POOL LAB PL Series User manual

OWNER'S MANUAL
PL Series Automatic Chlorinator
IMPORTANT
Read this manual carefully before operating your
Pool Lab Automatic Chlorinator
Ideal Salinity 3000ppm
KEEP THIS MANUAL IN A SAFE PLACE
FOR FUTURE REFERENCE
rev. 5
Manufactured by Poolpower Australia Pty Ltd
actory 1b, 39-45 Susan Street
ELTHAM, 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 SAFET 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.
•ollow all aspects of local and national Electrical Codes when installing Pool Lab
equipment.
•or 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.
•Maximum safe spa water temperature is 40ºC.
•Bathing in water at 40ºC should not exceed 15 minutes.
2

Table of Contents
IMPORTANT SA ETY INSTRUCTIONS...............................................................................2
Health and Hypothermia Warnings.............................................................................................................. 2
GENERAL PRECAUTIONS...................................................................................................4
ELECTROLYTIC CELL PRECAUTIONS...............................................................................4
INTRODUCTION....................................................................................................................5
CELL MAINTENANCE...........................................................................................................6
TO REMOVE & INSPECT THE ELECTRODE.............................................................................................6
CLEANING THE ELECTRODE – CALCIUM SCALE...................................................................................7
INSTALLING THE ELECTRODE................................................................................................................. 7
CONTROL PANEL OVERVIEW.............................................................................................8
SETTING THE TIME AND DATE...........................................................................................9
SETTING ON / O TIMERS................................................................................................9
SPECIAL EATURES..........................................................................................................10
USER AUTHORITY LEVEL....................................................................................................................... 10
PUMP PROTECTION MONITOR.............................................................................................................. 10
PLUMBING LUSH................................................................................................................................... 10
HYDROGEN GAS SA ETY....................................................................................................................... 11
DIAGNOSTIC MESSAGES.................................................................................................12
CHECK SALT............................................................................................................................................ 12
CHECK SALT CELL O ........................................................................................................................... 12
HIGH SALT................................................................................................................................................ 12
HIGH SALT CELL O .............................................................................................................................. 12
PUMP PROTECTION ACTIVE.................................................................................................................. 13
LOW LOW............................................................................................................................................... 13
SPA LOW DETECTED............................................................................................................................ 13
DE AULTS USED..................................................................................................................................... 13
MEMORY AULT....................................................................................................................................... 13
CHLORINE PRODUCTON AND CONTROL.......................................................................14
REE CHLORINE LEVEL.......................................................................................................................... 14
ALTERING CHLORINE OUTPUT..............................................................................................................14
WATER BALANCE...............................................................................................................15
pH.............................................................................................................................................................. 15
TOTAL ALKALINITY................................................................................................................................... 15
CALCIUM HARDNESS.............................................................................................................................. 15
SALT LEVEL.............................................................................................................................................. 15
CHLORINE STABILIZER – CYANURIC ACID........................................................................................... 16
Combined Chlorine - Chloramines........................................................................................................ 16
High Calcium (Hard) water sources – the Langlier Saturation Index.........................................................17
WATER CIRCULATION.......................................................................................................18
INSTALLATION....................................................................................................................19
PLUMBING................................................................................................................................................ 19
Cell Installation..................................................................................................................................... 19
Positioning the Cell............................................................................................................................... 19
Plumbing Example................................................................................................................................ 20
POWER SUPPLY AND CONTROLLER..................................................................................................... 21
SALT.....................................................................................................................................22
INITIAL SALT DOSING – IDEAL SALINITY 3000ppm...............................................................................22
SALT ADDITION TABLE............................................................................................................................ 22
TROUBLESHOOTING.........................................................................................................23
WARRANTY IN ORMATION ..............................................................................................26
DOMESTIC APPLICATIONS..................................................................................................................... 26
COMMERCIAL APPLICATIONS................................................................................................................ 26
3

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.
•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.
•ree 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 ppm for outdoor pools to help protect chlorine in the water
from destruction by sun light
ELECTROL TIC CELL PRECAUTIONS
•It is a condition of the warranty that the pool owner ensure that the cell is
inspected 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 pool owner's responsibility to ensure all materials in contact with the
pool or spa water are compatible with and intended for use with an
electrolytic salt chlorinator.
4

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.
Mild 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/O periods available for fully automatic operation of
your pump & chlorinator.
All models have a built in back up power system that will keep the timer clock
running for up to 7 days. This is particularly useful where the mains power is
interrupted.
Pool Lab PL Series does not contain batteries.
5

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. actors 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. 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 MANUALL REMOVE AN 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.
6

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.
ALWA S PUT WATER IN THE CONTAINER FIRST, THEN ADD ACID.
•Carefully place and stand the electrode in the container, taking care NOT to
submerge the 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.
•it 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).
•it the electrode into the cell housing, and orient it so that the cell cable can plug
into the cell easily and comfortably.
•it 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.
7

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 / O 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 / O 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 / O / AUTO running mode.
–Returns to HOME VIEW (from any top level view)
8

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 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 / O 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 O times the same.
A disabled timer will show ON and O times as dashes (--:--)
Timers are labeled #1, and #2.
The first column shows the ON time.
The second column shows the O 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 / O 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.
9

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 LIMITED level which prevents adjustment of all settings, and there are also
TECHNICIAN and ACTORY levels which require a PIN.
To enable editing of system settings, you must first raise the AUTHORITY level to
INSTALLER.
–rom the HOME VIEW, press and hold the VIEW button for at least 5 seconds.
–This will show the MAIN MENU.
–Navigate to SYSTEM CON IG, 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. or 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.
–rom 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.
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.
10