POOL LAB PL35 User manual

OWNER'S MANUAL
PL Series Automatic Chlorinator
IMPORTANT
Read this manual carefully before operating your Pool Lab Automatic Chlorinator
PL25, PL35, PL45 Ideal Salinity@ 25 ºC
3 ppm
ABSOLUTE AXI U SALINITY 6000ppm @ 25ºC
KEEP THIS MANUAL IN A SAFE PLACE FOR FUTURE REFERENCE
rev. 8
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

Table of Contents
I PORTANT SAFETY INSTRUCTIONS...............................................................................2
Health and Hypothermia Warnings.............................................................................................................. 2
GENERAL PRECAUTIONS...................................................................................................4
ELECTROLYTIC CELL PRECAUTIONS...............................................................................4
INTRODUCTION....................................................................................................................5
CELL AINTENANCE...........................................................................................................6
TO RE OVE & INSPECT THE ELECTRODE............................................................................................. 6
CLEANING THE ELECTRODE – CALCIU SCALE...................................................................................7
INSTALLING THE ELECTRODE................................................................................................................. 7
CONTROL PANEL OVERVIEW.............................................................................................8
SETTING THE TI E AND DATE...........................................................................................9
SETTING ON / OFF TI ERS................................................................................................9
SPECIAL FEATURES..........................................................................................................10
USER AUTHORITY LEVEL....................................................................................................................... 10
PU P PROTECTION ONITOR.............................................................................................................. 10
RECOVERY ODE................................................................................................................................... 11
PLU BING FLUSH................................................................................................................................... 11
HYDROGEN GAS SAFETY....................................................................................................................... 12
DIAGNOSTIC ESSAGES.................................................................................................13
CHECK SALT............................................................................................................................................ 13
CHECK SALT CELL OFF........................................................................................................................... 13
HIGH SALT................................................................................................................................................ 13
HIGH SALT CELL OFF.............................................................................................................................. 13
PU P PROTECTION ACTIVE.................................................................................................................. 14
LOW FLOW............................................................................................................................................... 14
SPA FLOW DETECTED............................................................................................................................ 14
DEFAULTS USED..................................................................................................................................... 14
E ORY FAULT....................................................................................................................................... 14
CHLORINE PRODUCTON AND CONTROL.......................................................................15
FREE CHLORINE LEVEL.......................................................................................................................... 15
ALTERING CHLORINE OUTPUT.............................................................................................................. 15
WATER BALANCE...............................................................................................................16
pH.............................................................................................................................................................. 16
TOTAL ALKALINITY................................................................................................................................... 16
CALCIU HARDNESS.............................................................................................................................. 16
SALT LEVEL.............................................................................................................................................. 16
CHLORINE STABILIZER – CYANURIC ACID...........................................................................................17
Combined Chlorine - Chloramines........................................................................................................ 17
High Calcium (Hard) water sources – the Langlier Saturation Index.........................................................18
WATER CIRCULATION.......................................................................................................19
INSTALLATION....................................................................................................................20
PLU BING................................................................................................................................................ 20
Cell Installation..................................................................................................................................... 20
Positioning the Cell............................................................................................................................... 20
Plumbing Example................................................................................................................................ 21
POWER SUPPLY AND CONTROLLER.....................................................................................................22
THIRD PARTY EQUIP ENT CONTROLLERS.........................................................................................22
SALT.....................................................................................................................................23
INITIAL SALT DOSING.............................................................................................................................. 23
SALT ADDITION TABLES.......................................................................................................................... 24
TROUBLESHOOTING.........................................................................................................25
WARRANTY INFOR ATION ..............................................................................................28
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.
•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 recommend the use of Cyanuric Acid (Stabilizer) at a concentration
of between 5 -8 ppm for outdoor pools to help protect chlorine in the water
from destruction by sun light
ELECTROLYTIC 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 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 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.
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 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. 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.
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. 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 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.
•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.
7

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)
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 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.
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 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.
10

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.
11

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 the worlds safest Cell
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.
12

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.
13

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.
14

CHLORINE PRODUCTON AND CONTROL
FREE CHLORINE LEVEL
A free chlorine residual of 1. ppm to 3. ppm must be maintained
in the pool / spa water at all times.
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.
15

