Pool Pro CPP Series Instruction Manual

TABLE OF CONTENTS
1. ImportantWarningsandSafetyInstrucons ............................................................................................. 3
1.1 Important Warnings ................................................................................................................ 3
  1.2 ImportantSafetyInstrucons ................................................................................................. 3
  1.3 ImportantWaterBalanceInformaon.................................................................................... 3
2. General Overview ....................................................................................................................................... 4
  2.1 RecommendaonsandHelpfulHints ..................................................................................... 4
2.2 Contents .................................................................................................................................. 4
2.3 Tools Needed .......................................................................................................................... 4
3. PoolPreparaon......................................................................................................................................... 5
4. PowerPack&CellElectrodeInstallaon............................................................................................... 6 - 7
  4.1 PowerPackInstallaon........................................................................................................... 6
  4.2 CellElectrodeInstallaon ....................................................................................................... 6
  4.3 InstallaonDiagram................................................................................................................ 7
5. PowerPackOperaon........................................................................................................................... 8 - 9
5.1 Timer Switch ........................................................................................................................... 8
5.2 Cell Switch ............................................................................................................................... 8
5.3 Circuit Breaker ........................................................................................................................ 8
5.4 AC Socket (Pump Outlet) ........................................................................................................ 8
  5.5 JunconBox............................................................................................................................ 8
5.6 Output Control Knob ............................................................................................................... 8
  5.7 FlashingLED(CPPSmodelonly).............................................................................................. 8
  5.8 ProduconOutputDisplayMeter........................................................................................... 9
  5.9 WaterHardnessSwitch(CPPSmodelonly)............................................................................. 9
5.10 Start Up Procedure ................................................................................................................. 9
6. TimerSeng ..................................................................................................................................... 10 - 11
7. ApplyingaChlorinatorSkin/FrontScker(CPPSmodelonly) .................................................................. 12
8. ChlorinatorMaintenance .................................................................................................................. 13 - 14
  8.1 InspecngandCleaningtheCellElectrode........................................................................... 13
  8.2 InspecngandCleaningthePowerPack .............................................................................. 14
9. ChlorinatorTroubleshoong ............................................................................................................. 14 - 15
10. SchemacsandPartNumbers .......................................................................................................... 16 - 17
11. SpecicaonTable.................................................................................................................................... 18
12. WarrantyandProductRegistraon................................................................................................... 19 - 20
13. Technical Support ..................................................................................................................................... 20

1. IMPORTANT WARNINGS & SAFETY INSTRUCTIONS
1.1 Important Warnings
AThis manual contains important information about the installation, operation and safe use of
this product. This information should be given to the owner and/or operator of this
equipment. When installing and using this electrical equipment, basic safety precautions
should always be followed. Failure to follow safety warnings and instructions in this manual
can result in serious injury and/or damage to your equipment. Read and follow all warning
notices and instructions which are included in this manual.
The Power Pack internally contains live components. There is a danger of electric shock if
opened. If the power cord is damaged then it should be replaced by the manufacturer, their
agent or similar qualified person, in order to avoid a hazard. The product shall be installed
according to AS/NZS 3000 wiring rules. It shall be installed outside the pool zone.
1.2 Important Safety Instrucons
A
To reduce the risk of injury, do not permit young children to use this product unless they
have been trained by the person responsible for their safety and they acknowledge their
ability to use such equipment. To reduce the risk of accidents or incidents, service on the unit
should only be performed by your local Pool Pro Professional.
When mixing acid with water, ALWAYS ADD ACID TO WATER. NEVER ADD WATER TO ACID.
DO NOT PLUG UNIT IN IF CARTON HAS BEEN WET.
CHLORINE GAS BUILD-UP CAN OCCUR WITH IMPROPER WIRING: To reduce the risk of
personal injury the Power Pack is designed so that the Electrolytic Cell will only receive power
when the pool pump is on. Otherwise, dangerous chlorine gas build-up can occur. If the
pump is not installed to the AC Socket (pump outlet) on the Power Pack then the installer
must ensure that the Electrolytic Cell is never energised when the pool pump is OFF or water
is not flowing through the unit.


3
A
1 . 3 I mportant W ater Balance I nformation
A•Only add chemicals in the method and quantities as indicated on the packaging provided
or advised by your local Pool Pro Professional. If in doubt of any results you achieve, do
not hesitate to consult with your local Pool Pro Professional.
•Check your salt levels with your local Pool Pro Professional before installing your unit.
•Salt levels should ideally be 3000-3500ppm and no more than 4000ppm.
•NEVER ADD SALT DIRECTLY TO THE SKIMMER BOX. This high concentration of salt will
pass through your filtration, pump and other pool equipment.
•Salt levels above 4000ppm may overload the unit and cause excessive heat.
•For all new pool installations please seek advice from your pool builder before adding salt
as some new surfaces request no salt to be added when initially completed.
•The Pool Pro unit is designed for use with swimming pool water balanced in accordance
with the Langlier Saturation Index with a pH range of 6.8-7.8.
•For best performance and operation of your Pool Pro unit, certain water balances must be
maintained within your swimming pool. Have your water tested regularly. Transport the
test water in an opaque container and have the test done as soon as possible for the most
accurate results. See page 5 for a list of recommended water chemistry levels.

