ControlOMatic ChlorMaker IL User manual

ControlOMatic, Inc. 12659 Arbor Lane, Grass Valley, CA 95949
www.ControlOMatic.com [email protected] 530-205-4520
Manual Version: 2/1/14 Made in the USA
ChlorMaker IL
TM
OPERATING
INSTRUCTIONS

INTRODUCTION
ChlorMaker IL is a semi-automated, salt water chlorine generation system specically designed for portable spas
up to 1000 Gallons. ChlorMaker IL generates chlorine from a small amount of ordinary salt (Sodium Chloride,
NaCl) dissolved in the spa water. The amount of salt added is very small in relation to the volume of the water in
the spa. It’s about 90% less concentration than ocean water and below the typical taste level of most humans.
The small addition of salt also benets users by providing a softening effect on the water, leaving hair and skin feel-
ing smoother and healthier than with traditional sanitizing products. Only 2.5 cups of salt per 100 gallons of water
is all it takes for ChlorMaker to produce fresh, pure chlorine leaving your water clean and clear day after day.
IMPORTANT SAFETY INSTRUCTIONS
READ & FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
When installing and using this electrical equipment, basic safety precautions should always be followed,
including the following:
WARNING: To reduce the risk of injury, do not permit children to use this product unless they are closely
supervised by at all times.
WARNING: Use ChlorMaker IL only according to these instructions. Any modication or misuse of this product
will void the warranty.
WARNING: Install ChlorMaker IL in accordance with all national and local electrical, plumbing, safety, and
other applicable codes.
WARNING: Connect ChlorMaker IL to a GFCI (ground fault circuit interrupt) or GFI (ground fault interrupt)
protected VAC power source only.
WARNING: Protect the power supply and outlet from exposure to the elements including direct sun, rain, snow,
condensation, etc.
WARNING: DO NOT use with extension cord. Injury may result.
WARNING: DO NOT insert objects into, or tamper with ChlorMaker IL’s body in any way. Inserting metal
objects into the body may cause damage and void the warranty.
WARNING: DO NOT operate ChlorMaker IL if damaged in any way.
WARNING: DO NOT pull on the cord to disconnect the Power Supply from power source. Do not allow the
cord to rest on sharp edges or corners or to be walked upon. Do not drop, throw, or otherwise
rough handle ChlorMaker IL.
WARNING: DO NOT handle the unit during chlorine production (visible bubbling). Slight discomfort may be felt
in cuts, sores, or sensitive skin areas due to chlorine concentration and the electrolysis process.
Stop chlorine production by either removing ChlorMaker IL from the water by lifting the cord (do
not grasp the housing), or by unplugging the power supply from the power source.
WARNING: Unit must be disconnected from power source before performing any maintenance or
troubleshooting operations.
WARNING: Disconnect, remove, and store or ChlorMaker IL indoors when spa has been winterized or drained.
CAUTION: Leave spa cover open at least 30 seconds to allow trapped gases to escape prior to use.
CAUTION: If unit is not working properly, or has been damaged in any way, contact technical support
immediately at 1-530-205-4520.
CAUTION: Measure water quality parameters and adjust if necessary prior to each spa use.
CAUTION: Make sure all spa electrical components and power cords have been thoroughly inspected by a
licensed electrician prior to using ChlorMaker IL.

WATER PREPARATION & MAINTENANCE
To ensure proper operation, the spa must be drained, rinsed, relled with fresh water, and balanced to the recom-
mended levels indicated in this section before installing the product. Use the test strips to measure water chem-
istry and verify that the water has been balanced properly. Replacing the lter is recommended but not required
unless the spa was previously sanitized with a hydrogen peroxide system. The combination of hydrogen peroxide
and chlorine may cause gum-like build up, water discoloration, and skin irritation.
It is important to properly maintain your spa for the health and safety of its users. Spas are unique in both size
and usage patterns. ChlorMaker IL will signicantly reduce the amount of spa maintenance required, but chemi-
cal check-ups including chlorine levels and PH are recommended before each use. Proper water maintenance
will prolong the life of ChlorMaker IL and the spa. The following table describes generally accepted optimum water
chemistry for portable spas.
PARAMETER RECOMMENDED LEVEL
Free Chlorine 3.0 to 5.0 PPM
PH Balance 7.2 to 7.6
Total Alkalinity 80 to 120 PPM
Calcium Hardness 300 to 400 PPM
It is recommended that chlorine and PH levels are checked before each use, or at least once per week when not in
use. Alkalinity, Calcium Hardness, and Salt Concentration should be checked at least once per month. It is recom-
mended that the spa is manually shocked after high usage (example: after a party with multiple users), or biweekly
if used frequently. Always remember to leave the spa circulating for several hours before retesting. Phosphates in
the spa water will increase the demand for chlorine and will reduce the life expectancy of the generator. Remove
Phosphates upon start up and each month there after. Phosphate Remover can be purchased at any local Pool &
Spa supply store.
WARNING: Consistent chlorine levels above 5.0 PPM or consistent salt concentration levels above 5,000
PPM may lead to corrosion of metal components in the spa.
WARNING: Consistently low Calcium Hardness levels below 150 PPM may lead to spa equipment damage
and failure. Make sure Calcium Hardness levels are within the recommended range above.

