ChlorKing CHLOR-2.0 User manual

2010-2077
2019-10-10
ChlorKing Saline Chlorination System, Model CHLOR-2.0
CHLORINE GENERATOR
CONTROLS BACTERIA AND ALGAE
in
Swimming Pool (and Spa) Waters
COMMERCIAL
A maximum of 113,600 L of water can be treated with
ChlorKing Saline Chlorination System, Model CHLOR-2.0
Maximum output of hypochlorous acid equivalent to 0.896 kg
of free available chlorine per day
For swimming pools, a range of 1.0 - 3.0 ppm of free available chlorine
must be maintained.
For spas, a range of 3.0 - 5.0 ppm of free available chlorine must be maintained.
KEEP OUT OF REACH OF CHILDREN
READ THE LABEL AND OPERATING MANUAL BEFORE USING
REGISTRATION NO. 29541 PEST CONTROL PRODUCT ACT
WARNING: Operating the ChlorKing Saline Chlorination System, Model CHLOR-2.0,
without water flow through the cell can cause a buildup of flammable gases
which can result in FIRE OR EXPLOSION.
WARNING: Do not use this device with bromide products.
NOTE TO USER: This pest control product is to be used only in accordance with the
directions on the label. It is an offence under the Pest Control Products Act, to use
this product in a way that is inconsistent with the directions on the label.
CHLORKING INC,
2935 NORTHEAST PARKWAY
ATLANTA, GEORGIA, U.S.A, 30360.1-800-536-8180

USER’S GUIDE
MODEL MINI-2.0

2
INTRODUCTION… ...................................................................................4
WARRANTY INFORMATION… ................................................................5
SAFETY INFORMATION… ................................................................... 6-7
PREPARING YOUR WATER BEFORE INSTALLATION… ..................8-9
SALT CHART FOR CORRECT MAINTENANCE…................................10
TOOLS AND PARTS REQUIRED FOR INSTALLATION… ...................11
INSTALLING YOUR SYSTEM – PLUMBING…..................................12-13
- ELECTRICAL….................................14
SPECIFICATIONS AND FUSE SIZING… ................................................15
STARTING THE SYSTEM… ....................................................................15
GENERAL OPERATION…....................................................................... 16
MAINTENANCE AND CLEANING…........................................................17
TABLE OF CONTENTS

3
ChlorKing Saline Chlorination System, Model MINI-2.0
CHLORINE GENERATOR
CONTROLS BACTERIA AND ALGAE
in
Swimming Pool (and Spa) Waters
COMMERCIAL
A maximum of 113,600 L of water can be treated with
ChlorKing Saline Chlorination System, Model MINI-2.0
Maximum output of hypochlorous acid equivalent to 0.896 kg
of free available chlorine per day
For swimming pools, a range of 1.0 - 3.0 ppm of free available chlorine
must be maintained.
For spas, a range of 3.0 - 5.0 ppm of free available chlorine must be maintained.
KEEP OUT OF REACH OF CHILDREN
READ THE LABEL AND OPERATING MANUAL BEFORE USING
REGISTRATION NO. 29541 PEST CONTROL PRODUCT ACT
WARNING: Operating the ChlorKing Saline Chlorination System, Model MINI-2.0,
without water flow through the cell can cause a buildup of flammable gases
which can result in FIRE OR EXPLOSION.
WARNING: Do not use this device with bromide products.
NOTE TO USER: This pest control product is to be used only in accordance with the
directions on the label. It is an offence under the Pest Control Products Act, to use
this product in a way that is inconsistent with the directions on the label.
CHLORKING INC,
2935 NORTHEAST PARKWAY
ATLANTA, GEORGIA, U.S.A, 30360. (1-800-536-
8180)

4
ChlorKing → inc
2935 NORTHEAST PARKWAY
ATLANTA, GEORGIA, U.S.A,
30360. 1-800-536-8180
Patent # US 6821398B2
EPA Est. #082229-GA-001
NSF-50 / UL-1081listed
Congratulations on purchasing your new ChlorKing→saline chlorination system,
we trust that this system will offer you the ultimate in swimming environments,
and give you years of trouble free operation.
This user’s manual will explain in detail the operation of your new system, as well
as water chemistry guides, warranty information, and much more.
If at any time you need additional information on your system, please feel free to
contact us.
Titanium Electrode
Replacement Electrode for the ChlorKing Saline Chlorination System, Model
MINI-2.0
REGISTRATION NO. 29541 PEST CONTROL PRODUCTS ACT
This electrode must only be used on this model of chlorine generating device.
READ THE LABEL AND REFER TO OWNER'S MANUAL OF THE
ChlorKing Saline Chlorination System, Model MINI-2.0, BEFORE USING.
CHLORKING INC,
INTRODUCTION

