ChlorKing NEXGEN80, Installation, Operation And Maintenance Manual

Page 1: ...NEXGEN80 InstallationREV3 Page 1 of 42 04 11 2022 NEXGEN80 and 80R Installation Operation and Maintenance Manual ...

Page 2: ...eder Installation 16 2 10 Plumbing the Overflow 17 2 11 Preparing the pH Neutral System 18 2 12 Plumbing the Hydrogen Vent 18 3 0 OPERATION 19 3 1 Start up Procedures and Checks 19 3 2 Adjusting Chlorine Output 19 3 3 Touch screen Icon Explanations 20 3 4 Using the Touchscreen 21 4 0 MAINTENANCE 28 4 1 Routine Maintenance 28 4 2 Cell Cleaning Procedure 28 5 0 WARRANTY INFORMATION 42 Note This manu...

Page 3: ...ly 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 basi...

Page 4: ...han 10 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 pr...

Page 5: ...208 240 VAC 87 12 A 60 Hz Requires a 208 240 volt single phase connection 100 amps minimum and 60Hz 120 volt connection to a chemical feed controller or 120 volt outlet 1 amp Internal System Fusing Power Supply NEXGEN80 and 80R 2 x 60 amp RK5 class fuse Circulation Pump 10 amp internal circuit breaker Chemical Metering Control 12 amp internal circuit breaker Certifications NEXGEN80 and NEXGEN80R a...

Page 6: ...NEXGEN80 InstallationREV3 Page 6 of 42 04 11 2022 MINIMUM SPACE REQUIREMENTS FOR NEXGEN80 18 24 31 ...

Page 7: ...NEXGEN80 InstallationREV3 Page 7 of 42 04 11 2022 MINIMUM SPACE REQUIREMENTS FOR NEXGEN80R ...

Page 8: ...NG 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 BE...

Page 9: ...TING 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 PROTECTION...

Page 10: ... IMPORTE 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 ...

Page 11: ... POOL TO ENSURE THAT YOUR CHLORKING NEXGEN SYSTEM NEVER OPERATES WHEN THE POOL PUMPS ARE OFF For ease of service it is recommended that a 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 240 VAC L1 L2 and ground Ensure that the electrical service is protected by a circuit interru...

Page 12: ...ord to a chemical feed controller or for manual operation into a 120V electrical outlet protected by a ground fault circuit interrupter 2 7 BONDING Connect a minimum 8awg bonding wire to the bonding lug on the bottom of the electrical enclosure Blue Controller Cord Bonding Lugs ...

Page 13: ...rKing 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 NEX...

Page 14: ... at least 3 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 PS HP 7 PSI 1 HP 12 PSI 2 HP 25 PSI 3 HP PLUMBING THE PRESSURE SWITCH Connect the pressure switch to the return line with tubing not supplied and the inch ...

Page 15: ...alt on a continuous basis Plumb the peristaltic pump suction lines to the salt outlets on the Saturated Salt Feeder with 1 4 tubing supplied with the peristaltic pump The salt outlets on the Saturated Salt Feeder two small blue and white valves 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 16: ...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 5 FPT low pressure connection with hose directed to a floor drain drain tube is not provided ...

Page 17: ... 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 EQUIPMENT OR PERSONS...

Page 18: ...a chemical feed controller and the controller is calling for feed or that the blue cord is plugged into a live outlet The NEXGEN will go through a series of startup steps and automatically start generating chlorine If the NEXGEN does not start automatically see Troubleshooting in section 6 3 2 ADJUSTING CHLORINE OUTPUT Adjust the flow through the flow meter for the following production rates 4 4 G...

Page 19: ...s 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 p...

Page 20: ... Home Screen Below is the HOME screen that will be displayed any time the NEXGEN is operating normally On Off Indicator Process Tank Temperature On Off Button Pool Feed Indicator Process Tank pH Electrolytic Cell Volts Menu Button Electrolytic Cell Amps Process Tank Salt Level ...

Page 21: ...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 22: ...UTS 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 ind...

Page 23: ...urrent value of all analog inputs The letters inside of the dot indicates the actual 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 actual output number on the PLC ...

Page 24: ... 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 25: ...adjusted The factory default is 7000 for salt 7 4 for pH and 60 seconds for feed time 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...

Page 26: ... 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 27: ...e gauge Check 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 production tank filter and dilution fan screen and clean as necessary 4 2 CELL CLEANING PROCEDURE Press MENU then SERVICE then CLEAN CELLS to access step by step ins...

Page 28: ... noticed 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 Prior to initiating the cell cleaning procedure the acid wash assembly must be filled to the 25 gallon mark on the acid tank Fill the tank with 20 gallons of water and then add 5 gallons of muriatic acid It is ...

Page 29: ... screen STEP 1 Close the Tank Fill Valve marked 3 Close the Product Flow Adjustment Valve marked 4 This will allow the tank to drain for cleaning Press NEXT to continue 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 Valve 4 Product Flow Adjustment Valve Valve 3 Tank Fill Valve ...

Page 30: ...rked 8 and the Pump Isolation Valve 7 Press NEXT to continue STEP 4 Connect Acid Wash Inlet Coupling to the Acid Wash Inlet Valve Connect Acid Wash Outlet Coupling to the Acid Wash Outlet Valve See acid wash coupling explanation on the next page Press NEXT to continue Valve 8 Cell Output Valve Valve 7 Pump Isolation Valve Acid Wash Inlet Valve Acid Wash Outlet Valve ...

Page 31: ...STEP 5 Open the Acid Wash Inlet and Outlet Valves Press NEXT to continue Acid Wash Outlet Coupling is attached to the other end of this tube Acid Wash Inlet Coupling is attached to the other end of this tube Acid Wash Inlet Valve Acid Wash Outlet Valve ...

Page 32: ...oth Acid Wash Valves marked A on the Acid Wash assembly Press NEXT to continue STEP 7 Close both Acid Wash Valves marked B on the Acid Wash assembly Press NEXT to continue Open Acid Wash Valve A Open Acid Wash Valve A Close Acid Wash Valve B Close Acid Wash Valve B ...

Page 33: ...tinue STEP 9 Press the blue Press to Acid Wash button The Acid Wash assembly will begin to fill the NEXGEN with muriatic 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 ...

Page 34: ...oth Acid Wash Valves marked B on the Acid Wash assembly Press NEXT to continue STEP 11 Close both Acid Wash Valves marked A on the Acid Wash assembly Press NEXT to continue Open Acid Wash Valve B Open Acid Wash Valve B Close Acid Wash Valve A Close Acid Wash Valve A ...

Page 35: ...ton The Acid Wash assembly will begin to drain the muriatic acid from the NEXGEN Draining will automatically stop when the cells are empty Press NEXT to continue STEP 14 Close the Acid Wash Inlet and Outlet Valves Press NEXT to continue Close Acid Wash Inlet Valve Close Acid Wash Outlet Valve ...

Page 36: ...6 of 42 04 11 2022 STEP 15 Unplug the Acid Wash Assembly from the Special Power Connector Press NEXT to continue STEP 16 Disconnect Acid Wash Coupling Inlet and Outlet from the Acid Wash Inlet and Outlet Valves Press NEXT to continue ...

Page 37: ...ve marked 8 and the Pump Isolation Valve marked 7 Press NEXT to continue STEP 18 Emptying any remaining acid from the cells When the process is complete the Press NEXT to Continue prompt will allow you to move to the next step Valve 8 Cell Output Valve Valve 7 Pump Isolation Valve ...

Page 38: ...GEN80 InstallationREV3 Page 38 of 42 04 11 2022 STEP 19 Open Tank Fill Valve marked 3 Press NEXT to continue STEP 20 This step will fill the tank and determine the current system pH Valve 3 Tank Fill Valve ...

Page 39: ...of 42 04 11 2022 STEP 21 Adjust the Production Flow Valve marked 4 to the desired flow rate outlined in Section 3 2 on page 19 Press NEXT to continue STEP 22 Cell cleaning is finished Press NEXT to continue Valve 4 Production Flow Valve ...

Page 40: ...2 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 41: ...egard 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 ...

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