Flotec FPPA-9IL3 User manual

Installation/Operation/Parts
For further operating, installation, or maintenance assistance:
Call 1-800-365-6832
©2000. PRINTED IN U.S.A. FP346 (9/5/00)
®
P.O. Box 342, Delavan, WI 53115
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Web Site: http://www.flotecwater.com
OWNER’S MANUAL
Chlorinator
3752 0900 ASB
FPPA-9IL

Safety 2
For parts or assistance, call Flotec Customer Service at 1-800-365-6832
READ AND FOLLOW
SAFETY INSTRUCTIONS!
This is the safety alert symbol. When you see this
symbol on your system or in this manual, look for
one of the following signal words and be alert to the
potential for personal injury.
warns about hazards that will cause death,
serious personal injury, or major property damage if
ignored.
warns about hazards that can cause death,
serious personal injury, or major property damage if
ignored.
warns about hazards that will or can cause
minor personal injury or property damage if ignored.
NOTICE indicates special instructions not related to
hazards.
Carefully read and follow all safety instructions in this
manual and on equipment. Keep safety labels in good
condition; replace if missing or damaged.
Incorrectly installed or tested equipment may fail, caus-
ingsevere injury or property damage. Read and follow
instructions in owner's manual when installing and oper-
ating equipment. Have a trained pool professional per-
form all pressure tests.
1. Do not connect system to a high pressure or city
water system.
2. Use equipment only in a pool or spa installation.
3. Trapped air in system can cause explosion. BE SURE
all air is out of system before operating or testing
equipment.
Risk of fire or explosion.
NEVER add acid to chlorinator.
Never mix Trichlor with Bromine or any other
chemicals in the chlorinator. Mixing chemicals may
cause fire or explosion in the chlorinator.
Do not use Calcium Hypochlorite (“Shock”), fast
dissolving Trichlor, or any granular material in the
chlorinator. These materials are less stable than slow-act-
ing chemicals; using them may cause pressure buildup,
toxic fumes, fire or explosion. Use only slow dissolving
Trichlor (Trichloro-S-Iazinetrione) sticks/tablets/pucks or
Bromine (Bromo-Chloro-Dimethylhydantoin) sticks/tablets
in this chlorinator. DO NOT put small particles of chemi-
cal in chlorinator.
DO NOT smoke near chlorinator; avoid sparks and
open flames. Many pool chemicals are flammable or
explosive if exposed to open flame. Always follow manu-
facturer’s label directions for pool cleaning products.
Risk of pressure buildup or possible explo-
sion. Never isolate chlorinator by closing valves on both
sides of it. Always keep pool return lines open except
when servicing chlorinator.
Risk of mucous membrane irritation and
chemical burns. Take extreme care not to inhale fumes.
Never attempt to remove partially used chemicals. Turn
off the pump and turn control dial to 0 before opening
chlorinator. Avoid inhaling chemical fumes. Keep the chlo-
rinator area well ventilated. Always wear protection for the
eyes, skin and clothing when working with chemicals.
To reduce the risk of injury, do not permit children to use
this product.
Maximum working pressure 50 PSI (345 kPa).
Model FPPA-9IL In-Line Chlorinator For pools up to
50,000 gallons using Trichlor; For pools of up to 25,000
gallons using bromine.
Model FPPA-9IL in-line chlorinators have an internal
baffle which prevents full flow through chlorinator;
install in-line only. Use an off-line chlorinator where an
installation in the pool return line is impractical.
Direction of flow through the chlorinator is not impor-
tant; install with either port as inlet port.
WARNING
Chemical burn hazard. Explosion Hazard.
Read owner’s manual with care before attempting
to install or operate this equipment.

Table of Contents 3
Page
General Safety .....................................................................................................2
Warranty..............................................................................................................3
Installation...........................................................................................................4
Operation.........................................................................................................5-8
Repair Parts..........................................................................................................9
For parts or assistance, call Flotec Customer Service at 1-800-365-6832
ATTACH ORIGINAL RECEIPT HERE FORWARRANTY CONSIDERATION.
FLOTEC warrants to the original consumer purchaser
(“Purchaser”) of its products that they are free from defects in
material or workmanship.
If within One (1) year from the date of the original consumer
purchase any such product shall prove to be defective, it shall
be repaired or replaced at FLOTEC’s option, subject to the
terms and conditions set forth below. Your original receipt of
purchase is required to determine warranty eligibility.
General Terms and Conditions
Purchaser must pay all labor and shipping charges necessary
to replace product covered by this warranty. This warranty
shall not apply to acts of God, nor shall it apply to products
which, in the sole judgement of FLOTEC, have been subject
to negligence, abuse, accident, misapplication, tampering,
alteration; nor due to improper installation, operation, main-
tenance or storage; nor to other than normal application, use
or service, including but not limited to, operational failures
caused by corrosion, rust or other foreign materials in the sys-
tem, or operation at pressures in excess of recommended
maximums.
Requests for service under this warranty shall be made by
returning the defective product to the Retail outlet or to
FLOTEC as soon as possible after the discovery of any alleged
defect. FLOTEC will subsequently take corrective action as
promptly as reasonably possible. No requests for service
under this warranty will be accepted if received more than 30
days after the term of the warranty.
This warranty sets forth FLOTEC’s sole obligation and pur-
chaser’s exclusive remedy for defective products.
FLOTEC SHALL NOT BE LIABLE FOR ANY CONSEQUEN-
TIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHAT-
SOEVER.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN
LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WAR-
RANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE
DURATION OF THE APPLICABLE EXPRESS WARRANTIES
PROVIDED HEREIN.
Some states do not allow the exclusion or limitation of inci-
dental or consequential damages or limitations on how long
an implied warranty lasts, so the above limitations or exclu-
sions may not apply to you. This warranty gives you specific
legal rights and you may also have other rights which vary
from state to state.
Flotec LimitedWarranty
FLOTEC • P.O. Box 342 • Delavan, WI U.S.A. 53115
Phone: [phone] • Fax: [phone]
E-Mail: [email protected] • Web Site: http://www.flotecwater.com

Installation 4
INSTALLATION INSTRUCTIONS
TOOLS/SUPPLIES NEEDED: (Not Included)
For All Installations:
• Pipe cutter or hacksaw
• wrench
• screwdriver.
Optional:
• Round head screws to fasten the chlorinator to a base.
FOR IN-LINE INSTALLATIONS
(Model FPPA-9IL):
In-ground Pool:
• Teflon tape,
• (2) 1-1/2” threaded x 1-1/2” slip PVC bushings
• PVC cement.
NOTICE: Install a corrosion resistant check valve and fit-
ting to prevent chlorine from backing up and damaging
other system components.
INSTALLING IN-LINE CHLORINATOR
In-ground Pool Installation (See Figure 1)
1. The in-line chlorinator can be plumbed directly into a
1-1/2” plastic pipe downstream from all other equip-
ment. To avoid corrosion damage, DO NOT plumb
the chlorinator into copper pipe (see Figure 1).
2. Find a suitable location downstream from the filter
and heater (if installed). Always install the chlorinator
as far as possible from the heater (or other metal
equipment) to avoid chemical corrosion damage to
system components.
3. Install the chlorinator standing upright. If installed on
the ground, mount chlorinator on a treated wood slab
using round head screws through the mounting slots
in the base.
4. Brush pipe thread sealant onto the threads of both
1-1/2 x 1-1/2” face bushings. DO NOT use teflon
tape; it can cause leaks or bushing failure. Hand tight-
en the bushings into the chlorinator ports, then tighten
1 to 2 more complete turns with a wrench. DO NOT
overtighten. Overtightening will strain the joint and
can lead to joint/bushing failure.
5. Cement the PVC pipe into the bushings according to
the PVC cement manufacturer’s recommendations.
6. Isolate the chlorinator by installing a corrosion resistant
check valve or a plumbing loop (Hartford loop)
between the chlorinator and the rest of the pool equip-
ment. This will protect other system components (espe-
cially the heater) from chemical corrosion damage.
NOTICE: In case of high water flow (80 gpm or greater)
or if additional equipment (such as an in-floor cleaning
device) will be included on the pool installation, isolate
the chlorinator from the rest of the system through
plumbing loops (Hartford loops) and/or check valves as
recommended.
See your in-floor manufacturer’s recommended guidelines
for using an in-floor cleaning system with an automatic
chemical system. An installation other than that shown in
Figure 3 or those recommended by manufacturer of in-
floor cleaning system may result in over-chlorination
and/or damage to the chlorinator or the in-floor system.
Special Installation of In-line Chlorinator
1. Valve Bypass (Figure 2): For high flow applications (80
gpm or greater), use a 2 way ball valve to control
water flow to the chlorinator. A corrosion resistant
check valve is recommended.
