ChlorKing ChlorSM Series User manual

ChlorSM Series
SALINE CHLORINATOR
Installation, Operation, and Maintenance
Manual

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TABLE OF CONTENTS
1.0 DESCRIPTION 3
1.1 General Information 3
1.2 Principals of Operation 3
1.3 General Specifications and Sizing Guidelines 4
2.0 INSTALLATION 8
2.1 Unpacking 8
2.2 Storage 8
2.3 Safety Considerations 8
2.4 Plan Ahead 10
2.5 Additional Parts Required for Installation 10
2.6 Installation Diagram 11
2.7 Power Supply Installation 12
2.8 Electrolytic Cell Installation 12
2.9 Install Kit Installation 13
2.10 Plumbing the System 16
2.11 Plumbing the Power Supply Cooling Lines 16
2.12 System Wiring 17
2.13 Instructions for Adding a Salt Feed Relay 19
2.14 Electrolytic Cell Wiring 19
2.15 Bonding the System 19
3.0 OPERATION 20
3.1 Preparing the Water 20
3.2 Starting the System 20
3.3 System Operation 21
3.4 Display Information 21
4.0 MAINTENANCE 27
4.1 Acid Wash Operation 30
5.0 WARRANTY INFORMATION 34
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
6767 Peachtree Industrial Blvd.
Norcross, GA 30092
1-800-536-8180

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SECTION 1
DESCRIPTION
1.1 GENERAL INFORMATION
The ChlorKing® SM Series Saline Chlorination system is the most electrically efficient on-site
sodium hypochlorite generator offered by ChlorKing®. The system is designed for commercial
swimming pool applications and is capable of producing up to 28 pounds of equivalent chlorine
per day. The system manufactures bleach continuously from a salt concentration of 3500 to
5000 ppm added to the pool. The ChlorKing® system is designed for commercial service and
can be operated 24 hours a day or controlled by any pool controller. All models have digital
displays that show system status, pool salt concentration, and temperature. Models are
available in non-reverse and reverse polarity.
1.2 PRINCIPALS OF OPERATION
Electrolytic Cell Assembly
The electrolytic cell assembly consists of a clear PVC cell housing containing an electrolytic
cell made from precious metal coated cell plates. Pool water from the pool circulation system
is directed through the cell in an off-line installation. The pool water, maintained between 3500
and 5000 ppm salt concentration is converted in the electrolytic cell to sodium hypochlorite.
The sodium hypochlorite is then circulated to the pool and combines with organics and further
combines to form salt to be used again by the electrolytic cell. This is called a closed loop
system because the salt is used repeatedly and is only lost through splash-out, backwashing
and rainfall.
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 uses switched-mode technology, currently the most
electrically efficient method of producing current for an electrolytic cell. The power supply
houses all the safety features to prevent system operation in the event of a malfunction.
Salt Control
Salt control can be added to the ChlorKing® SM Series Chlorinator. The ChlorKing® SM
Series Chlorinator monitors the salt concentration of the pool water and will only allow the
system to generate chlorine if the salt concentration is above 3000 ppm to protect the system
from low salt. The system uses a non-contacting torroidal sensor to monitor salt
concentrations. The torroidal probe is connected to the power supply. The LCD displays the
salt concentration. The controller is factory programmed to prevent chlorinator operation in the
event of low salt and can be used to automate salt concentrations in the pool with the addition
of a Saturated Salt Feeder, peristaltic pump, and relay box.