2. GENERAL OVERVIEW
Congratulations on your recent purchase of your Pool Pro Salt & Mineral Chlorinator. Please take a moment
to read through the entire manual before installing your new unit. Your chlorinator must be installed and
operated as specified.
While every effort has been made to ensure that the information contained in this guide is accurate and
complete, no liability can be accepted for any errors or omissions. Pool Pro reserves the right to change the
specifications of the hardware and software described herein at any time without prior notice.
Please remember that your Pool Pro Salt & Mineral Chlorinator is not designed to chemically maintain your
pool water and keep it balanced, but rather to produce chlorine from a mild salt solution within the water.
We encourage regular water testing, balancing and correction if and when required to maintain the
recommended balanced levels of your pool water. This is a vital part of a complete maintenance program
and will ensure trouble free performance as well as a healthy and sparkling clean pool.
There are two types of designs in the Pool Pro Range:
•A standard model known as CPP which is a non-reversing design and calcium build up needs to be
manually cleaned periodically from the electrode plates.
•A reverse polarity model known as CPPS which is a reversing design and automatically changes
direction every 6-10hrs (depending on your setting). This change of polarity causes the calcium to
dislodge and keep the Cell plates clean. Please note occasional cleaning of the electrode plates may be
necessary.
Thank you again for choosing a Pool Pro Salt & Mineral Chlorinator.
We wish you many happy years of swimming in your crystal clear pool.
2.1 Recommendations and Helpful Hints
• Read and keep your manual in a safe place.
• Increase chlorine production when temperature goes up.
• Increase chlorine production when number of swimmers increases.
• Use Stabiliser (Cyanuric Acid) to stabilise chlorine in Pool.
• Decrease production when temperature goes down (during winter).
• Take pool water sample to your local Pool Pro Professional at least twice a month.
2.3 Tools Needed
Drill with 7.0mm drill bit
Basic PVC fittings
Hacksaw No.2 Phillips head screwdriver
PVC Primer & PVC
Cement "Type P"
for pressure pipes
2.2 Contents
2 x Green Wall
Plugs with Screws
2x50/40
Reducing Bushes
Power Pack 2 x Skins (CPPS Model Only)
4
User Manual
Cell Housing & Electrode
Acrylic Cover &
2 x Black Plastic Rivets

3. POOL PREPARATION
Important Notes
•TIP 1: If you turn the Output Control Knob fully clockwise and the Meter needle reaches the top of
the GREEN then you have enough salt. DO NOT ADD ANY MORE SALT.
•TIP 2: If you turn the Output Control Knob fully clockwise and the Meter needle reaches the RED
then you have either just enough salt (if just reaches RED) or too much salt (if it goes in to the RED).
DO NOT ADD ANY MORE SALT.
•The colder the water the lower your output but this does not mean you need more salt. There will
always be less chlorine demand in colder water.
•We recommend 3.5kg of salt per 1,000L (1m3) of pool water. A 50,000L (50m3) new pool needs
approximately 175kg of salt to achieve 3000ppm.
•The unit can operate on mineral/magnesium chloride salts, allow an extra 20-30% on the ppm for
these types of salts.
•Salt should always be added to the shallow end of the pool and brushed until thoroughly dissolved.
Do not let the salt settle on the pool floor as this may cause damage or staining to the surface. Use
your pool brush to mix the salt into the water.
•Running the pump will mix the water and help the salt to dissolve. Only run the pump in the first
8-12 hours (ensure the Cell is switched off) to allow the salt to dissolve.
•Low salt levels (<1500ppm) will destroy the coating on the Cell and void the warranty.
•The Pool Pro unit is designed for use with swimming pool water balanced in accordance with the
Langlier Saturation Index with a pH range of 6.8-7.8. As previously advised, for best performance
and operation of your Pool Pro unit, certain water balances must be maintained within your
swimming pool. Have your water tested regularly. Transport the test water in an opaque container
and have the test done as soon as possible for the most accurate results.
5
Consult your local Pool Pro Professional to correctly balance your pool water. Follow instructions on the
packaging of each chemical. Always add chemicals to water, never add water to chemicals.
Recommended Values To Increase Value To Decrease Value Test
Frequency
pH Concrete: 7.2 – 7.6
Fibreglass/Vinyl: 7.0 – 7.2
Add Pool Pro pH
Increaser (Soda Ash)
Add Pool Pro
Hydrochloric Acid Weekly
Free
Chlorine 1 – 3ppm
Increase the chlorine
output on the
chlorinator unit
Add Pool Pro Chlorine
Out and decrease the
chlorine output on the
chlorinator unit
Weekly
T.A. (Total
Alkalinity)
Concrete: 80 – 150ppm
Fibreglass/Vinyl: 80 – 120ppm Add Pool Pro pH Buffer Add Pool Pro Hydrochloric Acid Fortnightly
Calcium
Hardness
Concrete: 250 – 300ppm
Fibreglass/Vinyl: 150 – 200ppm
Add Pool Pro Hardness
Raiser
Add Pool Pro Calcium
Remover Fortnightly
Stabiliser 30 – 60ppm Add Pool Pro Stabiliser or
Pool Pro Rapid Stabiliser
Contact your Pool
Pro Professional for
advice
Fortnightly
Salt 3000 – 3500ppm Add Pool Pro Ultrafine or
Premium Pool Salt
Partially empty the
pool and refill it Fortnightly
This is a guide only, does not constitute and should not be used as an alternative to specific professional
advice. Pool Pro and The POPS Group Pty Ltd accept no liability for any damage, loss or harm associated with
the use of this guide.

6
 
4 .1 Power Pack Installaon
A
•The Pool Pro Power Pack has an Ingress Protection Rating of IP23 enabling it to be installed
outdoors. Regulations require that the Power Pack shall be installed outside the pool zone.
•The Power Pack shall be installed according to AS/NZS 3000 wiring rules.
•The Power Pack should be installed in a well ventilated position ideally away from sunlight
and rain to prolong life and at least 1m above ground to prevent run off water entry.
•Ensure that the Power Pack is not stored near chemicals, fertilisers or in a closed
unventilated shed with similar products as the fumes will cause excessive corrosion and
damage to the Power Pack and Control Board.
•When mounting the Power Pack on a post it is recommended to install a flat panel at least
the size of the Power Pack to act as a waterproof backing plate.
•Mount the Power Pack with the Green Plugs and Mounting Screws provided.
•Fit the Black Plastic Rivets that hold the Acrylic Front in place as follows:
- Remove the outer plastic tube from the inner pin on both rivets.
- Align the Acrylic Front and insert the outer tube on both sides.
- Insert the inner pin that will expand the tube and hold the Acrylic Front in place.
The Power Pack should be mounted no further than 1.5 metres from the Chlorinator
Cell, for ease of operation of the controls on the Power Pack.
4 .2 Cell Electrode Installaon
•Connect the Cell Housing horizontally in the return line to the pool (use reducing bushes
supplied if 40mm PVC pipe) using high pressure PVC glue. The Cell Housing can be
mounted vertically but provision must be made for a gas trap.
•Direction of water flow though the Cell Housing is not critical although we do recommend
entry from the closed end of the Cell Housing and exit from the end closest to the Cell
Locking Ring. The reason is to cause less water hammer over time on the Cell plates.
•Check that the O-Ring is clean, greased with silicone grease (DO NOT use petroleum based
jelly) and securely located in the Cell Housing.
•Fit the Cell Electrode and ensure Cell Locking Ring is firmly tightened by hand (DO NOT use
a tool to tighten).
•Connect the leads from the Cell Electrode to the Junction Box under the Power Pack
ensuring the colours match that indicated on the Junction Box (RED - closest to the front,
WHITE - in the middle and BLACK - closest to the rear).
•Plug the Power Pack 3 pin plug into a suitable weatherproof RCD protected 10amp outlet
and then plug the pump into the 3 pin AC Socket located at the bottom of the Power Pack.

7
 
Important Notes
A•The pump rating must not exceed 5amps.
•Saltwater may damage Junction Box and electrical components in the Power Pack.
•DO NOT use a drill to tighten Junction Box screws - this may strip them - use a hand
held screw driver.
WARNING:
•We DO NOT recommend the use of valves on the inlet or outlet of the Cell Housing. If
you do use a valve then it is important to ensure that the valve cannot deadhead
(lock closed) while the pump is running. It is the installer's responsibility to ensure
some form of flow control is installed in this instance and it disables the pump.
•ALWAYS ensure that pipe work and equipment do not allow gases generated from
the Cell to collect and build up in any part of the installation.
•It is RECOMMENDED that the Cell Housing be installed horizontally to create a
natural gas trap that acts as a safety device. Installation in any other way may cause
explosion, injury or death if the installer does not allow for gas removal.
•The Cell Housing must be installed in the RETURN pipework to the pool. It must
always be installed after the filter, gas heater, solar heating or heat pump.
•DO NOT apply priming fluid to the Cell Housing, it is not needed and may react with
the plastic.
4.3 Installation Diagram
CELL
FILTER
PUMP
POWER
OUTLET
Make sure
that screws
are ght on wires
and colours match.
Red: Closest to front
White: Centre
Black: Closest to rear
RETURN
TO POOL
FROM
SKIMMER BOX
WARNING: DO NOT plug in if carton has been wet.
Water turbulance has less impact
on plates with entry this end but
Cell can be plumbed either way.
POWER PACK
(Ensure good venlaon)

8
5 .POWER PACK OPERATION

This switch position determines whether the unit is manually turned on or automatically
controlled by the Timer.
•Auto Position - the time clock controls the operating hours. See section 6 for Timer Setting.
•Manual Position - the unit is on and both the pump AC Socket and Cell will be powered up.

This switch position determines whether the Cell is turned on or off when power is supplied to it
from the above Timer Switch.
•OFF Position - even if the Timer Switch is powered on there will still be no power to the Cell.
•ON Position - if Timer Switch is powered on then there will be power to the Cell.
•Changing Direction - while the unit is running you can change direction by turning off the Cell
Switch, wait 3 seconds then turn it on again. The direction should change. If it does not then
repeat this again and it should change direction.

A Circuit Breaker is an automatically operated electrical switch designed to protect an electrical
circuit from damage caused by overcurrent, overload or short circuit. It can be reset by pressing
the button in after it has tripped. It may be damaged if you supply excessively high levels of salt
through the Cell.
5 
The AC Socket allows the pump to be electrically operated and controlled by the Power Pack.
WARNING: If you fail to control the pump this way then you must allow for a flow switch
mechanism to control the electrical supply to the Power Pack, so as to prevent gas build-up if the
pump stops.

The Junction Box allows rectified DC voltage to be coupled to the Cell. This is where the Cell
cable is connected to the Power Pack.

Simply turning the BLACK Output Control Knob counter clockwise decreases output and clockwise
increases it. Always leave it in a position where the Production Output Display Meter needle is in
the GREEN (never in the RED).

This LED serves a double function. It shows that there is power to the Main Control PCB and also
flashes every one second to indicate all is OK with the power it is receiving. The flashing 1 second
pulse is normal and not a fault indicator.

9
5 .POWER PACK OPERATION
5 .8 Producon Output Display Meter
•When the unit is turned on full (Black Output Control Knob fully clockwise) the needle
should reach the top of the GREEN, this shows that the water has the correct conductivity
and the salt level is correct.
•If the needle is slightly low (in the GREEN area below 90% mark), it may be that the water is
very cold, more salt may be needed or possibly a faulty Cell (see Troubleshooting). In cold
months it is normal to operate as low as 50% and more salt is not needed.
•If the needle reaches the RED then you have either just enough salt (if just reaches RED) or
too much salt (if it goes in to the RED). If unsure refer to your nearest Pool Pro Professional
for a water test before adding more salt.
CPP (STD) Meter CPPS (REV) Meter
5 .9 W ater Hardness Switch ( C PPS model only)
•This switch is only available in the reverse polarity models (self cleaning). The micro-
processor will automatically change direction of the current flow approximately every 10
hours (in the IF NORMAL position) and 6 hours (in the IF HIGH position) approximately, even
if the power is interrupted.
•You should always start off by running on the IF NORMAL position but if you have hard
water (high calcium) and the build-up on your electrode takes place too quickly, then you
can shorten the reversing hours by setting the switch to the IF HIGH position.
•The platinum coating on the Cell plates may not last as long on the hard setting as a
percentage of the wear on the coating is related to the number of current switches.
5 .10 Start Up Procedure
•Ensure 10amp wall outlet supply switch is turned "OFF".
•Water Hardness Switch in "IF NORMAL" position (or "IF HIGH" if required - see 5.9).
•"OUTPUT" Control Knob turned fully counter clockwise.
•Cell Switch in the "OFF" position.
•Timer Switch in the "MANUAL" position.
•Turn the 10amp wall outlet supply switch "ON".
•The pump should start up and prime.
•Allow the pump to run for 2 minutes and repair any leaks if needed.
•Turn the Cell Switch to "ON" and slowly turn the "OUTPUT" Control Knob clockwise until the
meter needle reaches the top of the GREEN indicator.
•Set the Timer to run 6-10 hours in the summer and 3-6 hours in the winter. Refer to section
6 Timer Setting for further details.
•Now turn the Timer Switch to "AUTO" and leave it here to run automatically.
All P ool P ro Self Cleaning models are controlled by a Micro-Chip controller that performs
several funcons, including the change of current direcon and water sensing.

10
6 .TIMER SETTING
AYour Pool Pro unit comes with a simple to operate quartz mechanical Timer which has a built
in battery back up function.
This area of set up is critical and we recommend you take time to read it and understand why
we recommend certain settings.
Obviously sunlight and higher bather loads in summer dissipate more chlorine than in winter.
That is why you need to check your chlorine reading regularly and adjust your settings when
required.
It is recommended to run the unit for 2 periods every day (early morning and evening) when
the sun extracts the least amount of chlorine from the pool, giving it time to do its work.


e

/I\
Ideally, run for 4 hours in the morning (6-10am) and 4 hours in the evening (4-8pm).
For a smaller pool you can run less hours. In extreme weather it may be necessary to run
longer hours.

* In winter you should lower your running time by up to 50% of your summer setting
depending on your free chlorine levels. You should ideally run 2-3 hours in the morning and
2-3 hours in the evening. This preserves and extends the life of your equipment.

AThe Timer Switch will override the Timer when it is in the Manual position. For timer
settings to control the unit the Timer Switch needs to be in the AUTO position.
WARNING: ALWAYS TURN THE CLOCK FACE CLOCKWISE, NEVER ANTI-CLOCKWISE.
You will strip plastic gears and damage the Timer.

11
6.TIMER SETTING
To adjust the time of the clock, simply hold the outside of the white segments
and turn the dial until the clock reads the right time and the number near the
timer on/off arrow is close to the same number.
Your Timer is simple to use, easy to understand and a reliable well known design.
It has a battery back up function if you operate your pool equipment from a low
tariff supply that turns off at times. It does require at least 12 hours charging at
first but simply leave it alone and it will charge itself as required.
This time is set at 8:00am and the dial pointer
shows the 8:00 position as does the clock face hands
The Timer comes on where the pins that are
pressed out reach the black dial pointer (in this
case it will be from 6 – 10am and 4 – 8pm)
When black adjustable segment pins reach this
dial pointer (in AUTOMATIC position)
the Power Pack turns: ON if pins pressed out
OFF if pins pulled in
With black Lever in this position Power Pack is ON
With black Lever in this position Power Pack is in
AUTOMATIC and the timer setting turns it ON/OFF
With black Lever in this position Power Pack is OFF

12
7 .A PP L Y IN G A CHLORINATOR SK IN /F RONT S TIC K ER (CPPS MODEL ONLY)
1. Remove the two Rivet Clips and the Acrylic Cover, and set them aside (see below diagrams).
2. Gently wipe the existing skin/sticker to remove any dust/dirt/oils, ensure it is clean & dry.
3. Do not remove the backing of the new skin/sticker (yet). Sit the new skin/sticker on top of the existing skin/
sticker to gauge how to position the new skin/sticker. Ensure the new skin fits over all the switches, knobs
etc.
4. Remove the backing of the new sticker to reveal the adhesive. Hold the sticker taut (but not over-
stretched) at each end and place it squarely over the top of the existing sticker. Ensure you apply it evenly,
pushing out air bubbles as you go. Tip: Begin placing the bottom edge first to ensure it fits over the knobs and
switches.
5. Rub a soft dry cloth over the new sticker including all edges, ensuring it has properly & fully adhered to
the chlorinator, and ensuring there are no air bubbles.
6. Re-install the Acrylic Cover. Push in the Rivet Clips to secure the Acrylic Cover.
7. Ensure all settings on the chlorinator are correct.
2
1
1
Push the rivet pin so the claws
retract, then slide rivet out.
RIVET CLIPS &
ACRYLIC COVER
EXISTING SKIN/STICKER

13
8 .CHLORINATOR MAINTENANCE
8 . 1 Inspecng and Cleaning the Cell Electre
Reverse Polarity cells (CPPS models) should not normally require cleaning, however, in areas with very
hard water a calcium deposit might form on the lower areas of the Cell, the sensor or the sides of the Cell
plates. This will NOT affect the operation of your chlorinator, however you can use Pool Pro Cell Cleaner
to clean the Cell.
Standard cells (CPP models) should be checked every two weeks for calcium build up. Clean at least every
4-8 weeks (or as required) using Pool Pro Cell Cleaner. IMPORTANT: Excessive calcium build up is not a
chlorinator problem but rather a water balance issue.
Chlorinator Cells must be cleaned before scale/calcium builds up to the point where the electrode gaps in
the Cell are bridged as this may cause damage and affect operation. Check the Cell frequently to prevent
the accumulation of pool debris that for any reason may have bypassed the pool filter, particularly after
backwashing. Check that the O-Ring is clean, greased with silicone grease (DO NOT use petroleum based
jelly) and securely seated in the Cell Housing. For cleaning, please follow these steps:
•Switch off the wall outlet switch as this ensures the pump and Pool Pro unit will not turn on.
•Unscrew the Cell Locking Ring and remove the electrode for inspection. If calcium build-up is present,
immerse the electrode in Pool Pro Cell Cleaner.
•A solution can be made by mixing 1 part Hydrochloric Acid to 10 parts of water. If excessive build up is
present a stronger solution may be used to remove the calcium. Using 5 parts of water will make a
more aggressive solution but will not damage the Cell. You can use Pool Pro Cell Cleaner and if you do
then follow the instructions supplied on the product label.
•Allow the cleaning solution to dissolve the calcium deposits for 10 minutes. Dispose of the cleaning
solution at an approved Council Depot and never into storm water or sewage drains.
•TIP: Returning this mix to your pool only returns the calcium you just removed. You can reuse the
solution until exhausted then dispose of it. Always store the solution safely (refer to product label).
•Do not scratch or bend the cell plates in the Cell Housing.
•Ensure that the O-Ring is clean, greased and properly seated.
•Rinse the electrode in clean water and re-fit the electrode in the Cell Housing, ensuring that the Cell
Locking Ring is hand tight and secure.
•Turn on the wall outlet switch and the pump, the chlorinator will return to the mode it was in before.
•Turn on the unit and confirm chlorine output and timer settings on the Power Pack.
WARNING
AWhen mixing acid with water, ALWAYS ADD ACID TO WATER. NEVER ADD WATER TO ACID.
Eye protection, mask and gloves should be worn when cleaning the Cell.
Maintenance of your Pool Pro Salt & Mineral Chlorinator is simple and easy. While water chemistry
will always be the most important form of maintenance there are also other pointers to take note of.
•DO NOT cover the Power Pack with towels or similar as it has air vents that need air circulation.
•Keep the chlorinator off at all times during backwash cleaning of your filter by turning the Cell
Switch to the OFF position. Please remember to turn it on once done and return the unit to AUTO
mode.
•Check Power Pack Junction Box screws are tight and Cell leads are in sound condition at least once
a year.

14
9 .CHLORINATOR TROUBLESHOOTING

When Timer Switch in MANUAL everything
works but nothing works in AUTO
1. Incorrect setting of Timer -see Timer Setting (sec. 6)
2. Faulty Timer - call for service
When in MANUAL only the pump works 1. Press in Circuit Breaker on Power Pack
2. Make sure Cell Switch is ON
Circuit Breaker stays out in a tripped state Faulty Circuit Breaker -call for service
Faulty Cell Switch or Circuit Breaker - call for service
Circuit Breaker looks OK but Cell
Switch light not coming on
Circuit Breaker resets but trips again
1.
2.
Excessively high salt-check salt and lower if needed
Short across Cell plates - remove Cell and check
the plates for any metal lying across plates
3. Faulty rectifiers, transformer or Cell cable -call for service
Cell Switch illuminated ON but
no output on Display Meter
1. Try adjusting the output Control Knob
2. If green LED is not flashing once every second then call for service
3. Check Cell lead connection at the Junction Box, repair if damaged
or return for service
Green LED flashing but still no
output-faulty parts
1. Check Cell lead connection at the Junction Box - repair if needed
2. Faulty PCB, return for service
3. Faulty rectifiers, transformer or internal wiring. Return for service
Green LED flashing but still no
output-low or no water flow
Green LED is not flashing
Ensure sufficient water flow through chlorinator Cell. Check that
the pump is on and running. Look for air pocket -perform backwash
if needed. Check skimmer and pump baskets are clean and securely
tightened. Check for suction leaks. Seek advice from your local Pool
Pro Professional for any of the above.
Make sure Cell Switch is ON, Timer Switch is in Manual and
Circuit Breaker is not tripped. Reason could be:
1. Faulty PCB, return for service
2. Faulty rectifiers, transformer or internal wiring, return for service
9.1 
 
Not plugged into power point or
power point not turned on
Check that unit power cord goes into wall outlet and outlet
is turned on
Test wall outlet with a working appliance
Plugged into power point and turned
on but still no power
Wall outlet working but still no power Press Timer Switch to MANUAL
9.2  N  p  r  i  g  -  igh 
If you have checked all of the above then there is an internal
fault - call for service
8 .CHLORINATOR MAINTENANCE
8. 2 Inspecng and Cleaning the Power Pack
Timer Switch in MANUAL still no lights

Ensure the Power Pack 3 pin plug plugs into a suitable weatherproof RCD protected 10amp outlet. Ensure
that the pump plugs into the 3 pin AC Socket located at the bottom of the Power Pack. Check all plugs and
cords for damage. If damaged then it should be replaced by the manufacturer, their agent or similar
qualified person, in order to avoid a hazard. If the chlorinator is to be hard wired, then a qualified
electrician must complete the installation.
The Pool Pro Power Pack has air vents to allow internal components to remain cool. A special oil is applied
to the inside of the unit during production to stop insects from entering the unit. To help assist in keeping
the insects away, apply a surface spray periodically on the wall or post that the unit is mounted on. DO
NOT spray directly into the Power Pack. Ensure the power is off when you spray. Allow adequate time for
the spray to dry before turning power on again.

15


Output Control Knob not turned up
Low salt level
Build up of calcium on the Cell plates
Water temperature is low
Insufficient water flow through the Cell
Cell could be damaged or at the end of
its life
Level low in 1 direction but OK in other
Screws not adequately tightened
during installation



Turn the Knob clockwise,the reading should increase
Check salt level (sec. 3)
Calcium acts as an insulator and needs to be removed.
See Cleaning of Cell Electrode (sec. 7.2)
Winter water temperature can be very low. For every 1oC below 28oC
the output can drop 2-3%
Check water flow and ensure a full chamber of water is passing over
the Cell. You may need to backwash your filter
Damaged coating will reduce Cell life and reduce output. If all conditions
are correct then Cell could be at the end of its life
Clean the cell (sec. 7.2) or Cell may have run its life in 1 direction

If melted then return for service, otherwise tighten as required.

Make sure Timer Switch is set to AUTO and black lever in the centre of
Timer is set to time clock position and not “I” or “O”. Refer to Timer
Setting in this manual (sec. 6)

 
Pump not plugged into chlorinator
Check pump is plugged into the bottom of the Power Pack and not
directly in to the wall outlet. Make sure you are set in AUTO mode and
not MANUAL for normal running
  

Excessively high calcium, change of
direction time set too high or
faulty PCB
1. See Calcium Hardness (sec. 3) and adjust water accordingly
2. Change Water Hardness Switch to IF HIGH (sec. 5.9)
3. Manually reverse direction (sec. 5.2 - Cell Switch Changing Direction).
Failure for this to work could indicate a faulty PCB - return for service


Unit not working correctly Go through Troubleshooting from 8.2
Unit not set correctly Check basic settings such as Output Control and Timer running hours
Salt level is to o low Check Salt (sec. 3)
pH is too high Check pH (sec. 3)
Stabiliser is too low Check Stabiliser (sec. 3)
Cell at the ends of its life If full output is not reached then it could be a failing Cell
 
 
Battery life expired Replace Timer - return for service
l
J
Incorrect timer settings
Return unit for service


Faulty Rectifiers, Transformer or PCB

9.3 Green LED near the SoHard switch ashing

This is not a fault but purely an indicator This indicates power is supplied to the PCB and is normal

8 .CHLORINATOR TROUBLESHOOTING





16
10. SCHEMATICS AND PART NUMBERS
27
5
26
9
8
7
2
3
18
17
19
20
21
22
16
412
11
10 13
15
23
24 14
1
6
25
53 52 56 50 54 51 55
57

