HOME screen that will be displayed any time the NEXGEN is operating
normally.
On/Off
Indicator
Process
Tank
Temperature
On/Off
Button
Pool Feed
Indicator
Process
Tank pH
Electrolytic
Cell Volts
Menu Button Electrolytic
Cell Amps
Process
Tank Salt
Level