Waterco HYDROCHLOR MK3 User manual

Waterco Limited ABN 62 002 070 733
www.waterco.com
WARNING
!
(646087) 04/2018
HYDROCHLOR MK3
mineral chlorinator
Owners Manual
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.
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NSW - SYDNEY
(HEAD OFFICE)
Tel: [phone]
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Sittingbourne, Kent, UK
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Augusta, Georgia, USA
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Longueuil, Quebec, Canada
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Auckland, New Zealand
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Table of
What’s in the Box? ---------------------------------------- 01
FEATURES ------------------------------------------------- 01
HYDROCHLOR MK3 ---------------------------------------- 01
Hydrochlor MK3 Control Unit --------------------------- 01
Time Switch --------------------------------------------- 01
Electrolytic Salt Cell ----------------------------------- 02
Self-Cleaning ------------------------------------------- 02
Battery Back up ---------------------------------------- 02
INSTALLATION -------------------------------------------- 02
PLUMBING DIAGRAM ------------------------------------ 03
Installing the Control Unit ----------------------------- 03
Installing/ Connecting Electrolytic Cell ------------- 04
OPERATION ----------------------------------------------- 04
Setting the time ---------------------------------------- 04
CHLORINE PRODUCTION LEVELS --------------------- 05
ALARMS --------------------------------------------------- 06
WATER CHEMISTRY ------------------------------------- 06
Salt Level ------------------------------------------------ 06
Water Chemistry --------------------------------------- 07
SALT CELL CLEANING PROCEDURE ------------------ 07
TROUBLESHOOTING ------------------------------------ 07
TECHNICAL SPECIFICATIONS ------------------------- 08
GENERAL SAFETY RULES ------------------------------ 09
WARRANTY ----------------------------------------------- 09
What’s In the Box?
• Hydrochlor MK3 Control Unit
• Manual Warranty Booklet
NOTE: If bought as Salt Water Chlorinator unit, the electrolytic cell is provided in a
separate carton.
FEATURES
Chlorine Generation
Through the process of electrolysis, a saline solution pass over an electrolytic cell,
then 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 organism in the water.
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.
Consistently maintained sanitizer 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.
HYDROCHLOR MK3
Hydrochlor consists of a Control Unit (power supply)with a
built in timer (Time Switch) and a electrolytic salt cell (where
the chlorine is produced).
Hydrochlor Control Unit
The Control Unit monitors and regulates chlorine production
by regulating the amount of electrical energy supplied to the electrolytic salt cell.
Time Switch
The Time Switch controls power
to the pump and electrolytic cell.
It can be programmed to turn
“ON” or “OFF” at any time that
suits your lifestyle.
Time Switch
I pg 01
Waterco Hydrochlor MK3

I pg 03
Waterco Hydrochlor MK3
GAS TRAP: The cell must be positioned in such a way as to provide a gas trap. The
bottom of the cell must be above the top surface of the pipe from the previous
piece of equipment, as per the below diagram.
PLUMBING DIAGRAM
Installing the Control Unit
Choose a location for the Control Unit close enough to the Cell/Housing and filtration
pump so that both may be connected/disconnected easily. The Control Unit should not
be mounted in areas where chemicals are stored (e.g. acid and chlorine). Also ensure
the Control Unit 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.
The PUMP socket outlet in the base of the Control Unit 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.
NOTE: For installations running on off-peak electricity supply, like Queensland Tariff 33,
it is required to connect the Control Unit to power supply for a period of at least of 170
hours to fully charge the backup super capacitor of the Time Switch.
Electrolytic Salt Cell
Waterco’s salt cell consists of a series of titanium electrodes
with opposite charges. Waterco’s clear salt cell housing allows
visual inspection of the salt cell plates and enables monitoring of
chlorine production.
The cell housing is constructed using clear U.V. stabilized acrylic. Both
anode and cathode of the self-clean chlorinator are made from uniquely
coated titanium plates for extra durability.
Self-Cleaning
Waterco’s Self Clean Salt Cell has the added ability to reverse the polarity of the voltage to clean
calcium build up off its electrodes.
The Hydrochlor Control Unit power up the salt cell (anode and cathode) and hold 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.
It is recommended that you obtain regular water chemistry tests from your local pool professional
to ensure your water balance is within range.
Battery Backup
The Time Switch comes with a a super capacitor incorporated to save your settings in the event
of a power failure. The super capacitor requires 70 hours of continuous power supply to achieving
a full charge.
The time switch specifications are the following:
Super Capacitor Charge Time: 70 hours.
Super Capacitor Power Reserve: 150 hours.
INSTALLATION
These guidelines should be followed to install the Hydrochlor MK3:
a. 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 equipments such as heaters.
b. The electrolytic cell may be installed above or below water level. If it is below water level,
please ensure that an isolation valve is installed so the unit can be serviced without losing
water from the pool.
c. The cell may be mounted on different angles so long as a gas trap is provided.
GAS TRAP
40/50mm glued
connections
Sell Clean Requires
Minimum Maintenance
Heat Pump
Water Out
Water By-pass
PUMP
Filter
Water In
From Spa From Pool
3 Way Valve
To Spa
SPA POOL
SPA POOL
Vertical Trap
Check
Valve
HYDROCHLOR MK3
ELECTROLYTIC CELL
Chlorinator or
Chlorine Generator
To Pool

Installing/Connecting Electrolytic Cell
The Cell/Housing assembly should be plumbed into the pool return line after all other
accessories (and prior to any heating take-offs). Note any water flow direction on
the Cell/Housing. The Cell will need to be removed from the housing periodically for
cleaning – do not place it where its removal can be difficult/obstructed.
The Electrolytic Cell is connected to Control Unit using the cell cable.
Ensure that the 4 connections (3 for Cell Power and 1 for flow detection) are not loose.
A loose connection is likely to cause arcing which may damage the entire system.
NOTE: Connect all plumbing to the Cell Housing taking care that all joints are glued or
tightened securely to prevent leaking.
Allow 24 hours for glue (solvent) to set before starting the Hydrochlor MK3.
OPERATION
Setting the time
To set current time, rotate minute hand until arrow-head aligns with correct time.
The clock operates in a 24 hour time sequence
Setting Filtration and Chlorinator Operation Time.
To set ON/OFF times, move all tappets
between ON and OFF times required
to outer position.
I.E. to set ON at 7.30 a.m. and OFF
at 10.30 a.m. move all tappets
between 7.30 and 10.30 to
outer position (see fig. 1).
Manual Override switch (see fig. 2)
ON Position:
the time switch is permanently ONirrespective oftappet positions. This is the recommended
setting to work in combination with Waterco’s Aquamaster or ChemfloPlus.
AUTO Position:
the time switch is operating on timed control as determined by tappet positions. This the
automatic operation position.
OFF Position:
the time switch is permanently OFF irrespective of tappet positions.
Tappets in OFF
position Tappets in ON
position
Figure 1
CHLORINE PRODUCTION LEVELS
The output of the chlorinator can be adjusted to reflect the different seasonal
requirements in order to maintain satisfactory chlorine sanitizer levels.
The amount of chlorine produced can be adjusted by pressing the CHLORINE
PRODUCTION key. Press button to raise production. If production already set at
maximum it will turn to zero and each press will raise production by one LED till MAX.
If the pool water is over chlorinated, simply reduce the chlorine production set level.
Pump Only Mode: The Chlorinator can be set to activate the pump only for maintenance
purposes (e.g. backwashing the filter). The pump only mode will disable the flow
detection and chlorine production in the cell. To set press CHLORINE PRODUCTION
key until Pump Only mode LED is lit.
“ON” Position “AUTO” Position “OFF” Position
Figure 2
Power
Connections
Flow Sensor
Cell Connections
I pg 05
Waterco Hydrochlor MK3

Water Chemistry
It is important to maintain the correct water chemical balance in the swimming pool;
this will help protect the Hydrochlor chlorinator and its cell.
Consult the local pool professional for the correct water balance according to the
swimming pool type.
The Hydrochlor chlorinator will run correctly at the following chemistry levels
SALT CELL CLEANING PROCEDURE
a. Set the Time Switch to “off” position.
b. Unscrew the barrel unions from the salt cell and disconnect the cables from the salt
cell’s brass connectors.
c. Turn the salt cell housing upside down with both ports facing upwards.
d. Pour the Cell Wash cleaning solution into the housing to dissolve the calcium build-
up from the salt cell plates. There should be just enough solution to cover the salt cell
plates.
e. Allow enough time for the solution to dissolve the calcium build-up from the salt cell
plates. Approximately 5 to 10 minutes.
f. Once the calcium build-up has been removed, pour out the Cell Wash solution into a
bucket and lightly rinse-off excess calcium and Cell Wash solution from the salt cell
assembly, with fresh water.
g. Reconnect the salt cell onto the filter system
h. Set the time back to original “ON” or “AUTO” position on the power pack to
reactivate the Hydrochlor.
Never use products that are not specifically manufactured to clean the Hydrochlor
MK3’s salt cell. Do not use raw acids such as Hydrochloric acid. This will damage
the salt cell and severely life and will void warranty. Please consult your local pool
professional for advice on salt cell cleaning products.
TROUBLESHOOTING
I pg 07
Waterco Hydrochlor MK3
ALARMS
Hydrochlor MK3 includes alarm signals to indicate potential problems associated with its
functionality and to protect the control unit/electrolytic cell. The chlorine production
LEDs will blink/lit or change the colour to indicate the correspondent situation.
• Low Chlorine Production Level LED blinking: Salt level is below the minimum
allowed, please add salt to pool. Consult your pool professional how to increase the
salt level. This condition may affect the longevity of the cell and void its warranty.
• High Chlorine Production Level LED blinking: Salt level is moderately above
the maximum operational level. It needs to be reduced below the maximum
recommended. Consult your pool professional how to reduce the salt level. This
condition may affect the longevity of the cell and void its warranty.
• Max Chlorine Production Level LED Amber: Salt level is too high. The control
unit will stop the chlorine production until it’s reduced below the maximum
recommended. Consult your pool professional how to reduce the salt level.
• No Water Flow: The flow sensor is not detecting water flowing through the cell
housing. Control Unit will stop chlorine production and power to pool pump. Please
refer to trouble shooting guide or consult your pool professional.
WATER CHEMISTRY
Salt Level
The Hydrochlor MK3 chlorinators must operate between the salt level ranges listed below.
• MINIMUM = 4000 TDS • OPTIMUM = 5500 TDS • MAXIMUM = 6000 TDS
Testing kits are available from the local pool professional and should be used to
accurately check the salt level in the pool water.
SYMPTOM POSSIBLE CAUSE REMEDY
Low chlorine level in pool Operating time too short Increase operating time
Production control set too low Set production higher
Low salt Add required amount of salt
Pool chemistry not correct Have water tested
Unit does not operate No electrical power
Hydrochlor MK3 switch off
Connect power, check fuse, switch on
Hydrochlor MK3
MAX
HIGH
MED
LOW
MIN
PUMP ONLY
CHLORINE
PRODUCTION
PRESSING CHLORINE
PRODUCTION
CONTROL BUTTON WILL CYCLE
THROUGH THE CHLORINE
PRODUCTION LEVEL AND PUMP
ONLY FUNCTION
Range Suggested
pH. 7.2 – 7.8 7.2 – 7.6
Total alkalinity 60 – 200ppm 80 – 150ppm
Calcium hardness 100 – 500ppm 60 – 250ppm
Stabilizer (Sun screen) 30 – 60ppm

Cell Housing dimensions
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.
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.
6) 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.
7) 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.
8) The operating safety of the chlorinator is only guaranteed if the Installation and Service
instructions are correctly followed.
9) The limit values stated in the Technical Specifications should not be exceeded under
any circumstance.
10) In the event of defective operation or fault, contact the manufacturer’s Technical
Support Department or its nearest Authorized Agent.
11) If the supply cord is damaged, it must be replaced by the manufacturer or its service
agent or a similarly qualified person.
12) 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.
13) 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.
WARRANTY
Two Years Warranty:
Hydrochlor MK3 2 years*
Electrolytic Salt Cell 2 years
Power pack 2 years
Commercial Installations 1 year
*Please refer to Waterco’s Warranty terms and conditions
TECHNICAL SPECIFICATIONS
Power Unit Waterco Salt Cell
Input 220-240V AC
Frequency 50/60 Hz
Current 1.6 A
Socket Outlet 220-240V AC
Maximum Current Output 8A
Minimum Salt Level 4000 TDS
Maximum Salt Level 6000 TDS
Type of Salt Standard Pool Salt/
Mineral Salt
Input 20V DC
Maximum Current Output 6A DC
Waterco Salt Cell Chlorine Production
(g/hr)
Max Pool Size/ Climate
Temperate Tropical
Series 2000 20 60,000 48,000
Series 2500 25 80,000 60,000
Series 3000 30 100,000 72,000
Recommended Pool Sizes
SYMPTOM POSSIBLE CAUSE REMEDY
Not keeping time Time clock setting, power
outage
Make sure battery have been
charged for a least 70hrs to achieve
max capacity
Electrical fault Return to distributor for repair
All LEDs blinking Electrical fault Return to distributor for repair
No chlorine production Control unit set to pump only Press Chlorine Production button to
set the desired level
Time Switch in OFF position Set Time Switch to ON or AUTO
position
Pump not working Pump not connected to pump
socket outlet
Plug pump lead to Pump Socket
outlet
No flow detected Check pool water level
Check position of multiport valve
Check connection of flow sensor pin
I pg 09
Waterco Hydrochlor MK3
A (mm) B (mm) C (mm) D (mm)
370.0 136.5 280.0 188.8