17
10. SCHEMATICS AND PART NUMBERS
# CODE DESCRIPTION
1 PPN00037 CPP/CPPS ALUMINIUM CHASIS
2 PPN00039-1 CPP/CPPS FRONT COVER BLACK
3 PPN00060 CPP/CPPS FRONT STICKER
4 PPN00033 CPP/CPPS ACRYLIC FRONT
5 PPN00038 CPP/CPPS TOP CASE LID
6 PPN00022 CPP/CPPS TRANSFORMER 220VA
FOR 20G/HR MODEL
6 PPN00023-1 CPP/CPPS TRANSFORMER 340VA
FOR 30G/HR MODEL
6 PPN00024-1
CPP/CPPS/NEPTUNE
TRANSFORMER 440VA FOR
40G/HR MODEL
7 PPN00027 CPP/CPPS THERMOSTAT 100oC
8 PPN00040 CPP/CPPS HEAT SINK 90MM 40G/
HR MODEL
8 PPN00041 CPP/CPPS HEAT SINK 30MM UP
TO 30G/HR MODELS
9 PPN00025 CPP/CPPS SCR 65AMP FLAT BACK
10 PPN00028-1 OLD STYLE CPP/CPPS STANDARD
TIMER - BOSCHE MECHANICAL
10 PPS0051
OLD STYLE CPP/CPPS DIGITAL
TIMER
- FRONTIER QUARTZ
10 PPN00414
NEW STYLE CPP/CPPS STANDARD
TIMER - QUARTZ BOSCHE
MECHANICAL BATTERY B/UP
11 PPN00029 CPP/CPPS TIMER - BRACKET
HOUSING
12 PPN00026 CPP/CPPS ROCKER SWITCH
13 PPN00018 CPP/CPPS CIRCUIT BREAKER
3AMP 20&30G/HR MODELS
13 PPN00019 CPP/CPPS CIRCUIT BREAKER
5AMP 40G/HR MODEL
14 PPN00011 CPP/CPPS POWER CORD-AU
15 PPN00001 CPP/CPPS AC SOCKET SQUARE -
PUMP OUTLET
16 PPN00072 CPP PLASTIC RIVET WHITE
17 PPN00172 CPP PCB STANDARD WITH 4&6
PIN CONNECTOR
17 PPN00030 CPPS PCB REVERSE POLARITY
18 PPN00003 CPP METER STANDARD
18 PPN00002 CPPS METER REVERSE POLARITY
19 PPN00035 CPP/CPPS KNOB FOR
POTENTIOMETER
20 PPN00020 CPP/CPPS JUNCTION BOX
COMPLETE WITH COVER
21 PPN00160 CPP/CPPS JUNCTION BOX SCREW
- CENTRE SMALL
22 PPN00159 CPP/CPPS JUNCTION BOX SCREW
- OUTER LARGE
23 PPN00021 CPP/CPPS TERMINAL BLOCK 2
PIN
# CODE DESCRIPTION
24 PPN00034 CPP/CPPS CABLE GROMMET
6N-4
25 PPN00042 CPP/CPPS SCR BRIDGE LONG
26 PPN00043 CPP/CPPS SCR BRIDGE SHORT
27 PPEC2000PP-C CPP POWER PACK COMPLETE
CPP20
27 PPEC3000PP-C CPP POWER PACK COMPLETE
CPP30
27 PPEC4000PP-C CPP POWER PACK COMPLETE
CPP40
27 PPRP2000PP-C CPPS POWER PACK COMPLETE
CPPS20
27 PPRP3000PP-C CPPS POWER PACK COMPLETE
CPPS30/CPPS30C
27 PPRP4000PP-C CPPS POWER PACK COMPLETE
CPPS40/CPPS40C
27 PPRP5000COMM CPPS POWER PACK COMPLETE
CPPS50C
57 PPN00670-1 CPP/CPPS PVC - REDUCING
BUSH 50X40MM
50 PPCC20EC
CPP20 REPLACEMENT CELL-5
PLATES 200MM, SOLID PLATE
CATHODE/ANODE
50 PPCC30EC
CPP30 REPLACEMENT CELL-7
PLATES 200MM, SOLID PLATE
CATHODE/ANODE
50 PPCC40EC
CPP40 REPLACEMENT CELL-9
PLATES 200MM, SOLID PLATE
CATHODE/ANODE
50 PPCC20RP
CPPS20 REPLACEMENT CELL-
5 PLATES 200MM, REVERSE
POLARITY
50 PPCC30RP
CPPS30 REPLACEMENT CELL-
7 PLATES 200MM, REVERSE
POLARITY
50 PPCC40RP
CPPS40 REPLACEMENT CELL-
9 PLATES 200MM, REVERSE
POLARITY
50 PPCC50RP-C
CPPS50 REPLACEMENT CELL-
13 PLATES 200MM, REVERSE
POLARITY
51 PPN00455 CPP/CPPS CELL CLIP 9 PLATE
BLUE CRYSTAL- NO ROD
52 PPSCCAP
CELL CAP (C/W CABLE, COVER,
CAP, BRASSWARE, WASHERS,
RESIN FILLED)
53 PPN00492 CELL CAP LOCKING RING
54 PPN00260 CPP/CPPS CELL SPACER (RODS
ONLY) BLACK
54 PPN00322 CPP/CPPS CELL SPACER (RODS
ONLY) BLUE
55 PPN00465 CPP/CPPS CRYSTAL CLEAR CELL
HOUSING - SMOKEY
56 OR925M CPP/CPPS O-RING CELL HOUSING
57 PPN00670-1 CPP/CPPS PVC - REDUCING
BUSH 50X40MM

18
11. SPECIFICATION TABLE
Domestic Models available:
MODEL
NUMBER
VOLTS
(Vac)
Input
AMPS*
(Aac)
Input
VOLTS*
(Vdc)
Output
AMPS*
(Adc)
Output
Chlorine*
(g/hr)
@3500
ppm salt
Power*
Consumption
(Watts)
Frequency
(Hz)
Weight
(kg)
Dimensions
(cm)
CPP20
CPP30
CPP40
CPPS20
CPPS30
CPPS40
210 – 265
210 – 265
210 – 265
210 – 265
210 – 265
210 – 265
1.02
1.35
1.97
1.02
1.35
1.97
6.60
6.60
6.60
6.60
6.60
6.60
9.5
11.3
13.2
9.75
11.32
13.56
20
30
40
20
30
40
50
50
50
50
50
50
20
30
40
20
30
40
222
304
425
222
304
425
41Lx35Wx19H
41Lx35Wx19H
41Lx35Wx19H
41Lx35Wx19H
41Lx35Wx19H
41Lx35Wx19H
Commercial Models available:
MODEL
NUMBER
VOLTS
(Vac)
Input
AMPS*
(Aac)
Input
VOLTS*
(Vdc)
Output
AMPS*
(Adc)
Output
Chlorine*
(g/hr)
@3500
ppm salt
Power*
Consumption
(Watts)
Frequency
(Hz)
Weight
(kg)
Dimensions
(cm)
CPPS30C 210 – 265
210 – 265
210 – 265
1.35
1.97
1.38
6.60
6.60
8.94
11.42
13.66
14.66
30
40
25
50
50
50
30
40
50
304
425
382
41Lx35Wx19H
41Lx35Wx19H
41Lx35Wx19H
MODEL
NUMBER
Chlorine
Output
Cal. Hypo.
Equivalent
(65%)
Sod. Hypo.
Equivalent
(12.5%)
Sod. Hypo.
Equivalent
(12.5%)
PER HOUR OVER 8 HOURS
CPP20
CPPS20
CPP30
CPPS30/CPPS30C
CPP40
CPPS40/CPPS40C
Chlorine
Output
Cal. Hypo.
Equivalent
(65%)
20g 31g
30g
160ml 160g 248g
1.28L
240ml 240g 368g
1.92L
320ml
400ml
320g
400g
496g
616g
2.56L
3.20L
40g
50g 77g
46g
62g
CPPS50C
Chlorine Production
* – all readings taken at 240Vac and in 3500ppm saltwater with a temperature of 28°C.
** – the configuration of this unit is based on a series/parallel cell.
AC Socket / Pump Outlet: Rated for 8amps - max is 1.5kW (2hp)
CPPS40C
CPPS50C**
CPP is a standard manual cleaning model
CPPS is a self cleaning model

