Pool Controls Chemigem CM55 User manual

Commercial & Semi-commercial
Water Management System
User Manual

Contents
Commercial Warranty 1
Warnings and Safety Measures 3
Prior to Installation 5
Items supplied 7
Installation 8
Operation 18
Chemicals 28
Using CO2Systems 29
Alarms 31
Maintenance & Troubleshooting 34
IMPORTANT
If the power cord is damaged the unit must be returned to
Pool Controls for repair.
Always read the instructions and warnings on chemical
containers before using chemicals.
Serial Number........................................
Date of Installation................................
Installed by.............................................

Page 1
Manufacturer’s Warranty for
COMMERCIAL INSTALLATIONS
Pool Controls products come with guarantees that cannot be excluded under
the Australian Consumer Law. You are entitled to a replacement or refund for a
major failure and for compensation for any other loss or damage. You are also
entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure. The
benefits under this warranty are in addition to other rights and remedies under a
law in relation to the goods.
1 YEAR WARRANTY ON COMMERCIAL INSTALLATIONS
Pool Controls warrants its products used in commercial installations to be
free from defects in material and/or workmanship for a period of 1 year from
the original date of purchase.
1 YEAR WARRANTY ON REPLACEMENT PARTS USED IN COMMERCIAL
INSTALLATIONS
Pool Controls warrants its replacement parts used in domestic installations,
including multi- electrodes (probes), solenoid valves and electrolytic cells (but
excluding wearing parts such as tubing and squeeze tubing) to be free from
defects in material and/or workmanship for a period of 1 year following
purchase.
EXCLUSION FOR WEARING PARTS
This warranty does not extend to wearing parts, in particular the squeeze
tubes fitted in peristaltic dosing pumps. Squeeze tubes should be replaced
every THREE months by a suitably qualified technician. Pool Controls is not
liable for any failure of its products or other damage caused by failure of a
squeeze tube that has been used for more than THREE months.
WARRANTY OBLIGATIONS OF POOL CONTROLS
If a defect in workmanship or materials in any Pool Controls product covered
by this warranty is discovered during the term of the warranty, and provided
the warranty holder follows the procedure set out below, Pool Controls will,
at its option repair or replace that item.

Page 2
PROCEDURE FOR CLAIMING UNDER THIS WARRANTY
In order to claim under this warranty, the warranty holder must:
•Contact Pool Controls Service as soon as possible after the discovery of
the defect and in any event, within the relevant warranty period;
•Confirm date of installation;
•Confirm that the installation was completed by a suitably qualified
technician, as set out in the installation manual; and
•If required, arrange for the relevant Pool Controls’ product to be returned
to Pool Controls for repair, and the warranty holder is responsible for the
cost and risk of any freight or transportation to and from Pool Controls.
CALL OUT FEES
This is a “Back to Base” Warranty, which means that if the Pool Controls
product needs to be serviced, replaced or repaired at a place other than Pool
Controls’ premises, a call out fee will be charged to cover the cost of travel by
an authorised Pool Controls technician. Please note that this call out fee will
NOT be charged when the relevant Pool Controls product is returned to Pool
Controls for repair. If an authorised Pool Controls technician repairs or
replaces a Pool Controls Product and this warranty does NOT apply, a fee for
labour and parts supplied will be charged in addition to the call out fee. If the
Pool Controls product needs to be returned for repairs under this warranty, the
warranty holder is responsible for the cost and risk of any freight or
transportation to and from Pool Controls.
WARRANTY EXCLUSIONS
This warranty extends to the original owner only, beginning on the date of
purchase and is not enforceable by any other party without the prior written
consent of Pool Controls. Pool Controls is not responsible for any cost of freight
or transportation to or from its Service Department. Pool Controls is not liable
under this warranty if the installation of the Pool Controls product was not
carried out by a suitably qualified technician.
To the extent permitted by law, Pool Controls is not liable for: any incidental or
consequential loss incurred in connection with the removal or replacement of the
Pool Controls product under this warranty; or product failure resulting from
misuse, freezing, accident, negligence, improper installation or inadequate
maintenance.
To the extent permitted by law, Pool Controls disclaims all other warranties,
either express or implied, including, but not limited to, implied warranties of
merchantability and fitness for a particular purpose with regard to Pool Controls
products, parts and/or any accompanying written materials.