5
The ChlorKing® system carries a limited 3 year warranty
1. 3 year warranty on assembly of electrical components andcell
housing.
2. 1 year on all electrical items.
3. 2 years or 15,000 hours, which ever occurs first, pro-rated hourly,
on titanium electrodes. (Year 1 is warranted fully, thereafter pro-
rated warranty applies, applicable over the full 2 yearperiod)
•ChlorKing® advises that titanium electrodes will have to be replaced
every 15,000 hours of operating time. Under no circumstances shall the
replacement titanium electrodes exceed the original 15,000 hour warranty.
•ChlorKing® warranties will not be honored should it be shown that the
operating and maintenance procedures have not been followed,
particularly with regard to the correct maintenance of salt concentration
and water chemistry.
•ChlorKing® warranties of the titanium electrodes will not be honored if
the system is operated in water temperatures lower than 15 degreesC.
•ChlorKing® warranties of the titanium electrodes will not be honored if
the system is operated in water where the salt concentration is lower than
3000 ppm.
•During the warranty period the customer shall return the defective
component, freight prepaid, accompanied by the original invoice or proof
of purchase, and ChlorKing® shall at it’s sole discretion elect to repair or
replace the defective component and return it to the customer, freight pre-
paid.
ChlorKing® accepts no responsibility other than to repair or replace a defective
component, and this warranty specifically excludes product failure due to
accidental damage, abuse, misuse, negligence, damage due to non-compliance
of the operating manual or unauthorized alterations or modifications to the
system. ChlorKing® accepts no responsibility and is not liable for any extended
warranties or variations to this warranty offered by re-sellers of ChlorKing®
systems.
WARRANTY INFORMATION

6
PLEASE READ THE FOLLOWING SAFETY INFORMATION CAREFULLY!
WARNING!
•Only a certified technician may install and service yourChlorKing®
system.
•Modifying your ChlorKing® system in anyway may cause bodily injury
and will void your warranty.
•Warning: To reduce the risk of injury, do not allow children to operate this
device.
•Only replace components with those specified bymanufacturer.
•When installing your system, ensure that power is linked to the main pump
power source for the pool to ensure that your ChlorKing® system never
operates when the pumps are off.
•All boxes on your ChlorKing® system contain high voltage components.
Never open any box while power is “on”.
•WARNING: Heavy pool (and/or spa) usage, and higher temperatures may
require higher chlorine output to maintain proper free available chlorine
residuals.
•If additional chlorine is required due to heavy bather loads, use granularor
liquid chlorine (Sodium Hypochlorite) to maintain appropriate chlorine
residual in the water.
•Maintaining high salt and chlorine levels above recommended range can
contribute to corrosion of pool (and/or spa) equipment.
•DO NOT add pool (and/or spa) chemicals directly to the skimmer. This
may damage the cell.
•Check the expiry date of the test kit as results may be inaccurate ifused
after that date.
SAFETY INFORMATION

7
•When replacing the cell, only use replacement cells having a label that
clearly states that it is a replacement cell for the chlorine generating
device ChlorKing Saline Chlorination System, Model MINI-2.0,
REGISTRATION NUMBER 29541, PEST CONTROL PRODUCTS ACT.
•Follow all aspects of the local and National Electrical Code(s) when
installing ChlorKing model MINI-2.0.
•NOTE: For outdoor pools, chlorine residuals can be protected from
destruction by sunlight by addition of stabilizer (cyanuricacid).
•NOTE FOR USE ON SPAS: For proper sanitation, spas must be
completely drained periodically. The number of days between COMPLETE
DRAINAGE is equal to the volume of spa water in litres, divided by 10
times the maximum number of daily spa users. Refill spa with water and
repeat DIRECTIONS FOR USE of the device.
•HEALTH AND HYPERTHERMIA WARNINGS FOR SPA DEVICES:
People with a medical condition should consult a physicianbefore
entering pool or spa water.
Maximum spa water usage temperature is 40 degrees C. Bathing in
spa water at 40 degrees C should not exceed 15 minutes.

8
ChlorKing® saline chlorination systems operate by utilizing the sodium chloride
that has been added to the pool water, to produce sodium hypochlorite (liquid
chlorine), through the process of electrolysis.
In order for your ChlorKing® system to operate correctly, sodium chloride (salt)
must be added directly to the pool at least 24 hours before the installation of the
equipment.
5kg’s of sodium chloride must be added for every 1,000 litres of pool water (ie: a
200,000-litre pool will require 1,000 kg’s of salt for start-up).
It is best to add the salt around the pool, and not load all salt in one section.
Once the salt has been added, brush the surface of the pool continuously until
the salt has all dissolved. You must never leave large amounts of salt on the
surface of the pool, as this may cause damage to the pool surface.
When you add the initial load of salt, you will need to add additional chlorine, as
the salt will cause a chlorine demand.
Your pool water should be balanced in the following range before turning your
ChlorKing® system on;
Water balance parameters
Swimming pool
Spa
Free available chlorine
1.0 – 3.0 ppm
3.0 – 5.0 ppm
pH
7.2 – 7.8
7.2 – 7.8
Total alkalinity
100 – 120 ppm
100 – 120 ppm
Calcium hardness
200 – 300 ppm
150 – 200 ppm
Cyanuric Acid (stabilizer)
30 – 100 ppm
30 – 100 ppm
Salt ranges
Swimming pool
Spa
Salt level
4,000 – 5,000 ppm
4,000 – 5,000 ppm
NOTE: Low salt levels will cause a reduction in chlorine production and will
damage the device. High salt levels will increase the possibility of corrosion on
pool equipment.
NOTE: If too much salt has been added, dilute with fresh water.
PREPARING YOUR WATER BEFORE INSTALLATION

9
Use standard test kits to check water chemistry, and use either a conductivity
tester or salt test strip to check saline levels.
(Note that most conductivity testers require frequent calibration to ensure
accurate readings, failure to calibrate the equipment will result in
inaccurate readings.)
How to Calculate volume of a pool
For a rectangular shaped pool
Length (ft) x Width (ft) x Average Depth (ft) x 7.5 x 3.8 = Litres of water
For an oval and round shaped pool
Average length (ft) x Average Width (ft) x Average Depth (ft) x 5.9 x 3.8 =
Litres of water

The following is a chart to determine the amount of salt required to raise a pool or spa to 5000 ppm
ppm Salt Levels
Number of KG's of Salt to Be Added
ppm Salt
Pool and or spa Volume (litres)
1,000
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
900,000
1,000,000
5000
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
CORRECT
4800
2
20
40
60
80
100
120
140
160
180
200
4400
6
60
120
180
240
300
360
420
480
540
600
4000
10
100
200
300
400
500
600
700
800
900
1000
3800
12
120
240
360
480
600
720
840
960
1080
1200
3500
15
150
300
450
600
750
900
1050
1200
1350
1500
3200
18
180
360
540
720
900
1080
1260
1440
1620
1800
3000
20
200
400
600
800
1000
1200
1400
1600
1800
2000
2700
23
230
460
690
920
1150
1380
1610
1840
2070
2300
2500
25
250
500
750
1000
1250
1500
1750
2000
2250
2500
0-(Initial Salt Addition) 50 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
“Note:
There may already be some salt present in the pool or spa water.
Be sure to test the salt levels prior to adding more salt to the water.”
SALT CHART FOR CORRECT MAINTENANCE

