POOL LAB MINERAL LAB ML45 User manual

OWNER'S MANUAL
Mineral Lab Automatic Chlorinator by Pool Lab
IMPORTANT
Read this manual carefully before operating your Mineral Lab Automatic Chlorinator
Ideal Salinity@ 25 ºC = 3000 m
Ideal Magnesium Level = 100 m
KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE
rev. 16.1
CLR-P 4- 74
Manufactured by Poolpower Australia Pty Ltd
Factory 1b, 39-45 Susan Street
ELTHAM, VICTORIA, AUSTRALIA 3095
email: [e-mail]
Patented Technology
Patent Technology Numbers:
Australia No. 004 45133
Canada No. 5 8374
Europe No. 04736187.8
New Zealand No. 544430
USA No. 7,658,84

IMPORTANT SAFETY INSTRUCTIONS
When installing and using this electrical equipment, basic safety precautions must always
be followed.
READ AND FOLLOW ALL INSTRUCTIONS
•WARNING: Disconnect all AC power during installation and or removal of the
equipment.
•WARNING: Potential risk of fire, electric shock, or injury to persons if the
installation and safety instructions listed in this manual, and on the equipment itself
are not followed.
•WARNING: To reduce the risk of injury, do not permit children to use this
equipment unless they are closely supervised at all times.
•WARNING: Always wear safety goggles and suitable gloves when handling pool
chemicals, and follow usage directions carefully.
•WARNING: Use of a suitable respirator is recommended when handling
Hydrochloric Acid (aka. Muriatic Acid).
•DANGER: DO NOT ADD WATER TO ACID. Always add acid to water
•SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
•Heavy pool (or Spa) usage, and/or higher temperatures may require higher chlorine
output to maintain proper free chlorine residuals.
•If additional chlorine is required due to heavy bather loads, use liquid chlorine
(Sodium Hypochlorite) to maintain appropriate free chlorine residual.
•High salt or chlorine levels above recommended range may contribute to corrosion
of pool or spa equipment.
•DO NOT add pool or spa chemicals directly to the skimmer.
•Check expiry dates of test kit consumables.
•Use only original Pool Lab replacement cells with identical model numbers.
•Follow all aspects of local and national Electrical Codes when installing Pool Lab
equipment.
•For outdoor pools, chlorine residuals can be protected from destruction from the
sun by appropriate addition of stabilizer (cyanuric acid)
•Excessive Magnesium concentration above 00ppm may contribute to staining of
pool surfaces
Health and Hypothermia Warnings
•People with a medical condition should consult a physician before entering the pool
or spa water.
•Maximum safe spa water temperature is 40ºC.
•Bathing in water at 40ºC should not exceed 15 minutes.

Table of Contents
IMPORTANT SAFETY INSTRUCTIONS...............................................................................
Health and Hypothermia Warnings..............................................................................................................
GENERAL PRECAUTIONS...................................................................................................5
ELECTROLYTIC CELL PRECAUTIONS...............................................................................5
INTRODUCTION....................................................................................................................6
CELL MAINTENANCE...........................................................................................................7
TO REMOVE & INSPECT THE ELECTRODE............................................................................................. 7
CLEANING THE ELECTRODE – CALCIUM SCALE...................................................................................8
INSTALLING THE ELECTRODE................................................................................................................. 8
CONTROL PANEL OVERVIEW.............................................................................................9
SETTING THE TIME AND DATE.........................................................................................10
SETTING ON / OFF TIMERS..............................................................................................10
SPECIAL FEATURES..........................................................................................................11
USER AUTHORITY LEVEL....................................................................................................................... 11
PUMP PROTECTION MONITOR.............................................................................................................. 11
RECOVERY MODE................................................................................................................................... 1
PLUMBING FLUSH................................................................................................................................... 1
SPA FLOW (PL PLUS AND MAX MODELS ONLY)...................................................................................1
DIAGNOSTIC VIEW.................................................................................................................................. 13
CELL TESTING FUNCTION...................................................................................................................... 13
Wi-Fi® (PL MAX MODELS ONLY).............................................................................................................14
Getting Started...................................................................................................................................... 14
How to Reset the Wi-Fi Module................................................................................................................. 15
MINERAL LAB CHLORINATOR MODELS..........................................................................16
Mineral Lab Classic................................................................................................................................... 16
Mineral Lab Plus........................................................................................................................................ 16
Mineral Lab MAX....................................................................................................................................... 16
Mineral Lab HYBRID (PL COMM & PL LT)................................................................................................16
RATED CHLORINE OUTPUT....................................................................................................................16
ADD-ON MODULES............................................................................................................17
ASP........................................................................................................................................................... 17
EXP........................................................................................................................................................... 17
HYDROGEN GAS SAFETY....................................................................................................................... 18
DIAGNOSTIC MESSAGES.................................................................................................19
CHECK SALT............................................................................................................................................ 19
CHECK SALT CELL OFF........................................................................................................................... 19
HIGH SALT................................................................................................................................................ 19
HIGH SALT CELL OFF.............................................................................................................................. 19
PUMP PROTECTION ACTIVE.................................................................................................................. 0
LOW FLOW............................................................................................................................................... 0
SPA FLOW DETECTED............................................................................................................................ 0
SCALE WARNING..................................................................................................................................... 0
DEFAULTS USED..................................................................................................................................... 0
MEMORY FAULT....................................................................................................................................... 0
CHLORINE PRODUCTON AND CONTROL....................................................................... 1
FREE CHLORINE LEVEL.......................................................................................................................... 1
ALTERING CHLORINE OUTPUT.............................................................................................................. 1
WATER BALANCE...............................................................................................................
pH..............................................................................................................................................................
TOTAL ALKALINITY...................................................................................................................................
CALCIUM HARDNESS..............................................................................................................................
SALT LEVEL..............................................................................................................................................
CHLORINE STABILIZER – CYANURIC ACID........................................................................................... 3
3