Page 3
It is important that the Chemigem CM55 is installed and operated in
accordance with the instructions provided in this manual.
IMPORTANT
If the power cord is damaged the unit must be returned to
Pool Controls for repair.
Always read the instructions and warnings on chemical
containers before using chemicals.
GENERAL WARNINGS:
1. Do not permit children to use this unit unless they are closely supervised at
all times.
2. To reduce the risk of electric shock, replace damaged cord immediately.
3. Do not use extension cord to connect unit to electric supply; provide a
properly located outlet.
4. Ensure all connections from the Chemigem to the electricity supply are made
in accordance with local safety codes.
5. Do not bury any electricity supply cords unless strictly following local safety
codes. Locate all cords, wires and tubes away from places where they may
become damaged by garden equipment.
6. The Chemigem contains microprocessors that may be disturbed by the
operation of electrical devices within a 6-metre radius.
7. The Chemigem must be connected so that it only operates when the pool
pump is running, otherwise incorrect pool water readings will occur and
concentrated chemicals may flow into the pool water pipes and/or the
chemical drums, where they can mix and produce poisonous Chlorine gas.
8. Before operating the Chemigem, bring the pool water chemical levels to
within the ranges given in this manual, but pay attention to the specific
requirements of the pool builder.
9. To ensure the desired chemical levels are being maintained, check the pool
water with a good quality test kit. This should be performed daily for the first
two weeks and on a regular basis thereafter.

Page 4
10. Always take water samples from a point near the skimmer box, for this is
where the water is completely mixed, giving the most accurate readings.
Never take water samples near the pool returns (“eye-balls”) where the
Chemigem may have freshly dosed the pool water.
11. It is very important that the reagents in the test kit are well within their use-
by date, otherwise false readings may result. If in doubt, take a water sample
to a pool shop for testing.
12. Chemicals must be carefully diluted according to the size of the pool or spa.
Always add the concentrated chemical to the water and never add the water
to the concentrated chemical. Some chemicals react violently with water and
can splash into face and eyes.
13. Always wear protective face-shield and gloves for such operations. Fully
observe all the chemical manufacturer’s safety instructions when handling
pool chemicals.
14. Ensure the chemical supplies (liquid Chlorine and pool Acid) are kept in
visually different containers to avoid wrong connection. Use colour or size
differences or both. When these two concentrated chemicals are mixed
together out of the pool water, poisonous gas is produced.
15. A qualified electrician must affix the electrical outlet (housing the power to
the pool) and, if required, to hard-wire the unit to the power source.
16. If it is decided to turn off the Chemigem audible alarm for any reason, the
unit will no longer have that warning capability and the pool owner will have
to rely on their own ability to monitor the indicator lights on the face of the
unit to verify that the Chlorine and pH levels are within acceptable limits.
IMPORTANT SAFETY MEASURES:
•Always add concentrated chemicals to water –not the other way around!
•Don’t allow chemicals to mix – dangerous, highly corrosive fumes will be
produced.
•Always wear protective clothing, footwear, gloves and eye protection when
handling pool chemicals to avoid injury.
•If a spill occurs, wash the affected area with fresh water immediately and seek
medical attention.
•Work in a well-ventilated area and avoid inhalation of fumes.
•Read and follow safety instructions on chemical drums.
SAVE THESE SAFETY INSTRUCTIONS

