ChlorKing NEXGEN User manual

2019-2078
2019-10-10
PRIMARY DEVICE LABEL
Chlorking Saline Chlorination System, Model NEXGEN
CHLORINE GENERATOR
CONTROLS BACTERIA AND ALGAE
in
Swimming Pool (and Spa) Waters
COMMERCIAL
A maximum of 1,420,000 L of water can be treated with
Chlorking Saline Chlorination System, Model NEXGEN
Maximum output of hypochlorous acid equivalent to 11.34 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. _33004 PEST CONTROL PRODUCT ACT
Warning: Operating the Chlorking Saline Chlorination system, Model NEXGEN, 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

2
REPLACEMENT CELL LABEL
Titanium Electrode
Replacement Electrodes for the Chlorking Saline Chlorination System, Model NEXGEN
REGISTRATION NO. _33004 PEST CONTROL PRODUCTS ACT
This electrode must only be used on this model of chlorine generating device.
READ THE LABEL AND REFER TO OWNERS MANUAL OF THE Chlorking saline
Chlorination System, Model NEXGEN BEFORE USING.
CHLORKING INC.
2935 NORTHEAST PARKWAY
ATLANTA, GEORGIA, U.S.A, 30360. 1-800-536-8180

3
OWNER MANUAL
USER’S GUIDE
MODEL NEXGEN

4
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
PLUMBING YOUR SYSTEM...................................................................12
ELECTRICAL SPECIFICATION…...........................................................13
ELECTRICAL SPECIFICATIONS AND FUSE SIZING… ........................ 13
STARTING THE SYSTEM........................................................................14
GENERAL OPERATION…....................................................................... 14
MAINTENANCE AND CLEANING…........................................................15
TABLE OF CONTENTS

5
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-1081 listed
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.
INTRODUCTION

6
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 hourwarranty.
•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 saltconcentration
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

7
PLEASE READ THE FOLLOWING SAFETY INFORMATION CAREFULLY!
WARNING!
•Only a certified technician may install and service your ChlorKing®
system.
•Modifying your ChlorKing® system in anyway may cause bodilyinjury
and will void your warranty.
•Warning: To reduce the risk of injury, do not allow children to operatethis
device.
•Only replace components with those specified by manufacturer.
•When installing your system, ensure that power is linked to the mainpump
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 voltagecomponents.
Never open any box while power is “on”.
•WARNING: Heavy pool (and/or spa) usage, and higher temperaturesmay
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 to maintain appropriate chlorine residual in thewater.
•Maintaining high salt and chlorine levels above recommended rangecan
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

8
•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 NEXGEN,
REGISTRATION NUMBER , PEST CONTROL PRODUCTS ACT.
•Follow all aspects of the local and National Electrical Code(s)when
installing ChlorKing model NEXGEN.
•NOTE: For outdoor pools, chlorine residuals can be protectedfrom
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 betweenCOMPLETE
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 physician before
entering pool or spa water.
Maximum spa water usage temperature is 40 degrees C. Bathingin
spa water at 40 degrees C should not exceed 15minutes.

9
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)
can be added directly to the pool at least 24 hours before the installation of the
equipment.
5kg of sodium chloride can be added for every 1,000 litres of pool water (ie: a
200,000-litre pool will require 1,000 kg 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

10
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 (m) x Width (m) x Average Depth (m) x 1000 = Litres of water
For an oval shaped pool
Length (m) x Width (m) x Average Depth (m) x 0.785 x 1000 = Litres of water
For an oval shaped pool
Diameter (m) x Diameter (m) x Average Depth (m) x 0.785 x 1000 = Litres of
water

2017-2433
2018-FEB-12 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

2017-2433
2018-FEB-12
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 drillset
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” (60cm)Level Tape Measure
Slip joint pliers Teflon Tape
Crescent wrench Allen Wrenches
True RMS Clamp Meter
Wire Cutters
TOOLS AND PARTS REQUIRED FOR INSTALLATION

13
1. Your ChlorKing® system requires a minimum of 300 Lpm of flow through the
venturi to produce the rated amount of chlorine.
2. If you elect to use the bypass plumbing method, you will need topurchase
a butterfly valve based on the size of the pipe you are using. Thiscan
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 also generally allows
for more flow through the cell, which is recommended.
3. 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.
PLUMBING YOUR SYSTEM
PLUMBING METHOD

14
Each ChlorKing® model has very specific wiring requirements based on its line
voltage and amperage draw.
•Model NEXGEN operates at 208 – 240v requiring advanced wiring, which
should only be done by a qualified electrician. 208 – 240v power needs to
be run from your main breaker panel to a safety switch, then into the
ChlorKing® main power box 1. As above, the cord labeled ORP must be
plugged into a controller, or a 120v outlet.
•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
NEXGEN
23
208 – 240v
40amp
Fuse sizing:
Model Fuse size and type
NEXGEN
40amp dual element, slow blow, RK5 fuse
Once your ChlorKing® system has been successfully wired and plumbed, it is
ready for use.
•Make sure that the valves to and from the system are in the openposition.
•Make sure that you have water flowing through the venturi.
•Ensure that the cord labeled ORP is either plugged into a controlleror
directly into a 110v outlet
ELECTRICAL SPECIFICATIONS
ELECTRICAL SPECIFICATIONS AND FUSE SIZING
STARTING THE SYSTEM

15
1. Move the safety switch to the “on” position.
2. Wait 10 seconds for the system to respond.
(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 bandmode,
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 thetime.
(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.)
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 increasing or decreasing the flow
through the venturi gauge.
7.5 litres / min = 11.34 kg per day
Normal operating amps and volts for this model device are:
NEXGEN - 100amps @ 23v
•Water flow through the ChlorKing® cell is critical. Please ensure that you
have at least 300 Lpm through the cell to achieve the rated chlorine
production.
GENERAL OPERATION

16
** 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.
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 tothe
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 partof
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.)
•Remember, the titanium plates that make up the cell are the most
expensive part of the ChlorKing® system and are going to need tobe
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 you money…
MAINTENANCE AND CLEANING