Combined Chlorine - Chloramines........................................................................................................ 3
High Calcium (Hard) water sources – the Langlier Saturation Index......................................................... 4
WATER CIRCULATION....................................................................................................... 5
INSTALLATION.................................................................................................................... 6
PLUMBING................................................................................................................................................ 6
Cell Installation..................................................................................................................................... 6
Positioning the Cell............................................................................................................................... 6
Plumbing Example................................................................................................................................ 7
POWER SUPPLY AND CONTROLLER..................................................................................................... 8
Mounting to brick or masonry................................................................................................................ 8
Mounting to timber post or beam.......................................................................................................... 9
THIRD PARTY EQUIPMENT CONTROLLERS.........................................................................................30
POWER RATINGS (Domestic Models)......................................................................................................31
PL 5 Classic/Plus/Max and PL ECO....................................................................................................31
PL35 Classic/Plus/Max......................................................................................................................... 31
PL45 Classic/Plus/Max......................................................................................................................... 31
POWER RATINGS (Commercial Models).................................................................................................. 3
PL COMM............................................................................................................................................. 3
PL LT.................................................................................................................................................... 3
Power Consumption ................................................................................................................................. 3
Pool Lab Add-on modules and accessories...............................................................................................33
ASP...................................................................................................................................................... 33
EXP...................................................................................................................................................... 33
SPA FLOW SWITCH (Plus and MAX models only)..............................................................................33
Mineral Lab Hybrid (PL COMM & PL LT) Models Installation.....................................................................34
SALT AND MINERALS.........................................................................................................35
INITIAL SALT DOSING.............................................................................................................................. 35
INITIAL MINERAL DOSING....................................................................................................................... 35
SALT ADDITION TABLES.......................................................................................................................... 36
MINERAL ADDITION................................................................................................................................. 36
TROUBLESHOOTING.........................................................................................................37
WARRANTY INFORMATION ..............................................................................................40
4

GENERAL PRECAUTIONS
•Do not use bromine based products in the pool. Use of bromine will void the
warranty on your chlorine cell.
•Avoid the use of ersulfate based products as this can adversely affect free
chlorine test results. Pool Lab recommends to shock dose with liquid chlorine.
•It is the pool owner's responsibility to ensure water is regularly tested and balanced.
Your local pool professional can advise you on appropriate testing frequency and
balance criteria in your area.
•Where calcium hardness of the pool / spa water exceeds 00ppm, the water must
be balanced as per the Langlier Index to ensure water is not scale forming. Consult
you local pool professional for advise.
•Do not assume the chlorinator is faulty if a chlorine test reveals a low free chlorine
level. There are many factors that relate to chlorine demand in the water. Refer to
the troubleshooting guide in this manual for more information
•Regular manual 'super chlorination' or 'shock dosing' may be required in pools
where chlorine demand or bather load is high.
•Manual addition of liquid chlorine may be required to supplement chlorine
requirement during peak usage periods.
•Test salt level before calculating your salt addition requirements, even on a new
installation – especially where liquid chlorine had been used previously.
•Free chlorine levels above 4.0ppm may void manufacturer warranties on your
equipment.
•Unnecessarily high salt levels may contribute to corrosion of pool and spa
equipment.
•Pool Lab recommend the use of Cyanuric Acid (Stabilizer) at a concentration
of between 50-80 m for outdoor ools to hel rotect chlorine in the water
from destruction by sun light
ELECTROLYTIC CELL PRECAUTIONS
•It is a condition of the warranty that the ool owner ensure that the cell is
ins ected and maintained in accordance with the directions in this manual.
•The chlorine cell is generally self cleaning, but certain water conditions can inhibit
the effectiveness of this function. Therefore the cell should be visually inspected on
a regular basis to ensure it is not fouled with debris or accumulating calcium. Refer
to instructions on cleaning the cell in this manual if required.
•If calcium scale is allowed to build up on the electrode plates to the point where the
calcium bridges the gap between the plates, this can permanently damage the
electrode and will void the electrode warranty.
•If you have water conditions that cause calcium to build up in the chlorine cell, then
the cell MUST be cleaned on a regular basis as per the instructions in this manual.
As a general rule, if the cell requires more than 15 minutes to clean, then it must be
cleaned more regularly.
•It is the ool owner's res onsibility to ensure all materials in contact with the
ool or s a water are com atible with and intended for use with an
electrolytic salt chlorinator.
5