Page 5
Prior to Installation and Operation
Initial pool balance
Before you begin using the Chemigem CM55 make sure your pool water is balanced as
follows:
Chlorine - general
If it is a new installation, add enough chlorine (liquid or granular) to achieve a reading of
3ppm on an appropriate test kit.
Stabiliser - general
If the pool is outdoors, it is vital that stabiliser (also known as cyanurate and cyanuric acid)
be added and maintained at 50ppm. This compound reduces chlorine destruction due to
sunlight. However, too much stabiliser will reduce the effectiveness of chlorine and can
result in poor quality water so ensure stabiliser does not exceed 80ppm.
Good stabiliser level keeps good chlorine levels and reduces maintenance.
pH
For chlorine to be effective, the pH must be within a certain range. This is usually between
6.8 (fibreglass/liner pools) or 7.2 (concrete/plaster) and 7.8.
Adjust pH down with acid –powder, liquid sulphuric or liquid hydrochloric. Be very careful
with acid as it can be harmful and corrosive.
Total Alkalinity (TA)
Total alkalinity is also known as carbonate hardness or TA for short. The recommended
level is between 80 and 120ppm.
TA is related to pH in that it stops the pH from varying quickly with small additions of acidic
or alkaline chemicals. When the TA is low it is almost impossible to control the pH.
To raise the TA, buffer (sodium bicarbonate) is added. This must be done slowly as buffer
will also cause the pH to rise. As an approximate rule every increase of 20ppm of TA will
also cause a 0.1 rise in pH. Once buffer is added it should be left to mix in the pool for a
few hours before reducing the pH.
Phosphates and Nitrates
Phosphate and ammonia nitrogen will make your garden green –and they will do the same
thing to your pool. Check for phosphates and add phosphate remover if necessary. Don’t
let fertiliser get into your pool! Phosphates are also in some cleaning products –check the
label if using around your pool.

Page 6
Chemigem CM55 Operation
It is important that it is installed and operated in accordance with the instructions provided in
this manual.
The Chemigem CM55 is designed to automatically assist in keeping the levels of Chlorine
and pH correctly balanced in swimming pools and spas and can cope with extreme variations
in bather load that is experienced in commercial pools. The unit continuously monitors and
adjusts pH and Chlorine levels while the pool pump is running, as and when required.
Stable controlling of the Chlorine and pH levels of the pool water should be achieved during
the first two weeks of operation. During this period, check the level of Chlorine, Total
Alkalinity and pH regularly with a good quality test kit to confirm that the unit is keeping to
the desired levels.
The chemical levels are set by the keypads. Once the correct positions have been set for
the pool water they should remain constant and do not have be changed from season to
season (however in winter the pool pump running times can be reduced). The unit has been
factory-set to achieve 650mV (milliVolts) Chlorine (ORP) and 7.7pH as the preferred levels
for Chlorine and pH respectively.
Electronic Clock
The Chemigem CM55 has a built-in real-time clock that may require setting to your local
time. It has a battery back-up (which should last for several years) that controls the
automatic switching on and off of the pool pump.
Pool Pump Times
The factory-set pool pump times are referred to on page 25. To change pumping times or to
turn the timer off refer to pages 25-27.
Pool Water Circulation
To enable the Chemigem CM55 to work efficiently, the mixing of the pool water has to be as
quick and complete as possible. Positioning the return nozzles (eyeballs) to the pool so that
the main water-body rotates is the best way to achieve this. Under no circumstances should
the eyeballs be positioned to produce opposing circulation patterns.
The Chemigem CM55’s multi-electrode (probe) monitors the chlorine and pH levels as the
water travels towards the pump. If the mixing of the pool water is slow, the probe will not
receive the signal until large amounts of chemicals have been added to the water.When the
probe finally receives the signal, the pool water may be overdosed and the excess warnings
will operate.
Heated Pool
If the one pool pump is required to service both the filter and the pool heating system, the
pool heating plumbing may need to be bypassed. (Refer to page 15)

