ControlOMatic MegaChlor User manual

ChlorMaker
MegaChlor
Installation & Operation
Manual
ControlOMatic, Inc.
12659 Arbor Lane, Grass Valley, CA 95949
[phone] • www.controlomatic.com
Manuals also available at:
https://www.controlomatic.com/documents
Support and Service: [email protected]
MegaChlor-CD

MegaChlor Manual • www.controlomatic.com • 530-205-4520 • 2
1 READ AND FOLLOW ALL INSTRUCTIONS
2 SAVE THESE INSTRUCTIONS
3 WARNING – To reduce the risk of injury, do not permit children to
use this product
4 WARNING – Use MegaChlor only according to these instructions.
Any modification or misuse of this product will void the warranty.
5 WARNING – Install MegaChlor in accordance with all national and
local electrical, plumbing, safety, and other applicable codes.
6 WARNING – Connect MegaChlor to a GFCI (ground fault circuit
interrupt) or GFI (ground fault interrupt) protected VAC power
source only.
7 WARNING – Protect the power supply and outlet from exposure to
the elements including direct sun, rain, snow, condensation, etc.
8 WARNING – Cutting the cord from the power supply to the
MegaChlor cell voids the warranty. Damage will occur if the
connection is reversed.
9 WARNING – DO NOT use with extension cord. Injury may result.
10 WARNING – DO NOT operate MegaChlor if damaged in any way.
11 WARNING – DO NOT pull on the cord to disconnect the Power
Supply from power source. Do not allow the cord be walked on, or to
rest on sharp edges or corners. Do not drop, throw, or otherwise
rough handle MegaChlor.
12 WARNING – Disconnect, remove and store MegaChlor indoors when
spa has been winterized or drained.
13 CAUTION – Leave spa cover open at least 1 minute to allow trapped
gases to escape prior to use.
14 CAUTION – Measure water quality parameters and adjust if
necessary prior to each spa use.
IMPORTANT WARNING AND SAFETY INSTRUCTIONS

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15 CAUTION – MegaChlor doesn’t measure the chlorine level and must
be adjusted properly in order to not over-chlorinate your spa. Over-
chlorination can lead to spa damage and un-healthy water
conditions.
16 WARNING – Remove the MegaChlor cell from the SPA when using
the SPA.
17 WARNING – DO NOT handle the MegaChlor cell 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.
18 WARNING – DO NOT insert objects into, or tamper with the
MegaChlor cell in any way. Inserting metal objects into the cell may
cause damage and void the warranty.
19 WARNING – DO NOT plug MegaChlor control box directly into the
VAC supply, this will damage the MegaChlor . Always use the low
voltage power supply.
20 DO NOT throw away. Please visit www.controlomatic.com
for recycling instructions.
IMPORTANT WARNING AND SAFETY INSTRUCTIONS

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MegaChlor Overview
MegaChlor is a semi-automated, salt water chlorine generation system specifically designed for swim
spas & pools up to 17,000 Gallons. MegaChlor generates chlorine from a small amount of ordinary salt
(Sodium Chloride, NaCl) dissolved in the water. The amount of salt added is very small in relation to the
volume of the water in the pool. It’s about 90% less concentrated than ocean water and below the typical
taste level of most humans. The small addition of salt also benefits users by providing a softening effect on
the water, leaving hair and skin feeling smoother and healthier than with traditional sanitizing products. A
minimum of only 2.5 cups of salt per 100 gallons of water is all it takes for MegaChlor to produce fresh,
pure chlorine leaving your water clean and clear day after day!
MegaChlor produces chlorine in its pure form using electrolysis in order to sanitize the pool/spa water.
MegaChlor has two versions: MegaChlor and MegaChlor-CD. The standard MegaChlor works on a timed
cycle and the -CD version turns on when the chlorine is gone. The only difference is the electrode, the -CD
version has a chlorine sensor that measures when the chlorine is gone. After the salt is converted to
chlorine, the chlorine will later be converted back to salt, keeping the salt level steady.
Water Preparation & Maintenance
To ensure proper operation it is recommended to balance the water prior to installing the MegaChlor.
Use the levels in the following table as a guide to balancing the water. Use the test strips to measure water
chemistry and verify that the water has been balanced properly. Cleaning the filter is recommended but not
required unless the previous sanitizer was 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 water for the health and safety of its users. MegaChlor may significantly reduce the
amount of maintenance required, but chemical check-ups including chlorine levels and PH are
recommended before each use. Proper water maintenance will prolong the life of MegaChlor and the pool
or spa. The following table describes generally accepted optimum water chemistry for portable pools and
spas.
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 recommended that the water is manually shocked after high usage (example: after a party
with multiple users), or biweekly if used frequently. Always remember to leave the water circulating for
several hours before retesting. Phosphates in the water 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 calcium hardness below 200 may lead to
corrosion of metal components in the pool or spa.
Paramater Recommended Level
Spa
Recommended Level Pool
Free Chlorine 1.5-3 PPM 1.5-3 PPM
pH 7.4-7.6 7.4-7.6
Total Alkalinity 100-140 PPM 100-140 PPM
Calcium Hardness 200-400 PPM 200-400 PPM
Cyanuric Acid 0 30-50 PPM

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Salt Requirement
Use only sodium chloride (NaCl) salt that is at least 99.8% pure. Do to the popularity of salt pools there
are now many stores that carry pool salt. It is also acceptable to use water conditioning salt but it may take
this type of salt longer to dissolve. Do not use iodized or yellow prussiate of soda colored salt. Salt is added
to the pool or spa water and the electrolytic cell will use this salt to make chlorine. The salt range for the
MegaChlor is 3000 to 4000 PPM. The salt is constantly recycled, salt is lost only when pool water is
removed from splashing or people getting out of the water. Salt is not lost due to evaporation. The
MegaChlor also works fine with lower levels of salt if desired to keep it extra low.
Adding Salt
1. Turn on the circulation system for the pool or spa.
2. Make sure the MegaChlor is off until the salt is completely dissolved.
3. Determine the amount of salt to add. Keep in mind that there may already be some salt in the water,
especially if the water was supplied through a water softener.
4. Evenly spread the salt around the inside perimeter of the pool.
5. Salt can be added in the skimmer. Make sure the salt doesn’t overfill the skimmer or the pump may
loose prime.
6. Once dissolved, turn the MegaChlor on.
Gallons Liters Salt lbs Salt Kgs
2,000 7,500 50 20
4,000 15,000 100 45
6,000 22,500 150 65
8,000 30,000 200 90
10,000 37,500 250 110
Calculating Required Salt
1. Calculate the volume of water. If you don’t have the information there are many pool water volume
calculators on the Internet.
2. Multiply gallons by 0.025 for pounds or liters by 0.003 for Kgs
MegaChlor or MegaChlor-CD
The MegaChlor has the same circuit for both modes of operation and the only difference is the electrode.
During power-up the lights that initially flash let you know which mode it is in. Pressing the Down arrow at
the same time power is turned on will cycle to the other mode.

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MegaChlor Installation
Control Box
Locate a suitable location for the control box meeting
the following conditions:
1. Close enough to the water for the 15 foot cell
cable to reach the water
2. Close enough to a GFCI protected outlet
3. Not in direct sunlight. If in direct sunlight that may
shorten the life of the controller
4. When the cables are routed, they should not be in
a path were people walk or can be damaged by
equipment such as a lawn mower.
5. A hard vertical surface for mounting the control
box.
6. Mount the control box with the supplied screws
using the mounting holes on the flange. There is
no need to open the control box.
MegaChlor is equipped with a 110/220 VAC Auto-Sensing Power Supply allowing MegaChlor to be
installed on almost any pool or spa. Please follow the installation instructions below. The power supply is
not an outdoor supply and needs to have protection from the environment.
Input Requirements: 100 to 240 VAC, 1.8A, 50-60 HZ. Output 12 VDC 5.0A, 60 Watts Maximum
Power Supply
MegaChlor power supply is a high output indoor power supply and the location must meet the following
requirements:
1. 110 or 220 VAC
2. Water protective cover if not indoors or in a protected area. The power cord should be plugged into a
GFCI protected outlet near the spa.
3. The power cable should have a routing path to the power supply where the cable is protected from
people tripping on it and lawn mowers.
4. NOT IN DIRECT SUNLIGHT. The power supply will heat up during operation and if in sunlight it may
overheat.
5. The best location for the power supply is behind the spa’s skirt. This will protect the power supply from
the elements. If the power supply is located outside it should be located inside a water proof box and
not on the ground.
6. The power supply must be located near the MegaChlor control box or an extension cable will need to
be added. If located behind the spa’s skirt a hole will be needed below the control box to route the
cable to the box.
7. Once the 12 Vdc cable is routed to the box, remove the cover from the box and route the cable into the
box through the open cable grip. The red wire goes to the Vdc In Red terminal and the black (or bare)
wire goes to the Black Gnd terminal. A small standard screwdriver will be needed to tighten the
connection. Make sure the ferrule is inserted properly, sometimes it slips below the post and doesn’t
make a connection. If the red and black wire are reversed damage to the circuit may occur if it is turned
on.
Cell
The MegaChlor cell will hang over the edge of the
pool or spa and hang down into the water. Find a
location where the cell will be at least 1” from the
side of the pool or spa and for best results as deep
as possible. The deeper the cell is the more time the
chlorine has to dissolve into the water before
reaching the surface. Placing by a jet is also
desirable as that will help to mix the chlorine.
If the cable is routed on the pool deck put a
protective mat over it to reduce tripping hazards.
Pool Cleaners: Make sure the cell is in a location
where the pool cleaner will not get tangled in the
cable.

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MegaChlor-IL Installation
The MegaChlor-IL includes an in-line cell body and in-line electrode for installing the MegaChlor in the
equipment area. There is no mounting kit for this product as each installation will be unique.
An in-line version allows for the electrode to be hidden in with the pool/spa equipment. This does bring up
some considerations:
●The electrode does need to be cleaned from time to time. If hidden with the hot tub equipment or hard
to access it can be a challenge to clean.
●The water flow needs to be 5 gallons/minute or less so a bypass is highly recommended. Do not install
in the main water flow.
●Many spas have a small pump that runs 24 hours per day and this is the recommended installation.
These pumps are very small and usually have 3/4” vinyl tubing which makes installation relatively easy.
●Without a 24 hour pump, the chlorine production will be unpredictable. The main pump is typically not
on the same amount of time per day.
●Without a 24 hour pump, the existing pump time may need to be increased to make the needed
amount of chlorine, this will lead to higher energy costs.
●The power supply will need to be controlled with the same voltage that turns on the circulation pump.
You do not want the MegaChlor making chlorine when there is no water flow because gasses will
accumulate in the plumbing.
WARNING: Making chlorine in the pipes when there is no water flow is dangerous and can lead to
damage, the MegaChlor does not detect water flow.
Note: Even though the cell has 2" NPT in and out connections the flow must be limited to 5GPM max to
prevent damage to the MegaChlor electrode. A bypass must be used.

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MegaChlor Operation
The MegaChlor has 3 buttons and 4 lights built into the overlay on the control box. With the buttons you
can check the power level, change the power level and put it into boost mode. The lights will indicate the
salt level, the current mode (making chlorine or standby), reading the power level and changing the power
level.
Power Up
When the MegaChlor turns on it will flash the lights as follows:
1. MegaChlor-CD: WHITE & GREEN: Blinks four or more times, the number is the software version
2. MegaChlor: WHITE & GREEN & BLUE: Blinks four or more times, the number is the software version
3. WHITE, RED, BLUE, GREEN - will flash in that order
Making Chlorine (Salt Level Indication)
MegaChlor measures the current to the electrode and uses that as an indicator of the salt level. Water
temperature and minerals in the water also impact the indication. If it is low that is OK, you could add more
salt if you want, but not required. If the lights are on solid or blinking (at a one second rate) the MegaChlor
is producing chlorine:
ŸSolid GREEN - Current to the electrode is over 3.6 amps, Salt Level High
ŸSolid BLUE - Current to the electrode is between 2.2 and 3.6 amps, Salt Level OK
ŸSolid RED - Current to the electrode is below 2.2 amps, Salt Level Low
ŸSolid RED / GREEN at the same time - Current to the electrode was over 4.4 amps and the MegaChlor
has shut down to protect the power supply and the cell. Drain out some water and refill to dilute the salt
level. Cycle power or press the boost button to have it check again. Perform the tests in the
troubleshooting section.
Standby Mode (Not Making Chlorine)
The MegaChlor will produce chlorine for a period of time and then go into an off cycle (standby mode). The
length of time for the on part of the cycle is determined from the power level setting. There will be visible
bubbles coming out of the cell and you can tell the salt concentration from the light color. When the time is
up it will turn off and wait at least 3 hours and then repeat. When it is in the off mode (standby) the lights
will flash WHITE every 10 seconds indicating standby mode.
MegaChlor-CD: When in standby mode it will be off at least 3 hours and wait until the chlorine is very low
before restarting.
MegaChlor: Will be in standby mode for 3 hours and then repeat.
Important - Electrode Life Indicator: When electrode life has reached 90%, the WHITE light will flash (2)
quick flashes every 10 seconds in standby instead of one flash. This is your reminder that the electrode is
almost at end of life, so it is time to order a replacement electrode.
Important - Vacation Mode (MegaChlor Only): When vacation mode is activated the MegaChlor will
decrease the on time to make less chlorine. Vacation mode is automatically activated when no buttons
are pressed for over a week. When activated, the lights will flash all lights every 10 seconds in standby
mode. To exit vacation mode press any button. The amount the time is decreased:
No button pressed for 1 to 2 weeks: On time * 0.75
No button pressed for over 2 weeks: On time * 0.5

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Power Levels
MegaChlor includes 10 power level settings that are set based on water volume, usage and testing. The
MegaChlor factory setting is 3 (2 hours). The output power to the cell is always the same, the power level
changes the amount of time the cell is energized when it turns on. Power level 1 is 30 minutes on, 2 is 1
hour on, 3 is 2 hours on and so on.
View the Current Power Level Setting
Simply press the UP or DOWN arrow button once and count the WHITE flashes. Each flash represents a
power level. For example: 3 WHITE flashes = power level 3, 7 WHITE flashes = power level 7. After the
power level is displayed MegaChlor-CD will display either the chlorine value, current to the electrode or the
zero point, see the section on OPTION: MegaChlor-CD at the end of this manual, the chlorine value and
the zero point are only used with the chlorine detecting electrode..
Change Power Level
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. Press the UP arrow to increase power - the GREEN light will flash each time the UP arrow is pressed. If
set at the maximum power level of 10, the GREEN light will be on solid.
3. Press the DOWN arrow to decrease power - the RED light will flash each time the DOWN arrow is
pressed. If at the minimum power level of 1, the RED light will be on solid.
Selecting the Right Power Level
Selecting the right power level requires some testing and adjustment. There are many factors that affect
the sanitizing needs of a pool such as: use, number of people, if there is an Ozone Generator,
temperature, last drain and refill, does it have a cover, cyanuric acid or stabilizer, etc. However, after the
testing and adjustment period, MegaChlor will take care of your sanitation needs day after day with minimal
Power Level Water Volume (gals)
1 to 3 Less than 1000
4 1000 to 3000
5 3000 to 6000
6 6000 to 10000
7 to 10 10000 and above
adjustments. As a starting point, please program MegaChlor
and set the power level to the general recommendations
shown in the table.
Test the Chlorine Level with test strips after 1 to 2 days. When
testing, always try to measure at the same time of the day. 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 may
be above what MegaChlor 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 conditions change on the pool usage make sure to adjust the power level. If usage significantly
increases, (return from vacation, etc) it is important to adjust the power level up accordingly. Always retest
and adjust the power level as needed.

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Power Level ON Time
1 00:30:00
2 01:00:00
3 02:00:00
4 03:00:00
5 04:00:00
Power Level On Time
6 05:00:00
7 06:00:00
8 07:00:00
9 08:00:00
10 09:00:00
Boost Mode & Power Level Times
Activating Boost Mode will start a chlorine production cycle. To activate Boost Mode simply press the Boost
Mode Button, the GREEN and BLUE led’s will flash letting you know a production cycle will start.
IMPORTANT: The MegaChlor can’t make chlorine faster. The Boost Mode simply turns it on for a single
cycle. If the pool chlorine has dropped to 0 PPM from heavy usage, chlorine may need to be added.
If currently in a production cycle pressing the Boost button will terminate the production cycle and place the
MegaChlor in standby mode for 3 hours. The boost button is an easy way to start or stop a chlorine
production cycle. When Boost Mode is active, the salt level light will flash.
MegaChlor CD: Chlorine Control
When using the MCCD-Electrode the MegaChlor will control the start of a production cycle based on the
chlorine level reaching a low enough level and a 3 hour minimum off time from the previous production
cycle. The MegaChlor control box works with either electrode: MC-Electrode = standard drape over
electrode without the chlorine sensor, MCCD-Electrode = electrode with the chlorine sensor. Both
electrodes have the same chlorine production rate.
Reading the flashing color values: Count the GREEN/BLUE/RED flashes to get the value. The calculation
is: GREEN*100 + BLUE*10 + RED = the value. No GREEN, three BLUE and 4 RED flashes would be
34.
Electrode Life Span Indicator
This feature tracks the amount of time the MegaChlor electrode has been actively producing chlorine. The
typical life span of the electrode is 7,000 hours of chlorine production. The life span indicator is displayed
by a series of flashing lights that represent the percentage of electrode life used.
1. Press the Boost and Down arrow at the same time.
The following lights will flash to indicate the percentage used:
GREEN = 100
BLUE = 10
RED = 1
Example: (5) BLUE flashes would mean 50% life has been used on the electrode.
2. When electrode life has reached 90%, the WHITE light will flash (2) quick flashes every 10 seconds
in standby instead of one flash. This is your reminder that the electrode is almost at end of life, so it
is time to order a replacement electrode.
3. Reset the indicator: Press all three buttons at the same time to zero out the indicator. This should
be done when replacing the electrode.