ChlorKing NEXGEN50, Installation, Operation And Maintenance Manual

Page 1: ...NEXGEN50R InstallationRev2 Page 1 of 38 04 11 2022 NEXGEN50 and 50R Installation Operation and Maintenance Manual ...

Page 2: ...der Installation 13 2 10 Plumbing the Overflow 14 2 11 Preparing the pH Neutral System 15 2 12 Plumbing the Hydrogen Vent 15 3 0 OPERATION 16 3 1 Start up Procedures and Checks 16 3 2 Adjusting Chlorine Output 16 3 3 Touch screen Icon Explanations 17 3 4 Using the Touchscreen 18 4 0 MAINTENANCE 25 4 1 Routine Maintenance 25 4 2 Cell Cleaning Procedure 25 5 0 WARRANTY INFORMATION 38 Note This manua...

Page 3: ...sly from a salt concentration of 5000ppm to 7000ppm and uses the water from the pool as a raw material This unique feature eliminates issues with high TDS levels and requires less salt as raw material than traditional methods The NEXGEN is designed for commercial service and can be run 24 hours a day or controlled by any pool controller R models are reverse polarity for reduced maintenance The bas...

Page 4: ...0 degrees F above the pool water Dilution Fan Electrochemical production of sodium hypochlorite produces hydrogen as a byproduct The dilution fan pumps fresh air into the production tank to dilute the hydrogen and force it out the vent The vent must be vented to outside atmosphere Saturated Salt Feeder The saturated salt feeder supplies the production tank with a constant supply of salt to produce...

Page 5: ... A 50 60 Hz Requires A 208 240 volt single phase connection 60 amps minimum and 50 or 60Hz 120 volt connection to a chemical feed controller or 120 volt outlet 1 amp Certifications NEXGEN50R is certified for indoor installation NSF Standard 50 UL Standard 1081 CSA Standard C22 2 218 1 PRMA Reg No 33004 Sizing guidelines Chlorinator sizing must comply with local codes Please contact your local heal...

Page 6: ...NEXGEN50R InstallationRev2 Page 6 of 38 04 11 2022 DIMENSIONS 18 24 31 ...

Page 7: ...ING THIS EQUIPMENT KEEP SAFETY CONSIDERATIONS FOREMOST USE PROPER TOOLS PROTECTIVE CLOTHING AND EYE PROTECTION WHEN WORKING ON OR INSTALLING THE EQUIPMENT FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND TAKE ANY ADDITIONAL SAFETY MEASURES APPROPRIATE BE EXTREMELY CAREFUL IN THE PRESENCE OF HAZARDOUS SUBSTANCES THE PERSONNEL RESPONSIBLE FOR INSTALLATION OPERATION AND MAINTENANCE OF THIS EQUIPMENT MUST B...

Page 8: ...ATING THE EQUIPMENT DO NOT ENERGIZE OR OPERATE THE SYSTEM IF THE CELL HOUSING IS DAMAGED OR IMPROPERLY ASSEMBLED THE MOUNTING LOCATION OF THE UNIT MUST BE AT LEAST 1 5 METERS FROM THE POOL CONSERVEZ CES INSTRUCTIONS LORS DE L INSTALLATION DE FONCTIONNEMENT ET L ENTRETIEN DE CET ÉQUIPEMENT GARDEZ LES CONSIDÉRATIONS SUR LA SÉCURITÉ AVANT TOUT UTILISER DES OUTILS APPROPRIÉS DES VÊTEMENTS DE PROTECTIO...

Page 9: ...E QUELLE BOÎTE TANDIS QUE L APPAREIL EST ALLUMÉ LE SYSTÈME A LA POSSIBILITÉ DE LIBÉRER DES DOSES ÉLEVÉES DE CHLORE SOYEZ PRUDENT LORS DE MANIPULATION ENTRETIEN OU FONCTIONNEMENT DE L ÉQUIPEMENT NE PAS METTRE SOUS TENSION OU FAIRE FONCTIONNER LE SYSTÈME SI LE BOÎTIER DE LA CELLULE EST ENDOMMAGÉ OU MAL ASSEMBLÉ L EMPLACEMENT DE MONTAGE DE L UNITÉ DOIT ÊTRE D AU MOINS 1 5 MÈTRES DE LA PISCINE 2 4 PLA...

Page 10: ...manual disconnect be installed between the electrical service and the NEXGEN system Connect the electrical supply from the pool equipment room to the connections marked Line and Ground on the power distribution terminal block Ensure that the electrical service is protected by a circuit interrupter and is rated for the model NEXGEN that is installed Connect the blue control cord to a chemical feed ...

Page 11: ...for booster pump sizing The booster pump is powered by the NEXGEN and must be installed within 10 feet of the NEXGEN skid to ensure the electrical connection will reach the pump The pump wiring is located on the bottom side of the enclosure Wire the booster pump to the NEXGEN with the cable provided and to the pump according to the instructions on the pump for 208 240 VAC connections The NEXGEN sh...

Page 12: ... at least 2 inch PVC pipe for this connection It is recommended that a valve be installed at this connection so that the system can be isolated from the pool Size Booster Pump based on return line pressure Return Line Pressure Pump Horsepower 5 PSI HP 7 PSI 1 HP 12 PSI 2 HP 30 PSI 3 HP PLUMBING THE PRESSURE SWITCH Connect the pressure switch to the return line with tubing not supplied and the inch...

Page 13: ... salt on a continuous basis Plumb the peristaltic pump suction line to the salt outlet on the Saturated Salt Feeder with 1 4 tubing supplied with the peristaltic pump The salt outlet on the Saturated Salt Feeder is a small blue and white valve located at the bottom of the salt feeder Plumb the Saturated Salt Feeder water supply to the fitting on the chemical metering assembly using inch tubing ...

Page 14: ...N TANK OVERFLOW Install the overflow with the T provided in the installation kit This T will remain open on top to prevent syphoning in case of tank overflow The bottom of the T receives a 1 FPT low pressure connection with hose directed to a floor drain drain tube is not provided ...

Page 15: ... STOP ventilation is inadequate Leave area immediately If the work area is not well ventilated you MUST use a properly fitted and maintained NIOSH approved respirator for acid fumes For best results fill the acid tank with a 1 to 1 water muriatic acid solution 2 12 PLUMBING THE HYDROGEN VENT WARNING EXOLOSION RISK FAILURE TO PLUMB THE HYDROGEN VENT TO OUTSIDE ATMOSPHERE MAY RESULT IN DAMAGE TO EQU...

Page 16: ...o a chemical feed controller and the controller is calling for feed or that the blue cord is plugged into a live outlet The NEX GEN will go through a series of startup steps and automatically start generating chlorine If the NEX GEN does not start automatically see the Troubleshooting Guide 3 2 ADJUSTING CHLORINE OUTPUT Adjust the flow through the flow meter for the following production rates 2 5 ...

Page 17: ...is displayed if cell cleaning mode has been selected This icon will be displayed until the cell cleaning process is complete This icon indicates a failure during the acid wash sequence for cell maintenance Press this icon to clear the fault described above This icon indicates that acid is being pumped during the cell cleaning cycle Faults are accompanied by a beeping sound If this icon is visible ...

Page 18: ...N Home Screen Below is the HOME screen that will be displayed any time the NEXGEN is operating normally Process Tank Temperature Pool Feed Indicator Process Tank pH On Off Indicator On Off Button Electrolytic Cell Volts Menu Button Electrolytic Cell Amps Process Tank Salt Level ...

Page 19: ...n the system on or off press and hold the ON OFF button until the desired ON OFF indicator is displayed The NEXGEN may take several minutes to completely turn on or off The Menu Press the MENU button to access the HOME SERVICE and EVENTS buttons On Off Indicator On Off Switch Menu Button ...

Page 20: ... INPUTS to manually TEST system outputs to view or set system SETPOINTS and to view recorded data View System Digital Inputs Press MENU then SERVICE then INPUTS to display the current state of all digital inputs An active input is indicated by the GREEN dot next to the input name A check mark indicates the parameter is OK A RED dot indicates an inactive input The number or letter inside of the dot...

Page 21: ...y the current value of all analog inputs The letters inside of the dot indicates the input number on the PLC View System Outputs Press MENU then SERVICE then OUTPUTS to display the current state of all outputs An active output is indicated by an icon next to the output name The number next to the output indicates the output number on the PLC ...

Page 22: ...e second TEST screen The following components can be manually operated for testing from these screens Booster Pump and Booster Pump Flow Switch Circulation Pump and Circulation Pump Flow Switch Salt Pump and Salt Sensor Reaction pH Pump and pH Reaction Press for 2 seconds Acid Wash Pump Press for 2 seconds Hydrogen Vent Blower and Flow Switch Feed Valve 1 Feed Valve 2 ORP 2 must be active for this...

Page 23: ...d The factory default is 7000 for salt 7 4 for pH and 100 for minimum salinity Adjusting pH Feed Times Press MENU then SERVICE then SETPOINT to access the set point screen From this screen the PH FEED TIME can be adjusted The factory default is 60 seconds Accessing the Recorded Event Log Press MENU then SERVICE then RECORD to access the event log screen The event log will store every system event ...

Page 24: ...s pH and low pH can be seen over history Accessing the Current Event Log Press MENU then EVENTS to access the current event log This screen lists current events or faults This screen will also activate automatically whenever a fault occurs A current fault is displayed in black Pressing the red ACKNOWLEDGE ALL EVENTS button and then the RESET ALARM button will reset all alarms ...

Page 25: ... the flow through the flow meter Weekly Clean the electrode stacks each week or as needed based on the presence of calcium buildup Check the salt in Saturated Salt Feeder and fill as needed Monthly Check the system filter if installed production tank filter if installed and dilution fan screen and clean as necessary 4 2 CELL CLEANING PROCEDURE Press MENU then SERVICE then CLEAN CELLS to access ste...

Page 26: ... Leave area immediately If the work area is not well ventilated you MUST use a properly fitted and maintained NIOSH approved respirator for acid fumes Fill the acid wash tank with a 5 to 1 water muriatic acid solution Press NEXT to continue All valves on the NEXGEN are clearly marked with valve tags The valves to be adjusted in each step will be flashing on the screen STEP 1 Close the Tank Fill Va...

Page 27: ...38 04 11 2022 STEP 2 During this step the booster pump will start and the product tank will empty When the tank is empty the GREEN Low Level Sw will turn RED When the tank has emptied the TANK EMPTY will be displayed Press NEXT to continue ...

Page 28: ...d 7 Press NEXT to continue STEP 4 Connect Acid Wash Inlet Coupling to the Acid Wash Inlet Valve colored White Connect Acid Wash Outlet Coupling to the Acid Wash Outlet Valve colored Gray Press NEXT to continue Close Valve 8 Cell Output Valve Close Valve 7 Pump Isolation Valve Acid Wash Outlet Valve Gray Acid Wash Inlet Valve White ...

Page 29: ...pen the Acid Wash Inlet and Outlet Valves Press NEXT to continue STEP 6 Open both White Acid Wash Valves on the Acid Wash assembly Press NEXT to continue Open Acid Wash Outlet Valve Open Acid Wash Inlet Valve Open White Acid Wash Valve Open White Acid Wash Valve ...

Page 30: ...e both Gray Acid Wash Valves on the Acid Wash assembly Press NEXT to continue STEP 8 Plug the Acid Wash Assembly into the Special Power Connector and turn on the Acid Wash Pump on the skid Press NEXT to continue Close Gray Acid Wash Valve Close Gray Acid Wash Valve ...

Page 31: ...iatic acid and circulate the acid through the cells for as long as 30 minutes If the cells are clean before the 30 minute time interval has expired press the blue Acid Wash button to stop the process Press NEXT to continue STEP 10 Open both Gray Acid Wash Valves on the Acid Wash assembly Press NEXT to continue Open Gray Acid Wash Valve Open Gray Acid Wash Valve ...

Page 32: ...the Acid Wash assembly Press NEXT to continue STEP 12 Press the blue Press to Drain button The Acid Wash assembly will begin to drain the muriatic acid from the NEXGEN When the draining is complete CELL EMPTY will be displayed Press NEXT to continue Close White Acid Wash Valve Close White Acid Wash ...

Page 33: ...38 04 11 2022 STEP 14 Close the Acid Wash Inlet and Outlet Valves Press NEXT to continue STEP 15 Unplug the Acid Wash Assembly from the Special Power Connector Press NEXT to continue Close Acid Wash Inlet Valve Close Acid Wash Outlet Valve ...

Page 34: ...g Inlet and Outlet from the Acid Wash Inlet and Outlet Valves Press NEXT to continue STEP 17 Open Cell Output Valve marked 8 and the Pump Isolation Valve marked 7 Press NEXT to continue Acid Wash Inlet Valve Open Valve 8 Cell Output Valve Valve 7 Pump Isolation Valve Acid Wash Outlet Valve ...

Page 35: ... 11 2022 STEP 18 This step will empty any remaining acid from the cells When the process is complete CELL EMPTY will be displayed Press NEXT to continue STEP 19 Open Valve 3 the Tank Fill Valve Press NEXT to continue Open Valve 3 Tank Fill Valve ...

Page 36: ...ystem Once filling and flushing is complete the current system pH will be displayed and you will be prompted to press NEXT to continue STEP 21 Adjust the Production Flow Valve marked 4 to the desired flow rate outlined in Section 3 2 on page 17 Press NEXT to continue Valve 4 Production Flow Valve ...

Page 37: ...inished Press NEXT to continue The home screen will be displayed The NEXGEN will start automatically The startup process will include automatic adjustment of the pH and salt concentration in the production tank Once this process is complete the NEXGEN will resume normal operation ...

Page 38: ...regard to the cleaning frequency program ChlorKing warranties of the titanium electrodes will not be honored if the system is operated in water temperatures lower than 59 degrees F During the warranty period the customer shall return the defective component freight prepaid accompanied by the original invoice or proof of purchase and ChlorKing shall at its sole discretion elect to repair or replace...