Your ChlorKing® system will include an installation kit comprising of the
following items:
Description Qty
Strainer clear bowl with 20 mesh
1
PVC ball valve Sch. 40
2
PVC male adaptor Sch. 40
4
PVC nipple SCH 80
2
PVC bushing Threaded
1
PVC union S EPDM w/o
O-ring Sch. 80 threaded
2
Akenstrut clamps
2
Polypropylene valve, speed fit
2
Elbow street 90, SCH 80
2
Salt test strips
1
Additionally you will need the following items, not included, to complete
the installation:
•Polypropylene tubing
•Flex PVC tubing
•Wall anchors
•Disconnect box, fuse box, conduit, wiring and related material to supply 220v to systems
(220v systems only)
The following tools will be required to complete the installation:
Power Tools Drill Bits
Drill Hole saw
Hammer Drill Paddle bit
Steel bit drill set
Mason bit
Hand Tools Taps
Set of sockets 2.5cm
Hammer 0.9cm
Screw Drivers – Flat & Phillips
Wire Strippers
PVC Cutters Hand Tools cont..
24” Level Tape Measure
Slip joint pliers Teflon Tape
Crescent wrench Allen Wrenches
True RMS Clamp Meter
Wire Cutters
TOOLS AND PARTS REQUIRED FOR INSTALLATION

12
Your ChlorKing® system can be plumbed using two different methods. Both will
work fine, however, the following must be taken into account before making the
decision of what method to use.
1. Your ChlorKing® system requires a minimum of 75 Lpm of flow through the
cell to produce the rated amount of chlorine. Be sure that if you use the
pressure drop plumbing method [1] you have sufficient pressure drop across
your filter to adequately flow 75 Lpm through the cell.
2. When using the pressure drop plumbing method [1], you aresending
un-filtered water through the cell, so you need to ensure that you clean the
included strainer at least 1 time per week to remove any debris. Failure to
clean the strainer will result in a lack of flow, reducing chlorine production, and
ultimately reducing flow to the point that the flow switch de-activates the
system.
3. If you elect to use the bypass plumbing method [2], you will need to purchase
a butterfly valve based on the size of the pipe you are using. This can
sometimes be cost prohibitive, but the upside of this plumbing method is that
you are sending filtered water through the cell, which reduces the frequency of
needing to clean the strainer. Bypass plumbing method [2] also generally
allows for more flow through the cell, which is recommended.
4. Remember, always ensure that the return line from the ChlorKing® cell is
plumbed after the heater. Never plumb the return line before the heater, as
you will be sending a high ppm of chlorine through heater, which maycause
damage.
5. No matter which plumbing method you use, you will always have to plumb the
cooling line into box 3 (rectifier) using filtered water. This cooling line allows
the heat sink in box 3 to cool the critical components.
PLUMBING YOUR SYSTEM

13
ChlorKing® power supply ChlorKing® cell
NOTES:
THE RECTIFIER COOLING LINES MUST BE CONNECTED FROM
THE SUCTION SIDE OF THE PUMP AND AFTER THE FILTER.
ALWAYS USE FILTERED WATER.
IF THERE IS A CONTROLLER PRESENT, THE OUTLET LINE THAT
FEEDS THE CONTROLLER PROBES COULD BE CONNECTED TO
THE RECTIFIER.
NOTES:
THE RECTIFIER COOLING LINES MUST BE CONNECTED FROM
THE SUCTION SIDE OF THE PUMP AND AFTER THE FILTER.
ALWAYS USE FILTERED WATER.
ALTERNATIVELY, IF THERE IS A CONTROLLER PRESENT, THE
OUTLET LINE THAT FEEDS THE CONTROLLER PROBES COULD
BE CONNECTED TO THE RECTIFIER.
ChlorKing® power supply ChlorKing® cell
PRESSURE-DROP PLUMBING METHOD [1]
BYPASS MANIFOLD PLUMBING METHOD [2]

14
Each ChlorKing® model has very specific wiring requirements based on its line
voltage and amperage draw.
•Model MINI-2.0 operates at 110 – 120v. A power cord will be supplied out
of the power box. Plug this into any standard 110 – 120v outlet. As above,
the cord labeled ORP must be plugged into a controller, or a 120voutlet.
•Your ChlorKing® system must be wired to the main pump power supply,
so that if the pump is shut down, the power to your ChlorKing® system is
lost.
MODEL:
MAX PRIMARY AC
AMPS
SYSTEM INPUT
VOLTAGE
BREAKER
REQUIRED
MINI-2.0
3.7
110 – 120v
20amp
Fuse sizing:
Model Fuse size and type
10amp dual element, slow blow, RK5 fuse
ELECTRICAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS AND FUSE SIZING
MINI-2.0

