Polaris Watermatic C-660 User manual

Table of Contents
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
II. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
III. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
IV. Pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
A. Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .4
B. Acid/Base Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
C. Optional Switch Settings . . . . . . . . . . . . . . . . . . . . . . .5
V. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
A. Feeding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B. Site Assessment and Controller Installation . . . . . . . . .9
C. Sensor Bypass Assembly . . . . . . . . . . . . . . . . . . . . . .9
D. Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .10
E. Start-up Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .10
F. pH Level Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .11
G. Sanitizer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .12
VI. Panel Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
VII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
A. Starting the Controller . . . . . . . . . . . . . . . . . . . . . . . .15
B. Automatic Presets . . . . . . . . . . . . . . . . . . . . . . . . . . .15
C. Feed Light Activation . . . . . . . . . . . . . . . . . . . . . . . . .15
C. Out-of-range Alert . . . . . . . . . . . . . . . . . . . . . . . . . . .16
D. Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
E. Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
VIII. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
A. Cleaning the Sensor Tips . . . . . . . . . . . . . . . . . . . . . .17
B. Checking the ORP Sensor . . . . . . . . . . . . . . . . . . . . .17
C. Checking the pH Sensor . . . . . . . . . . . . . . . . . . . . . .18
IX. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
X. Guidelines for Using ORP for Water Maintenance . . . . . .20
XI. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
XII. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

I. Introduction
For your protection, read all instructions carefully before
installing or operating this automatic controller.
The Polaris Watermatic C-660 ORP/pH Controller is designed to
automatically monitor and maintain both the sanitizer level and
the pH balance in swimming pools, spas, or any circulating water
system that requires management of its water chemistry. The
C-660 Controller is designed for easy installation and simple
operation. It may be used with liquid feed pumps, granular feed-
ers, tablet erosion feeders, and ozone generators. It is not war-
ranted or recommended for use with chlorine gas systems.
The C-660 has two standard power receptacles for the ORP and
pH outputs. During the filtration cycle of the pool or spa, the
sanitizer level and pH balance are displayed on the controller’s
ORP and pH digital readouts (see drawing below) and main-
tained by a constant measurement of the ORP (Oxidation-
Reduction-Potential) and pH balance of the water. If the saniti-
zer level (ORP) falls below the desired set point for the sanitizer
level, the controller will activate the chemical feeder until the pre-
set point is reached. The pH of the pool or spa is maintained in
a similar manner.
Various safety features prevent the feeding systems from activat-
ing if the sanitizer or pH balance are outside of the controller’s
range. Additional safety features and options are described in
further detail in the Pre-installation section of this manual.
The C-660W model is a version of the C-660 designed to be
used with the G-1000 or G-7500 feeder. The controller is
equipped with a circular connector on the ORP output and
includes a cord for connection between the controller and feeder.
ALERT FEED MANUAL
FEED
SENSOR
CALIBRATION
SET
ALERT FEED MANUAL
FEED
SET
ON
OFF FLOW
ORP pH
ORP pH ORP SENSORS pH
C-660 ORP/pH Controller
750 7.5
2

II. Specifications
pH Control Range: 7.0 to 8.2
ORP Range: 100 mV to 900 mV
Input Power: 115 VAC 60 Hz, 3-wire grounded power
cord. GFCI source required
Controller Power: Less than .5 amp internally fused
Output Power: 660:115 VAC 60 Hz, 5 amp fused, two
3-wire grounded power receptacles
660W: 115 VAC 60 Hz, ORP: circular
connector 1-1/2 Amp Slo-Blo fuse,
pH: 5 amp fused, 3-wire grounded power
receptacle
Display: Digital readouts
Operating
Temperature: 40 - 120°F
Sensors: pH: glass combination with 10' cable
ORP: platinum combination with 10'
cable
Selectable features:
•Desired ORP/pH settings
•pH calibration
•ORP and pH timed or continuous feed
•Safety interlock between pH and ORP
•Safety lockouts for low or high (out-of-range) pH or ORP levels
•Visual alert and optional audible alert for self-correcting and
non-correcting conditions
Note: When automating a body of water, it is essential to size
the feeders so desired levels can be attained in short operating
cycles. If the feeders are unable to keep up with demand within
a short time frame, automation becomes ineffective.
3