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ChlorKing® Acid Wash
The ChlorKing® Classic SM System (non-reverse polarity) is supplied with a clean in place
Acid Wash System. The clean in place Acid Wash System makes cell maintenance quick and
easy.
1.3 GENERAL SPECIFICATIONS
SODIUM HYPOCHLORITE PRODUCTION:
Model
Designation
Sodium
Hypochlorite
Production
(lbs/day)
Rated
Power in
DC Amps
Rated
Pressure
Minimum
Water Flow
Rate (gpm)
Inlet
Diameter
(Inches)
Outlet
Diameter
(Inches)
Chlor7.5SM 8lbs/day 50 50 psi 20 gpm 1 inch 1 inch
Chlor10.0SM 11lbs/day 50 50 psi 20 gpm 1 inch 1 inch
Chlor12.5SM 14lbs/day 50 50 psi 20 gpm 1 inch 1 inch
Chlor15.0SM 17lbs/day 100 50 psi 20 gpm 1 inch 1 inch
Chlor20.0SM 22lbs/day 100 50 psi 20 gpm 1-1/2 inch 1-1/2 inch
Chlor25.0SM 28lbs/day 100 50 psi 20 gpm 1-1/2 inch 1-1/2 inch
Chlor7.5CSM 8lbs/day 50 50 psi 20 gpm 1 inch 1 inch
Chlor10.0CSM 11lbs/day 50 50 psi 20 gpm 1 inch 1 inch
Chlor15.0CSM 17lbs/day 100 50 psi 20 gpm 1 inch 1 inch
Chlor20.0CSM 22lbs/day 100 50 psi 20 gpm 1 inch 1 inch
Chlor25.0CSM 28lbs/day 100 50 psi 20 gpm 1 inch 1 inch
ELECTRICAL REQUIREMENTS:
These systems require a 120 VAC control signal from a chemical feed controller or from a
standard 15 amp wall outlet. The control connection is rated at 1 amp.
Model Designation
AC Input Voltage Phases Frequency Amps Fuse Size GFCI Breaker
Chlor7.5SM 110 to 240 1 50/60Hz 15/7.5 20 20
Chlor10.0SM 110 to 240 1 50/60Hz 15/7.5 20 20
Chlor12.5SM 110 to 240 1 50/60Hz 15/7.5 20 20
Chlor15.0SM 208 to 240 1 50/60Hz 15 20 30
Chlor20.0SM 208 to 240 1 50/60Hz 15 20 30
Chlor25.0SM 208 to 240 1 50/60Hz 15 20 30
Chlor7.5CSM 100 to 240 1 50/60Hz 15/7.5 20 20
Chlor10.0CSM 100 to 240 1 50/60Hz 15/7.5 20 20
Chlor15.0CSM 208 to 240 1 50/60Hz 15 20 30
Chlor20.0CSM 208 to 240 1 50/60Hz 15 20 30
Chlor25.0CSM 208 to 240 1 50/60Hz 15 20 30

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SPACE REQUIREMENTS:
CHLOR7.5CSM AND CHLOR10.0CSM
CHLOR7.5SM AND CHLOR10.0SM
Cooling Water
Lines
DC Power to
Cell
20
16
11
15
6"
Cell
Tube
11
27
6"
Cell
Tube
Cooling Water
Lines
DC Power to
Cell
20
16

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CHLOR15.0SM, CHLOR15.0CSM, CHLOR20.0CSM, AND CHLOR25.0CSM
CHLOR20.0SM AND CHLOR25.0SM
Cooling Water
Lines
DC Power to
Cell
20
20
27
14
8"
Cell
Tube
Cooling Water
Lines
DC Power to
Cell
11
27
6"
Cell
Tube
20
20

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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.
HEAD LOSS DATA
0.00
20.88
37.15
61.7
88.6
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Head Loss Data for Chlor-25.0C.
Head loss data reported in ft
H2O as measured by NSF.
Chlor-7.5, Chlor-10.0, Chlor-
15.0, Chlor-5.0C, Chlor-7.5C,
Chlor-10.0C, Chlor-15.0C,
Chlor-20.0C, Chlor-25.0C
similar.

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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. Check against the parts list to be
sure that all items are accounted for and intact.
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.
 ONLY A CERTIFIED TECHNICIAN MAY INSTALL AND SERVICE THE
CHLORKING® SYSTEM.

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 MODIFYING THE CHLORKING® SYSTEM IN ANY WAY MAY CAUSE BODILY
INJURY AND WILL VOID THE WARRANTY.
 DO NOT ALLOW CHILDREN TO OPERATE THE CHLORKING® 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® SYSTEM NEVER OPERATES WHEN THE PUMPS ARE OFF.
 ALL BOXES ON THE CHLORKING® 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.
 CORD CONNECTED AT TIME OF MANUFACTURE
o DANGER – Risk of injury
 Replace damaged cord immediately
 Do not bury cord
CONSIGNES DE SÉCURITÉ IMPORTANTES
LISEZ ET SUIVEZ TOUTES LES INSTRUCTIONS
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

CHLORKING ® SYSTEMES SONT DESTINES A ETRE INSTALLES SELON TOUS
LES REGLEMENTS LOCAUX ET NATIONAUX.

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
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
CHLORKING ® SYSTEM.

MODIFIANT LA CHLORKING ® SYSTEM EN QUELQUE SORTE PEUT CAUSER
DES LESIONS CORPORELLES ET LA GARANTIE ANNULATION.

NE LAISSEZ PAS LES ENFANTS A EXPLOITER LE CHLORKING ® SYSTEM.

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 CHLORKING ® FONCTIONNE JAMAIS
QUAND LES POMPES SONT HORS SERVICE.

TOUTES LES CASES SUR LE CHLORKING ® SYSTEME 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.

CORDON CONNECTE AU MOMENT DE LA FABRICATION
o
DANGER-RISQUE DE BLESSURE

REMPLACEZ IMMEDIATEMENT LE CORDON D'ALIMENTATION

NE PAS ENFOUIR LE CORDON
2.4 PLAN AHEAD
Almost every pump room encountered is different. It is imperative to have prior knowledge of
the facility in which the unit is to be installed and to evaluate what type of tools, wall anchors,
etc. will be needed to make the installation as problem free as possible.
2.5 ADDITIONAL PARTS REQUIRED FOR INSTALLATION
Polypropylene tubing, both ½ and 3/8 inch
1 or 1-1/2 inch PVC tubing or pipe
PVC fittings as needed
Anchors and mounting hardware

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2.6 INSTALLATION DIAGRAM
Suction Line
From Pool
Filter
Waste Line
Heat
Exchanger
Pump
Strainer
Flow
Sensor
Electrode
Stack
Return
Line
Power Supply Cooling Line
Power Supply
Ball Valve
Ball Valve
Ball Valve
Salt
Sensor
Bonding Lug
Pump ( Optional)
Disconnect
Rated
VAC In
See Table
Control Cord
Controller

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2.7 POWER SUPPLY INSTALLATION
WARNING
THE MOUNTING LOCATION OF THE UNIT MUST BE AT LEAST 1.5 METERS FROM THE
POOL.
NEVER TRY TO SUPPORT THE WEIGHT OF THE POWER SUPPLY OR ELECTROLYTIC
CELL USING ONLY DRYWALL ANCHORS.
Locate a space on the wall, in the equipment room, that will accommodate the dimensions of
the system. Mount the power supply to the wall using appropriate hardware. The power
supply must be installed no more than 8 feet from the cell housing to ensure that the cables
will reach the cell.
2.8 ELECTROLYTIC CELL INSTALLATION
WARNING
THE MOUNTING LOCATION OF THE ELECTROLYTIC CELL MUST BE AT LEAST 1.5
METERS FROM THE POOL.
Install the cell mounting bracket to the wall using appropriate hardware. Ensure that the wall
mount is level. Mount the electrolytic cell and tube to the mounting backboard. Ensure that
the cell and tube are mounted within 8 feet of the power supply and that nothing is installed
above the cell tube. The cell may need to be removed for service.

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2.9 INSTALL KIT INSTALLATION
Install the parts found in the installation kit in the order shown in the following diagram. NOTE:
The flow switch must be installed with the arrow facing the bottom of the cell tube.
Chlor7.5SM, Chlor10.0SM, Chlor15.0SM
Assembly Diagram

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Chlor20.0SM, Chlor25.0SM
Assembly Diagram

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Chor7.5CSM, Chlor10.0CSM, Chlor15.0CSM, Chlor20.0CSM,
Chlor25.0CSM
Assembly Diagram

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2.10 PLUMBING THE SYSTEM
Chlorking® systems require a minimum of 20 gpm of flow through the electrolytic cell to
achieve the rated production of chlorine. The cell housing is plumbed using a bypass to
achieve the 20 gpm of flow required. The cell housing must be installed as the last component
in the return line of the pool, after all other equipment. See the plumbing diagram below.
2.11 PLUMBING THE POWER SUPPLY COOLING LINES
The power supply cooling lines are plumbed from the return line to pump suction. The cooler
lines on the power supply will accommodate 3/8 inch tubing.
NOTE: If a chemical feed controller is being used, the same 3/8 inch tubing can be used for
both the sample cell and power supply cooling. Plumb the tubing from the return line into the
controller sample cell, then from the sample cell to the power supply cooler, and from the
cooler to pump suction.
Suction Line
From Pool
Filter
Waste Line
Heat
Exchanger
Pump
Strainer
Flow
Sensor
Electrode
Stack
Return
Line
Power Supply Cooling Line
Power Supply
Ball Valve
Ball Valve
Ball Valve
Salt
Sensor
Pump ( Optional)
DisconnectController

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2.12 SYSTEM WIRING
WARNING
THE EARTH TERMINALS AND THE EQUIPMENT BONDING WIRE MUST BE
CONNECTED. THE ELECTRICAL SUPPLY MUST MATCH THE SYSTEM RATED
VOLTAGE AND CURRENT. ENSURE THAT POWER IS LINKED TO THE MAIN PUMP
POWER SOURCE FOR THE POOL TO ENSURE THAT THE CHLORKING® SYSTEM
NEVER OPERATES WHEN THE POOL PUMPS ARE OFF.
For ease of service it is recommended that a manual disconnect box be installed
between the electrical service and the system.
Connect the electrical supply from the pool equipment room to the terminal block on the lower
left side of the power supply enclosure. Ensure that the electrical service is protected by a
ground fault circuit interrupter and is rated for the model that is installed. Chlor7.5 models to
Chlor12.5 models can be wired with 110V or 208/240V. Chlor15.0 models to Chlor25.0
models use 208/240V only. See Electrical Requirements on page 4 for details.
7.5 Through 12.5: 110V 7.5 Through 12.5: 208/240V
Line
(Black) Neutral
(White)
Ground
(Green)
Ground
(Green)
Line 2
(Red)
Line 1
(Black)

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15.0 Through 25.0: 208/240V Only
Connect the blue control cord to a chemical feed controller or for manual operation, to a 120
volt AC outlet. When connecting to a chemical feed controller, be sure the controller is set to
continuous feed and not set on proportional control. Proportional control will reduce the life of
power supply components.
Connect the four pin salt sensor connector to the four pin connector labeled SALT SENSOR.
Connect the two pin flow switch connector to the two pin terminal labeled FLOW SWITCH.
The terminal labeled FEED SALT is used with the optional Saturated Salt Feeder. When using
the optional Salt Feeder, plug the cable from the Saturated Salt Feeder Relay Box to the
terminal marked FEED SALT.
Connect the red connector from the power supply to the red connector on the cell. NOTE:
Never remove the cables from the top of the cell. Always disconnect the cell with the
red connector.
Ground
(Green)
Line 1
(Black)
Line 2
(Red)

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2.13 INSTRUCTIONS FOR ADDING A SALT FEED RELAY
Mount the salt feed relay box to the wall close enough to the power supply so that the patch
cord will connect to the FEED SALT connector on the power supply. Plug the relay box into a
120 VAC outlet. Plug the peristaltic pump used for feeding salt into the output plug on the
relay box.
2.14 ELECTROLYTIC CELL WIRING
Connect the red connector from the power supply to the red connector at the cell. NOTE:
Never remove the cables from the top of the cell. Always disconnect the cell with the
red connector.
2.15 BONDING THE SYSTEM
All ChlorKing® systems include cell-bonding assemblies. These assemblies are included in
the install kit. The bonding assemblies must be connected with a minimum of 8 AWG bonding
wire. Connect the bonding wire from the top cell grounding assembly to the bottom cell
grounding assembly and then from the bottom cell grounding assembly to the bonding lug
located on the outside of the power supply. The bonding lugs on the power supply are clearly
marked with a decal that reads “Bonding Lugs”. Connect the second bonding lug on the power
supply to the bonding grid at the facility.

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SECTION 3
OPERATION
3.1 PREPARING THE WATER
ChlorKing® saline chlorination systems operate by electrolyzing sodium chloride (salt) that has
been added to the pool into sodium hypochlorite (liquid chlorine). In order for the ChlorKing®
system to operate salt must be added directly to the pool at least 24 hours before the system is
started.
40 pound of salt must be added for every 1,000 gallons of pool water to reach 5000 ppm (i.e.:
a 50,000 gallon pool will require 2000 pounds of salt or 50 x 40 pound bags to reach 5000
ppm). Once the salt has been added, brush the surface of the pool continuously until the salt
has dissolved. Never leave large amounts of salt on the surface of the pool.
Only use pure NACl. Do not use salt with additives. Contact your dealer or ChlorKing® for a
list of approved salt.
Your pool water should be balanced in the following range before turning your ChlorKing®
system on:
Chlorine: 2 – 5 ppm
Total Chlorine: No more than 0.5 ppm above free chlorine
Ph: 7.2 – 7.6
Alkalinity: 80 – 120
Hardness: 180 – 280 ppm
Salt: 3500 – 5000 ppm
Cyanuric acid: 20 – 50 ppm (Outdoor Pools only)
Phosphates: Less than 100 ppm
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.)
3.2 STARTING THE SYSTEM
Confirm that the salt concentration is 3500 to 5000 PPM.
Confirm that the valves to and from the cell are in the open position and water is flowing
through the cell tube.
Make sure that water is flowing through the water-cooled heat sink.