2. Plumbing Loop (Figure 3): When installed with an in-
floor cleaning system, install the chlorinator in a
plumbing loop (gas trap) so that it is isolated from all
other equipment. To trap corrosive gasses and avoid
damage to other system components, make sure that
the piping both before and after the chlorinator is 3”
to 6” below the pool water level.
For parts or assistance, call Flotec Customer Service at 1-800-365-6832
Figure 1
Pump
Filter Heater (If
installed)
Chlorinator
Check
Valve
Suction
From
Pool or
Spa
Figure 2
Chlorinator
Pump Filter
Ball
Valve
Check
Valve
To
Pool
Figure 3
3-6” Below Pool
Water Level
Plumbing Loop
(Gas Trap)
Chlorinator
Filter
In-floor Valve
Pump

Operation 5
OPERATION/SAFETY INSTRUCTIONS-
READ CAREFULLY
Risk of fire, explosion, or chemical burns.
Never mix Trichlor with Bromine or any other chemicals
in the chlorinator. Do not use Calcium Hypochlorite
(“Shock”), fast dissolving Trichlor, or any granular mater-
ial in the chlorinator. Use only slow dissolving Trichlor
(Trichloro-S-Iazinetrione) sticks/tablets/pucks or Bromine
(Bromo-Chloro-Dimethylhydantoin) sticks/tablets in this
chlorinator.
Risk of mucous membrane irritation and
chemical burns. Take extreme care not to inhale fumes.
Using settings higher than manufacturer’s
recommendations may damage pool liner and waste
chemicals. Settings higher than the manufacturer’s guide-
lines may result in over-sanitation, wasting chemicals,
allowing particles of chemical to pass through chlorina-
tor, and bleaching or discoloration of pool liners or
paint. Do not put small particles of chemical into chlori-
nator. Check chemical residuals daily.
NOTICE: Turn off chlorinator when shocking pool. Do
not add shock to the chlorinator or to the skimmers; it
could damage equipment and cause potential risks when
coming in contact with the chemicals in the chlorinator.
This chlorinator is a maintenance system only and is not
designed for shock treatment of pools. See your local
pool professional for additional information concerning
shock treatments.
UNDERSTANDING SANITIZERS
Trichlor
Trichlor is a stabilized chlorine product that comes in
sticks, tablets or pucks. Trichlor can be either fast dissolv-
ing or slow dissolving. Slow dissolving Trichlor is best
suited for automatic feeding. Fast dissolving Trichlors are
added directly to the pool daily. DO NOT use fast dis-
solving Trichlors in the chlorinator; explosion could
result.
The chlorinator’s erosion technology and dial setting
control allow most of the Trichlor to remain above the
water level so there is minimal soaking of the chemical.
Trichlor output may be too great when using tablets (for
example, on smaller pools or with a long pump run-time
per day). If so, use pucks with a 3" surface area to reduce
output (the dissolution rate for pucks is lower).
Bromine
Bromine is a chlorine derivative that is used in pools and
most commonly in spas. It is more stable and dissolves
slower than Trichlor. Therefore, it requires greater move-
ment of water over chemical (“scrubbing action”) to
achieve the same output as Trichlor. For this reason, the
control dial settings will always be higher when using
bromine.
Water Balance
Periodically check the water balance in the pool/spa
with a test kit. Consult your pool or spa professional for
precise water conditioning ranges in your area. The fol-
lowing parameters should be used only as general guide-
lines.
Sanitizer (Trichlor or Bromine) 1-3 ppm
pH control 7.2-7.8
Total Alkalinity 80-150 ppm
Total Hardness 175-300 ppm
Total Dissolved Solids 0-2000 ppm
Stabilizer 20-100 ppm
The sanitizer demand depends on many factors: bather
load, pump filtration time, gallonage, temperature, sun
light, etc. Initially, there will be a trial period to deter-
mine the correct control setting for your pool. Check the
sanitizer residual parts per million (ppm) daily and adjust
the control dial accordingly until you reach the correct
setting (see Operating Instructions).
NOTICE: These recommended starting points are based
on a 12,500 gallon pool with a pumping time of 8 hours
per day, an average water temperature of 82° F, and an
average bather load. Under these conditions the sanitizer
should last approximately three weeks. Sanitizer con-
sumption will increase by 25% for every 10° increase
over the average temperature. Thus the sanitizer will last
approximately one week less for every 10° Increase in
water temperature.
After a winter shutdown, the water balance will need to
be checked with a test kit. During spring start-up, the
water will need chemical conditioning and substantial
filtration time (a minimum of 8 hours per day is recom-
mended). Shock treatment is recommended to set the ini-
tial sanitizer residual. After shocking has brought residual
up to 1 to 3 ppm, use the chlorinator to maintain this
residual level.