Page 7
ITEMS SUPPLIED
Chemigem CM55 Commercial Chemical Controller
Key features:
•A see-through protective faceplate covering the front of the unit
•A computerised on-screen HELP menu
•An automatic pool pump timer
•An easy-to-read screen showing chemical settings and actual chemical readings
•Indicator light and audible alarm showing if pool water chemical levels are in
range
Multi-electrode (Probe)
The Probe is fitted on the inlet (suction) side of the pool pump and one Probe monitors both
the Chlorine and pH levels. Chemical readings obtained by the Probe are monitored by the
Chemigem, and Chlorine and/or pool Acid is dosed into the pool water as required.
Where 40 or 50mm pipe is used, the Probe can be fitted via an injection manifold (sold
separately). Where larger pipe is used, the Probe is fitted inside of the Reducing Nipple that
is then inserted directly into the PVC pipe running to/from the pool.
Tubing
To connect the delivery system to the chemical drums and the injection point.
Do not use any tubing other than that supplied. To do so may result in damage to the
Chemigem CM55 and negate the Warranty.
Filters & Sinkers
Drum Filters are connected to the plastic tubing. One is placed in the Chlorine drum and the
other is placed in the pool Acid drum.
Sinker sets are fitted above the Drum Filters. The purpose of the sinkers is to provide added
weight to the Drum Filters so that the filters do not float and are positioned close to the bottom
of the chemical drums.
Metal Mounting Plate
The metal plate is affixed to a solid surface in a sheltered location. The Chemigem fits onto
the metal plate.
Solenoid Valves or Peristaltic Pumps
Depending on the Chemigem model selected, the controller may be supplied with a set of
solenoid valves or peristaltic pumps.

Page 8
Multiple Sets of Peristaltic Pumps (or Solenoid Valves)
A maximum of four sets of peristaltic pumps (or solenoid valves) can be provided; one for
each pump and filter.
If multiple sets of solenoid valves are used, a Valves Junction Box may be required. The
Valves Junction Box is connected to the Chemigem, with each set of solenoid valves
connected to the Valves Junction Box. If one or more pool pumps are turned off (as may
occur in colder months), the electrical lead to the Solenoid Valves (that would normally
service the turned off pool pump) should be disconnected at the same time from the top of
the valve pack. See Installation Diagram on page 16.
INSTALLATION
Select a good location
For ease of installation and for safety, the Chemigem CM55 should be installed as follows:
•In a normal upright position (with the printing on the front reading horizontally) and
protruding cords facing toward the ground
•Attached to a solid vertical surface to provide easy access to the power supply and
should preferably be fixed at eye level
To obtain maximum life for the unit it is recommended that it be located in a sheltered and
shaded position.
To avoid the risk of electric shock do not use extension cord to connect unit to electric
supply. Provide a properly located outlet.
Refer to pages 15-17 for the special procedures required for the placement of the Chemigem
when the pool pump and filter are located below pool water surface level and when the pool
has a heater unit
Installing the Power Supply
Position the Chemigem CM55 within 2.5 metres of the Probe at a convenient height for easy
operation, preferably at eye level.
If it is impractical to install the unit at eye level because of site restrictions, install it at any
height that provides ease of access and operation in a normal upright position (with the
printing reading horizontally and protruding cords facing toward the ground).
Installation diagrams
The diagram on the next page shows the standard installation method for a Chemigem CM55
utilising peristaltic pumps and the “Drill & Tap” installation method for large diameter pipe.

Page 9

Page 10
“Drill & Tap”Installation for Large Diameter Pipe
The “Drill and Tap” method for fitting the Probe and Injection Elbow is used when the pipe
size is more than 50mm and can be used for both peristaltic pump and solenoid valve
models.
If the pipe size is 50mm or less, it may be preferable to use an injection manifold –please
discuss with Pool Controls the best installation method for your application.
There are two separate installations for the “Drill and Tap” method: one for fitting the Probe
and one for fitting the Injection Elbow.
When drilling and tapping, select a position where the work can be carried out satisfactorily
on the pool pipe. The recommended minimum distance between the Probe and the
Injection Elbow is 100mm. The Injection Elbow is fitted between the Probe and the pool
pump.

Page 11
Installing the Probe
•Remove the Probe protective cap before fitting the Probe
•The protective cap should be retained for possible future use.
•Fully insert the Probe (with “O” ring fitted) into the reducing nipple.
•To avoid contaminating the sensing part of the Probe, do not use grease or sealant on
this connection.
When the Chemigem is working it is essential that the Probe and Injection Elbow be
in a rapidly moving laminar water stream. If not, the unit will display incorrect and
erratic readings and may cause additions of concentrated chemicals. Avoid installing
the Probe and Injection Elbow close together after an elbow in the pipe.
Note that the Probe must be fitted horizontally.
•If the Probe is positioned with the sensor tips aiming downwards it will trap air bubbles
•If the Probe is positioned with the sensor tips aiming upwards it will trap dirt or debris
Both of these positions will cause erratic and false readings of the swimming pool chemical
levels.
Drill and Tap Probe Installation Diagram

Page 12
Injection Elbow Installation
Air Leaks
Before commencing the installation of the Injection elbow, check for air leaks in the suction
line by switching on the pool pump and checking the ‘strainer’. If there are a lot of air
bubbles swirling around which do not clear within 2 to 3 minutes, it is likely the system has
an air leak in the suction line between the pool and the pool pump. If a pool-cleaning
device is in use, carefully check the flexible hose for small pinholes
that allow the entry of air into the suction line.
Turn off the pool pump before commencing the installation. Refer to the general diagram
on page 9:
•The components to be connected to the PVC pipe
•The connection of the Probe to the inlet line
•The location of the Probe must be prior to the Injection Elbow in the water flow.
Drill and Tap Injection Elbow Installation Diagram

Page 13
Installing Peristaltic Pumps
If peristaltic pumps are being used to deliver chemicals, these can be installed on the
pressure side of the pump, after equipment such as heaters. See diagram on page 9.
Fix the peristaltic dosing pump unit to the wall close to the Chemigem CM55 Power Supply
The Injection Elbow is supplied with a gas loop (see illustration on next page). The outlet of
each dosing pump is to be connected to each arm of the gas loop. The pumps are marked
for Acid or Chlorine.
Do not place the Y-piece directly under the pump module –this will reduce the life of
the pump squeeze tubes. Each pump outlet should have a long run of tube with a
gas-trap loop close to the Y-piece near the injection point.(See illustration on next
page.)
Cut a length of tubing that will reach from the base of the peristaltic pump to the injection
elbow including enough for a loop to act as a gas-trap. Connect one end of the tubing
to the outlet side of the peristaltic pump (the direction of flow is indicated by an arrow on
the front cover of the pump.) Connect the other end of the tube with loop to the Y-piece
near the Injection Elbow.
Cut another length of tubing that will reach from the base of the peristaltic pump to the
base of the chemical drum. Connect the end of this tube to the inlet side of the peristaltic
pump - the direction of flow is indicated by an arrow on the front cover of the peristaltic
pump.
Installing Solenoid Valves
The procedure for installing solenoid valves is very similar to that for the peristaltic pumps,
however, special considerations for valve installations are set out on page 15
The solenoid valves must be fitted as near as possible to the injection elbow and the
Chemigem CM55 power supply. Ensure that the tubing is absolutely clean and free from
sand and dirt before fitting, as particles may enter the valve and cause leakage.
The valves must be screwed to a vertical surface, above the top of the chemical drums and
no more than 75mm from the ground so that the pool pump may easily raise the chemicals
from the drums. The chemical drums must be below the valves.
The Injection Elbow is supplied with a gas loop (see illustration on next page). The outlet of
each solenoid valve needs to be connected to each arm of the gas loop. The valves are
marked for Acid or Chlorine.
Cut another length of tubing that will reach from the base of each valve to the base of the
chemical drum. Position the chemical drums in a safe and secure location, preferably
about 2 metres from the Chemigem CM55 Power Supply.

Page 14
Do not place the Y-piece directly under the solenoid valves –this will reduce the life
of the pump squeeze tubes. Each valve outlet should have a long run of tube with a
gas-trap loop close to the Y-piece near the injection point. (See diagram below
Gas Loops Prior to Injection Elbow
Ensure that there are loops to trap gas when
chemicals mix at the Y-piece and injector.
The gas can cause the valve diaphragms or
squeeze tubes to deteriorate faster than normal
resulting in increased maintenance.
Chemical Drum Installation
Ensure the Chlorine and pool Acid are kept in visually different drums to avoid wrong
connection. Use colour or size differences, or both.
Refer to the cutaway diagram of chemical drum on page 16:
Position the Chlorine and Acid drums in a safe and secure location about 2 metres from the
Chemigem CM55
Drill a hole in each of the screw-on drum caps (slightly larger than the diameter of the tubing)
Pass each length of supplied tubing through the hole in the appropriate drum cap
Place the supplied sinkers onto the tubing and attach the appropriate drum filter. When
placing the tubing into the drums, measure the tubing against the outside of each drum so
that the drum filter will be 2cm above the bottom of the drum and then apply several turns of
PVC tape at a point above the cap to prevent the tubing from slipping further into the drum
Lower the drum filter and sinker into the drum and screw on the cap
Refer to page 30 for chemical dilution details.
Neatening Up
Finish the installation by taping all loose wires and tubing together and place off the ground
to prevent damage and possible electrical shorting.

Page 15
SPECIAL CONSIDERATIONS FOR VALVE MODELS
A typical installation of a solenoid valve model Chemigem CM55 is illustrated on the next
page.
It is imperative to fit the Injection Elbow to the inlet (suction) side of the pool pump for
Solenoid Valve installations. The required minimum negative pressure/suction is negative
20 kPa.
In selecting the position for the Injection Elbow on the pool pump inlet pipe, ensure that it is
as near as possible to the pool pump.
Installation Below Pool Water Level
See diagram on page 17
When the pool pump and filter are fitted below the pool water surface level, the suction line
may be under positive pressure even with the pump running. In this case an isolating valve
must be fitted to enable the pump and filter to be serviced.
Fit the Injection Elbow between the isolating valve and the pool pump and close the isolating
valve sufficiently to obtain the required suction so as to allow the unit to operate effectively.
Minimum suction is negative 20kPa when the pool pump is running and the filter is clean.
Methods to obtain improved suction involve using venturi devices or orifice plates. Contact
the supplier of the Chemigem or a qualified pool maintenance technician for information on
these.
If the pool pump is more than one metre below the pool water surface it is essential
to fit Non-Return Valves into the chemical supply tubing to prevent back-flow into the
chemical drums.
Failure to prevent the back-flow into the chemical drums would cause spillage from the
drums, which in turn may result in the two concentrated chemicals mixing together out of the
pool water and producing poisonous chlorine gas. In addition, there is the serious possibility
of personal injury from contact with the chemicals and breathing the fumes.
(Refer to diagram on page 17)
Installation to a Heated Pool
Where solenoid valves are used to dose the pool and one pool pump is required to service
both the pool heating system and the filter, the pool heating plumbing must be bypassed.
This is typically done with a Venturi System which allows chemicals to be injected on the
return (pressure) side of the filtration system.
Note that it is simpler to use peristaltic pumps for these types of installations.

Page 16

Page 17
FITTING SOLENOID VALVE MODEL CHEMIGEM CM55
BELOW POOL WATER SURFACE LEVEL
Note: inlet and outlet isolation valves required for these types of installations.

Page 18
OPERATION OF THE CHEMIGEM CM55
What is ORP?
For over 30 years operators in many parts of the world have used Oxidation-Reduction-
Potential (ORP or Redox) values as a measure of Chlorine activity in water. ORP is a
measure of the oxidising properties of the Chlorine in the water and is easily monitored by
the Chemigem probe (also called a multi-electrode). When the probe is placed into water
containing Chlorine it behaves like an electric cell and creates a small but measurable
electric voltage. This voltage is a measure of the activity (effectiveness) of Chlorine in the
water.
The Chemigem is designed to measure and automatically adjust the Chlorine and pH levels
of the water in all types of pools. Once levels are finally set or adjusted, the unit should be
left alone. The unit has been factory-set to achieve 650mV (milliVolts) Chlorine (ORP) and
7.7pH. It has been found that if ORP is maintained at 650mV, the kill time of E-coli type
bacteria is about one second. If the ORP is lowered to 550mV, the same organisms could
take up to 2 hours to be eliminated.
If the unit is used with these factory-set points as the selected levels, it should obtain
approximately 2-4ppm Chlorine and 7.7pH, providing the stabilizer level is at 50ppm. If the
stabiliser level is 30ppm or less, the Chlorine will be around 1ppm.
A test kit will measure Chlorine as parts per million (ppm) but the activity level of the
Chlorine depends upon the other materials dissolved in the pool water.
Dosing of Chemicals
Dosing of chemicals will commence a few minutes after the pool pump has been switched
on to allow for adequate mixing and accurate sensing. Similarly, the safety warning
sounds and alarm signals will not operate for the first 4 minutes.