SALT REQUIREMENT
ChlorMaker IL can generate both Chlorine or Bromine. It all depends on which sanitizer the user prefers. Use So-
dium Chloride Salt if you prefer Chlorine Generation and Sodium Bromide Salt if you prefer Bromine. Please Note:
Each salt requires a different level of salinity for ChlorMaker IL to operate effectively. WARNING: SALT ONLY
NEEDS TO BE ADDED ONCE AND BROUGHT TO THE APPROPRIATE SALT LEVEL (BLUE LIGHTS) PER
SPA WATER CHANGE. DO NOT KEEP ADDING SALT (See Salt Level Indicator Section Below).
CHLORINE SALT - SODIUM CHLORIDE (NaCl): Raise Salt Level to 1,500 to 2,000 PPM (Parts Per Million).
Approved salts include “pool salt” made for salt water chlorine generating systems, canning and pickling salt from
your local market, and some water softener salts that are 99% pure sodium chloride or better. These approved
salts are generally available at pool & spa supply stores, home improvement centers and On-Line stores in a
variety of sizes. Never use rock salt or salts that have more than 1% “anti-caking agents”, “yellow prussiate of
soda”, or “sodium ferrocyanide”. These compounds may cause surface staining. Please use chart below.
BROMINE SALT - SODIUM BROMIDE (NaBr): Raise Salt Level to 2,500 to 3,000 PPM (Parts Per Million).
There are several manufacturers of Sodium Bromide Salt to choose from. Please make sure the Sodium Bro-
mide you purchase is 99% pure or better. Ask your local pool and spa dealer for assistance. Please use chart
below.
Chart is Based on 100 Gallons or 379 Liters of Spa Water
SALT TYPE POUNDS CUPS
99% Pure Sodium Chloride (NaCl) - Pool Salt, Water Softener &
Other Coarse Grain Salts 1.5 2.5
99% Pure Sodium Bromide (NaBr) Fine Grain Salt 2.5 4.0
The amount of salt to add and dissolve is dependent upon the size of the spa. Determine the volume of water in
gallons or liters by checking the spa owner’s manual or use any internet volume calculator.
99% Pure Sodium Chloride (NaCl) Coarse Grain Example For a 350 Gallon Spa: Divide 350 Gal by 100 Gallons
then multiply answer by 2.5 Cups. (350 / 100 = 3.5 x 2.5 = 8.75 Cups)
99% Pure Sodium Bromide (NaBr) Fine Grain Example For a 1,326 Liter Spa: Divide 1,326 Liters by 379 Liters
then multiply answer by 4.0 Cups. (1,326 / 379 = 3.5 x 4.0 = 14 Cups)
Simply pour the recommended amount of salt directly into the spa water to bring the concentration to the recom-
mended level. Turn the spa jets on to help dissolve the salt. Warmer water will aid in dissolving the salt faster. If
the water is cold it may take several hours for the salt to fully dissolve.
WARNING: Do not turn ChlorMaker IL on until all the salt has fully dissolved.
SALT LEVEL INDICATOR
This Salt Water System will indicate if the salt level is within the recommended range listed above. It will indicate
proper salt levels by showing solid BLUE lights WHILE PRODUCING CHLORINE. When NOT producing chlorine
it will be in Standby Mode which is indicated by a quick GREEN ash every 10 seconds (see below).
Solid RED & GREEN lights: Salt Level Too High (Cell Shuts Off To Protect Cell & Spa) - Dilute Salt
Solid GREEN lights WHILE producing chlorine: Salt Level On The High Side
Solid BLUE lights WHILE producing chlorine: Salt Level Within Normal Range
Solid RED lights WHILE producing chlorine: Salt Level On The Low Side
STANDBY MODE: Quick GREEN ash every 10 seconds when NOT producing chlorine (Very Normal)
IMPORTANT: It is important to occasionally check that the lights are indicating proper salt level. Always
use Salt Test Strips to check the salt level and adjust the water according to the Test Strips. If Test Strips
Show Too High: remove some water from the spa and replace with fresh water. Re-test and adjust as nec-
essary. If Test Strips Show Too Low: Add salt, re-test and adjust as necessary.