III. Components
The C-660 ORP/pH controller box contains:
• ORP/pH Controller
• Sensor Bypass Assembly (part# 9-735)
• ORP Sensor (part# 3-250)
• pH Sensor (part# 3-260)
IV. Pre-installation
A. Dip Switch Settings
The controller is factory set to provide continuous feed of both
ORP and pH. Before installing the controller, make sure that the
dip switch settings are consistent with the settings shown below.
To view or adjust the dip switch settings, make sure the con-
troller is unplugged from the power source. Remove the face
plate screws and expose the dip switches which are located on
the back of the module (see the drawing below).
pH Switches ORP Switches
(located behind (located behind
the pH display) the ORP display)
1. OFF ON
2. OFF ON
3. OFF OFF
4. OFF OFF
5. OFF OFF
6. OFF OFF
7. OFF OFF
8. ON OFF
9. ON ON
10. ON ON
For most controller applications, the continuous feed mode
is appropriate. However, if you are using the controller in
one of the following situations, you may need to change the
settings to allow for a timed feed cycle followed by a delay
cycle.
Please see the Appendix on page 24 for instructions.
•Using a peristaltic pump to feed the sanitizer or pH and you
are experiencing overfeeding
Flow
Jumper
Remote
Monitor
Connection
pH ORP
Dip
Switches
Back of Controller Module
4

•Using an erosion feeder with a spa or small body of water
and you are experiencing spiking
•The ORP sensor is located downstream from the introduc-
tion of the sanitizer (the pH sensor should always be located
upstream from the introduction of the pH balance)
•With a Watermatic G-1000, G-1000A or G-7500 feeder
B. Acid/Base Feed
The controller is pre-set at the factory to feed acid. If you are
going to feed base, turn off pH switch #8:
pH Dip Switch #8
ON = Acid Feed
OFF = Base Feed
C. Optional Switch Settings
1. Sanitizer Feed Dependent on pH Being Within Range—
pH Switch #1
The controller is pre-set at the factory to allow the ORP to
feed regardless of the pH level.
Turning on this switch will override this feature and allow the
feeding of the sanitizer, only if the pH reading is within the
controller range (above 7.0 or below 8.2). Since the ORP
reading is dependent on the pH (i.e. as the pH rises, the
ORP lowers), this setting avoids oversanitizing as a result of
a high pH level. If the pH is out of range, the sanitizer will
not feed and the pH alert light will illuminate.
2. No ORP and pH Simultaneous Feeding—pH Switch #2
The Controller is pre-set at the factory to allow simultaneous
feeding of pH and ORP.
Turning on this switch will not allow the ORP and pH to feed
at the same time. In some installations, both the sanitizer
and the pH are introduced into the filtration system in close
proximity to each other. When using acid for pH control and
liquid chlorine as the sanitizer, feeding both liquids simulta-
neously could cause chlorine gas bubbles to be created in
the return lines. The ON setting prevents the sanitizer from
feeding until the pH feed cycle is complete.
5

Please note: If the system happens to run out of acid to
feed, the pH feeder will continue to run and the sanitizer
feeder will not be activated.
3. Cancel High pH Alert for Acid Mode and Low pH Alert
for Base Mode—pH Switch #9
The controller has a pH operating range of 7.0 to 8.2. If the
pH reading falls outside of this range for more than 10 min-
utes, the pH alert light comes on and the unit will not feed.
If you are feeding acid and your system has a pH that fre-
quently jumps above 8.2, you can cancel the high pH alert
by moving the pH switch #9 to the ‘off’position. Thus, the
alert light will not come on and the unit will continue to feed.
Please note: If the sensor fails, the pH could continue to
feed, adding an excessive amount of acid to the pool. For
this reason, we strongly recommend leaving the pH
switch #9 in the ‘on’ position and use the maximum feed
time feature described below.
If you are feeding base, you can cancel the low pH alert by
moving the pH switch #9 to the ‘off’position.
4. Cancel Low ORP Shutoff—ORP Switch #9
The controller is programmed to shut down when the ORP
level drops below 100 mV for more than 10 minutes. This
prevents overfeeding if there is an ORP sensor failure. If you
would like to cancel this feature, move the ORP switch #9 to
the ‘off’position.
This change might be required for spas or extremely small
bodies of water where sudden organic loads dissipate the
sanitizer in a very short time.
5. Setting a Maximum FeedTime
As an added safety feature, some operators set maximum
allowable feed times for their sanitizer and pH. These times
represent the maximum time either system would be expect-
ed to run under normal operation. If the feed times reach
these predetermined maximum time limits (due to some mal-
function), the system shuts down and the controller goes into
the service mode (the entire display flashes). To reset, rem-
edy the malfunction, then turn the controller off and then on.
6

