Lonza pulsar system 140 User manual

Operator’s Manual
Model # PS 140Dealer Contact
1200 Lower River Road, P.O. Box 800
Charleston, TN 37310-0800
1-800-4-PULSAR
rev.3 (3/12/14)
140

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Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR 3
rev.3 (3/12/14)
The Major Components - How They Work
General Principles of Operation
The three main components of the Pulsar® 140
Chlorinator are (from top to bottom) the Briquette
Hopper, the manifold spray section and the
discharge tank. The water from the pool enters
the Pulsar® 140 Chlorinator via the inlet port.
The spray manifold then distributes the water
onto the briquette grid creating a chlorinated
solution. The chlorinated solution falls into the
discharge tank and is discharged into the pool
recirculation system by the evacuation system.
The amount of chlorine discharged from the
feeder is determined by the ORP controller or the
Timer. When using an ORP controller with this
unit, select “Yes” for the ORP or “No” to use
the internal Timer.
Inlet water pressure of 35 to 45 psi [2.41-3.10
bar] is required to provide sufficient flow into
the Pulsar® 140. These pressures will result in
an inlet flow of 0.75 gallons/minute [2.84 lpm].
The Pulsar® 140 feed rate settings referred to
in the Pulsar System Owners manual (right) are
calibrated for this flow rate.
Flow out of the Pulsar® 140 discharge tank
requires a vacuum to drain. A minimum outlet
flow-rate of 2.5 gpm [9.46 lpm] ensures that the
flow out of the Pulsar® 140 exceeds the flow in.
Once the Pulsar® 140 is installed, outlet flow can
be measured by watching the level in the bottom
tank. If the level is rising as the feeder is running,
there is insufficient flow out.
Figures in Chart below represent Chlorinator
Output in Pounds of Available Chlorine per Day
Using the arrows on the touch screen, set the
timer to the desired “% output rate”
% output rate lbs [kg] Av. Cl
100 163 [73.9]
95 155 [70.2]
90 147 [66.5]
85 139 [62.8]
80 130 [59.1]
75 122 [55.5]
70 114 [51.8]
65 106 [48.1]
60 98 [44.4]
55 90 [40.7]
50 82 [37.0]
45 73 [33.3]
40 65 [29.6]
35 57 [25.9]
30 49 [22.2]
25 41 [18.5]
20 33 [14.8]
15 24 [11.1]
10 16 [7.4]
58[3.7]
00[0.0]

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR
4rev.3 (3/12/14)
Operational Requirements:
Inlet pressure (Range) ................................... 35-45 psi [2.41-3.10 bar]
Ideal ................................................ 37psi [2.55 bar]
Outlet vacuum ........................................ 15-29” Hg. [38.1-73.7cm]
Operating Temperature .................................. 40-115ºF [4.4º to 46.1º C]
Supply power ......................................... 110V, 15A (NEMA 5-15R)
Operational Characteristics:
Inlet flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 gpm [2.84 lpm]
Outlet flow ........................................... 2.5 gpm [9.46 lpm]
Dimensions:
Tubing .............................................. 1/2” [12.7mm] O.D. Polyethylene
Chlorinator dimensions.................................. W:25” [63.5cm] x D: 30” [76.2 cm]
Chlorinator height...................................... 35” [88.9cm]
Chlorinator weight (full).................................. 150 lbs [68.0kg]
Chlorinator weight (empty) ............................... 50lbs [22.7kg]
Capacity:
100 lbs [45.4kg] Pulsar®Plus Dry Chlorinator Briquettes (equivalent to 68 lbs [30.8kg] available chlorine)
Feed Rate:
Pulsar®Plus Briquettes: 8-163 lbs [3.7-73.9kg] of Available Chlorine per day
Recommended Pool Size1:
15,000-200,000 gallon [56,781-757,082 liter] un-stabilized1
50,000-600,000 gallon [189,271-2,271,247 liter] stabilized1
1Subject to local health codes
SPECIFICATIONS – Model PS 140

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR 5
rev.3 (3/12/14)
Components
General Principles of The Pulsar®140
Lid
Hopper
Spray Manifold
Discharge Valve Float
Junction Box
Lid/Hopper Shut-Off
Switch/Contact
Inlet Manifold and
Solenoids Assembly
Wash-down Manifold
and Well Agitation
Safety Overflow Switch
Discharge Valve
Discharge Valve Outlet
and Check Valve
The Pulsar® 140 employs an “HMI/PLC”
electronics package for efficient operation and
enhanced safety features. The power to the
chlorinator is reduced to 24VDC with the use of
a step-down transformer in the control panel. The
Pulsar® 140 utilizes a PLC Timer with 21 presets
for 0-100% control of chlorine output rates.
Additionally, Safety Switches are used to interrupt
spray to the nozzles when the lid is opened or when the hopper is removed. The Pulsar® 140 also
incorporates improved maintenance features. Water flow in the unit is designed to remove residue from
the chlorinator base. Listed below is a description of each component of the Electronics Package:
Lid Safety Switch:
The Pulsar® 140 is equipped with a Lid Safety
Switch. This switch will interrupt flow to the spray
jets when the lid is opened. The design of this
feature incorporates a proximity switch so there
are no wires connecting the lid to the chlorinator
hopper or the hopper to the base. When the
hopper is separated from the chlorinator base,
power to the solenoid is turned off.

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR
6rev.3 (3/12/14)
General Principles of The Pulsar®140
The Pulsar® 140 utilizes a Safety Overflow
Switch to prevent the unit from overflowing.
Outlet flow can be slowed or stopped by many
causes, which can ultimately lead to the unit
overflowing. The most common cause would
be scale buildup in the venturi, discharge valve
and/or outlet tubing. The electronic overflow
switch will interrupt power to the solenoid if
the level in the discharge tank reaches a set
height. When power is interrupted, the solenoid
will close and shut off the inlet flow to the
spray manifold. The switch, when triggered,
also energizes the booster pump.
The Pulsar® 140 relies on a control panel
with internal timer and solenoid to control
output rate. The Pulsar Control Panel uses a
120V power supply (plug in control panel to
dedicated 15A circuit breaker) and the solenoid
uses on a 24VDC power supply (powered by
the control panel). The Pulsar® 140 can also
be used in conjunction with an ORP controller.
The yellow male pigtail from the Pulsar® 140
controller should be plugged into the 120V
chlorine pigtail of the ORP controller. The
signal from the ORP controller will be relayed
to the solenoid to feed chlorine.
Safety Overflow Switch:
Solenoid/Timer Assembly:
Pulsar®Control Panel
ORP Controller
Chlorine Pigtail

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR 7
rev.3 (3/12/14)
General Principles of The Pulsar®140
Test Operation of Electronic
Switches:
Note: Close inlet and outlet valves.
Before start up, lift the briquette screen out of the
hopper and set aside on a clean surface. Plug the
power cord from the Pulsar® 140 controller into a
dedicated 15amp GFCI outlet. The touchscreen
should be illuminated. Lift the hopper off the base.
The lid alarm light will come on. This indicates
that the lid switch is working properly.
Next, with the hopper off, remove the valve plate
and manifolds and place off to the side. Remove
the shield and place to the side. Reach into the
base and lift the safety overflow switch. An alarm
page for High Level should pop up, indicating
that the switch is working properly. Replace the
shield, valve plate with manifolds and place the
hopper on the base. Next lift the lid. The lid alarm
light should come on.
This concludes the test procedure. Should the
test procedures fail, refer to the Electrical and
Control Panel Set-up section (pages 12-14) for
more information or contact your Dealer for
additional information.
Safety Features
Overflow Port:
In the event that the solenoids fail to close, an
overflow port has been incorporated into the
Pulsar® 140 design. PVC pipe should be run from
this overflow port to a floor drain. The solenoid
should be checked when an abnormally low or
high chlorine reading is indicated in the pool or
when water is flowing out of the overflow port
through the pipe down to the drain.
Unplug the controller from the outlet or ORP unit
and call the dealer. If water continues to flow
into the chlorinator, the solenoid is stuck open or
water is backflowing through outlet piping.
If flow stops when the controller is unplugged,
the problem is the electronic overflow switch,
or outliet piping allowing water to backflow into
feeder. In either situation, the inlet ball valve
should be closed and the dealer should be
contacted for assistance.
Overflow Port

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR
8rev.3 (3/12/14)
General Principles of The Pulsar®140
Maintenance Features
Well Agitator:
The Well Agitator is designed to keep solids in
suspension for removal by the suction created by
the venturi. The Well Agitator nozzle can become
blocked over time. Remove the well agitator
nozzle and clean nozzle orifice if needed.
Drain Port:
The Drain Port is used to clean excess residue
and scale buildup from the chlorinator discharge
tank. Remove the 3/4” [19mm] plug and flush
system as needed.
Wash-down & Shield:
Below is a picture of the shield and wash-down
manifold assembly. This assembly is designed to
wash loose solids into the base where they are
removed with the chlorine solution.
The shield protects the valve, float and electronic
level switch from scale and residue deposits.
Without this shield, scale and residue will
increase float weight and decrease buoyancy.
In addition, scale buildup can bind pivot points,
which could result in valve failure.
Drain Port

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR 9
rev.3 (3/12/14)
Pre-Startup Checklist
Following the procedure outlined below will
ensure a smooth start-up of the Pulsar®140
Chlorinator. For seasonal operation, perform
this procedure each spring.
IMPORTANT!!
Do NOT put Pulsar®Plus Briquettes in the
Chlorinator during the start-up operation.
Inlet Water Flow
The inlet water flow system is designed to provide
a steady side-stream of clean filtered pool water
to the Chlorinator.
1. Switch on pool recirculation system, then open
valves associated with Chlorinator (suction/
discharge valves). Then start Booster pump.
MAKE SURE BOOSTER PUMP VALVES TO
SUCTION AND DISCHARGE ARE OPEN TO
PREVENT DEAD HEADING.
2. With lid open, place a metal object over the
lid switch to see that the four nozzles are
spraying water onto the Briquette-Tank grid.
3. Check all lines leading to the Chlorinator for
leaks. Hand tighten all fittings if any leaks are
found.
4. Check to make sure Safety Overflow Switch
is oriented properly with the float above the
switch.
Outlet Water Flow
As the Discharge Tank fills with water, the float on
the Discharge Valve rises with the water level and
allows the pump suction to draw the chlorinated
water into the pool’s recirculation system. When
the water level drops, the float falls, shutting
off the valve. There is a Check Valve mounted
vertically on the Discharge Valve to prevent pool
water from backing up into the Discharge Tank.
Use the following procedure to ensure that the
outlet flow system is operating properly.
1. With the Briquette Hopper of the chlorinator
temporarily off the discharge tank, use a
hose or pail to fill the Discharge Tank with
sufficient water to open the Discharge Valve.
2. The float should rise, opening the Discharge
Valve, allowing water to be drawn out by the
Pulsar®evacuation system.
3. Check the system for leaks. If small air
bubbles are visibly moving, there may be an
air leak. Tighten the connectors and make
sure that the O-ring is properly installed in the
fittings. (NOTE: Air bubbles near the Pulsar®
140 Chlorinator body that do not move are
normal and do not indicate leaks.)
4. Tighten connections on check valve true
union fittings and Tubing nut on Parker fitting.
Chlorine Solenoid
Check Valve
union fittings
Tubing nut on
Parker Fitting
Wash-down/
Well Agitator
Solenoid
Inlet Flow to
Chlorinator
Inlet Ball Valve
Line Strainer

Lonza • 1200 Lower River Road, P.O. Box 800 • Charleston, TN 37310-0800 • 1-800-4-PULSAR
10 rev.3 (3/12/14)
Startup Procedures
After completing the PRE-START-UP CHECKLIST,
and establishing that all components of the
Chlorinator are operating properly, your Pulsar®
140 Chlorinator is ready for start-up.
Routine maintenance of the Pulsar®140
Chlorinator is minimized when proper pool
water balance is maintained. Maintain pool water
chemistry as follows:
Total Alkalinity 60 - 80ppm
Calcium Hardness 200 - 1800ppm
PH 7.2-7.6
LSI –0.3-+0.5
On the ORP screen, there is a button for “Chem
Balance” which will calculate the Langelier
Saturation Index given the user input values for
TA, pH, Hardness, Temperature and TDS.
Adherence to these recommendations at all times
will ensure the most effective and economical
performance from the Pulsar®140 Chlorinator.
NOTE: The use of Carbon Dioxide gas (CO2) to
lower pH will raise the Total Alkalinity significantly.
High total alkalinity (over 80 ppm) will increase
scale and solids buildup in Chlorinator.
WARNING
The Pulsar Chlorinator can only be
installed with the Booster Pump, Venturi
and Flow switch provided with the unit.
These components, combined with the
Booster pump interlock with the main pool
pump, will prevent high levels of chlorine
in the pool after Pool pump shut-down.
DANGER: Under no circumstances should
you mix calcium hypochlorite with other
forms of concentrated chlorine or other
chemicals. Fire and/or explosion may
result. Caution must be used when refilling
dispenser.
KEEP OUT OF REACH OF
CHILDREN
1. Fill the Briquette Hopper with Pulsar®Plus
Briquettes. The Briquette Hopper holds 100
pounds [45.4kg] of Pulsar®Plus Briquettes.
2. Check the chart on page 11 to determine an
approximate start-up timer setting for your
pool.
3. Open all valves to the pool and to the
chlorinator.
4. Monitor the water flow to the chlorinator
daily to ensure that a proper flow is being
maintained.
5. During the first few days of operation,
check chlorine level in the pool frequently
to establish the best Timer setting (or ORP
Controller setting) for your pool. Adjust the
chlorine output either up or down according
to the table or, adjust the ORP set-point.
WARNING
Always monitor the free chlorine residual
in the pool water per the health code
requirements. If the FAC level exceeds
acceptable levels, do not enter the pool
until the residual in the acceptable range.