19
12. WARRANTY & P R ODUC T R EGIS TRAT IO N
THIS EQUIPMENT HAS BEEN MANUFACTURED AND TESTED TO THE HIGHEST
STANDARD AND ACCORDINGLY CARRIES THE FOLLOWING WARRANTY.
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
The Pool Pro Power Pack and Electrolytic Cell will be repaired at no charge for a period of
three (3) years from the date of purchase should it be found, after examination, that the
failure has been caused by faulty workmanship or materials. This is a back to base warranty.
The warranty applicable to commercial application is limited to 12 months from the date of
installation unless a commercial model is purchased then this is 24 months.
Adverse operating conditions beyond the control of the manufacturer such as improper
voltage or water pressure, excessive ambient temperature or any condition that adversely
affects the performance of the equipment will render this warranty null and void.
Defective equipment must be returned to the manufacturer or dealer as soon as the
purchaser becomes aware of the defect and all transport must be prepaid. Neither the
manufacturer nor the dealer shall be responsible for any goods damaged in transit.
If after examination the equipment is found to be defective it will be repaired or replaced free
of charge (other than transport costs which will be borne by the purchaser). However, if upon
inspection of the equipment it is found that the terms of this warranty are not satisfied, then
the usual charges of the manufacturer for repair or replacement will be made.
Any liability of the manufacturer pursuant to the Trade Practices Act 1974, as amended for a
breach of a condition or warranty shall be limited to replacing or acquiring the equipment (or
part thereof) where the same has been supplied.
The maximum liability incurred by the manufacturer shall not in any case exceed the contract
price for the equipment or the product parts or components thereof claimed to be defective.
Further, the manufacturer shall not be liable for any loss, damage or delay directly or
indirectly caused by any malfunction of or defect of or failure of the equipment other than as
expressly provided in this warranty.
Products sold by the manufacturer are designed for use with swimming pool water balanced
in accordance with the Langelier Saturation Index (AS 3633-1989) with a pH range of 6.8-7.8.
Chlorine level should not exceed 4ppm and the salt level should not exceed 4000ppm.
The manufacturer will not be held liable for damage caused by, but not limited to, corrosion,
scaling or stress.
The Warranty is void under the following circumstances:
•Installation is carried out incorrectly by any person other than a person authorised by us to do so.
•The Power Pack or Cell is serviced by any person other than a person authorised by us to do so.
•Correct salt levels are not maintained at all times.
•The Power Pack is not protected from the elements.
•The Power Pack is not operated in a position/area with good ventilation.
•Water has been allowed to enter the Power Pack or Junction Box.
•Run in a commercial installation (these have a 1 year warranty on Power Pack and Cell unless a
commercial model is purchased then this is 24 months).
•Insect infestation or penetration by dust, sand or other foreign particles inside the Power Pack.
•Damage beyond our control.
•Equipment that has been misused, neglected, damaged, repaired without authorisation or altered in any
way.
This warranty is applicable to workmanship and materials only.
This warranty is not transferable under any circumstance.
This unit is for use in domestic swimming pools only where the correct size unit produces enough chlorine in
approximately 8 hours. Extended periods to gain more chlorine production voids the Warranty.
Keep your original purchase invoice and serial number in a safe place.

20
12. WARRANTY & PRO D UCT RE G ISTRATION
Please contact your original place of purchase, local distributor or Pool Pro directly to submit your
warranty/service claim, or visit www.poolpro.com.au/serviceclaim. When making a warranty claim,
please note the following information MUST be provided or your claim may not be approved.
•Model Number
•Power Pack & Cell Serial Numbers
•Proof of Purchase showing Purchase Date and
Purchased From
•Installation Date & Installer
•Your Full Name & Address
•Your Phone Number
•Details of the Issue
We keep extensive production and sales records so this information will expedite the processing
of your claim. Pool Pro reserves the right to modify any model without notice.
13. TECHNICAL SUPPORT
For product support please contact your local distributor or contact Pool Pro directly by emailing
[email protected].

Information in this guide is intended to provide general information on a particular subject(s) in good
faith and is not an exhaustive treatment of such subject(s). Its use is beyond the control of the author,
contributor, publishers and distributors and should not be relied upon without consulting your local
Pool Pro Professional for comprehensive advice.
This guide includes subject(s) that should only be performed by or under the direction and advice of
your local Pool Pro Professional and under no circumstances should the guide be used as a substitute
for such professionals.
No representations or warranties are made that the content, advice and recommendations in this
guide are current, free from errors or omissions, or appropriate for the user's circumstances or
abilities. No liability or responsibility is accepted for any loss suffered as a result of any user's reliance
on such content.
Repairs should only be carried out by qualified persons or Pool Pro appointed agents.
Pool Pro reserves the right to refuse warranty if any damage caused to the chlorinator or auxiliary
pool equipment that is not a result of a manufacturer's defect.


p  p 
T  pp 
 b 
Please register your product online at www.poolpro.com.au/product-registration within
30 days from date of purchase, or any warranty claim may be voided.
R  Y  P 