Waterco ELECTROCHLOR PLUS User manual

WARNING
!
(W99368) 09/2018
www.waterco.com
Waterco Limited ABN 62 002 070 733
Owner's Manual
ELECTROCHLOR®
Mineral Chlorinator PLUS
This equipment must be installed and serviced by a qualified technician.
Improper installation can create electrical hazards which could result in
property damage, serious injury or death. Improper installation will void the
warranty.
Notice to Installer
This manual contains important information about the installation, operation
and safe use of this product. Once the product has been installed this manual
must be given to the owner/operator of this equipment.
OFFICES – AUSTRALIA
NSW - SYDNEY
(HEAD OFFICE)
Te l : [phone]
VIC/TAS - MELBOURNE
Te l : [phone]
WA - PERTH
Te l : [phone]
QLD - BRISBANE
Te l : [phone]
SA/NT - ADELAIDE
Te l : [phone]
ACT DISTRIBUTOR
Te l : [phone]
OFFICES – OVERSEAS
WATERCO (EUROPE) LIMITED
Sittingbourne, Kent, UK
Te l : [phone]
WATERCO USA
Augusta, USA
Te l : [phone]
WATERCO CANADA
Boucherville, QC, Canada
Te l : [phone]
WATERCO (NZ) LIMITED
Auckland, New Zealand
Te l : [phone]
WATERCO (C) LIMITED
Guangzhou, China
Te l : [phone]
WATERCO (FAR EAST) SDN BHD
Selangor, Malaysia
Te l : [phone]
PT WATERCO INDONESIA
Jakarta, Indonesia
Te l : [phone]
WATERCO SINGAPORE INTL PTE LTD
Nehsons Building, Singapore
Te l :[phone]

Table of
SAVE THESE INSTRUCTIONS.
This equipment must be installed and serviced by a qualified technician.
Improper installation can create electrical hazards which could result in
property damage, serious injury or death. Improper installation will void
the warranty.
Electrochlor operates with 240 volts and must be installed by licensed
electricians and must be installed in accordance to the local statutory
authority regulations.
Electrochlor is not intended for use by persons (including children) with
reduced physical sensory or mental capabilities, or lack of experience and
knowledge, unless they have been provided supervision or instruction
concerning use of the appliance by a person responsible for their safety.
Children should be supervised to ensure they do not play with the
appliance.
In certain situations, unexpected start-up may occur when the appliance
is in automatic mode. The installer should assess the risk associated with
unexpected start-up of any connected device which, in any circumstance
should have no hazardous effect.
The appliance should be supplied through a residual current device (RCD)
having a rated residual operating current not exceeding 30mA.
Parts incorporating electrical components, except remote control devices,
must be located or fixed so that they cannot fall into the spa – pool.
Disconnect all AC power during installation.
Electrochlor should be deactivated if the pool or spa has been drained.
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Warning
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GENERAL SAFETY RULES 4
1. WHAT’S IN THE BOX? 5
2. INTRODUCTION 6
3. INSTALLATION CONSIDERATIONS 7
4. INSTALLING THE CHEMICAL INJECTION
POINTS 11
5. CONNECT THE CHEMICAL
SUPPLY TUBES 12
6. CONNECT CHEMICAL INJECTION POINTS
TO THE CHEMICAL DOSING UNIT 13
7. ASSEMBLE THE FOOT FILTER 14
8. ELECTROCHLOR MAINTENANCE 15
9. INSTALLING THE PH SENSOR 17
10. SETTING THE PH SETPOINT 18
11. CALIBRATING THE SENSOR 21
12. CHEMICAL HANDLING 23

GENERAL SAFETY RULES
1. The equipment mentioned in this manual is specially designed for the sanitizing of
water in swimming pools.
2. It is designed to work with clean water at a temperature not exceeding 35°C (95°F).
3. The installation should be carried out in accordance to the safety instructions of
swimming pools especially Standard HD 384.7.702 and the specific instructions for
each facility.
4. The rules enforced on accident prevention should be carefully followed.
5. Any modification of the chlorinator requires the prior consent of the manufacturer.
6. Original replacement parts and accessories authorized by the manufacturer ensure
a high level of safety. The manufacturer accepts no liability for the damage and
injuries caused by unauthorized replacement parts and accessories.