WATER BALANCE
The balance of your pool water is no less critical because you have installed a salt
chlorinator. All the parameters relating to water balance in Pool and Spa water must be
constantly checked and adjusted.
We strongly recommend you seek advice from a pool professional regarding the balancing
of water for your pool. A correctly balanced pool will protect it and the equipment from
chemical damage and ensure bathers are swimming in clean clear healthy pool water.
pH
A high pH will reduce the effectiveness of chlorine, potentially cause scale on both the pool
and the equipment, and irritate bathers. A low pH may cause the water to become
corrosive, damaging the pool interior finish, equipment (heat exchangers especially) and
also irritate bathers. Each pool finish and type has a specific range in which the pH should
remain. Generally a pH of between 7.2 – 7.6 is suitable for most pool types, however those
requiring a higher pH will also require a higher chlorine residual. (Consult with your pool
shop)
TOTAL ALKALINITY
The total alkalinity is a measurement of all the alkalis in your pool water, (Carbonates,
Bicarbonates and Hydroxides). When adjusted within the accepted levels, T.A. acts as a
pH buffer, resisting changes to the pH level. The recommended T.A. level of your pool may
vary from 80ppm – 120ppm depending on the pool finish, consult with a pool water
professional for advice on the recommended range for your pool.
CALCIUM HAR NESS
The hardness of your pool water is very important in controlling scale and the corrosive
effects of water. A low calcium level may cause pool water to become corrosive even if the
pH is within its recommended range. A sign of this is brown stains on the pool finish and in
adjoining Spas especially. This is metal staining, the source of which is usually the heater.
A high calcium level may cause pool water to deposit scale, even if the pH is within its
recommended range. The salt chlorinator cell may require very frequent cleaning and
scale may deposit on pool finish and equipment. Generally a level of 100ppm – 200ppm is
recommended. Consult with your pool builder or pool shop for specific advice on the
correct level for your pool.
SALT LEVEL
The salt level in pool water is usually approximated either by measuring the conductivity of
the water, or by using a test strip or reagent kit. Sometimes also referred to as T.D.S. Total
Dissolved Solids, or salinity, which while technically slightly different are all close enough
approximations for the range used in pool water. With a salt chlorinator, it is essential to
have approximately the correct amount of salt in the water to achieve the conductivity
required for the chlorine cell to work efficiently.
Pool Lab recommend using regular pool salt (Sodium Chloride).
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CHLORINE STABILIZER – CYANURIC ACI
The sun’s ultraviolet light breaks down chlorine rapidly, so in domestic applications it is
highly beneficial to use a chlorine stabilizer in pools with exposure to the sun. Indoor pools
will only benefit if there is direct sunlight on the water for a significant part of the day.
The importance of its use is such that our range of chlorinators are sized with the express
requirement that chlorine stabilizer be used as per the directions. Cyanuric acid or chlorine
stabilizer, when dissolved in the pool water to achieve levels of between 40ppm to 80ppm
will effectively reduce the breakdown of chlorine by ultraviolet light.
Higher stabilizer levels (greater than 100ppm) may in fact be detrimental to the pool water,
and will actually stop the chlorine from killing bacteria and algae effectively. Consult with
your local pool professional for the appropriate amount to use in your pool.
Combined Chlorine - Chloramines
A common cause for unusually high chlorine demand is the presence of chloramines in the
pool water, detectable when a Total Chlorine test result is higher than a Free Chlorine test
result by greater than 1.0ppm. The difference between these two test results is known as
the “Combined Chlorine”. ore advanced test kits will include the Total Chlorine test,
otherwise you will need to have your water tested professionally to check for this.
Chloramines are formed when free chlorine reacts with ammonia like compounds called
'amines', and this will build up over time. Chloramines are a poor disinfectant and also
reduce the disinfecting power of the free chlorine in the water. Chloramines are irritating
to the eyes and respitory system, and are responsible for the “chlorine smell” most
noticeable around heavily used indoor pools.
As a general rule Pool Lab recommend shock dosing your pool with liquid chlorine at least
once every swim season as this can significantly reduce chlorine demand and greatly
improves the disinfecting power of the free chlorine in the water. For pools with heavier
bather loads this may need to be done more often.
An accurate measurement of the pool volume and combined chlorine level is essential for
calculating the required amount of chlorine to perform the shock dose.
You should consult your local swimming pool professionals for advice on this
procedure, and how often is appropriate for your pool.
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High Calcium (Hard) water sources – the Langlier Saturation Index
The Langlier Saturation Index (Si) is a relationship between the Calcium Hardness, Total
Alkalinity, pH and water temperature. When the water is balanced correctly, the Si value
should be somewhere between -0.2 and +0.2. A value lower than -0.2 indicates the water
is corrosive, and a value higher than +0.2 indicates the water is scaling.
If you are in a situation where the water source for the pool contains a higher level of
calcium than is recommended for you pool, then this index can be very useful. It will allow
you to find a pH value that will not be corrosive or scale forming, and this pH value will
generally be slightly lower than what would normally be recommended for your pool.
The following formula and reference chart can be used to find the current Si for your water.
You will need to know the pH level, Total Alkalinity, Calcium Hardness and Temperature of
your water.
Use the chart to determine the values for Ti, Ci, and Ai, and insert these values into the
formula, along with the measured pH value to determine your Si value.
If you get an Si value higher than +0.2, then your water is scaling. In this case you should
reduce the pH in your water by the value of Si to ensure your water is neither scaling or
corrosive.
Si = pH + Ti + Ci + Ai – 12.1
Temperature
Degrees C
Ti Calcium
Hardness
Ci Total
Alkalinity
Ai
12 0.3 75 1.5 75 1.9
16 0.4 100 1.6 100 2.0
19 0.5 125 1.7 125 2.1
24 0.6 150 1.8 150 2.2
29 0.7 200 1.9 200 2.3
34 0.8 250 2.0 250 2.4
39 0.9 300 2.1 300 2.5
400 2.2 400 2.6
600 2.4 600 2.8
800 2.5 800 2.9
Example:
ph = 7.6, Temp = 24 (Ti = 0.6), Calcium = 4 (Ci = 2.2), Alkalinity = 125 (Ai = 2.1)
Si = 7.6 + 0.6 + 2.2 + 2.1 – 12.1,
Si = +0.4, so the water is scaling.
In this case we would take 0.4 away from the measured pH to find the ideal pH is 7.2. A
pH value anywhere between 7.0 and 7.4 would be acceptable in this case.
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WATER CIRCULATION
In general the total volume of swimming pool water should be turned over at least 1.5 to
2.0 times per day through the filtration system. Where traditional single speed pumps are
used, this is normally achieved within an 8 hour period.
With the introduction of energy efficient multi-speed and variable speed pumps it has
become more complicated than just running the pump for a certain amount of time.
It is important to ensure you are maintaining at least the minimum daily turnover of water.
If using a multi or variable speed pump at low speed, you may need to consult the pump
documentation to help determine the approximate flow rate you have.
If daily turnover is not maintained the chemical and sanitizer distribution in the water may
not be uniform, and water test samples may not be representative of the entire pool
volume. This can make chemical dosing inaccurate, and can increase the chance of
forming black-spot algae on your pool surfaces.
See examples below:
Traditional Fixed Speed Pool Pump
Pool Volume: 50,000 Litres
Pump Rated Flow: 210 LP (Litres per minute)
Turnover Rate: approx. 4 hours. (238 minutes)
Time to turn over 1.5 x pool volume: approx. 6 hours (357 minutes)
Time to turn over 2.0 x pool volume: approx. 8 hours (476 minutes)
Energy efficient Variable Speed Pump, operating at approx ½ flow rate
Pool Volume: 50,000 Litres
Pump Approximated Flow: 1 5 LPM (Litres per minute)
Turnover Rate: approx. 8 hours. (476 minutes)
Time to turn over 1.5 x pool volume: approx. 12 hours (714 minutes)
Time to turn over 2.0 x pool volume: approx. 16 hours (952 minutes)
This example illustrates that when you halve the flow rate, you effectively need to double
the filtration time.
When performing manual pH and chlorine tests for comparison with ASP results, always
obtain the sample as close as possible to the filtration system inlet – usually the skimmer
box. This place will be most representative of the readings acquired by the Pool Lab ASP.
Also ensure the displayed results are up-to-date by initiating a water test via the ASP
TOOLS menu.
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INSTALLATION
PLUMBING
Cell Installation
The Cell housing must be installed vertically with the inlet and discharge plumbing
positioned such that the water enters and exits the cell chamber at the lowest point of the
vertical cell.
50mm pipe must be plumbed directly onto both ends of the cell with the water flowing in
the direction as indicated by the arrow on the cell housing.
50-40mm reducing bushes will be required for 40mm plumbing.
Do not use barrel unions directly on both sides of the horizontal plumbing that connect to
the cell housing. Unions may loosen and cause the cell to rotate from a vertical upwards
position which will disable the physical ability for the cell to contain a hydrogen gas build
up.
Barrel unions can be used, but must be arranged so that the cell cannot rotate if they are
loosened. For example, if at least one of the unions is on a vertical or perpendicular pipe
leading to the cell.
Positioning the Cell
The cell must be installed on the pool return line, DOWN STREA of all other equipment
such as the filter, heaters and solar heaters. This is very important in preventing
accumulation of Hydrogen gas as well as corrosion of equipment such as a heat
exchange. Where the cell is installed below pool water level, ensure isolating valves are
installed somewhere either side of the cell, so it can be inspected or removed.
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