ControlOMatic MegaChlor User manual

ControlOMatic, Inc. 12659 Arbor Lane Grass Valley, CA 95949
www.controlomatic.com [e-mail]
530-205-4520
Manual Version: 12/09/15
Made in the USA - Please like us at www.facebook.com/controlomatic
MegaChlor
OPERATING
INSTRUCTIONS
Pool & Spa saltwater chlorine generator

IMPORTANT SAFETY INSTRUCTIONS
READ & FOLLOW ALL INSTRUCTIONS
When installing and using this electrical equipment, basic safety precautions should
always be followed, including the following:
WARNING: Cutting the cord from the power supply to the MegaChlor cell voids the warranty.
Damage will occur if the connection is reversed.
WARNING: To reduce the risk of injury, do not permit children to use this product unless they
are closely supervised at all times.
WARNING: Use MegaChlor only according to these instructions. Any modification or misuse of
this product will void the warranty.
WARNING: Install MegaChlor in accordance with all national and local electrical, plumbing,
safety, and other applicable codes.
WARNING: Connect MegaChlor 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 operate MegaChlor 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 be walked on, or to rest on sharp edges or corners. Do not drop, throw, or
otherwise rough handle MegaChlor.
WARNING: DO NOT operate or leave the power supply in temperatures below 32ºF or 0ºC. The
power supply may not survive in extremely cold temperatures.
WARNING: Disconnect, remove and store MegaChlor indoors when pool has been winterized
or drained.
CAUTION: Leave spa/pool cover open at least 1 minute to allow trapped gases to escape prior
to use.
CAUTION: Measure water quality parameters and adjust if necessary prior to each spa use.
CAUTION: MegaChlor doesn’t measure the chlorine level and must be adjusted properly in
order to not over-chlorinate the water. Over-chlorination can lead to equipment damage and un-
healthy water conditions.
WARNING: Remove the MegaChlor cell from the SPA when using the SPA.
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.
WARNING: DO NOT insert objects into, or tamper with the MegaChlor cell in any way. Inserting
metal objects into the cell body may cause damage and void the warranty.
WARNING: DO NOT plug MegaChlor control box directly into the VAC supply, this will damage
the MegaChlor. Always use the low voltage power supply.
SAVE THESE INSTRUCTIONS

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
INTRODUCTION
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 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 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!

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 MegaChlor can handle any salt level and a good target is 3000 PPM. If the salt is lower that will reduce
the efficiency of the chlorine generation and may lead to low chlorine levels. You may be able to taste the
salt above 3500 PPM. The salt that is added is constantly recycled, salt is lost only when pool water is
removed from the water from splashing or people getting out of the water. Salt is not lost due to evaporation.
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. Brush the pool bottom to speed up the dissolving process.
7. 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 volume calculators on the
Internet.
2. Multiply gallons by 0.025 for pounds or liters by 0.003 for Kgs

MegaChlor Installation
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
Control Box
Locate a suitable location for the control box meeting the following conditions:
1. Close enough to the water for the 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. The only time the control box needs to be opened is if the electrode needs to be
replaced.
Power Supply Location
The power supply location must meet the following requirements.
1. 110 or 220 VAC
2. Water protective cover. The 12 Vdc supply may require a larger
protective cover.
3. NOT IN DIRECT SUNLIGHT. The power supply will heat up
during operation and if in sunlight it may overheat.
4. The power cable should have a routing path to the control box
where the cable is protected from people tripping on it and lawn
mowers.

MegaChlor Cell Installation
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.
Power Supply
The MegaChlor power supply is a high output indoor power supply and the following guidelines should be
followed
1. The pins on the power supply are polarity sensitive and reversing the connection will damage the
MegaChlor. Make sure the connector key and groove are lined up when making the connection. Do not
make the connection if it is dark and you can’t see the key.
2. Locate the power supply out of sunlight. The power supply will overheat which will lower the life span of
the power supply.
3. The power supply is for indoor use and if used outside it must be protected with a suitable water tight rain
guard.

MegaChlor Inline Installation
The MegaChlor electrode can be removed from the cell and installed into an inline cell that is with the
main plumbing of the pool or spa. Use the following guidelines when installing:
1. Do not install into the main circulation flow, that will damage the electrode. Only install into a bypass.
The electrodes titanium plates are designed for a couple of gallons per minute maximum.
2. If installing into a portable spa or swim spas equipment area, that may void the warranty and UL
safety certifications.
3. The 2” fittings can be reduced and then barb fittings used to tap into the main water flow. You may
need saddle clamps and valves.
4. The MegaChlor is designed to be on all the time and doesn’t have a flow switch. Traditional chlorine
generators include a flow switch so that they will turn off when there is no flow to prevent gasses
from building up in the plumbing and filters. WARNING: If installing inline, provide a means that will
turn the MegaChlor off if there is no flow.
●Wire the power supply into the pumps timer, when the pump is on the MegaChlor is on.
●Add a flow switch or a pressure switch that will break the AC connection to the power supply when
the pressure is low.
5. If the cell is below the main water level, install a valve on the inlet and outlet sides so that water can
be shut off when cleaning the electrode.
6. If the cell is above the main water level install at least one valve so the flow can be adjusted. If the
cell is below the filter two valves may also need to be installed.
7. Orientation doesn’t matter as the water flow will take the gasses into the main body of water.
8. The inline cell has clear PVC and a 2” T. This can be purchased from ControlOMatic and your local
hardware store would also have the items except for the clear PVC.

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. All lights on
2. WHITE (may flash indicating software version), RED,BLUE,GREEN
3. WHITE will now flash the power level, count the flashes
Making Chlorine (Salt Level Indication)
MegaChlor will indicate if the salt level is low or normal. If it is low that is OK, you could add more salt if you
want but not required. The MegaChlor has constant current mode of operation meaning that if the salt is high
the output will adjust to protect the cell and the power supply. If the lights are on solid or blinking at a one
second rate the MegaChlor is producing chlorine:
●Solid BLUE - Salt Level Normal
●Solid RED - Salt Level On The Low Side
●Blinking BLUE - Salt Level Within Normal Range
●Blinking RED - Salt Level On The Low Side
Not Making Chlorine (Standby Mode)
The MegaChlor works on a 3 hour cycle and the first part of the 3 hours is chlorine production mode where
there will be visible bubbles coming out of the cell and the last part of the 3 hours is standby mode where the
cell is not making chlorine. This mode is indicated with a GREEN light flash every 10 seconds to let you know
that the MegaChlor has power and is on but just waiting for the 3 hour period to end. To start chlorine
production when in Standby, simply press the Boost button and MegaChlor will resume chlorine production.

POWER LEVELS
MegaChlor includes 10 power level settings that need to be set based on water volume, usage and testing.
MegaChlor is set to power level 3 straight from the factory. The output power to the cell is always the same,
the power levels change the amount of time the cell is energized every three hours. At the start of the three
hour period the cell will be energized and then after the time indicated by the power level the cell will be put
into standby mode and stop producing chlorine and at the start of the next 3 hour period will repeat. Please
follow the steps below to increase or decrease the power from the factory default power level 3.
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, 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 flash each time the UP arrow is pressed.
Or press the DOWN arrow to decrease power. The RED light will flash each time the DOWN arrow is
pressed.
3. When finished do not press any buttons for 3 seconds. The WHITE light will flash (count the flashes)
confirming the new power level setting.
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 2000
5 2000 to 4000
6 4000 to 6000
7 to 10 6000 and above
adjustments. As a starting point, please program MegaChlor
and set the power level to the general recommendations
shown in the chart below.
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.

Boost Mode & Power Level Times
TROUBLE SHOOTING
It is always a good idea to revisit the user manual to make sure installation or maintenance steps were not
overlooked before referring to the trouble shooting section.
Problem Possible Causes Corrective Action
Low Chlorine
Power level too low Increase power level
Plates need cleaning
Calcium white buildup can happen even with self cleaning.
Soak in white vinegar or mild acid and rinse. Repeat if needed.
Salt level low Add salt
Lots of swimmers Additional chlorine shock may be needed
Doesn’t Keep Up Clean the filter
Remove phosphates, remove organic material such as leaves
High Chlorine Power level too high Lower the power level
Cell Dirty High hardness Calcium white buildup can happen even with self cleaning.
Soak in white vinegar or mild acid and rinse. Repeat if needed
Power Level On Time Boost Time
1 00:02:00 00:12:00
2 00:07:30 00:45:00
3 00:15:00 01:30:00
4 00:30:00 03:00:00
5 00:45:00 04:30:00
6 01:00:00 06:00:00
7 01:30:00 09:00:00
8 02:00:00 12:00:00
9 02:30:00 15:00:00
10 03:00:00 15:00:00
Boost Mode is designed to help replenish chlorine that was
used when the pool is used. IMPORTANT: The MegaChlor
can’t make chlorine faster and Boost Mode will only keep it
on for a longer period of time, if the pool chlorine has
dropped to 0 from heavy usage chlorine may need to be
added. Activating Boost Mode will take MegaChlor out of
regular production mode or standby mode and re-start the
production of chlorine according to the following table. To
activate Boost Mode simply press the Boost Mode Button. The
Salt Light will begin flashing indicating that MegaChlor is in
Boost Mode.
The titanium plates will last around 7000 hours of chlorine
production and