7. During operation, some parts of the chlorinator are subject to dangerous electric
voltage. Work may only be performed on the chlorinator or on the equipment
connected to it after disconnecting them and the starting device from the mains
power.
8. The user should make sure that assembly and maintenance tasks are carried out
by qualified authorized persons and that these persons have first carefully read the
Service and Installation Instructions.
9. The operating safety of the chlorinator is only guaranteed if the Installation and
Service instructions are correctly followed.
10. The limit values stated in the Technical Specifications should not be exceeded under
any circumstance.
11. In the event of defective operation or fault, contact the manufacturer’s Technical
Support Department or its nearest Authorized Agent.
12. If the supply cord is damaged, it shall be replaced by the manufacturer or its service
agent or similarly qualified person in order to avoid a hazard.
13. This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety.
14. The appliance is not intended for use by young children. Young children should be
supervised to ensure that they do not play with the appliance.
These chlorinators are approved and conformed to AS3136 Swimming Pool Equipment,
as a prescribed article under Australian Registration.
These chlorinators conform to the Australian Electromagnetic Compatibility Standard
marked by the C-tick.
1. WHAT’S IN THE BOX?
• Electrochlor Power Pack
• Electrochlor Accessories kit
• Owner’s Manual
• Warranty Booklet
If bought as Salt Water Chlorinator unit, the electrolytic cell is provided in
a separate carton.
NOTE:
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2. INTRODUCTION
Consistently maintained sanitiser levels in the pool water will prevent the growth of all
common algae and bacteria. A salt-water chlorinated pool requires much less attention
than a chlorine pool.
A chlorine generator’s main function is to produce chlorine for the pool. This keeps
a residual of chlorine in the pool that prevents algae and bacteria from growing. The
chlorine then turns back into salt and the system continues as long as the generator is
functioning properly.
Through the process of electrolysis, a saline solution passing over an electrolytic cell,
the saline solution is separated into its basic components: chlorine and sodium. The
chlorine is instantaneously transformed into hypochlorous acid; this the chlorine form
that kills algae and other harmful organisms in the water.
About the ELECTROCHLOR
Electrochlor Mineral Chlorinator consists of a Power Pack (power supply) and an
electrolytic salt cell (where the chlorine is produced).
Electrochlor Power Pack
The Power Pack monitors and regulates chlorine production by regulating the amount
of electrical energy supplied to the electrolytic salt cell.
Electrolytic Salt Cell
Waterco’s salt cell consists of a series of titanium electrodes with opposite charges.
Waterco’s clear salt cell housing is constructed using clear U.V. stabilized acrylic, and
allows visual inspection of the salt cell plates.
Both anode and cathode of the self-clean chlorinator are made from uniquely coated
titanium plates for extra durability.
Self-Cleaning Cell - How it works
The Electrochlor Power Pack powers up the salt cell (anode and cathode) and holds
an electrical potential difference between them for a designated period of time. This
difference is reversed after that period of time has expired and then the anode becomes
the cathode and the cathode becomes the anode.
The reversing of polarity or electrical potential difference will then start to remove any
calcium build-up, which may have been deposited onto the cathode.
This continuous reversing of polarity will keep the cell clean from calcium deposits
during its operation, providing the chemical balance and flow of the pool water thru the
cell is maintained within normal parameters.
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3. INSTALLATION
Ensure that the electrolytic cell is the last piece of equipment installed
on the filtration system – this is so the chlorine produced will not damage
other equipment such as heaters.
The Power Pack should not be mounted in areas where chemicals are
stored (e.g. acid and chlorine).
The electrolytic cell may be installed above or below water level. If it is
below water level, an isolation valve must be installed so the unit can be
serviced without losing water from the pool.
Installing the Power Pack
Choose a location for the Power Pack close enough to the Cell/Housing and filtration
pump so that both may be connected/disconnected easily. The PowerPack should not
be mounted in areas where chemicals are stored (e.g. acid and chlorine). Also, ensure
the Power Pack can be connected to the mains power outlet of the pool area. Note that
this outlet must meet the current applicable local standards at the time of installation.
Install the Power Pack in a protected location out of direct sunlight. At top rear of the
control panel locate two keyhole fixing points. Mount two pan head type screws at
216mm centres using a spirit level on an adequately stable vertical surface. Align the
screw heads with the keyhole fixing points and allow the enclosure to slide down on
the screws.