To set a maximum feed time, set the dip switches as shown
below to correspond to your desired maximum feed time.
7
Maximum* pH Switches ORP Switches
Feed Time #3 #4 #3 #4
60 Minutes ON ON ON ON
120 Minutes OFF ON OFF ON
240 Minutes ON OFF ON OFF
NO LIMIT OFF OFF OFF OFF
*This maximum feed time option is only available
when in the continuous feed mode. It is unlikely that
feed times will exceed one hour with properly sized
feeders.

8
V. Installation
CONTROLLER
115 VAC 60 HZ
GFCI RECEPTACLE
PRESSURE
SWITCH
(OR FLOW SWITCH)
ORP
FEED PUMP
CHEMICAL
TANK
pH
FEED PUMP
TO POOL
CHEMICAL
TANK
HEATER
pH SENSOR
ORP SENSOR
SENSOR BYPASS
FILTER
PUMP
FROM POOL
FLOW
B
A
Liquid Feeder
CONTROLLER
115 VAC 60 HZ
GFCI RECEPTACLE
24V
TRANSFORMER
24V
SOLENOID
VALVE
CHECK
VALVE
EROSION
FEEDER CHEMICAL
TANK
pH
FEED PUMP
HEATER
TO POOL
pH SENSOR
ORP SENSOR
SENSOR BYPASS
FILTER
PUMP
FROM POOL
FLOW
A
B
Erosion Feeder

9
A. Feeding Systems
Install the chemical pump and erosion feed systems as shown in
one of the figures on page 8. If your model differs from the pre-
viously mentioned systems, see the installation manual that was
provided with it for the appropriate installation methods.
Note: The controller may have to be set for the particular feeder
system used. See the appendix on page 24.
B. Site Assessment and Controller Installation
Before installing the controller, it is important to do a site assess-
ment and consider where and how you will mount the controller.
The controller should be mounted on a wall or other surface
within eight feet of the feeder, at least ten feet away from the
edge of the water, in close proximity to the time clock and within
six feet of the GFCI power source.
Once you determine the best site, obtain all necessary mounting
screws or anchors (no mounting screws are provided with the
controller). Securely mount the controller on a wall or panel.
C. Sensor Bypass Assembly
Locate the sensor bypass assembly within eight feet of the con-
troller, and mount it using the brackets provided. The sensor
bypass (flowcell) must be plumbed so the pressure difference
between the inlet and outlet is sufficient to ensure flow through
the bypass. It is also desirable to have filtered water pass over
the sensors to minimize cleaning. One method to accomplish
this is to plumb the inlet to the bypass assembly after the filter
(see A in the diagrams on page 8) and plumb the output of the
bypass assembly after the heater (see B) using the saddle
clamps provided.
Mounting Brackets
Compression
Fittings - Sensors
Compact Ball Valves
Ball Valve (Sample Port)
Clear Tees
Check/Flow
Indicator
Sensor Bypass
Assembly

If this does not provide sufficient and consistent flow through the
bypass assembly, other configurations can be used, including:
a) from before the filter to after the heater, an inline filter should
be used to minimize the debris coming in contact with the sen-
sor; b) from after the filter to before the pump, excellent flow is
ensured, but the flow must be adjusted so the sensors are not
subjected to a suction environment. Solar systems and other
factors can alter pressure differentials in a system, adversely
impacting flow through the assembly.
D. Sensor Installation
Carefully unpack the ORP and pH sensors and remove the plas-
tic protective caps from the sensor tips. Store the protective
caps inside the controller enclosure for possible future use (win-
terizing or reshipping).
Attach the pH sensor BNC connector and
the ORP sensor BNC connector to the
controller as shown on page 14. Slide the
pH and ORP sensors inside the compres-
sion fittings on the bypass assembly so
that the sensor tips are below the water
line in the pipe. Tighten the nuts of the fit-
tings until they are finger tight. DO NOT
USE A WRENCH.
Make sure the controller power switch is
off. Plug the power cords from the pH
and ORP feeders into the controller. Plug
the power cord from the controller into the
GFCI receptacle. It is recommended
that the controller be used with a flow
or pressure switch to ensure that feed-
ing does not occur when the main fil-
ter/circulation pump is not running.
E. Start-up Operation
Do not add chemicals to the feeders until all of the following
start-up operations have been completed.
1. Turn the filter pump on and check for water flow through the
sensor bypass assembly. Water should pass over the ORP
and pH sensors for at least five minutes to allow for accurate
ORP and pH readings from the pool or spa.
10
Coil Extra
Sensor Cable
Externally
Controller
Sensor Compression
Fitting
PVC Tee
Sensor Tip

2. Check for leaks and correct as necessary.
3. Set the ORP set knob (#5 on page 14) to minimum (counter-
clockwise).
4. Hold in the pH set button (#4 on page 14) and adjust the pH
set knob (#15) to maximum (clockwise) if in the base feed
mode (see B on page 8) or minimum (counterclockwise) if in
the acid feed mode.
5. Turn on the power switch. The red power indicator light and
the digital display will activate.
Note: If the ORP and pH lights are illuminated but the power
light is not, there is no flow or pressure and the feed cycles
are inactive. If the flow or pressure switches are not being
used and the power light is off, the flow jumper is not in
place
6. Using a DPD test kit, manually adjust the pool water to the
desired sanitizer and pH levels.
Leave the power switch on.
F. pH Level Settings
1. Prior to setting the desired pH level, the pH sensor must be
calibrated. To do this, the pH sensor must be in a known pH
solution that is near 7.5. If the pH sensor is installed in a
bypass or flow cell with a sample port, test the water from
the sample port. If it is installed in a position where the
direct water that the sensor is sitting in cannot be tested,
place the sensor in a glass of pool water.
Calibrate the sensor to the reading using the calibration
knob. The pH sensor should be calibrated every 4 to 8
weeks.
2. Hold in the set button and turn the pH set knob until the
desired pH level appears in the display. Acceptable levels
are 7.2 to 7.8.
3. Allow the system to operate for 24 hours. With the filtration
system running, retest the pool water pH using a test kit and
adjust the pH set knob if necessary.
4. Adjust the pH feed system for a feed rate that is not too low
or too high. Due to the lag time between the beginning of
11

the chemical feed cycle and and the sensor detection of the
chemical levels after recirculation through the pool or spa, a
low feed rate can either cause the feeder to lag or the feed-
ing to be extended, and a high feed rate can result in too
much pH being added.
To check the feed rate, immediately after a pH feed cycle
ends, use a test kit to test the pH balance of the water. If the
pH is high (above the preset point of the pH set knob), the
feed rate is too high. If overfeeding persists, timed feed may
be required (see the Appendix on page 24).
Note: If feeding liquid acid (muratic acid), it is generally
advisable to dilute the acid (in the water) to avoid overshoot-
ing the set point.The smaller the body of water, the greater
the acid dilution is necessary.
5. The green pH feed light will activate only when the controller
is operating the pH feeding system. In constant feed, the
feed light will flash while feeding. The feed light will not acti-
vate when the pH alert light is on (pH is below 7.0 or above
8.2). If using timed feed, the feed light will flash during feed
cycle and be constant during the delay cycle.
Note:To verify the acid/base feed mode, set the desired pH
above the pH indicated on the digital display. The feed light
should come on if the controller is set for acid feed. If the
controller is set for base feed, the feed light will come on
when the desired pH is set below the pH indicated on the
digital display. The unit is normally set for acid feed mode
unless specified for base feed (see page 5 to change the
acid/base mode setting).
G. Sanitizer Settings
This controller displays direct ORP readings. While ORP
indicates the effectiveness of the sanitizer, it does not direct-
ly correlate to a ppm reading. If you desire ppm, use the
ORP reading as a relative indication of sanitizer level. Use
your DPD test kit to measure the free chlorine. If you need
more sanitizer than that indicated by the ORP display, set the
desired level above that point. If you require less sanitizer,
set the desired level below that point.
1. Hold in the set button, then turn the set knob until the
desired ORP level appears in the ORP display. Then release
12

the button. After six seconds, the digital display reverts back
to the pool reading. (The World Health Organization sug-
gests maintaining an ORP at or above 650mV. This is a
good starting point.)
2. Allow the system to operate for 24 hours. With the filtration
system running, retest the sanitizer level and adjust the ORP
set knob if necessary.
Please Note: The knob is very sensitive; an adjustment
from 700 to 750 mV could increase the sanitizer level by sev-
eral parts per million (ppm).
3. The feed rate of the sanitizer feeder should be adjusted in the
same manner as the pH feeder (see #4 on page 11).
4. The yellow ORP feed light will activate only when the controller
is operating the ORP feed system. In constant feed, the feed
light will flash while feeding. If using timed feed/delay (see
the Appendix on page 24), the feed light will flash during the
feed cycle and remain on constantly during the delay cycle.
13

VI. Panel Features
14
ALERT FEED MANUAL
FEED
SENSOR
CALIBRATION
SET
ALERT FEED MANUAL
FEED
SET
ON
OFF FLOW
ORP pH
ORP pH ORP SENSORS pH
C-660 ORP/pH Controller
917
18
750 7.5
2
5
3
8
1
4
6
716
15
14
13
12
11
10
# DESCRIPTION FUNCTION
1 ORP Digital Display Indicates sanitizer level
2 ORP Manual Feed Button Instantly feeds sanitizer (if feed light is off)
3 ORP Feed Light Indicates the ORP sanitizer feeder is activated (or in delay)
4 ORP Alert Light Indicates the ORP level is out of range
5 ORP Set Knob Sets the desired sanitizer level of the water
6 ORP Set Button Holding in allows desired sanitizer level to be
changed
7 Power On/Off Switch Turns power on and off
8 ORP Flow Light Indicates there is sufficient flow/pressure to operate
9 Power Cord 3-wire grounded power cord with plug
10 pH Digital Display Indicated pH level
11 pH Alert Light Indicates that pH is out of range
12 pH Feed Light Indicates the pH feeder is activated (or in delay)
13 pH Manual Feed Button Instantly feeds pH adjuster (if feed light is off)
14 pH Set Button Holding in allows desired pH level to be changed
15 pH Set Knob Sets the desired pH level of the water
16 pH Sensor Calibration Calibrates the pH sensor
17 ORP and pH Sensor BNC jacks
Conncectors
18 5 amp ORP/pH Outlets 3-wire grounded power receptacles

15
VII.Operation
A. Starting the Controller
When the controller power switch is turned on, the red flow light
and the ORP and pH digital display will come on. Once initiated,
the controller has a one minute to avoid unnecessary feeding.
If a flow or pressure switch is being used and if the system
does not have sufficient flow or pressure, the array lights
will be on but the power light will be off. In this condition,
the controller will not feed.
Note: Prior to starting the system, balance the body of water to
approximate the desired levels.The controller should be used to
maintain the body of water and not to balance it.
B. Automatic Presets
When the controller is initially powered up, the ORP setting will
be 650mV and the pH setting will be 7.4. If the controller loses
power or the power is turned off, the settings will revert back to
the 650mV and 7.4 pH. If the controller is turned off by the
Watermatic pressure or flow switch, the settings will remain at
those set by the operator.
C. Feed Light Activation
1. The ORP feed light (#3) will flash to indicate when sanitizer
is being dispensed. The pH feed light (#13) will flash to indi-
cate when pH is being dispensed.
2. Do not adjust the set knobs when the sanitizer/pH are feed-
ing (feed light is flashing). When the system is feeding, the
digital display may register an inaccurate sanitizer/pH level
because the system is still circulating a dose of sanitizer/pH.
3. The system can be set for timed feed and delay cycles (see
the Appendix on page 24). This method can be used to pre-
vent too much sanitizer or pH from being dispensed into a
small pool or spa. Once the feeder has dispensed a dose of
sanitizer or pH, the feeder is unable to dispense again for a
set period of time. This delay allows the sanitizer/pH to be
circulated through the pool or spa and returned through the
filtration system where the sensors can test the sanitizer/pH
level. After the delay period, another dose of sanitizer/pH
will be dispensed if needed.

16
C. Out-of-range Alert
1. Unless the ORP dip switch #9 has been turned off (see #4
on page 6), the ORP alert light will flash when the ORP has
been out-of-range (less than 100 mV or more than 900 mV)
for ten consecutive minutes. Once the alert light comes on,
the controller will stop activating the feeder.
2. Unless the pH switch #9 has been turned off (see #3 on
page 5), the pH alert light will flash when the pH has been
out-of-range (less than 7.0 or more than 8.2) for ten consec-
utive minutes. Once the alert light comes on, the controller
will stop activating the feeder.
3. Once the out-of-range condition has been corrected, the
controller will reactivate automatically. After a one-minute
delay, it will activate the feeders, if necessary.
D. Manual Feed
1. The manual feed button can be used to manually dispense
sanitizer/pH. To signify that the controller is feeding chemi-
cal, the alert light will come on when the manual feed button
is pushed.
2. The manual feed button cannot be used while the feed light
is on.
E. Winterizing
If the system is subject to extended shutdowns or is located in
colder climates, it is important to winterize the system.
1. Turn off the controller (or better yet, shut off the main power
to the controller).
2. Loosen the compression fitting nuts and gently remove the
sensors from the bypass assembly.
Note:The sensor tips
must be stored in a protective cap or bottle filled with a
liquid solution of one teaspoon salt and three teaspoons
water.
Mix the solution thoroughly and make sure the solu-
tion completely covers the tip of the sensors. STORE THE
SENSORS IN A WARM PLACE –THEY CANNOT BE
EXPOSED TO FREEZING TEMPERATURES.
3. Drain the water from the bypass assembly.

17
VIII. Maintenance
A. Cleaning the Sensor Tips
1. It is important to keep the sensor tips clean to assure accu-
rate readings. When the sensor tips become dirty, the indi-
cator lights will read lower than the actual sanitizer/pH level
and can cause too much sanitizer/pH to be dispensed.
Note: A sensor tip coated with calcium scale will not look
visibly dirty.
2. As a general rule, the sensor tips should be cleaned every
one to four weeks for commercial pools and spas, and once
each month for residential pools and spas. However, clean-
ing frequency can vary from one body of water to another.
To determine the appropriate frequency for your pool or spa,
note reading prior to cleaning. After cleaning the sensor,
allow a stabilizing period of approximately ten minutes. If the
reading is identical to the reading prior to cleaning, the sen-
sor was not dirty and the time between sensor cleanings can
be increased.
3. To clean the sensor tip, turn off the controller. Loosen the
compression fitting nut and gently remove the sensor from
the bypass assembly. Swirl the tip for five seconds in
Muriatic acid or white vinegar, and rinse it in water.
Do not
touch, wipe or brush the end of the sensor
.
4. For commercial pools and spas, every third cleaning, swirl
the sensor tip in a solution of liquid soap and water. Rinse
with water.
5. Gently replace the sensor in the bypass assembly and turn
on the controller.
6. Allow the controller to operate for a few minutes to get an
accurate reading. Adjust the set knob if necessary.
B. Checking the ORP Sensor
1. The ORP sensor should be checked every six months or
anytime the feeder oversanitizes the water.
2. Clean the sensor tip as noted above.
3. Place the sensor in a clean glass of tap water. This should
give a reading of between 200 and 400 mV. Adding a pinch
of Dichlor or Trichlor should cause the ORP level to jump to
between 750 and 800 mV. (If Dichlor or Trichlor are not

available and a sanitizer with a high pH such as calcium
hypochlorite or liquid chlorine (sodium hypochlorite) is used,
the ORP level may only rise to between 650 and 750 mV.)
4. If the sensor does not respond as indicated, the sensor
should be replaced.
C. Checking the pH Sensor
1. The pH sensor should be checked every six months or any-
time the pH goes out of range.
2. Place the sensor in a clean glass of tap water. Add a small
amount of acid to the glass. The pH reading should drop to
the lowest red light. Then place the sensor in any solution
with a pH above 7.5. The pH reading should move up.
3. If the sensor does not respond as indicated, the sensor
should be replaced.
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IX. Troubleshooting
PROBLEM POSSIBLE CAUSE SOLUTION
SANITIZER LEVEL Set knob set too low Adjust knob clockwise until the
TOO LOW proper sanitizer level is reached and
stabilized
pH level too low (less than 7.2) Check pH level with a test kit
and adjust as required
Chemical feeder empty Refill chemical feeder
Controller malfunction Replace controller module
Sensor failure Replace sensor
SANITIZER LEVEL Sensor dirty Clean according to the mainte-
TOO HIGH nance instructions
Set knob set too high Test the sanitizer with a test kit and ad-
just the ORP knob counterclockwise
until the proper sanitizer level is reached
pH too high (above 7.8) Check pH level with a test kit and
adjust as necessary
pH LEVEL Set knob set too low Adjust pH set knob
TOO LOW pH calibrate knob Adjust pH calibrate knob
improperly adjusted
Chemical feed rate too high Lower feed rate
Chemical feeder empty Refill chemical feeder
(if using base)
Controller malfunction Replace controller module
Sensor failure Replace sensor
pH LEVEL Sensor dirty Clean according to the mainte-
TOO HIGH nance instructions
pH sensor calibration Adjust pH sensor calibration
improperly adjusted
pH set knob set too high Adjust knob counterclockwise
Chemical feeder empty Refill chemical feeder
(if using acid)
Feed pump malfunction Repair feeder pump
Chemical feed rate too low Increase feed rate
RED pH ALERT pH level is below 7.0 or Manually adjust pH in the pool
LIGHT ON above 8.2
DISPLAY LIGHTS No power supply Check circuit breaker
OFF
FEEDER DOES Bad fuse Replace fuse
NOT OPERATE
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X. Guidelines for Using ORP for Water
Maintenance
Q. Why should I maintain a pH level between 7.2 and 7.8?
A. pH levels below 7.0 can cause eye irritation, metal corrosion,
etching of plaster, stains, damage to vinyl liners, and loss of
sanitizer. In addition to eye irritation, pH levels above 8.0 can
cause cloudy water, scale formation and loss of sanitizer effi-
ciency (low ORP).
Q. How do I increase the pH level?
A. Small amounts of basic (alkaline) chemicals such as pH Plus or
pH Up can be added.
Q. How do I lower the pH level?
A. Small amounts of liquid or dry acid (muriatic) such as pH Minus
or pH Down can be added.
Q. How does 650 mV relate to the ppm of chlorine?
A. Pure water, without conditioner, at a pH level of 7.5 corresponds
to approximately 1.5 ppm of chlorine. Actual pool or spa water
usually takes at least 1-2 ppm of chlorine to generate 650 mV
ORP (although the Total Dissolved Solids and pH can affect the
activity of the chlorine and thus change the level of ORP).
Q. Does an ORP of 650 mV stop algae?
A. No. Because algae is a living organism that adapts genetically
to a constant level of sanitizer, the periodic addition of an algi-
cide or shocking may be necessary. Please note that the addi-
tion of some chemicals can change the ORP readings for up to
several days.
Q. What causes a low ORP?
A. A low sanitizer level, a pH level above 8.0, a conditioner level
above 200 ppm or a TDS (Total Dissolved Solids) above 3,000
ppm can all cause a low ORP.
Q. How do I make sure the ORP sensor is working properly?
A. Watch the sensor reading when adding sanitizer. If it does not
respond properly, follow the recommended sensor tip cleaning
procedures on page 16. If cleaning does not solve the problem,
check the sensor as outlined on page 16.
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