POOL LAB EXP Series User manual

OWNER'S MANUAL
PL Series EXP – Expansion Module
IMPORTANT
Read this manual carefully before operating your Pool Lab EXP
Before use ensure the unit is securely mounted as per the I STALLATIO GUIDE in this
manual, with the outlet sockets facing DOW WARDS.
KEEP THIS MANUAL IN A SAFE PLACE
FOR FUTURE REFERENCE
rev. 1
Manufactured by Poolpower Australia Pty Ltd
Factory 1b, 39-45 Susan Street
ELTHAM, VICTORIA, AUSTRALIA 3095
email: [e-mail]
Patented Technology
Patent Technology umbers:
Australia o. 2003240282
Canada o. 2,483,477
France o. FR 1 511 976
Germany o. 603 28 601.1-08
ew Zealand o. 537012
Spain o. EP 1 511 976
Switzerland o. CH 1 511 976
UK o. UK 1 511 976
USA o. 7,988,916

Table of Contents
PACKAGE CO TE TS.........................................................................................................3
EXTRAS – SOLD SEPARATELY................................................................................................................. 3
IMPORTA T SAFETY I STRUCTIO S...............................................................................4
Health and Hypothermia Warnings.............................................................................................................. 4
I TRODUCTIO ....................................................................................................................5
CO TROL PA EL OVERVIEW.............................................................................................6
USER PREFERE CES - SETTI GS..........................................................................................................7
Pool Temperature................................................................................................................................... 7
Spa Temperature.................................................................................................................................... 7
I STALLATIO GUIDE..........................................................................................................8
MOU TI G LOCATIO .............................................................................................................................. 8
Mounting on Brick or Masonry Wall - Example.......................................................................................9
ELECTRICAL POWER CO ECTIO .....................................................................................................10
TEMPERATURE SE SORS..................................................................................................................... 10
HEATER CO ECTIO ............................................................................................................................ 11
AUTOMATIC VALVE ACTUATORS............................................................................................................ 11
AUXILIARY EQUIPME T.......................................................................................................................... 11
PLUMBI G EXAMPLES............................................................................................................................ 11
SYSTEM CO FIGURATIO ..................................................................................................................... 12
Authority Level...................................................................................................................................... 12
Pool and Spa Volumes......................................................................................................................... 12
Heater Configuration............................................................................................................................. 13
Solar Configuration............................................................................................................................... 14
Auxiliary Configuration.......................................................................................................................... 15
Valve Configuration............................................................................................................................... 16
I STALLATIO SCHEMATIC.................................................................................................................... 17
WIRI G..................................................................................................................................................... 17
TROUBLESHOOTI G GUIDE............................................................................................18
WARRA TY I FORMATIO ..............................................................................................20
DOMESTIC APPLICATIO S..................................................................................................................... 20
COMMERCIAL APPLICATIO S................................................................................................................ 20
CO DITIO S............................................................................................................................................ 20
OTES.................................................................................................................................21
2

PACKAGE CONTENTS
Qty escription Image
1 x EXP – Expansion Module
(EXP5 shown)
1 x Water Temperature Sensor
OTE: 2 x additional sensors
are required for solar control
function – sold separately.
1 x Wall Mounting Bracket and
fastener kit
EXTRAS – SOLD SEPARATELY
Pool and Spa Combination systems require a “SPA FLOW SWITCH” to be fitted to the
spa suction line. This is so that the system is able to determine which body of water is
being treated by the chlorinator. It is also required for the solar, heater and automatic
valve actuator functions to operate correctly.
The Integrated Solar controller requires two additional temperature sensors. One is a
roof temperature sensor for measuring available solar energy, and the other is for the solar
collector water inlet temperature.
Automatic Valve Actuators can be fitted for automated control of pool and spa flow
control valves, as well as up to two additional valves for other functions such as solar
control, in-floor cleaning systems, or water features, etc.
3

IMPORTANT SAFETY INSTRUCTIONS
➔Read all sections of this owner's manual before installing or operating the
equipment
➔Do not allow children or any unqualified person to operate or perform any
maintenance on this equipment.
➔Always ensure free chlorine level is maintained above 1.0ppm and avoid free
chlorine levels above 3.0ppm
➔Ensure water is regularly tested by a pool professional, and ensure all aspects of
water balance are properly maintained.
➔Do not allow bathers to use pool or spa if the free chlorine level is above 8.0ppm
➔FOR SPA O LY I STALLATIO S: Proper sanitation requires the spa be
periodically drained completely. As a guide, the number of days between complete
spa drainage should be equal to the volume of the spa in litres, divided by 10 times
the maximum number of daily spa users
Health and Hypothermia Warnings
➔People with medical conditions should consult a physician before entering pool or
spa water
➔Maximum spa water temperature is 40 degrees C
➔Bathing time in spa water at (or near) 40 degrees C should not exceed 15 minutes
4

INTRO UCTION
The Pool Lab EXP (Expansion Module) is a feature packed pool and spa automation
system that integrates all of your equipment into one powerful controller.
Available in two models to suit your requirements:
All models features integrated gas heater and solar heating system controls, and
connections for up to four automated flow control valves.
EXP5 – is a plug-in appliance that comes with a standard 10 Amp power lead. This model
is simple to install, and installation does not require an electrician.
Features 5 x 240V, 10 Amp outlet sockets and is perfect for smaller systems where the
total load of the connected equipment does not exceed 10 amps.
EXP9 – is a hard-wired appliance that requires an electrician for installation. This model
features 9 x 240V, 10 Amp outlet sockets separated into two 15 Amp circuits for a
maximum total load of 30 Amps.
Flexible configuration options allow the Pool Lab EXP to adapt to almost any residential or
small commercial pool and spa configuration.
The solar controller can be configured to suit both integrated or isolated solar systems with
options to suit simple valve controlled systems, booster pump (retro-fit) systems, or even
multiple pump solar systems.
Multiple outputs can be grouped together where preferable, for example where multiple
lighting transformers are connected and you do not need to control them independently.
Over 20 years of ground breaking research and development have led to this unique
Australian product, with pool owner's globally enjoying the benefits of Pool Lab's
innovative technology.
Welcome to Pool Lab!
5

CONTROL PANEL OVERVIEW
LCD DISPLAY
–The display has three top level views, and a menu system:
HOME – Displays running mode, chlorine and ph levels.
TIME/DATE – Displays current time and date
TIMER – Displays filtration O / OFF times
MAI ME U – Access settings and configuration items
UP / DOW BUTTO S
–Adjust the chlorine output level (view “HOME”)
–Adjust the time / date (view “TIME/DATE”)
–Adjust the O / OFF times (view “TIMER”)
–avigate menu system (menu system list views)
–Adjust values (menu system field editing)
VIEW BUTTO
–Switch between LCD display top level views
–Moves to the next adjustable field, or set adjusted field
–Hold for 5 seconds to enter the MAI ME U
(view “HOME” only)
–Select a menu item, or edit a field (menu system views)
BACK BUTTO
–Return to previous view, or return to view “HOME”
–Exit adjustment mode
–Display detailed cell output data (view “HOME”)
MODE BUTTO
–Toggle O / OFF / AUTO running mode.
–Returns to HOME VIEW (from any top level view)
6

USER PRE ERENCES - SETTINGS
User preferences can be changed at any time. The SETTI GS menu is accessed from
the MAI ME U. The following settings are available:
Pool Temperature
Use the UP/DOW buttons to adjust the value between 0 – 40°C (default setting 25).
This temperature limit will be used for gas and solar heating when the system is in POOL
mode.
In the case of an ISOLATED solar system that always returns water to the pool, this
temperature limit will be used for solar heating in both POOL and SPA modes. This allows
the solar system to heat the pool while the spa is in use.
Gas heating will only be used in POOL mode if the HEATER configuration item HEAT
POOL is set to YES.
Solar heating will only be used in POOL mode if the SOLAR configuration item HEAT
POOL is set to YES.
Spa Temperature
Use the UP/DOW buttons to adjust the value between 0 – 40°C (default setting 35).
This temperature limit will be used for gas and solar heating when the system is in POOL
mode.
Gas heating will only be used in SPA mode if the HEATER configuration item HEAT SPA is
set to YES.
Solar heating will only be used in SPA mode if the SOLAR configuration item HEAT SPA is
set to YES.
7

INSTALLATION GUI E
MOUNTING LOCATION
The EXP module must be mounted on a vertical wall or post, with the power sockets
facing downwards.
The unit will need to be mounted within approximately 2.5 meters of the Pool Lab
Chlorinator control box to allow connection of the data cable. Both units must be mounted
outside the pool zones as defined by A / ZS 3000:2000.
As a general rule for swimming pools, the Pool Lab units must be mounted at least 3.5
meters away from the inside edge of the pool to be clear of the pool zones, and at least
45cm above the ground to protect the outlet sockets from water being splashed up from
the ground.
The EXP module should be mounted so that the equipment can be easily connected.
Masonry plugs and screws are provided with the mounting bracket, and the screws
provided are also suitable for mounting to timber.
Secure the mounting bracket in place with the slotted edge to the top, and ensure the
bracket is level and firmly secured before mounting the EXP module onto it.
The bracket at the back of the EXP module hooks over the slots on the top edge of the
mounting bracket. Secure the EXP module to the bracket with the M3x16mm screws
provided.
8

Mounting on Brick or Masonry Wall - Example
•Use the bracket as a stencil to mark the hole locations. Avoid locating holes near
the edge of bricks or in mortar joints where possible. Ensure the bracket is level
and the slotted edge is to the top.
•Use a hammer drill with a 6.5mm masonry bit, and drill holes to a depth of at least
40mm.
•Use a hammer or mallet to drive the masonry plugs provided into the drilled holes.
•Attach bracket to the wall with the screws provided, and ensure screws are firmly
tightened using a Phillips Head screwdriver, or clutched drill / driver with a PH2 bit.
•Mount the EXP module by hooking the bracket at the back of the unit into the slots
in the top of the bracket. Secure the unit to the bracket with 2 x M3x16mm screws
provided.
9

ELECTRICAL POWER CONNECTION
EXP5 models are fitted with a power cord for connection to a standard 10 amp power
outlet. The unit is protected from overload by a 10 amp manual reset circuit breaker.
EXP10 models require an electrician to complete the electrical power connections before
commissioning the unit. The power input is divided into two 15 amp circuits with a manual
reset circuit breaker on each circuit. Power may be provided by either 1 x 32 amp circuit,
or 2 x 16 amp circuits. An isolator switch must also be installed nearby.
The Pool Lab EXP module is intended to be powered at all times. Power should only be
turned off when the system is not in use for an extended period of time.
TEMPERATURE SENSORS
FILTRATION CIRCUIT TEMP SENSOR
The Pool Lab EXP is shipped with 1 x temperature sensor included for the filtration circuit.
This sensor should be installed on the filtration system pipework before any solar or other
heating equipment. This sensor is required for the integrated gas heater controller to
function, and also enables water temperature display.
–Find a suitable location as close to the EXP module as practical.
–If the pipework is below water level, close isolation valves.
–Drain water from the pipework if necessary.
–Drill a 10mm hole in the pipe, and insert the temperature sensor. Fix in place with
the gear clamp provided.
–Run the temperature sensor wire to the EXP module terminal block at the base of
the unit. Fix wiring to the pipework with cable ties where necessary.
–Trim length if required.
–Connect temperature sensor wires to terminals marked FILTER CIRCUIT TEMP
SE SOR (any polarity).
Note: The terminal block is removable to make connection easier.
SOLAR TEMP SENSORS
If the integrated solar controller is to be used this will require 2 x additional temperature
sensors which are sold separately. *** SOLAR SE SOR KIT??? ***
One must be installed on the pipework on the inlet side of the solar collector in a location
where the water does not drain from the system. Generally the inlet side of the solar pump
is an ideal location.
This sensor should be connected to the terminals marked SOLAR I LET TEMP SE SOR.
The other sensor should be installed away from the pipework in a location that is exposed
to direct sunlight at approximately the same time as the solar collector.
*** Fit outer sheath??? ie. Piece of solar matting???***
This sensor should be connected to the terminals marked SOLAR ROOF TEMP SE SOR.
10