INTRODUCTION
Congratulations, you have wisely purchased the most technologically advanced mineral
chlorinator in the world. The benefits of doing so will be evident for many years to come.
Pool Lab’s research and development team is committed to producing the finest
chlorination systems and being recognized world wide as the leaders in salt and mineral
chlorination technology.
Mineral Lab's exclusive mineral additives are made with the highest purity magnesium to
provide a luxurious bathing experience that will leave your skin feeling silky, soft and
hydrated after bathing.
Your Mineral Lab chlorinator will eliminate the need to store dangerous quantities of
chlorine, daily manual chlorine dosing and the risks associated with these practices. It is
automatic, clean, safe and economical and for these reasons, mineral chlorination as a
method for treating pool water is increasing world-wide.
Mild salt water enhanced with minerals is gentle on eyes and skin and is said to benefit
asthma sufferers and those people who find conventional chlorinated pools irritating. The
salinity of seawater is approx. 35,000ppm or 3.5%, while Mineral Lab chlorinators require
only 3,000ppm or 0.3%. The human body has a salinity of approx. 4500ppm and fresh
water is zero. It is the similarity between the salinity of the human body and that of a
Mineral Lab pool that make for a silky luxurious swimming experience.
The chlorinator comprises two basic components, the power supply and cell. It is within the
cell that the electrolytic reactions occur. Chloride ions in the water are converted into
chlorine gas, this dissolves immediately into the water to ultimately form sodium
hypochlorite (liquid chlorine). The chlorine oxidizes bacteria, algae and other harmful
matter in the pool water and through this process reverts back into available chloride ions.
UV light from the sun reacts with chlorine in the pool to produce hydroxyl radials to further
assist in removing organic and even some inorganic contaminants in the water.
With the addition of Mineral Lab minerals the electrolytic process also produces
Magnesium Hydroxide, a mild coagulant which greatly assists filtration to clarify the water
and ensure your pool is crystal clear.
The major by-product of the reaction in the cell is the liberation of Hydrogen gas at the
cathode. This explains the small bubbles often seen passing out of the pool returns. Pool
Lab’s patented vertical cell is the worlds safest and ensures the excess hydrogen gas can
not accumulate to dangerous levels.
No salt or magnesium is lost through the electrolytic process. The necessity to top up the
salt and magnesium levels are only due to loss of water from backwashing or splashing
out etc. Water loss due to evaporation does not cause any loss of salt or minerals.
All models have a built in back u ower system that will kee the timer clock
running for u to 7 days. This is articularly useful where the mains ower is
interru ted. Mineral Lab does not contain batteries.
6

CELL MAINTENANCE
Where calcium levels are below 00ppm, the mineral content is low and the water is
correctly balanced, little or no maintenance to the cell is normally required. The automatic
reversing of the electrode polarity will be sufficient to dissolve the calcium scale formed.
Periodic inspections must however be made to ensure scale and or debris is not forming
or building up on the electrodes within the cell. If a calcium scale has formed it must be
removed by cleaning in an acid solution.
Where calcium levels are higher than 00ppm and or mineral content is high, regular
inspections of the cell must be performed. If calcium scale is present, the cell must be
cleaned in an acid solution. The higher the water temperature, the greater the capacity for
the water to deposit scale on the cell. Each pool will vary with regard to the frequency of
cell maintenance. Factors which increase the cell cleaning frequency are:
•Calcium Hardness above 00ppm
•High Water Temperatures
•Low water velocity
•Poor Water Balance
•Excessive salt level
•Electrode breakdown – ensure a qualified technician evaluates the cell
TO REMOVE & INSPECT THE ELECTRO E
•Switch off power to the chlorinator and pump(s).
•Close all relevant valves – especially where the cell is located lower than the pool
water level, or where the pump(s) are significantly above the water level.
•Unplug the cell cable from the cell, and place cable end in a dry location.
•Loosen the large cell nut, and remove it from the cell.
•Carefully remove the electrode from the cell housing. Where the cell is located
above the pool water level, and the cell is not completely isolated by valves, beware
that there may be a vacuum in the cell housing. This can sometimes make the
electrode difficult to remove. Take care not to lose the o-ring.
Depending on your system setup, the vacuum can sometimes be relieved by briefly
pushing down on the multi-port valve handle on a sand filter, or by opening a relief
or drain valve momentarily.
•Visually inspect for debris accumulated at the bottom of, or between the electrode
plates. Most debris can usually be cleared by simply dunking the electrode up and
down rapidly in water. Excessive debris could indicate a filtration problem.
* DO NOT USE A METAL TOOL TO REMOVE DEBRIS AS THIS WILL DAMAGE
THE ELECTRODE COATING!!
* DO NOT ATTEMPT TO MANUALLY REMOVE ANY CALCIUM SCALE
•Visually inspect between the electrode plates for calcium build up. This appears as
a hard white material that coats the surface of the plates and can also bridge the
gap between the plates. Electrode plates should be smooth and matte black.
7