15
Once your ChlorKing® system has been successfully wired and plumbed, it is
ready for use.
•Make sure that the valves to and from the cell are in the openposition.
•Make sure that you have water flowing through the water-cooled heat sink
in box 3.
•Ensure that the cord labeled ORP is either plugged into a controller or
directly into a 110v outlet
1. Move the safety switch to the “on” position.
2. Wait 10 seconds for the system to respond.
3. Turn the black knob on the side of box 1 clockwise, and watch the
amp or voltmeter on box 3 slowly increase.
(If your system is linked to an automatic ORP controller, we suggest you
turn the system to maximum, which will allow for full production every time
the controller calls for it. If you are running your system manually you will
need to find the point at which you keep a satisfactory level of chlorine in
the water. It may take several days to find this point.
•If your ChlorKing® system is linked to an automatic controller, remember
that it will only work when the controller is in feed mode. It is also a good
idea to make sure that your controller is not set in proportional band mode,
instead try using double set point control (if your controller supports this
function). An example of this is if you want to maintain a 700 ORP, have
the controller set to turn on at 695 ORP and turn off at 705 ORP, that way
your ChlorKing® system is not switching on and off all the time.
(Call the manufacturer of your controller if you are having difficulties in
comprehending the saline chlorination system set up instructions. Most
controllers also require a “gold tip” ORP probe when working with a saline
chlorination system.)
STARTING THE SYSTEM

16
Your ChlorKing® system operates when power is activated by the main pumps,
and from your ORP controller, and will continue to operate for as long as power
is applied from those two sources.
•The system has an output range of 5-100% of the rated chlorine
production, and can be adjusted by turning the black knob of the side of
box 1 in a clockwise or anti-clockwise motion. When adjusting thecontrol
knob on the side of box 1, you will notice the amperage needle of the
gauge on box 3 increases or decreases.
Higher amperage = higher chlorine production.
Normal operating amps and volts for this model device are:
MINI-2.0 - 10 amps @ 15v
•Water flow through the ChlorKing® cell is critical. Whether you plumbed
your system in using the pressure drop or bypass method, pleaseensure
that you have at least 75 Lpm through the cell to achieve the rated
chlorine production.
** Remember, your ChlorKing® system is a chlorine generator, and
will only operate as well as you maintain it. Careful attention must
always be paid to proper chemical balancing, and regular service.
GENERAL OPERATION

17
Your ChlorKing® systems is designed to operate 24/7 at max power, and will
give you years of trouble free use if you follow these basic maintenance and
cleaning instructions.
•Remember, this system produces sodium hypochlorite “liquid chlorine”
from the salt that you have added to the water. It will only continue to
operate correctly if salt is maintained at the correct 5000ppm level. Low
salt will lower the amount of chlorine produced, and cause damage to the
electrolytic cell. (Warranty’s will not be honored if it is determined that salt has
been run low.)
•There is a strainer mounted at the bottom of your ChlorKing® cell, which
will trap debris and stop it from entering the cell, this strainer needs to be
cleaned regularly.
•The plates that are inside the PVC cell housing are the most critical part of
the system. You will notice that over time a white substance (calcium
minerals) will build up on the plates, especially at the top of the cell. This
buildup needs to be cleaned by removing the cell from the housing and
soaking it in a dilute muriatic solution (1:5) for about 10 – 15 minutes.
Reverse polarity systems will need to be cleaned every 3 – 6 months.
(Warranty’s will not be honored if it is determined that the cell has not been
cleaned regularly.) Muriatic acid is corrosive, please follow safety instructions and
wear protective clothing. To avoid splash, always ADD MURIATIC ACID TO
WATER, rather than water to muriatic acid.
•Remember, the titanium plates that make up the cell are the most
expensive part of the ChlorKing® system and are going to need to be
replaced roughly every 15,000 hours of operating time. By ensuring
that salt is always at the correct level, and plates are cleaned
regularly, you will increase their “life”, thus saving youmoney…
ChlorKing® offers a wide range of other products that can help you maintain salt
levels in your pool, including conductivity controllers and saturated salt feeders
for those pools that loose large amounts of water.
MAINTENANCE AND CLEANING

******************************
This label transcript service is offered by the Pest Management Regulatory Agency to provide
efficient searching for label information. This service and this information do not replace the
official hard-copy label. The PMRA does not provide any guarantee or assurance that the
information obtained through this service is accurate, current or correct, and is therefore not
liable for any loss resulting, directly or indirectly, from reliance upon this service.