POOL LAB PL25 User manual

OWNER'S MANUAL
PL Series Automatic Chlorinator
IMPORTANT
Read this manual carefully before operating your Pool Lab Automatic Chlorinator
PL25, PL35, PL45 Classic, Plus and MAX Mod ls
Id al Salinity@ 25 ºC = 3000ppm
ABSOLUTE AXI U SALINITY = 6000ppm @ 25ºC
PL ECO Mod ls
Id al Salinity@ 25 ºC = 5600ppm
ABSOLUTE AXI U SALINITY = 8600ppm @ 25ºC
KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE
rev. 10
anufactured by Poolpower Australia Pty Ltd
Factory 1b, 39-45 Susan Street
ELTHA , VICTORIA, AUSTRALIA 3095
email: [e-mail]
Patented Technology
Patent Technology Numbers:
Australia No. 2004245133
Canada No. 2528374
Europe No. 04736187.8
New Zealand No. 544430
USA No. 7,658,842

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. uriatic 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)
Health and Hypothermia Warnings
•People with a medical condition should consult a physician before entering the pool
or spa water.
•aximum safe spa water temperature is 40ºC.
•Bathing in water at 40ºC should not exceed 15 minutes.
2

Tabl of Cont nts
I PORTANT SAFETY INSTRUCTIONS...............................................................................2
Health and Hypothermia Warnings..............................................................................................................2
GENERAL PRECAUTIONS...................................................................................................5
ELECTROLYTIC CELL PRECAUTIONS...............................................................................5
INTRODUCTION....................................................................................................................6
CELL AINTENANCE...........................................................................................................7
TO RE OVE & INSPECT THE ELECTRODE............................................................................................. 7
CLEANING THE ELECTRODE – CALCIU SCALE...................................................................................8
INSTALLING THE ELECTRODE................................................................................................................. 8
CONTROL PANEL OVERVIEW.............................................................................................9
SETTING THE TI E AND DATE.........................................................................................10
SETTING ON / OFF TI ERS..............................................................................................10
SPECIAL FEATURES..........................................................................................................11
USER AUTHORITY LEVEL....................................................................................................................... 11
PU P PROTECTION ONITOR.............................................................................................................. 11
RECOVERY ODE................................................................................................................................... 12
PLU BING FLUSH................................................................................................................................... 12
SPA FLOW (PL PLUS AND AX ODELS ONLY)...................................................................................12
Wi-Fi® (PL AX ODELS ONLY).............................................................................................................13
Getting Started...................................................................................................................................... 13
How to Reset the Wi-Fi odule................................................................................................................. 14
PL CHLORINATOR ODELS..............................................................................................15
PL Classic / PL ECO.................................................................................................................................. 15
PL Plus...................................................................................................................................................... 15
PL AX...................................................................................................................................................... 15
PL HYBRID (PL CO & PL LT)..............................................................................................................15
RATED CHLORINE OUTPUT.................................................................................................................... 15
ADD-ON ODULES............................................................................................................16
ASP........................................................................................................................................................... 16
EXP........................................................................................................................................................... 16
HYDROGEN GAS SAFETY....................................................................................................................... 17
DIAGNOSTIC ESSAGES.................................................................................................18
CHECK SALT............................................................................................................................................ 18
CHECK SALT CELL OFF........................................................................................................................... 18
HIGH SALT................................................................................................................................................ 18
HIGH SALT CELL OFF.............................................................................................................................. 18
PU P PROTECTION ACTIVE.................................................................................................................. 19
LOW FLOW............................................................................................................................................... 19
SPA FLOW DETECTED............................................................................................................................ 19
DEFAULTS USED..................................................................................................................................... 19
E ORY FAULT....................................................................................................................................... 19
CHLORINE PRODUCTON AND CONTROL.......................................................................20
FREE CHLORINE LEVEL.......................................................................................................................... 20
ALTERING CHLORINE OUTPUT.............................................................................................................. 20
WATER BALANCE...............................................................................................................21
pH.............................................................................................................................................................. 21
TOTAL ALKALINITY................................................................................................................................... 21
CALCIU HARDNESS.............................................................................................................................. 21
SALT LEVEL.............................................................................................................................................. 21
CHLORINE STABILIZER – CYANURIC ACID...........................................................................................22
Combined Chlorine - Chloramines........................................................................................................22
High Calcium (Hard) water sources – the Langlier Saturation Index.........................................................23
WATER CIRCULATION.......................................................................................................24
3

INSTALLATION....................................................................................................................25
PLU BING................................................................................................................................................ 25
Cell Installation..................................................................................................................................... 25
Positioning the Cell............................................................................................................................... 25
Plumbing Example................................................................................................................................ 26
POWER SUPPLY AND CONTROLLER..................................................................................................... 27
THIRD PARTY EQUIP ENT CONTROLLERS.........................................................................................28
POWER RATINGS (Domestic odels)......................................................................................................29
PL25 Classic/Plus/ ax and PL ECO....................................................................................................29
PL35 Classic/Plus/ ax......................................................................................................................... 29
PL45 Classic/Plus/ ax......................................................................................................................... 29
POWER RATINGS (Commercial odels)..................................................................................................30
PL CO ............................................................................................................................................. 30
PL LT.................................................................................................................................................... 30
Power Consumption ................................................................................................................................. 30
Pool Lab Add-on modules and accessories...............................................................................................31
ASP...................................................................................................................................................... 31
EXP...................................................................................................................................................... 31
SPA FLOW SWITCH (Plus and AX models only)..............................................................................31
PL Hybrid (PL CO & PL LT) odels Installation...................................................................................32
SALT.....................................................................................................................................33
INITIAL SALT DOSING.............................................................................................................................. 33
SALT ADDITION TABLES.......................................................................................................................... 34
TROUBLESHOOTING.........................................................................................................35
WARRANTY INFOR ATION ..............................................................................................38
4

GENERAL PRECAUTIONS
•Do not use bromine based products in the pool. Use of bromine will void the
warranty on your chlorine cell.
•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 200ppm, 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.
•anual 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 r comm nd th us of Cyanuric Acid (Stabiliz r) at a conc ntration
of b tw n 50-80 ppm for outdoor pools to h lp prot ct chlorin in th wat r
from d struction by sun light
ELECTROLYTIC CELL PRECAUTIONS
•It is a condition of th warranty that th pool own r nsur that th c ll is
insp ct d and maintain d in accordanc with th dir ctions 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 UST 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 th pool own r's r sponsibility to nsur all mat rials in contact with th
pool or spa wat r ar compatibl with and int nd d for us with an
l ctrolytic salt chlorinator.
5

INTRODUCTION
Congratulations, you have wisely purchased the most technologically advanced salt water
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 chlorination
technology.
Your Pool 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, salt chlorination as a method for
treating pool water is increasing world-wide.
ild salt water 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 Pool 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 salt 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.
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 is lost through the electrolytic process. The necessity to top up the salt level is only
due to loss of salt water from backwashing or splashing out etc. Water loss due to
evaporation does not cause any loss of salt. All Pool Lab models contain digital time
clocks with two programmable ON/OFF periods available for fully automatic operation of
your pump & chlorinator.
All mod ls hav a built in back up pow r syst m that will k p th tim r clock
running for up to 7 days. This is particularly us ful wh r th mains pow r is
int rrupt d.
Pool Lab PL S ri s do s not contain batt ri s.
6

CELL MAINTENANCE
Where calcium levels are below 200ppm, 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 200ppm 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 200ppm
•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. ost 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. ake 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 car NOT to
subm rg th top part 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:
HO E – Displays running mode and chlorinator output.
TI E/DATE – Displays current time and date
TI ER – Displays filtration ON / OFF times
AIN ENU – Access settings and configuration items
UP / DOWN BUTTONS
–Adjust the chlorine output level (view “HO E”)
–Adjust the time / date (view “TI E/DATE”)
–Adjust the ON / OFF times (view “TI ER”)
–Navigate menu system (menu system list views)
–Adjust values (menu system field editing)
VIEW BUTTON
–Switch between LCD display top level views
–oves to the next adjustable field, or set adjusted field
–Hold for 5 seconds to enter the AIN ENU
(view “HO E” only)
–Select a menu item, or edit a field (menu system views)
BACK BUTTON
–Return to previous view, or return to view “HO E”
–Exit adjustment mode
–Display detailed cell output data (view “HO E”)
ODE BUTTON
–Toggle ON / OFF / AUTO running mode.
–Returns to HO E VIEW (from any top level view)
9

SETTING THE TIME AND DATE
Time is displayed in 24 hour format. 00:00 is midnight, 12:00 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 HO E VIEW to display the TI E / 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 INUTES field.
–Use the UP and DOWN buttons to select the correct INUTES value
–Continue this process for YEAR, ONTH, 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 #2.
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 HO E VIEW to display the TI ERS 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 Pool Lab PL Series 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 LI ITED 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 HO E VIEW, press and hold the VIEW button for at least 5 seconds.
–This will show the AIN ENU.
–Navigate to SYSTE 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 AIN ENU
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 PU P PROTECTION TI E period:
–Set the AUTHORITY level to INSTALLER as described above.
–From the AIN ENU navigate to SETTINGS, and press VIEW.
–Navigate to the PU P PROTECTION field and press VIEW to edit.
–Use the UP and DOWN buttons to adjust the time in INUTES.
–Press the view button to save the setting.
–Press the BACK button to exit.
The pump protection feature will be enabled when the PU P PROTECTION TI E is set to
any number greater than ZERO.
To disable PU P PROTECTION ONITOR, set the PU P PROTECTION TI E 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 24 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 HO E 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 ODE 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 ODE timer period:
–From the AIN ENU 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.
12

Wi-Fi® (PL MAX MO ELS ONLY)
PL ax 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 Pool Lab AX model Salt
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 2 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.
G tting Start d
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 Pool 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 Pool Lab Chlorinator after the
next step.
The second step is to search for your Pool 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 “123456789”.
Once you have completed this step, the connection details for your selected Wi-Fi network
will be sent to the Pool Lab Chlorinator via a secure peer-to-peer connection. The Pool
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.
13

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 2 hours, 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 “123456789”.
If you do not complete the Setup Wizard within 2 hours 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 Pool 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 HO E view, press and hold the VIEW button until the AIN ENU
appears.
–Navigate to SYSTE 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 SYSTE 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.
14

PL CHLORINATOR MODELS
PL Classic / PL ECO
Stand-alone salt chlorinators 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 AX models below.
PL Plus
An advanced salt 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 AX) models are also suitable for spa only2 systems when used in conjunction
with the Pool Lab ASP.
PL MAX
The flagship of the Pool Lab Salt 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.
PL HYBRI (PL COMM & PL LT)
The commercial version of the Pool Lab Salt Chlorinator is a system that can be scaled to
suit your requirements. The PL CO is the “Commander” and you can add up to four
additional PL LT “Lieutenant” chlorinators for a total chlorine output of between 45 – 225
grams per hour (chlorine gas). The PL CO 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 AX models are available in 25gm/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 225gm/hr.
1 Pool and Spa combination systems require a spa flow switch, sold separately.
2 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 Pool Lab AX is connected to and internet
connection on the device running the Pool Lab app.
15

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 odule allows you to control of all of your pool and spa
equipment from your Pool Lab Salt Chlorinator and for Pool Lab AX 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 240V 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, 240V 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, 240V standard outlet sockets with a maximum total load of
20 Amps. The power lead on this model is fitted with an Industrial 3 (round) pin 20 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.
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HY ROGEN GAS SAFETY
You may take comfort from the fact that the Pool Lab Cell has worldwide patents on its
design relating to safety.
Pool Lab has th worlds saf st C ll
Your Pool 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 Pool 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 Pool 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 2lts 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.
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DIAGNOSTIC MESSAGES
Diagnostic messages will be displayed on the bottom line of the LCD when in HO E
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.
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PUMP PROTECTION ACTIVE
The system has detected a low flow condition for longer than the time specified in the
PU P PROTECTION TI E setting. The pump has been turned off, and will not restart
until the filtration mode is changed manually.
–Press the ODE 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.
EFAULTS USE
The system could not read valid user settings from EEPRO 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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CHLORINE PRODUCTON AND CONTROL
FREE CHLORINE LEVEL
A fr chlorin r sidual of 1.0ppm to 3.0ppm must b maintain d
in th pool / spa wat r at all tim s.
The ability of the chlorine generator to maintain this level will alter with respect to the
chlorine demand imposed by bather load and environmental factors.
The chlorine output level [%] is displayed on the LCD and may be altered using the UP
and DOWN buttons. This allows you to increase or decrease the chlorine production
without alteration of the operation time.
Testing for chlorine levels is very important and should be performed on a daily basis. The
sample of water to be tested should be taken at arms depth away from the pool returns.
This avoids highly chlorinated water, which has traveled directly from the chlorinator cell
and ensures the reading will be a true representation of the pools residual level.
The requirement to super chlorinate or shock dose the pool manually during periods of
high chlorine demand is highly recommended, and in some cases absolutely necessary.
When a test reveals low chlorine (or zero) chlorine, always treat manually with liquid
chlorine and investigate if the chlorine generator is operating to its maximum capacity and
for sufficient hours to meet the demand.
Contrary to popular belief, a Chlorine generator can not shock dose the pool water. It is
however beneficial especially where high bather loads exist to perform this task. Shock
dosing the water manually with chlorine, breaks irritating chloramines down and provides
for safer water with reduced chlorine demand.
ALTERING CHLORINE OUTPUT
The chlorine output may be altered in two ways:
Increasing or decreasing the operating time
Increasing or decreasing the output percentage level
anual addition of liquid chlorine may be required during peak usage periods if the
chlorinator cannot meet the demand.
When a Pool Lab ASP add-on module is connected, the chlorine output percentage will be
adjusted automatically. However if the chlorine level is persistently too low, you may need
to increase the filtration time to allow for more chlorine production, or consider shock
dosing the water to reduce chlorine demand.
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