CLEANING THE ELECTRO E – CALCIUM SCALE
You will need hydrochloric acid (33%), and a plastic container or bucket deep enough to
stand the electrode vertically in with the electrode plates fully submerged. The container
or bucket should be preferably not too broad, as this will require a larger amount of acid.
A standard 10 Litre bucket is usually acceptable.
You will also need safety goggles and protective gloves.
•Remove any loose debris from the electrode by dunking it up and down rapidly in
water.
•In your container or bucket mix approximately 1 part hydrochloric acid to 5 parts
water. Make the solution slightly too shallow at first, then top up later with water to
just cover the electrode plates.
Note Less acid can be used (down to 1 10 ratio) if the calcium build up is not too
excessive, but the cleaning process will take longer.
ALWAYS PUT WATER IN THE CONTAINER FIRST, THEN ADD ACID.
•Carefully place and stand the electrode in the container, taking care NOT to
submerge the to art where the electrical connector is. Top up the container with
fresh water if required until the electrode plates are just covered by the solution.
Note ACID REACTING WITH THE CALCIUM SHOULD PRODUCE BUBBLES
•Leave the electrode in the solution until the bubbles stop. The reaction will usually
be fast initially, then slow down.
•Once you are satisfied the reaction has stopped, carefully remove the electrode
from the solution, and rinse with fresh water.
Note If calcium scale was excessive you may need to repeat this process with a
fresh acid solution.
•Visually inspect the cell to ensure you are satisfied it is clean. If some scale-like
build up remains and it appears that acid is not removing it, then it may not be
calcium scale. You can try rinsing the cell with hot tap water (not boiling water)
which can sometimes help.
INSTALLING THE ELECTRO E
•Visually inspect the condition of the o-ring, and replace if necessary.
•Apply a small amount of silicone grease to the o-ring if required.
•Fit the o-ring to the cell head, ensuring it is on the bottom side of the cell head
flange (same side as the electrode plate bundle).
•Fit the electrode into the cell housing, and orient it so that the cell cable can plug
into the cell easily and comfortably.
•Fit the cell nut, and tighten by hand only.
•Connect the cell cable to the cell.
•Open any valves that were closed prior to the electrode being removed.
•Re-connect power to the chlorinator and pump(s).
•Run the system – and check for any leaks.
8

CONTROL PANEL OVERVIEW
LCD DISPLAY
–The display has three top level views, and a menu system:
HOME – Displays running mode and chlorinator output.
TIME/DATE – Displays current time and date
TIMER – Displays filtration ON / OFF times
MAIN MENU – Access settings and configuration items
UP / DOWN BUTTONS
–Adjust the chlorine output level (view “HOME”)
–Adjust the time / date (view “TIME/DATE”)
–Adjust the ON / OFF times (view “TIMER”)
–Navigate menu system (menu system list views)
–Adjust values (menu system field editing)
VIEW BUTTON
–Switch between LCD display top level views
–Moves to the next adjustable field, or set adjusted field
–Hold for 5 seconds to enter the MAIN MENU
(view “HOME” only)
–Select a menu item, or edit a field (menu system views)
BACK BUTTON
–Return to previous view, or return to view “HOME”
–Exit adjustment mode
–Display detailed cell output data (view “HOME”)
MODE BUTTON
–Toggle ON / OFF / AUTO running mode.
–Returns to HOME VIEW (from any top level view)
9

SETTING THE TIME AND DATE
Time is displayed in 4 hour format. 00:00 is midnight, 1 :00 is midday.
Date is displayed in day / month / year format.
Setting the correct date will allow the system to automatically adjust for daylight savings
time.
The clock will continue to run for several days without power. If power is disconnected for
an extended period of time, the clock may reset.
–Press the VIEW button once from the HOME VIEW to display the TIME / DATE
VIEW.
–Current time and date settings are displayed.
–Press either the UP or DOWN button once to enter adjustment mode.
–The HOUR digits will be flashing to indicate adjustment mode.
–Use the UP and DOWN buttons to select the correct HOUR value
–Press VIEW to switch to the MINUTES field.
–Use the UP and DOWN buttons to select the correct MINUTES value
–Continue this process for YEAR, MONTH, and DAY fields.
–Press VIEW to save the settings.
SETTING ON / OFF TIMERS
Two separate ON / OFF time periods for the filtration pump are available. You can use
either one, both or none of these depending on your requirements.
Time periods can be set to traverse midnight.
Time periods can overlap, in which case they will be treated as one time period.
Either or both of the timers can be disabled by setting both ON and OFF times the same.
A disabled timer will show ON and OFF times as dashes (--:--)
Timers are labeled #1, and # .
The first column shows the ON time.
The second column shows the OFF time.
Time period settings should be retained even after extensive periods without power.
–Press the VIEW button twice from the HOME VIEW to display the TIMERS VIEW.
–Current ON / OFF times are displayed.
–Press either the UP or DOWN button once to enter adjustment mode.
–The HOUR digits of ON time #1 will be flashing to indicate adjustment mode.
–Use the VIEW button to cycle to the field you need to adjust.
–Use the UP and DOWN buttons to select the correct value.
–When finished, use the VIEW button to cycle past the last adjustable field to save
the settings.
10

SPECIAL FEATURES
USER AUTHORITY LEVEL
To prevent accidental changes to critical settings, the Mineral Lab incorporates a user
authority level. By default the authority level is set to USER. Before any critical settings
can be edited, the user authority level must be raised to INSTALLER. There is also a
LIMITED level which prevents adjustment of all settings, and there are also TECHNICIAN
and FACTORY levels which require a PIN.
To enable editing of system settings, you must first raise the AUTHORITY level to
INSTALLER.
–From the HOME VIEW, press and hold the VIEW button for at least 5 seconds.
–This will show the MAIN MENU.
–Navigate to SYSTEM CONFIG, and press VIEW
–Navigate to AUTHORITY, and press VIEW
–Press VIEW again to edit the AUTHORITY setting.
–Press the UP / DOWN keys to change the setting to INST (ie. INSTALLER)
–Press the VIEW button to save the setting.
–Press BACK button twice to return to MAIN MENU
PUMP PROTECTION MONITOR
This feature monitors the amount of time the system has been in a low flow situation and
will turn off the filtration pump after a predetermined amount of time to protect the pump
from damage. For systems with a sand filter we recommend a minimum of 5 minutes so
that the feature does not interrupt backwashing.
To set the PUMP PROTECTION TIME period:
–Set the AUTHORITY level to INSTALLER as described above.
–From the MAIN MENU navigate to SETTINGS, and press VIEW.
–Navigate to the PUMP PROTECTION field and press VIEW to edit.
–Use the UP and DOWN buttons to adjust the time in MINUTES.
–Press the view button to save the setting.
–Press the BACK button to exit.
The pump protection feature will be enabled when the PUMP PROTECTION TIME is set to
any number greater than ZERO.
To disable PUMP PROTECTION MONITOR, set the PUMP PROTECTION TIME to ZERO.
11

RECOVERY MO E
(included in software revision CLR-P24F-253 and above)
Recovery mode will run the filtration system and chlorinator for the amount of time set in
SETTINGS - RECOVERY (default setting is 4 hours), then revert back to AUTO filtration
mode. This may be useful when additional filtration and/or chlorination is required after
periods of heavy use, or when cleaning / preparing a pool for the swimming season.
To enter RECOVERY mode:
–From the HOME view, press and hold the UP button for at least 5 seconds.
–The display will cycle to show the recovery time remaining.
To exit RECOVERY mode:
–Press the MODE button once to put the system into OFF mode.
–This will cancel the recovery timer.
–Set the mode as required to resume normal operation.
To set the RECOVERY MODE timer period:
–From the MAIN MENU navigate to SETTINGS, and press VIEW.
–Navigate to the RECOVERY field and press VIEW to edit.
–Use the UP and DOWN buttons to adjust the time in HOURS (1 – 48 hours).
–Press the view button to save the setting.
–Press the BACK button to exit.
PLUMBING FLUSH
This feature is automatic, no programming or adjustments are necessary. When in AUTO
mode, the cell power will automatically switch off 30 seconds before the pump to ensure
cell housing and plumbing is flushed of concentrated chlorine. This unique feature
prevents high chlorine levels in the pipework diffusing through and corroding heater tube
bundles and the possibility of damaging other sensitive equipment up-stream of the cell.
SPA FLOW (PL PLUS AN MAX MO ELS ONLY)
A spa flow switch (sold separately) is available for use on pool and spa combination
systems. This should be installed on the spa suction line so that the Pool Lab Chlorinator
will know when the spa is in use. Stand-alone chlorinators will cease chlorine production
when the spa flow switch is activated to prevent over-chlorination of the spa while in use.
If a Pool Lab ASP is connected, the system will adjust its chlorine and acid delivery
algorithms to suit the smaller volume of water while the spa is in use.
1

IAGNOSTIC VIEW
To access the Diagnostic View, from the HOME VIEW press and hold the BACK button for
approx. 3 seconds until the DIAGNOSTIC VIEW appears.
This view is designed to help diagnose any problems with the power supply or electrode,
and shows real-time information on the power output to the cell.
VOLTS is the output voltage of the internal power supply. This should be in the range of
4 – 6 V under normal operating conditions. The voltage may drop slightly when the
chlorinator cell is active.
AMPS is the output current to the chlorinator cell. Under normal operating conditions this
may cycle ON and OFF over a 3 minute DUTY CYCLE to regulate the chlorine output (if
the cell current is high enough).
The cell polarity is indicated by a “+” or “-” symbol before the cell AMPS. The cell polarity
will automatically switch occasionally to assist in descaling of the cell electrode plates.
Consult the Pool Lab PL Series Technical Manual for more information on cell diagnostics.
To force a cell polarity change press and hold the VIEW button. This allows the user to
compare the cell performance on each polarity.
To initiate the CELL TESTING function press and hold the UP button.
CELL TESTING FUNCTION
(included in software revision CLR-P24F-274 and above)
The cell testing function is accessed from the DIAGNOSTIC VIEW (above). This should
only be performed if you have been instructed to by a qualified service person, or if you
suspect there is a problem with the chlorinator cell.
This is a very basic self-diagnosis program that will compare the cell current on each
polarity and show the user a basic diagnosis.
The prerequisites for this test are that the system must be in MANUAL ON mode. From
the HOME VIEW use the MODE button to select ON.
For best results the chlorinator cell should be cleaned prior tot he test as per the CELL
MAINTENANCE section of this owner's manual.
“AMP DIFF x.x%” shows the calculated percentage difference between the two cell
polarities. This should be <10% if the cell is working correctly.
“SALT LEVEL OK” indicates that the salt level appears to be suitable for the test.
“FLOW OK” indicates there were no flow issues during the test.
“TEST COMPLETED” indicates the test completed without interruption.
“PASS / GOOD CELL” indicates that no problems were found
For more information consult the Pool Lab PL Series Technical Manual.
13

Wi-Fi® (PL MAX MO ELS ONLY)
PL Max model chlorinators are equipped with a Wi-Fi module that will allow remote control
and monitoring of your system via the mobile apps available for iOS and Android.
A small Wi-Fi antenna is supplied in the box along with your Mineral Lab MAX model
Chlorinator. After the chlorinator is installed, attach the antenna to the connector on the
bottom of your chlorinator. Tighten nut with fingers only – do not over tighten.
When you first power up a new chlorinator the Wi-Fi module will be in setup mode (aka.
Hotspot mode) and will appear as a wireless access point with SSID “poolLab”. It will
remain in this mode for up to hours before timing out. If you do not complete setup
within two hours, you will need to reset the Wi-Fi module (next page) or cycle power to the
chlorinator to restart setup mode.
Getting Started
Download the app on your mobile device from the app store. Search for “Pool Lab”, by
Poolpower Australia Pty Ltd.
Open the app and sign up for a free account. This will require an account name, email
address and password.
Sign into your account, and the setup wizard will begin automatically.
The first step is to let the app know which Wi-Fi network you wish the Mineral Lab
Chlorinator to connect to – for example, your home Wi-Fi. You will also need to enter the
password for this connection as this information will need to be sent to the Mineral Lab
Chlorinator after the next step.
The second step is to search for your Mineral Lab chlorinators Wi-Fi module, which should
be in setup mode (aka. Hotspot mode). It should appear as a network with the name/SSID
“poolLab”. Depending on your operating system and security settings it may ask for a
password, which is “1 3456789”.
Once you have completed this step, the connection details for your selected Wi-Fi network
will be sent to the Mineral Lab Chlorinator via a secure peer-to-peer connection. The
Mineral Lab chlorinator will then attempt to connect to the network you selected, and if
successful the Setup Wizard will finish automatically.
If the setup wizard fails for any reason you may need to restart it and try again.
If the “poolLab” network does not appear, you may need to cycle power to your chlorinator,
or reset your Wi-Fi module (see below). Also, ensure the Wi-Fi antenna supplied with the
unit has been attached on the bottom of your chlorinator.
14

How to Reset the Wi-Fi Module
Resetting the Wi-Fi module will clear any saved Wi-Fi connection information and set the
Wi-Fi module into “Hot Spot” mode ready for running the Setup Wizard in the Pool Lab
mobile apps.
The Wi-Fi module will remain in “Hot Spot” mode for up to 15 minutes, or until the Setup
Wizard is complete. During this time the Wi-Fi module will appear as a Wi-Fi access point
with the SSID “poolLab”, and password “1 3456789”.
If you do not complete the Setup Wizard within the 15 minute window, the Wi-Fi module
will turn OFF. To re-enter “Hot Spot” mode you can either reset the Wi-Fi module again, or
simply cycle power OFF and back ON to the Mineral Lab Chlorinator.
Once the Setup Wizard has been completed the Wi-Fi connection information will be
saved to the memory of the Wi-Fi module, allowing it to connect automatically to your
selected Wi-Fi network as required. The saved information will persist through power
outages and Wi-Fi network interruptions, etc.
If your Wi-Fi network password or SSID changes, then you will need to reset the Wi-Fi
module and complete the Setup Wizard again.
–From the HOME view, press and hold the VIEW button until the MAIN MENU
appears.
–Navigate to SYSTEM CONFIG and press the VIEW button.
–Navigate to AUTHORITY and press the VIEW button.
–Press the VIEW button once more to edit the AUTHORITY level (flashing), and
press UP once to set this to “INST”. Press VIEW again to save the value.
–Press BACK once to return to the SYSTEM CONFIG menu.
–Navigate down to RESET WIFI and press the VIEW button.
(Note: this option will only appear if AUTHORITY is set to INST or higher)
–Press VIEW to reset the Wi-Fi module, or press BACK to cancel.
Open the Pool Lab app on your compatible smart phone or device.
Log into your account (or create a new account).
New accounts will automatically start the setup wizard, otherwise open the main menu and
select SETTINGS – SETUP WIZARD to begin the setup procedure.
15

MINERAL LAB CHLORINATOR MODELS
Mineral Lab Classic
Stand-alone mineral chlorinator that includes all the features you need for a basic system.
Suitable for use on swimming pools that are a single body of water. These models are not
recommended for spas or pool and spa combination systems, and do not provide
connectivity with the Pool Lab add-on modules. See Plus and MAX models below.
Mineral Lab Plus
An advanced mineral chlorinator suitable for use on pools, and pool and spa combination
systems1. Compatible with the Pool Lab ASP that enables automatic pH and free chlorine
level control, and the Pool Lab EXP that enables additional features such as integrated
solar and gas heating controls as well as control of third party equipment such as lighting,
pumps and flow control valves.
Plus (and MAX) models are also suitable for spa only systems when used in conjunction
with the Pool Lab ASP.
Mineral Lab MAX
The flagship of the Mineral Lab Chlorinator range. This model includes all the features of
the Plus model and also includes multi-speed pump control, and is Wi-Fi® enabled. With
apps available for iOS and Android this allows for remote monitoring and control of your
system from anywhere in your home, or anywhere in the world3! Smart speaker
integration is also possible with skills available for most popular devices.
Mineral Lab HYBRI (PL COMM & PL LT)
The commercial version of the Mineral Lab Chlorinator is a system that can be scaled to
suit your requirements. The PL COMM is the “Commander” and you can add up to four
additional PL LT “Lieutenant” chlorinators for a total chlorine output of between 45 – 5
grams per hour (chlorine gas). The PL COMM is specifically designed to operate in
conjunction with the Pool Lab ASP and also features the ability to feed liquid chlorine to
meet chlorine demand even under extreme conditions. This model includes compatibility
with the Pool Lab add-on modules, multi-speed pump control, and is Wi-Fi® enabled with
apps available for iOS and Android.
RATE CHLORINE OUTPUT
Chlorine output is measured in units of grams of chlorine gas per hour (gm/hr).
PL Classic, Plus and MAX models are available in 5gm/hr, 35gm/hr and 45gm/hr
variations. PL Hybrid models are all rated at 45gm/hr, and one Commander can operate by
itself or optionally control up to 4 x Lieutenants for total rated output options of 45gm/hr,
90gm/hr, 135gm/hr, 180gm/hr and 5gm/hr.
1 Pool and Spa combination systems require a spa flow switch, sold separately.
Spa only systems require the ASP add-on module, and do not require a spa flow switch.
3 Requires internet connection on the network that the Mineral Lab MAX is connected to and internet
connection on the device running the Pool Lab app.
16

ADD-ON MODULES
ASP
The Pool Lab ASP or Auto Sampling Photometer is the World's most reliable and accurate
water management system. The ASP will periodically test your water for Free Chlorine
and pH levels and adjust the chlorinator output and feed acid as required. Developed and
Patented by Poolpower Australia Pty Ltd, the ASP does not suffer from the limitations of
ORP probe based systems and the accuracy is not affected by stabiliser levels, hydrogen
gas or changes in pH. The ASP does not require cleaning or calibration and is suitable for
use on both pools and spas, as well as combination pool and spa systems. Reagent sets
require replacement after approximately 700 tests, or 6 – 8 months at 3 tests per day.
EXP
The Pool Lab EXP or Expansion Module allows you to control of all of your pool and spa
equipment from your Mineral Lab Chlorinator and for Pool Lab MAX models, from the
convenience of your mobile device or smart speaker. The system features:
–Fully integrated solar heating control. Compatible with isolated solar systems,
multi-pump split solar systems, retro-fit or boost pump systems, as well as valve
controlled solar on single pump systems.
–Fully integrated gas heating control, which is also compatible with heat pumps that
have the option for external control.
–Control of up to 4 flow control valve actuators for pool and spa combination
systems, solar systems, water features, in-floor cleaning systems, etc.
–Control up to 9 x 40V outlet sockets for equipment such as lighting, pumps,
cleaners, or any other plug in equipment.
The EXP is available in two models:
EXP5 – features 5 x 10 Amp, 40V standard outlet sockets with a maximum total load of
10 Amps. This model plugs into a standard 10 Amp power socket so in most cases will not
require an electrician to install, and is suitable for many simple domestic systems.
EXP9 – features 9 x 10 Amp, 40V standard outlet sockets with a maximum total load of
0 Amps. The power lead on this model is fitted with an Industrial 3 (round) pin 0 Amp
plug, so installation may require an electrician to provide a suitable switched power outlet
socket.
In cases where control of higher power or 3 phase equipment is required, an electrician
may be required to install contactors to control this equipment.
17

HY ROGEN GAS SAFETY
You may take comfort from the fact that the Mineral Lab Cell has worldwide patents on its
design relating to safety.
Mineral Lab has the worlds safest Cell
Your Mineral Lab Chlorinator must be installed in accordance with the installation
instructions listed in this manual.
The cell, apart from producing chlorine, produces a byproduct gas Hydrogen. Hydrogen is
not readily dissolved in the water and under normal filtration conditions passes through
and out of the pool returns, harmlessly dissipating into the atmosphere.
If however the water flow is restricted (blocked skimmer box or filter, incorrectly closed
valve, etc) then these gases can collect in the system. A potentially explosive mixture
could result under certain conditions.
The Mineral Lab chlorinator has eliminated this potential hazard with in-build electronic
and physical safety features.
Primarily it is important that whenever chlorine is produced that we have water flow to
transport the byproduct hydrogen gas through the return pipes, to the eyeball returns and
to atmosphere. We have three mechanisms that ensure this occurs:
–If the water flow stops, or slows to the point where hydrogen gas is not being
expelled from the cell housing, then the sensor at the top of the chlorinator cell
detects this, and switches power off to the cell. The unit remains on standby until
correct water flow is re-established. A message Low Flow – OFF is displayed on
the LCD.
–It is an installation requirement that the filter pump is electrically interconnected with
the chlorinator and operating from the one time clock. This ensures simultaneous
operation of the filtration pump and the chlorine cell.
–The most important hydrogen gas containment feature is the Mineral Lab's physical
cell design. It’s unique patented vertical design ensures that even in the unlikely
event that the electronic flow protection features fail, the gas will be contained to a
volume of less than lts within the cell housing. In this situation, no more gas can
possibly be produced, since the electrode plates are no longer in contact with the
water.
18

DIAGNOSTIC MESSAGES
Diagnostic messages will be displayed on the bottom line of the LCD when in HOME
VIEW. The messages and their meanings are explained below, with some basic tips to
rectify the issue if necessary. If the problem persists, consult the troubleshooting guide for
more information.
CHECK SALT
The system has detected unusually low conductivity in the cell, possibly due to a low salt
level, and is running inefficiently. The system will continue to run as normal, but may not
be able to produce chlorine to its full potential. This can also be caused by very cold
water, in which case the message can generally be ignored.
–Check the salt level, and add salt if required
–Inspect the cell for debris or calcium scale
CHECK SALT CELL OFF
The system has detected critically low conductivity in the cell, possible due to a very low
salt level. Power to the cell has been turned off to prevent damage. The filtration system
will run as normal, but no chlorine will be produced. Once every five minutes, the system
will re-check and resume normally if the condition is rectified.
–Check the salt level, and add salt if required
–Inspect the cell for debris or calcium scale
HIGH SALT
The system has detected unusually high conductivity in the cell, possibly due to a high salt
level. Usually no user action is required, this is just a warning not to add any more salt.
Chlorine can still be produced efficiently, but it is nearing the threshold where it could
trigger HIGH SALT CELL OFF. This message is more likely to appear at higher water
temperatures.
–Check the salt level, and top up the pool with fresh water if possible
–DO NOT ADD SALT
HIGH SALT CELL OFF
The system has detected critically high conductivity in the cell, possibly due to a very high
salt level, or a combination of high salt and high water temperatures. Power to the cell has
been turned off to prevent damage. The filtration system will continue to run as normal,
but no chlorine will be produced. Once every five minutes, the system will re-check and
resume normally if the condition is rectified.
–Check the salt level, and top up the pool with fresh water if possible
–DO NOT ADD SALT
–If the salt level is significantly too high, it may be necessary to drain some water and
top up with fresh water.
19

PUMP PROTECTION ACTIVE
The system has detected a low flow condition for longer than the time specified in the
PUMP PROTECTION TIME setting. The pump has been turned off, and will not restart
until the filtration mode is changed manually.
–Press the MODE button to toggle the filtration mode back to AUTO or ON.
–Refer to LOW FLOW recommendations below.
LOW FLOW
The system has detected a low flow condition, and will not be producing any chlorine.
–Check visually for water flowing through the cell. An air or gas pocket at the top of
the cell housing indicates that there is not enough flow.
–Inspect the cell for debris or calcium scale
–Check skimmer baskets and pump baskets, empty them if required.
–Backwash the filter if necessary - (sand filters only)
–Clean the filter cartridge(s) if necessary – (cartridge filters only)
–Check all valve positions are correct.
SPA FLOW ETECTE
The system has detected spa flow. Chlorine production will be halted to prevent over
chlorination of the spa.
SCALE WARNING
This is a warning that the system has detected a pattern that is consistent with an
unusually large amount of scale forming on the cell electrode plates.
Have your pool water tested and balanced by your local swimming pool professionals.
Check for unusually high calcium and/or Langelier Index > +0. , and correct as required.
NOTE In some cases this warning can be falsely triggered by rapid changes in water
temperature. eg. Retro-fitted solar systems that discharge through the chlorinator cell may
trigger this warning through normal operation. The warning is safe to ignore in this case.
EFAULTS USE
The system could not read valid user settings from EEPROM memory, therefore factory
default settings have been loaded. It is normal for this to occur on a new unit at initial
power up, or after a memory reset. Otherwise it could indicate that the memory was
somehow corrupted, for example if power was cut whilst a changed setting was being
saved to memory. Although it would be extremely rare for this to occur.
MEMORY FAULT
The system could not successfully write to and read back from the internal memory. This
generally indicates a major fault with the PCB, and it is likely that user settings, timers,
running modes, etc. may not be able to be saved. Operation of the unit could be
unpredictable. Try to cycle power to the unit off, and back on again. If the problem
persists – return the unit for service.
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