For ease in cap removal, always make sure the cap O-
ring is lubricated with the liquid silicone included with
your chlorinator; tighten the cap by hand only. Use the
cap tool included with your chlorinator for additional
help with cap removal, but do not use the tool to tighten
the cap. The tool handle can also be used for aid in
adjusting the control dial.
For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Operation 6
For parts or assistance, call Flotec Customer Service at 1-800-365-6832
OPERATING INSTRUCTIONS
Fire or explosion hazard. NEVER add acid
to chlorinator. Always follow manufacturer’s label direc-
tions for pool cleaning products.
Risk of pressure buildup or possible explo-
sion. Never isolate chlorinator by closing valves on both
sides of it.
Risk of mucous membrane irritation and
chemical burns. Take extreme care not to inhale fumes.
1. Set control dial to “0”. Adjust pH level of pool to 7.2 -
7.8. Bring chemical residual to 1 - 3 ppm with a
shock. When using shock, do not add shock to chlori-
nator or to skimmer.
2. Stabilize the pool with cyanuric acid stabilizer.
Fire or explosion hazard. NEVER add
acid to chlorinator. Always follow manufacturer’s
label directions for pool cleaning products.
3. When the pool is at the optimum levels (see the Water
Balance Guidelines on page 5 or consult your pool
professional), fill chlorinator with the appropriate sani-
tizer using guidelines below.
a. Turn off pump. Control dial should be at 0.
Unscrew knob on side of body to relieve pressure.
Turn (but do not remove) cap to break seal (using
tool if needed) and allow any excess water to drain
from inside the chlorinator.
b. Wait approximately one minute; then close knob
and remove cap.
Risk of mucous membrane irritation
and chemical burns. Take extreme care not to
inhale fumes.
c. Fill chlorinator with sanitizer. Do not mix chemicals
in the chlorinator. Do not change sanitizers unless
you have followed instructions under “To Change
Sanitizers” . Use only slow dissolving Trichlor or
Bromine.
d. Replace cap and hand tighten only. DO NOT over-
tighten.
e. Turn pump on. Initially set the control dial at setting
2 if using Trichlor and 4 if using Bromine.
4. Test your water every day at approximately the same
time of day. If the sanitizer reading drops below your
desired level, increase the control dial setting by 1/2
increment. Repeat this process until the desired sani-
tizer residual level is maintained.
5. If your sanitizer level should drop below 1 ppm dur-
ing this procedure, set the chlorinator control dial to 0
and shock the pool again using 1/2 the suggested
amount of shock for your pool size (enough to
increase reading to 3 ppm – see your shock manufac-
turer’s recommendations).
6. When you have achieved the desired sanitizer level
through shocking, increase the dial setting by 1/2
increment from the initial setting and begin the
process again. To avoid over-sanitation, DO NOT
increase the dial more than 1/2 increment. Do not let
the sanitizer residual level remain below 1 ppm or
algae growth may occur.
7. If your sanitizer level is too high at the initial setting,
turn control dial to setting 0 and decrease pump run
time if possible (but not to less than 8 hours per day).
When desired sanitizer residual is reached again, turn
control dial to 1/2 increment lower than original set-
ting and repeat this process until the desired sanitizer
residual level is maintained.
FOR SPAS
This unit using bromine will effectively sanitize larger
spas of 1,000 gallons or more. Based on a 6 hour pump
running time to maintain 3 ppm on a 1500 gallon spa,
begin on control dial setting 3 and follow operating
instructions to adjust the dial to reach the desired sanitiz-
er residual level.
NORMAL MAINTENANCE
1. Once you have determined the proper setting for your
pool you should not have to readjust the dial under
normal conditions. Should conditions (that is, air or
water temperatures, rain, bather load, etc.) change,
adjust the control dial by no more than 1/2 increment
daily to increase or decrease the sanitizer output.
2. Turn control dial setting to zero and shock pool when
needed. Add shock directly to pool. DO NOT add
shock treatment to the skimmer or chlorinator. Once
sanitizer residual level has settled back to desired
level (1 to 3 ppm), return the control dial to the nor-
mal operating setting.
3. Periodically check the chlorinator and replace sanitiz-
er when empty. Test for pH and sanitizer residual
level daily.
To Change Sanitizers from Trichlor to Bromine
or vice versa
Risk of respiratory irritation and chemical
burns. Take extreme care not to breath fumes. Never
attempt to remove partially used chemicals.
1. Operate unit until empty of all chemical. Do not
attempt to remove partially used chemicals.
2. When unit is empty, turn control dial to setting #9 and
run pump for 24 hours to thoroughly rinse unit.
3. Follow steps 3a through 3e under “Operating
Instructions” for removing the cap. Fill the unit with
the appropriate sanitizer.
4. Replace cap and turn pump on. Follow steps 3
through 7 of “Operating Instructions” to determine the
proper setting with the new sanitizer.

Operation 7
To Winterize Units
1. Follow safety rules and steps 1 and 2 outlined in the
procedure "To Change from Trichlor to Bromine”.
2. After running the unit empty for 24 hours, stop pump
and remove all knobs.
3. Remove cap. Drain unit and tubes to prevent freezing.
4. Replace knobs and cap loosely to allow drainage of any
water that might back up into the chlorinator system.
Replacement of Cap O-Ring
(Key No. 3, Page 9)
Hold cap in front of you upside down with O-ring
groove facing up. Place one end of O-ring into cap
groove closest to you. Hold O-ring down with the thumb
and middle finger of one hand. Take hold of the far end
of the O-ring with the thumb and index finger of your
other hand. Roll O-ring slightly back towards you as you
lift up and stretch O-ring into the remainder of the cap
groove. This method will prevent the O-ring from rolling
out of the groove. Run finger over the O-ring In the
groove to make sure it is in place. Finally, lubricate O-
ring with the liquid silicone lubricant provided with your
unit.
LUBRICATION OF CAP O-RING
If lubrication of O-rings becomes necessary, use a sili-
cone lubricant only (not sealants or caulks). Do not use
petroleum or teflon based products, as they will form a
sticky, gummy residue that could restrict the chlorinator
cap, cause the control dial to become inoperable and
cause deterioration of the O-rings. When lubricating
O-rings, always make sure the O-ring grooves are clean
and free of any grit and old lubricant.
REPLACEMENT OF O-RING
ON CONTROL VALVE
1. Using needlenose pliers, find the snap ring tail located
approximately at the 5:00 o’clock position under the
control dial (see Figure 4).
2. Pull it down and out of its groove (see Figure 5).
3. Use a large screwdriver to loosen the control dial by
carefully prying up under each side, a little at a time
(see Figure 6).
4. Pull the dial out of the housing (see Figure 7).
Figure 4
Figure 5
Figure 6
P
O
OL
S
A
N
I
T
I
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E
R
Figure 7
For parts or assistance, call Flotec Customer Service at 1-800-365-6832

Operation 8
For parts or assistance, call Flotec Customer Service at 1-800-365-6832
5. Carefully replace the O-Ring (see Figure 8). Do not
stretch it. Squeeze a little silicone lubricant (included
with your chlorinator) directly onto the O-Ring and
spread it over the O-Ring surface with your finger.
6. Push the control dial completely into the housing and
turn the dial to setting 2 (see Figure 9).
7. Insert the non-lipped end of the snap ring into the
groove in the housing, beginning at the 5:00 o’clock
position. Push it up so that it threads itself around the
control dial (see Figure 10).
8. Guide the snap ring with a small screwdriver (or other
pointed tool) to keep it in the groove in the housing as
it is inserted (see Figure 11).
1
3
4
5
6
7
9
B
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P
O
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2
T
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L
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MIN
MAX
8
L
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G
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P
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M
A
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P
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Figure 10
1
3
4
5
6
7
9
B
R
O
M
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P
O
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S
2
T
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MIN
MAX
8
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Figure 11
3758 0900
Figure 8
Figure 9

Repair Parts 9
For parts or assistance, call Flotec Customer Service at 1-800-365-6832
1
2
3
4
5
6
7
8
1
3752 0900
Key Part Part
No. Description Qty. Number
1Plug with O-Ring 2 01-22-9940
2 Cap with O-Ring (Incl. Key No. 2) 1 01-22-9411
3 Cap O-RIng 1 01-22-9920
4 Mesh Screen 1 01-22-9660
5 Body 1 **
6 Pressure Relief Valve 1 01-22-9480
7 Control Dial O-Ring Kit 1 01-22-9450
8 Control Dial w/Ass’y Kit (Incl. Key No. 7) 1 01-22-9440
• Danger/Instruction Label 1 903
• Cap/Control Dial Tool 1 01-22-8870
• Silicone Lubricant 1 01-22-9970
** Not available separately.
• Not illustrated