PRODUCT INSTALLATION
ChlorMaker IL is equipped with a 110/220 VAC Auto-Sensing Power Supply allowing ChlorMaker IL to be installed
on almost any spa with a 24 Hour Circulation Pump. Please follow the installation instructions below.
1. Prepare Spa For Installation: Shut down main power to spa and drain water completely. Open access
panel to the spa exposing the spas plumbing area.
2. Find Power Supply Location & Route Power Supply Cable (DO NOT FASTEN POWER SUPPLY TO THE
CABLE OR TO POWER SOURCE AT THIS POINT): Find the power source location and rout the power sup-
ply cable from the control panel to the power source. The black cable clips can be used to secure the cable
in place. IMPORTANT: Make sure the power source is GFI Protected and is protected by a weather protec-
tive cover. Single Gang and Double Gang weather protective covers can be purchased at any local hardware
store. Please see weather protective cover example in the picture below.
3. Find Skirting Location For Control Panel: Find a convenient location on the skirting just below the ber-
glass lip of the spa. It is important that the location is near the access panel to the spa compartment allowing
the cell cable to be routed appropriately. Rout the Cell Cable from the control panel through the spas access
panel. Most access panels have a small gap at the bottom of the panel. See Picture Below.

PRODUCT INSTALLATION CONTINUED
4. Remove Top Cover To Control Panel: IMPORTANT: First make sure power supply is unplugged from
power source. Then remove the top cover of the control panel by unfastening the 4 screws as shown in the
picture below allowing the top cover to freely separate from the bottom section of the control panel.
5. Fasten Bottom Section Of Control Panel To Skirting: Locate the two fastening holes as shown in the pic-
ture below. Use the supplied screws to securely fasten the bottom section of the control panel to the skirting.
6. Fasten Top Cover of Control Panel: Make sure the black rubber gasket is secured in the grove on un-
derside of the top cover. Replace the top cover of the control panel and securely tighten the 4 panel cover
screws. WARNING: Do not remove power cable or cell cable from the connectors inside the control
panel. Should cables become disconnected, make sure they are reconnected with the correct polar-
ity. Reversing will damage the control panel.
Unfasten Screws Unfasten Screws
Watertight Cable Grips
Fastening Holes
Fastening Holes

PRODUCT INSTALLATION CONTINUED
7. Find 24 Circulation Plumbing: Locate the continuous (24 Hour) circulating pump and the 3/4 inch tubbing
connected to the pump. The ChlorMaker IL cell should be installed on the OUTPUT side of the pump. The
tube will need to be cut and reconnected to the ChlorMaker IL cell. Additional tubing may be needed if the
existing tube is not long enough or is hard to access. Additional tubing is available at most hardware stores.
The location of the cell should have no obstructions at the cable end of the cell to allow for cell removal,
replacement and cleaning. Water shut-off valves may be installed at this point to aid in the maintenance and
cleaning of the cell. Water shut-off valves may be purchase at any local hardware store.
8. Fasten ChlorMaker IL Cell: Mount the cell using the two supplied brackets shown in the diagram below -
Item (A). Cell Orientation: The cell must be mounted relatively vertical to prevent chlorine gas from
being trapped in the cell.
9. Connect Tubing To Cell: Cut the existing tube and reconnect the ends to the two 3/4 inch barb ttings on
the cell. Use the supplied clamps at (B) to securely fasten the tube to the barbs on the cell. Note that some
water will spill from the cut tube even though the spa has been drained or shut-off.
10. Rell Spa, Balance Water & Add Salt: Rell the spa with water, balance the water, and pour/dissolve the
recommended amount of salt in the water (See “Salt Requirement” Section). Please make sure the salt is
fully dissolved before proceeding to the next step.
11. Fasten Power Supply to Power Supply Cable: Attach the cord’s watertight connector to the black power
supply and make sure the watertight connector is turned clockwise and the nut is hand tight.
12. Fasten Power Supply to Power Source: Plug the black power supply into the 110VAC or 220VAC power
source. ChlorMaker IL will begin the chlorine generation process.

SELECTING THE RIGHT POWER LEVEL
Selecting the right power level requires some testing and adjustment. There are many factors that affect the sani-
tizing needs of a spa such as: Frequency of spa use, number of people, if there is an Ozone Generator, spa tem-
perature, last drain and rell, etc. However, after the testing and adjustment period, ChlorMaker IL will take care of
your sanitation needs day after day. As a starting point, please program ChlorMaker IL and set the power level to
the general recommendations shown in the chart below.
Power
Level
ChlorMaker IL
Spa (Gallons)
1 to 3 Less than 200
4 200 to 300
5 300 to 400
6 400 to 500
7 to 10 500 and above
Test the Chlorine Level with test strips after 1 to 2 days. When testing, the best readings are always done about an
hour after restarting ChlorMaker IL by simply pressing the up or down arrow. If the chlorine level is LOW, increase
the power level by one level. If the chlorine level is HIGH decrease the power level by one level. Wait a day or so
after this initial adjustment, re-test and repeat as necessary until a consistent chlorine residual has been achieved.
If the chlorine level is VERY high or VERY low, adjust by 2 levels, as needed.
IMPORTANT NOTE: If the chlorine level is zero 24 hours after installation, the initial chlorine demand on
the spa may be above what ChlorMaker IL can produce to break away from zero. In this case, manually
add chlorine or shock (according to the company product label) to assist in the initial set-up.
If spa usage drops (vacation, winter, etc), it is important to re-set the power level down several levels. If usage
signicantly increases, (return from vacation, etc) it is important to adjust the power level up accordingly. Always
retest and adjust the power level as needed.
CHANGING POWER LEVELS
ChlorMaker IL is designed with 10 power level settings. ChlorMaker IL is set to power level 3 straight from the fac-
tory. Please follow the steps below to increase or decrease the power levels from the factory default power level 3.
VIEW THE CURRENT POWER LEVEL SETTING
1. Simply press the DOWN arrow button once and count the white ashes. Each ash represents a power level.
For example: 3 white ashes = power level 3, 7 white ashes = power level 7, and so on.
CHANGE POWER LEVELS
1. Press both the UP arrow and the DOWN arrow at the same time. The White Light will turn on solid indicating
that it is in power change mode.
2. Then press UP arrow to increase power. The GREEN light will ash each time the UP arrow is pressed. Or
press the DOWN arrow to decrease power. The RED light will ash each time the DOWN arrow is pressed.
3. When nished do not press any buttons for 3 seconds. The White light will ash (count the ashes) conrming
the new power level setting.
STANDBY MODE
ChlorMaker IL operates in 3 hour cycles. Which means it will be generating
chlorine for a period of time in that 3 hour cycle depending on the power level
setting. When ChlorMaker IL is not generating chlorine (off) it is in Standby
Mode. Standby Mode is indicated by a quick GREEN ash every 10 sec-
onds. ChlorMaker IL will remain in Standby Mode until it engages its next 3
hour cycle. To start chlorine production when in Standby, simply press the
Boost button and ChlorMaker IL will resume chlorine production.

TROUBLE SHOOTING
It is always a good idea to revisit the user manual to make sure installation or maintenance steps were not over-
looked before referring to the trouble shooting section.
Problem Possible Causes Corrective Action
Consistently Low
Chlorine
Power level too low Increase the power level
Plates need cleaning Soak the unit in Vinegar for 30 minutes
Low salt level Adjust the salt level as necessary - use test strips
Large bather load Additional chlorine or shock may be needed
Just doesn’t keep up Remove organic material, such as leaves, etc.
Clean the lter
Remove Phosphates
Shock the water
Consistently High
Chlorine
Power level too high Lower the power level
No Chlorine (Solid
RED & GREEN
Lights)
Salt level may be too high
and engaged the automat-
ic shut down feature.
Dilute the spa water by draining some of the spa water and
relling with fresh water.
Plates Are Dirty
With White Or
Scale Build Up
Hard water, high calcium
and minerals in water.
Soak the cell in vinegar or diluted acid for 30 minutes. Re-
duce calcium level in water.
BOOST MODE
Boost Mode is designed to replenish chlorine that was just used during the last spa use. Activating Boost Mode will
take ChlorMaker IL out of regular production mode or standby mode and re-start the production of chlorine accord-
ing to the following table. To activate Boost Mode simply press the Boost Mode Button. The Salt Light will begin
ashing indicating that ChlorMaker IL is engaged in Boost Mode.
Power
Level
Normal Time
(Minutes)
Boost Mode Time
(Minutes)
1 2 8
2 7.5 30
3 15 60
4 30 120
5 45 180
6 60 180
7 90 180
8 120 180
9 150 180
10 180 180

DISASSEMBLY & MAINTENANCE
ChlorMaker IL is designed with an automatic self cleaning feature. However, there are some spa water conditions
that are well beyond the control of ChlorMaker IL’s reverse polarity and self cleaning design. If a visible white or
scaly substance builds up on the plates, please follow the simple disassembly and cleaning instructions below.
1. Turn main power off to spa and un-plug ChlorMaker’s black power supply from the power source.
2. Caution: Some water will drain out of the cell housing during this step. Firmly hold cell housing with a pair of
large pliers or channel locks and turn the large Hex Nut at top of cell housing counter-clockwise with a large
wrench as shown in picture below. The cell plates will turn with the Hex Nut. Loosen the Hex Nut to a point
that can be turned by hand. Loosen all the way and gently pull the cell plates out of the cell housing. Immedi-
ately replace with the spare cap that is provided with ChlorMaker IL to prevent additional water from draining.
3. Place the cell plates in a glass of white vinegar for about 30 minutes to remove any and all scale build up. Do
not scrap plates with any foreign objects. Rinse plates clean with fresh water.
4. Reverse the steps above: Reinstall cell plates, tighten Hex Nut (Use Teon Tape on threads to create a water
tight seal). Turn main spa power back on and plug the black power supply into the power source to complete
the cleaning process.

LIMITED WARRANTY
Models: This warranty applies to ChlorMaker IL models referenced as “System”.
ControlOMatic, Inc. Warrants the system to be free of all defects in material and workmanship for one (1) year from
the original purchase date. The system includes the power supply unit, cable, electronics, and electrolytic genera-
tor for residential use only. The product must be installed properly and used in accordance with this manual and all
applicable local codes and regulations. This warranty is not transferable.
In no event shall ControlOMatic, Inc. be liable for consequential damages for breach of this warranty. Some states
do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion
may not apply. The warranty does not cover any loss or damage to the product due to improper installation, product
abuse, misuse, negligence, or improper maintenance of the system, pool or spa. The warranty does not cover any
loss or damage to the spa, spa components, users, or anything outside the system due to system failure. Purchas-
er assume all responsibility for using the system.
This warranty does not apply to any costs, repairs, services, damages, claims or losses for all of the following: Ser-
vice calls to install, re-install or correct the installation of the product, or to explain the usage of the system to the
buyer, repairs necessitated by use other than normal home use, damage resulting from misuse, unintended use,
unforeseen use, non pool or spa use, abuse, accidents, alterations, improper installation, or corrective work neces-
sitated by repairs made by anyone other than an authorized service technician.
THE FOREGOING WARRANTIES ARE CONTINGENT ON THE PROPER USE OF THE SYSTEM IN ACCOR-
DANCE WITH THESE INSTRUCTIONS AND SPECIFICATIONS AND SHALL NOT APPLY TO ANY SYSTEM
THAT HAS BEEN REPAIRED OR MODIFIED BY PERSONS OTHER THAN THE MANUFACTURER.
THE EXPRESS WARRANTIES SET FORTH IN THIS AGREEMENT ARE IN LIEU OF ALL OTHER WARRAN-
TIES, EXPRESS OR IMPLIED. MANUFACTURER HEREBY SPECIFICALLY DISCLAIMS ANY OTHER REPRE-
SENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN-
TIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
IN NO EVENT WILL MANUFACTURER’S LIABILITY FOR ANY CLAIM, WHETHER IN CONTRACT, TORT OR
UNDER ANY OTHER THEORY OF LIABILITY, EXCEED THE AMOUNT NECESSARY TO REPAIR OR RE-
PLACE THE COVERED SYSTEM.
Damage to the system from improper water maintenance is not covered in this warranty.
Should any problem develop during the warranty period, go to: www.controlomatic.com to obtain the proper techni-
cal support phone number. You will need the serial number visible in the clear part of the system body. You may be
required to return the defective component, and if necessary, the component will either be repaired or replaced.

PRODUCT REGISTRATION
Please ll out the information below and send to ControlOMatic to properly register your prod-
uct. Or register your product on line at www.ControlOMatic.com.
First Name:
Last Name:
Address:
City: State / Province: Postal Code:
Phone: E-Mail:
Please copy this section and forward a copy to
ControlOMatic, Inc.
12659 Arbor Lane
Grass Valley, CA 95949
Or Register At www.ControlOMatic.com
Product Model: Serial Number: