Pentair Onga FREEFLO User manual

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Owner’s Manual
SALT CHLORINATOR
FREEFLO

2FREEFLO Salt Chlorinator Owner’s Manual
Foreword
Congratulations on purchasing a Pentair Onga FREEFLO Salt Chlorinator for your swimming pool.
This system is designed for robust reliability and easy operation to give you many years of trouble
free service.
Please read the instructions thoroughly before operating your unit. If you have any concerns or
require any further assistance, then please do not hesitate to contact our friendly staff or any of
our Pentair distributors.
Chemicals
It is important to note that the Pentair Onga FREEFLO Salt Chlorinator does not maintain the
water chemistry of your swimming pool water; it simply produces chlorine from a mild salt
solution. To ensure that your chemical balances are within the guidelines listed below you should
also have your water tested regularly at your local pool shop to encourage a sparkling clean
healthy pool.
PH 7.2 – 7.4
Total Alkalinity 90ppm – 150ppm
Cyanuric Acid 40ppm – 65ppm
Salt 4000ppm
Chlorine 1.5ppm – 2.0ppm
Calcium hardness: 200-400ppm
For the best chlorine results in a balanced pool a salt level of 4000 parts per million (ppm) is
required. This is easily achieved by using the formula below or approximately 20kg of salt per
every 5000 litres.
For example:
Pool volume = Length x Width x Average Depth x 1000
= 9m x 4m x 1.5m x 1000
= 54000 litres
Salt required = Pool Volume x 4 (salt level required, 4000ppm)
1000
= 54000 x 4 / 1000 = 216kg
Or 11 x 20kg bags of pool salt
NB: Before adding salt to your swimming pool, please make sure your Pentair Onga FREEFLO
Salt Chlorinator is switched off to avoid overload damage. THIS WILL VOID ALL WARRANTY.
It is recommended to manually add chlorine to your swimming pool on initial startup as a Salt
Chlorinator is designed to maintain chlorine levels and not run for unnecessary long hours to
try to build an acceptable chlorine level. The manual addition of chlorine may also be required
for unforeseen situations where your swimming pool has required a high chlorine demand, for
example after large bather load.
PENTAIR ONGA FREEFLO SALT CHLORINATOR

3
FREEFLO Salt Chlorinator Owner’s Manual
Page
FREEFLO Salt Chlorinator Overview 2
Cell Housing Installation
Installation No Heater 4
Installation With Heater 5
Installation With Solar 5
Installation With Automation - Single Speed Pump 6
Installation With Automation - Intellio Variable Speed Pump 6
Power Pack Installation 7
Functions 7
Time Settings 8
Maintenance 9
Troubleshooting 10
Spare Parts 11
Warranty 12
TABLE OF CONTENTS

4FREEFLO Salt Chlorinator Owner’s Manual
The electrolytic cell housing must be plumbed into the return line after the lter. Please see the
installation diagram, g.1, below for the preferred method. If a heater is plumbed into the system
then the cell housing must be installed after the heater in the return line with a check-valve
between the heater and the chlorinator to protect the elements or heat exchanger. If a solar
heating system is installed then the cell housing should be tted after the line going up to the roof
and after the return line coming back from the roof if it rejoins the main swimming pool return.
The cell housing has allocations for either 40mm PVC pipe or 50mm PVC pipe with the use of the
supplied PVC reducing bushes.
INLET OUTLET
From pool
skimmer /
main drain
To pool
return jets
Backwash
to sewer
CELL HOUSING INSTALLATION
Installation No Heater
- - Please note the installation position of the electrolytic cell for water probe positioning - -
Fig.1
Fig.2

5
FREEFLO Salt Chlorinator Owner’s Manual
From pool
skimmer /
main drain
To pool
return jets
Backwash
to sewer
To solar
From solar
Check-valve
Actuator valve
From pool
skimmer /
main drain
To pool
return jets
Backwash
to sewer
Check-valve
Installation With Heater
Installation With Solar
Fig.3
Fig.4

6FREEFLO Salt Chlorinator Owner’s Manual
Installation With Automation - Single Speed Pump
Installation With Automation - Intellio Variable Speed Pump
Fig.5
Fig.6

7
FREEFLO Salt Chlorinator Owner’s Manual
Mounting the Pentair Onga FREEFLO Chlorinator power pack is done by either using the supplied
mounting bracket or directly hanging on the wall with screws. If mounting directly on the wall, use
the guide notches on the top vents to position the holes for installation. The chlorinator power pack
is to be mounted at least 800mm above ground level.
It is strongly recommended that the unit be installed where it is protected from the elements. Rain
and sunlight will prematurely age your unit. It should also be mounted in a position where it is away
from accidental water spray. The unit should be installed so that adequate air ow can circulate
freely around the power pack to allow the chimney drafting effect to perform eciently.
1. Chlorine Output LEDs - If the correct salt level is in the pool then all 10 lights will illuminate. Each
light represents 10% chlorine output. If all lights are not illuminated then a higher salt level will be
required. Make sure all salt is dissolved properly before adding more. The chlorine control, (2 in g.
7), will increase or decrease the chlorine output to suit your chlorine demand. If all of the indicator
lights ash then there is a water fault problem.
2. Chlorine Control – The chlorine controller determines the amount of chlorine production. By
simply turning the control anti-clockwise you increase the chlorine output and by turning the
control clockwise you reduce the chlorine output. Do not force the control past its stop as this will
damage the unit and void warranty.
3. High Salt Light – This light is a red warning indicator and will only illuminate when the salt level in
the swimming pool is higher than 4500 parts per million. If this light is on, decrease the output by
turning the chlorine control, (2 in g.7), clockwise until the high salt (red light) goes off and the 10
chlorine output LEDs are on (1 in g 7). If this light is the only one illuminated then the unit has gone
into over temperature cutout and will reset once back to normal running temperature.
4. Polarity Light – The polarity light is the rst indicator light, 10% in the chlorine output array, (4 in
g.7). This light will alternate between orange and green every reversing cycle, 4-12 hours. Factory
setting is a 12 hour cycle.
5. Timer – The time clock is designed for control of the chlorinator and circulation pump.
POWER PACK INSTALLATION
FUNCTIONS
All Pentair Onga FREEFLO Chlorinators are tted with a 240v 10A power socket located on the right
hand underside of the power pack. Your pool pump should be plugged into this socket so that the
chlorinator and pump activate together when the timer switches on at the allocated time settings or
in a model without a timer the pump and chlorinator is controlled by the on/off switch. (7 in g 7).
Failure to plug the pool pump into this socket could lead to the chlorinator staying on with no water
circulation. In case of water probe failure, over heating and a possible gas build up may occur.
Please see g.7 below in regards to function control.
Fig.7
3
2
4
16
7
5

8FREEFLO Salt Chlorinator Owner’s Manual
Setting the Analogue Clock
To set the time, turn the minute hand clockwise until the time of day is set on the Inner Dial. For
example, to adjust the time to 8:00pm, adjust the Timer as per Fig 8. The Outer Dial has 24-hour
markings with 15-minute increments to match the Inner Dial time at the Activation Point.
It is important to ensure that if the time is set to 8.00pm, the Activation Point on the Outer Dial
will align with 20, not 8, which would be 8.00am.
Program the Timer by pushing the captive trippers to the outer position for the entire period that
the chlorinator and pump are to be turned “ON”. Each tripper corresponds to 15 minutes on the
24-hour dial. When the tripper is pushed inwards, the Timer is in the “OFF” position.
6. Circuit Breaker: A circuit breaker is mounted on the front of the Pentair Onga FREEFLO
Chlorinator and is designed to activate in the event of power surge or overload. When activated
the yellow centre button will pop out turning off the unit. To reset, press the yellow centre button
back in to resume normal function. Important note, turn off the chlorinator at the power point
before attempting to reset the circuit breaker. Should the circuit breaker continually activate
then you should contact your local Pentair distributor.
7. Timer/Off /Manual Switch: This switch allows you to choose the timer operation mode for
your chlorinator and pool pump. Switched to the left position, Timer, allows the chlorinator and
pool pump to turn off and on at your designated timer settings. The Manual selection, switched
to the right, allows the chlorinator and pump to work continuously until you physically change the
chlorinator’s mode. The Off position in the middle will turn the power off to the chlorinator and
circulation pump.
TIME SETTINGS
To set the time, turn the minute hand clockwise until the time of day is set on the Inner Dial. For
example, to adjust the time to 8:00pm, adjust the Timer as per Fig 3. The Outer Dial has 24-hour
markings with 15-minute increments to match the Inner Dial time at the Activation Point.
It is important to ensure that if the time is set to 8.00pm, the Activation Point on the Outer Dial
will align with 20, not 8, which would be 8.00am.
Program the Timer by pushing the captive trippers to the outer position for the entire period that
the chlorinator and pump are to be turned “ON”. Each tripper corresponds to 15 minutes on the
24-hour dial. When the tripper is pushed inwards, the Timer is in the “OFF” position.
TIME SETTINGS
Fig.3
Inner Dial
Outer Dial
Minute Hand
One tripper equates
to 15 minutes
Activation Point
Fig.8

9
FREEFLO Salt Chlorinator Owner’s Manual
Setting the Digital Timer
To set the chlorinator scheduled ON/OFF times, press the TIMER button. The rst ON time (1ON)
will appear on the screen. The Digital Timer has 15 inbuilt daily program settings. Press the DAY
button to scroll through these programs. Generally, the every-day program should be selected
(Mo Tu We Th Fr Sa Su). This will enable the chlorinator scheduled ON/OFF times to activate every
day.
Press the HOUR and MIN buttons to set the ON time. Press the TIMER button again, the rst OFF
time (1OFF) will appear on the screen. Press the HOUR and MIN buttons to set the OFF time.
Pressing the TIMER button again will show the second ON time (2ON). Repeat the programming
procedure above to complete additional ON/OFF schedules if required. When nished
programming the schedules, press the CLOCK button to return to the home screen. On this
screen, the current timer state is shown.
To reset a timer schedule, go to the schedule by pressing the TIMER button as required, then
press and hold the TIMER button again to reset.
MAINTENANCE
Correct pool water chemistry is important and regular testing should be carried out. In areas
where pool water quality is poor some calcium build up may occur on the cell plates. This may
require periodical cleaning in a mild hydrochloric acid solution. For more details contact your
local pool shop or pool maintenance technician.
When cleaning the cell you must turn the chlorinator off or it will damage your unit and void
warranty. Do not use any utensils or harsh chemical cleaners to remove any calcium buildup from
the cell as it will damage the cell’s semi precious coating and void warranty.
The chlorinator power pack should only be serviced by qualied electrical technicians. For your
nearest Pentair recommended service technician, please contact us (see contact details at the
back page of this manual).
TIME SETTINGS
Setting the Digital Clock
Press and hold the CLOCK button. Press the DAY button until the correct day is displayed. Do the
same with the HOUR and MIN buttons to set the clock.
Fig.9

10 FREEFLO Salt Chlorinator Owner’s Manual
FAULT / PROBLEM POSSIBLE CAUSE REMEDY
No ow.
All chlorine output LED`s
ashing as per page 4, note1.
Pump turned Off. Ensure pump is turned ON.
Closed valve. Open valve.
Air in system. Check all O-rings & grease.
Dirty lter. Clean or backwash lter.
Low water level. Fill up pool.
Calcium build-up on water probe
sensor.
Clean probe in a mild hydrochloric
acid- ref. page 4.
High Salt
Red LED illuminated.
Salt level too high,
above 4500ppm.
Turn chlorine control clockwise as per
page 7 note 2, until salt levels reduce.
Comment: This remedy does NOT
reduce the salt levels in the pool water,
it reduces the chlorine output of the
chlorinator to protect it.
No lights.
Circuit Breaker tripped. Fig 2. Note 6. Reset Circuit Breaker as per
page 8, note 6.
Mains power failure. Check switches and switchboard
circuit breaker.
Low / No chlorine
production.
Chlorine output too low. Increase chlorine production as per
page 7, note 2.
Salt level too low. Increase salt level to 4000ppm and
check stabiliser (Cyanuric) levels.
PH too high. Adjust PH between 7.2-7.4
Timer period too short. Increase running time.
High phosphate levels. Add starver.
Cell connection. Check connection at the junction box
on the underside of the unit.
Abnormal calcium
build-up in cell.
Calcium levels in swimming pool water
extremely high or water chemistry.
Reduce calcium level in pool. Lower
water level and ll with clean water.
Use a calcium reduction agent. Clean
cell with mild HCl solution.
Timer times-out of sync.
Timer not set correctly. Check setting procedure as per
page 7, note 5.
Chlorinator installed on off-peak tariff. Timer will need battery backup if
installed on off tariff.
Timer / Off / Manual switch not switched
correctly.
Make sure switch is selected as per
page 8, note 7.
Over temperature
Red LED only.
Salt too high, above 4500ppm.
Turn chlorine control clockwise as per
page 7, note 2. until salt levels (no other
lights) reduce.
Comment: This remedy does NOT
reduce the salt levels in the pool water,
it reduces the chlorine output of the
chlorinator to protect it.
Installed in an area where the ambient
temperature is extremely high.
Supply adequate cooling. Install outside
of the extreme temperature area.
TROUBLESHOOTING

11
FREEFLO Salt Chlorinator Owner’s Manual
NO. PART NO. QT Y. DESCRIPTION
1801933 Replacement Cell 15g
1801934 Replacement Cell 25g
1801935 Replacement Cell 35g
1801972 Replacement Cell 50g
2FM1STUH01 Analogue Time Clock
2801974 Digital Time Clock
3801937 Power PCB Kit
4801938 Control PCB Kit
5801939 Control PCB Knob
6801940 Transformer
7801941 Cell Lock Nut
8801942 O-ring Cell Union
9801943 Cell Casing
10 801944 Perspex Cover
11 801948 Overload
12 801970 Rocker Cover
13 801971 Rocker Switch
NOT SHOWN
801959 Mounting Plate
801947 Blanking Cap
800100 Junction Box
SPARE PARTS
Fig.10
1
2
3
4
9
10
5
6
7
12
13
11
8

12 FREEFLO Salt Chlorinator Owner’s Manual
Your Pentair Onga FREEFLO Chlorinator is covered by a 3 year warranty on the power pack and a 5 year pro-rata
warranty on the cell from the date of purchase. The power pack controller and electrolytic cell are covered
against defects in materials and assembly from the date of purchase in a domestic application. Warranty will
not be given without proof of purchase, so keep your original purchase invoice in a safe place.
Unfavourable environments and operating conditions beyond the control of the manufacturer such as incorrect
power supply (must be 230V 50 Hz), the Pentair Onga FREEFLO Chlorinator plugged into an ancillary device
such as a Variable Frequency Drive, wear and tear, water and insect damage, extreme ambient temperatures
or any other adverse situation that affects the Pentair FREEFLO Chlorinator will void warranty. All warranties
only apply if the equipment is installed and operated in complete compliance with the installation and operating
instructions.
Pentair Onga FREEFLO Chlorinators and electrolytic cells installed in a commercial situation are covered by a
1 year warranty. Commercial situations meaning motels/hotels, health spas, apartment/town house complexes
and any situation with an unusually high bather load or abnormal conditions.
Pentair Australia will not accept liability for any consequential loss or damage of any kind.
FOR ALL WARRANTY ENQUIRIES, PLEASE CALL 1300 137 344.
WARRANTY
PURCHASED FROM:
PURCHASE DATE:
SERIAL NO:
MODEL NO:
IMPORTANT
Please attach your sales invoice/docket here as proof of purchase should warranty service be
required. Please do not return warranty form to Pentair Australia. Retain for your records.

13
FREEFLO Salt Chlorinator Owner’s Manual
NOTES

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