Warning
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To access the Electrochlor for connection of cabling and sensors, there are screw wells
in each corner of the front panel. To open the panel, insert a flat blade screwdriver and
half turn anti-clock wise to release the spring-loaded locking pin. Ensure the pins are
fully released prior to opening the hinged front panel.
Electrochlor Mineral Chlorinator Power Outlets/Inputs
The Electrochlor has the following input/output connections:
1. A GPO for the pool pump or auxiliary equipment (AUX2) with a maximum current
output of 7.0A and 240V.
2. A GPO for a pool light or auxiliary (AUX1) with a maximum current output of 1.0A
and 240V.
3. A 24VAC jack socket to supply power to valve actuator with a maximum current
input of 2.0A.
4. Provision for 2 cables input/output for a variable speed control cable and for low
chlorine/spa signal cable (dry connection).
The PUMP socket outlet in the base of the Power Pack is dedicated
to the filtration pump only. Do not use a double adaptor to connect
another pump as this will overload the system and void warranty.
Warning
Resetable
Fuse
Bottom View Electrochlor Mineral Plus Chlorinator
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Typical Installation Layout
4. INSTALLING THE CHEMICAL INJECTION POINTS
4.1. The acid injection point is to be installed on the pool return line, after all
other pool equipment.
4.2. Dry fit the chemical injection point saddle to ensure sufficient space and
clearances.
4.3. Ensure that the heads of the chemical injection points have a minimum of
200mm clearance so that the chemical feeder hoses may attach freely.
4.4. Whilst in dry fit, mark the holes to be drilled into the pipes, so they are directly
under the open head of the chemical injection point.
4.5. Using a hole saw (22 mm), drill the first hole and clean the swarf (Figures 4.1
and 4.2).
4.6. Install the lower and upper clamps (Figure 4.3 and 4.4), so that the hole is
directly beneath the open head of the upper clamp. Then secure the clamps
together using the nuts and bolts provided, tightening with an adjustable
wrench or 10mm socket wrench.
Figure 4.7Figure 4.6 Figure 4.8 Figure 4.9 Figure 4.10
Figure 4.2
Figure 4.1 Figure 4.3 Figure 4.4 Figure 4.5
4.7. Using the Teflon tape provided, install the reducing bush to the top of the
acid injection clamp (Figures 4.6 and 4.7). Hands tighten, and then ½turn
with an adjustable wrench (Figures 4.8). Do not overtighten.
4.8. Using the Teflon tape provided, install the chemical injector to the reducing
bush. Hand tightens, and then ¼turn with an adjustable wrench (Figures 4.9
and 4.10).
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Figure 5.1 Connection Point Assembly
Suction Hose
Tightening Nut
Holding Ring
Pipe Holder
O-ring
Valve
Figure 5.2 Connecting acid feed line to injector
5. CONNECT THE CHEMICAL SUPPLY TUBES
The Electrochlor pH is supplied with ample chemical supply tubes which may be
cut to length using a sharp utility knife.
5.1. Connect to chemical injection assembly, use Figure 5.1 as a reference for the
assembly of the connection point of the tubing to injection valve and the acid
dosing pump.
6. CONNECT CHEMICAL INJECTION POINTS TO
THE CHEMICAL DOSING UNIT
6.1 Cut the chemical supply tube connected to the chemical injection point to
a suitable length allowing enough slack. Then feed the tightening nut and
holding ring over the tube. Push the open end of the tube onto the pipe
holder in the base of the chemical dosing unit RIGHT-HAND SIDE (OUT/
discharge side Figure 6.1) and screw the collar hand tight (Figures 6.2 to 6.4).
6.2 Repeat so both tubes are now connected with one end joined to the chemical
injection point and the other joined to the RIGHT-HAND SIDE (discharge
side) of the chemical dosing unit pumps.
5.2 Take one end of the chemical supply tube and feed it through the tightening
nut and holding ring. Then push the end of the tube over the pipe holder.
Ensure that the tube is pushed on firmly over the tip and screw the tightening
nut hand tight. See images below.
Figure 6.1 Peristaltic Pumps Layout
Figure 4.2 Figure 4.3 Figure 4.4
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7. ASSEMBLE THE FOOT FILTER
7.1 Position the chemical drums in a safe and secure location, preferably about 2
metres from Electrochlor Power Pack.
7.2 Ensure acid have been diluted if necessary (See page 23 for details on how
to dilute chemicals).
7.3 Drill a 10mm hole in the lid of the drum and pass a length of tubing through
the hole.
7.4 Place a foot filter on the end of the tubes and then attach the appropriate
drum filter.
7.5 Lower the drum filter and sinker into the drum and screw on the lid.
8. ELECTROCHLOR MAINTENANCE
The Electrochlor ensures that the correct residual level of pH is maintained
within the swimming pool. Periodical maintenance of the Chemical Dosing unit
is required.
8.1. pH Probe/Sensor
The Probe should be removed and cleaned every 3-6 months.
Turn the system OFF. Remove the Probe, being careful not to touch the
sensor tip. Clean the tip with a soft, clean cloth dipped in a small amount of
mentholated spirits.
8.2. Peristaltic Pump
The squeeze tubes of the peristaltic pump should be replaced every one (1)
year depending on the amount of chemical being used. The higher the usage,
the more often replacement is required.
8.3. Changing of the tube without dismantling the rotor
Important: Use originals squeeze tube only!
Important: Never grease the tube!
Caution: Before changing the tube always ensure, that the tubes don’t
contain residual chemical. Acid may cause dangerous injuries to your
eyes and to your skin. Wear protection glasses and gloves and protect
the environment from escaping dosage product with a cloth if necessary.
Caution: The turning rotor can cause dangerous contusions! Always first
ensure that the pump stays disconnected from the operational voltage
during the changing of the tube (Switch off power to the Electrochlor!).
Figure 8.1 Figure 8.2 Figure 8.3 Figure 8.4
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Acid

DAILY MAINTENANCE
• Clean skimmer baskets if required.
• Remove floating leaves if required.
• Remove any large accumulation of debris on the bottom with a leaf scoop.
• Check that the water level is high enough for the pump to operate correctly.
• (water level should be in the middle of the skimmer mouth opening).
WEEKLY MAINTENANCE
If the Pool/Spa is heavily used (such as in hot weather) it must be checked more
frequently. As a general guide, it is recommended that the check should be made at least
twice weekly in the swimming season and once every two weeks in the non-swimming
period. Seek guidance from your local authority or qualified Pool/Spa maintenance
technician if necessary.
• Check and clean pump and leaf baskets if required.
• Check filter and backwash the media filter or clean cartridge filter as necessary.
• Make sure there is adequate diluted acid in the tank of the automatic feeder for the
next week.
• Always add acid to the water, never water to acid.
• Test the pH & free chlorine levels in the Pool/Spa water.
MONTHLY MAINTENANCE
• Test the TA, adjust if required.
• Check the stabiliser level and make sure it is in range.
• Check Squeeze tubes.
• Change water, spa applications only.
QUARTERLY, HALF YEARLY OR YEARLY MAINTENANCE
• Check and clean probe if required.
• Check squeeze tubes & all tubing; Squeeze tubes need to be replaced based.
• on usage. If tubing is stiff or swollen then replace tubing. Take care as chemical will be
in tubing.
• Clean salt cell: follow chlorinator manual instructions to accomplish this step.
9. INSTALLING THE PH SENSOR
9.1. The pH sensor is to be installed on the pool suction line, before acid injection
point and salt cell.
9.2. Dry fit the pH sensor saddle to ensure sufficient space and clearances.
9.3. Whilst in dry fit, mark the holes to be drilled into the pipes, so they are directly
under the open head of the chemical injection point.
9.4. Using a hole saw (22 mm), drill the first hole and clean the swarf (Figures 9.1
and 9.2).
9.5. Install the lower and upper clamps (Figure 9.3 and 9.4), so that the hole is
directly beneath the open head of the upper clamp. Then secure the clamps
together using the nuts and bolts provided, tightening with an adjustable
wrench or 10mm socket wrench, (Figure 9.5).
9.6. Using the Teflon tape provided, install the 20mm probe nipple on the injection
clamp Hands tighten, and then ½turn with adjustable wrench Do not over
tighten (Figure 9.6).
9.7. using the Teflon tape provided, install the pH sensor injector to the probe
nipple. Hand tightens (Figures 9.7).
9.8. Connect the pH Sensor BNC connector Electrochlor (Figure 9.8).
Figure 9.6 Figure 9.7 Figure 9.8
Figure 9.2
Figure 9.1 Figure 9.3 Figure 9.4 Figure 9.5
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Figure 10.1 Navigate to the setting menu
Figure 10.2 Using arrows () Navigate to pH Settings
Figure 10.3. Dene pH Range
Figure 10.4 Dene dosing pump duty
Setpoint photo here
Figure 10.5 Setting Operating Values for pH
10. SETTING THE PH SETPOINT
Proportional Controller
The Electrochlor use a proportional controller using a calculated percentage
between two set values that enable or disable the pH dosing pump.
Push the Electrochlor Plus wheel, navigate to the Settings Menu. Navigate using
the arrow to Setpoint Menu.
Setting the Setpoint and Pump Duties
Select the high value, in this example 7.6pH, the select the duty (%) in the below
example 50% Select the lower value (min value) in this example 7.2pH, set the
duty to 0%.
Example: Proportional mode with a range of 7.2pH (0%) and 7.6pH (100%). In this
mode, the pH peristaltic pump will be ‘ON’ for values greater than 7.6 pH and it’ll
be ‘OFF’ for values lower than 7.2 pH. For values of the 7.4pH peristaltic pump will
be ‘ON’ for 20 seconds out of every 100 seconds.

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Figure 11.1 pH Settings Menu
Figure 11.2 pH Calibration Menu
Figure 11.3 Calibration pH Sensor
11. CALIBRATING THE SENSOR
This step requires a pH 7.00 reference solution (Waterco P/N 60121387). This step
requires the sensor to be removed from its saddle clamp. It is also important to
disconnect/stop the pump while performing this operation.
With the Electrochlor On, push the wheel and navigate to pH, select this option
and using the wheel navigate to Calibrate and press enter.
Table 10.1 Reference pH Settings for Dierent Pool Sizes
Should any adjustment be required, adjust the desired set point in increments of
0.1. The proportion (%) can be adjusted as desired. Allow the pool to circulate for
48 hours before testing and adjusting again.
Pool Size Range Proportion (%) Response rate
< 20kL 7.2-7.6 5% Slow
40-60kL 7.2-7.6 50% Average
> 80kL 7.2-7.6 100% Fast

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12. CHEMICAL HANDLING
Important Safety Measures
• Always add concentrated chemicals to water.
• Don’t allow chemicals to mix.
• Always wear protective clothing, footwear, gloves and eye protection when
handling pool chemicals to avoid injury.
• If a spill occurs, wash the affected area with fresh water immediately and seek
medical attention.
• Work in a well-ventilated area and avoid inhalation of fumes.
• Read and follow safety instructions on chemical drums.
Diluting Chemicals
• Always wear protective clothing, footwear, gloves and eye protection when
handling pool chemicals to avoid injury.
• Always add acid to the water, never water to acid.
Calibration Procedure:
11.1 Switch the pool pump OFF and unplug it from the POOL PUMP GPO.
11.2 Remove the pH sensor from the tapping saddle. For installations where this
fitting is below the level of the pool, close the Isolation valve before removing
the probe.
11.3 Plug the pH sensor into the pH sensor BNC connector socket (if not already
connected).
11.4 Rinse probe in distilled water. Shake off as much water as possible. Blot the
outside of the probe dry.
11.5 Place the pH probe into a small sample of pH 7.00 buffer. Ensure that the
entire and reference junction is immersed, as per the diagram below.
DO NOT place pH Sensor directly into buffer bottles.
11.6 Wait until the reading value is stable according to the buffer solution value
and then rotate the wheel until it is the same as on the display. Default value
is 7.00pH.
11.7 Save the setting by rotating the wheel to the checkmark.
11.8 Re-install the sensor to the pipeline on the saddle clamp, reconnect the pump
and set Chlorinator back to operation.
buffer solution value may change if the solution temperature is different
than 20°C. Read the buffer solution’s label for more information. If the
value is different from the default value of 7.00 then the ‘pH Default’ value
must be changed to the correct one.
NOTE: