ChlorMaker - ControlOMatic
Contents
1. Phosphates upon start up and each month there after Phosphate Remover can be purchased at any local Pool amp Spa supply store WARNING Consistent chlorine levels above 5 0 PPM or consistent salt concentration levels above 5 000 PPM may lead to corrosion of metal components in the spa WARNING Consistently low Calcium Hardness levels below 150 PPM may lead to spa equipment damage and failure Make sure Calcium Hardness levels are within the recommended range above SALT REQUIREMENT ChlorMaker can generate both Chlorine or Bromine It all depends on which sanitizer the user prefers Use So dium Chloride Salt if you prefer Chlorine Generation and Sodium Bromide Salt if you prefer Bromine Please Note Each salt requires a different level of salinity for ChlorMaker to operate effectively CHLORINE SALT SODIUM CHLORIDE NaCl Raise Salt Level to 2 000 PPM Parts Per Million Ap proved salts include pool salt made for salt water chlorine generating systems canning and pickling salt from your local market and some water softener salts that are 99 pure sodium chloride or better Some high end mineral enriched salts can be used but require higher quantities to achieve 2 000 PPM sodium chloride salt level These approved salts are generally available at pool amp spa supply stores home improvement centers and On Line stores in a variety of sizes Never use rock salt or salts that have more than 1 anti caking agents yell2. UNDER ANY OTHER THEORY OF LIABILITY EXCEED THE AMOUNT NECESSARY TO REPAIR OR RE PLACE THE COVERED SYSTEM Damage to the system from improper water maintenance is not covered in this warranty Should any problem develop during the warranty period go to www controlomatic com to obtain the proper techni cal support phone number You will need the serial number visible in the clear part of the system body You may be required to return the defective component and if necessary the component will either be repaired or replaced PRODUCT REGISTRATION Please fill out the information below and send to ControlOMatic to properly register your prod uct Or register your product on line at www ControlOMatic com First Name Last Name Address City State Province Postal Code Phone E Mail Please copy this section and forward a copy to ControlOMatic Inc 13433 Lime Kiln Road Grass Valley CA 95949 Or Register At www ControlOMatic com Product Model Serial Number
3. bring the concentration to the recom mended level Turn the spa jets on to help dissolve the salt Warmer water will aid in dissolving the salt faster If the water is cold it may take several hours for the salt to fully dissolve WARNING Do not turn ChlorMaker on until all the salt has fully dissolved SALT LEVEL INDICATOR ChlorMaker will indicate if the salt level is within the recommended range listed above When the Generating LED light is on the Check Cell LED light should be off if the salt is at the recommended level Please see below Check Cell Light Flashing Salt Level Too High Check Cell Light Off Salt Level Within Normal Range Check Cell Light On Not Flashing Salt Level Too Low IMPORTANT It is important to occasionally check that the lights are indicating proper salt level Always use Salt Test Strips to check the salt level and adjust the water according to the Test Strips If Test Strips Show Too High remove some water from the spa and replace with fresh water Re test and adjust as nec essary If Test Strips Show Too Low Add salt Re Test and adjust as necessary PRODUCT INSTALLATION ChlorMaker is equipped with a 110 220 VAC Auto Sensing Power Supply allowing ChlorMaker to be installed on almost any spa with a 24 Hour Circulation Pump Spa Dealers or Licensed Electricians are required to install this product as they are familiar with the electrical codes in your area ChlorMaker needs to be wired to a
4. CHLORMAKER OPERATING INSTRUCTIONS ControlOMatic Inc 13433 Lime Kiln Road Grass Valley CA 95949 www ControlOMatic com Support ControlOMatic com 530 205 4520 Manual Version 4 1 12 Made in the USA INTRODUCTION ChlorMaker is a semi automated salt water chlorine generation system specifically designed for portable spas up to 1 250 Gallons ChlorMaker generates chlorine from a small amount of ordinary salt Sodium Chloride NaCl dissolved in the spa water The amount of salt added is very small in relation to the volume of the water in the spa It s about 90 less concentration than ocean water and below the typical taste level of most humans The small addition of salt also benefits users by providing a softening effect on the water leaving hair and skin feel ing smoother and healthier than with traditional sanitizing products Only 2 5 cups of salt per 100 gallons of water is all it takes for ChlorMaker to produce fresh pure chlorine leaving your water clean and clear day after day IMPORTANT SAFETY INSTRUCTION WARNING Use ChlorMaker only according to these instructions Any modification or misuse of this product will void the warranty WARNING Install ChlorMaker in accordance with all national and local electrical plumbing safety and other applicable codes WARNING Connect ChlorMaker to a GFCI ground fault circuit interrupt or GFI ground fault interrupt protected 110 or 220 VAC power source only WARNING Prot
5. ect the power supply and outlet from exposure to the elements including direct sun rain snow condensation etc WARNING DO NOT allow children to operate ChlorMaker unless under adult supervision WARNING DO NOT insert objects into or tamper with ChlorMaker s body in any way Inserting metal objects into the body may cause damage and void the warranty WARNING DO NOT operate ChlorMaker if damaged in any way WARNING DO NOT pull on the cord to disconnect the Power Supply from power source Do not allow the cord to rest on sharp edges or corners or to be walked upon Do not drop throw or otherwise rough handle ChlorMaker WARNING Unit must be disconnected from power source before performing any maintenance or troubleshooting operations CAUTION Leave spa cover open at least 30 seconds to allow trapped gases to escape prior to use CAUTION If unit is not working properly or has been damaged in any way contact technical support immediately at 1 530 205 4520 CAUTION Measure water quality parameters and adjust if necessary prior to each spa use CAUTION Make sure all spa electrical components and power cords have been thoroughly inspected by a licensed electrician prior to using ChlorMaker AAW me sinai N o Ba Lodia a a WATER PREPARATION amp MAINTENANCE To ensure proper operation the spa must be drained rinsed refilled with fresh water and balanced to the recom mended levels indicated i
6. emove Phosphates Shock the water Consistently High Power level too high Lower the power level Chlorine Plates Are Dirty Hard water high calcium Unplug power supply and reconnect to manually reverse With White Or and minerals in water polarity If still dirty soak the unit in vinegar for 30 minutes Scale Build Up Also reduce calcium level in water DISASSEMBLY amp MAINTENANCE ChlorMaker is designed with an automatic self cleaning feature However there are some spa water conditions that are well beyond the control of ChlorMaker s reverse polarity and self cleaning design If a visible white or scaly substance builds up on the plates please follow the simple disassembly and cleaning instructions below Turn main power off to spa and disconnect the water tight connector from the cell housing as shown in the picture below Turn the black twist lock identified in picture below counter clockwise Then unplug wire from the cell housing Twist Lock Caution Some water will drain out of the cell housing during this step Firmly hold cell housing with a pair of large pliers or channel locks and turn the large Hex Nut at top of cell housing counter clockwise with a large wrench as shown in picture below The cell plates will turn with the Hex Nut Loosen the Hex Nut to a point that can be turned by hand Loosen all the way and gently pull the cell plates out of the cell housing Imme diately replace with the spare cap that is provided
7. n this section before installing the product Use the test strips to measure water chem istry and verify that the water has been balanced properly Replacing the filter is recommended but not required unless the spa was previously sanitized with a hydrogen peroxide system The combination of hydrogen peroxide and chlorine may cause gum like build up water discoloration and skin irritation It is important to properly maintain your spa for the health and safety of its users Spas are unique in both size and usage patterns TechniChlor will significantly reduce the amount of spa maintenance required but chemical check ups including chlorine levels and PH are recommended before each use Proper water maintenance will prolong the life of TechniChlor and the spa The following table describes generally accepted optimum water chemistry for portable spas PARAMETER RECOMMENDED LEVEL 150 to 300 PPM It is recommended that chlorine and PH levels are checked before each use or at least once per week when not in use Alkalinity Calcium Hardness and Salt Concentration should be checked at least once per month It is recom mended that the spa is manually shocked after high usage example after a party with multiple users or biweekly if used frequently Always remember to leave the spa circulating for several hours before retesting Phosphates in the spa water will increase the demand for chlorine and will reduce the life expectancy of the generator Remove
8. needed IMPORTANT NOTE If the chlorine level is zero 24 hours after installation the initial chlorine demand on the spa may be above what ChlorMaker can produce to break away from zero In this case manually add chlorine or shock according to the company product label to assist in the initial set up If spa usage drops vacation winter etc it is important to re set the power level down several levels If usage significantly increases return from vacation etc it is important to adjust the power level up accordingly Always retest and adjust the power level as needed BOOST MODE Boost Mode is designed to replenish chlorine that was just used during the last spa use Activating Boost Mode will take ChlorMaker out of stand by and re start the production of chlorine at the power level it is currently set at To activate Boost Mode simply turn the dial up 1 power level wait a few seconds then turn the dial back down to its original setting After a few brief moments ChlorMaker will re start the chlorine production process at the original power level TROUBLE SHOOTING It is always a good idea to revisit the user manual to make sure installation or maintenance steps were not over looked before referring to the trouble shooting section Possible Causes Corrective Action Consistently Low ans Just doesn t keep up Remove organic material such as leaves etc Make sure the unit is at the lowest point in the spa Clean the filter R
9. ow prussiate of soda or sodium ferrocyanide These compounds may cause surface staining Please use chart below BROMINE SALT SODIUM BROMIDE NaBr Raise Salt Level to 3 000 PPM Parts Per Million There are several manufacturers of Sodium Bromide Salt to choose from Please make sure the Sodium Bromide you purchase is 99 pure or better Ask your local pool and spa dealer for assistance Please use chart below Chart is Based on 100 Gallons or 379 Liters of Spa Water POUNDS _ 99 Pure Sodium Chloride NaCl Pool Pickling Canning amp 14 23 Other Fine Grain Salts 99 Pure Sodium Chloride NaCl Water Softener amp Other l 1 5 2 5 Coarse Grain Salts Hymalayan Salt Fine Grain Salt Mineral Enriched Dead Sea Salt Coarse Grain Salt Mineral Enriched 99 Pure Sodium Bromide NaBr Fine Grain Salt The amount of salt to add and dissolve is dependent upon the size of the spa Determine the volume of water in gallons or liters by checking the spa owner s manual or use any internet volume calculator 99 Pure Sodium Chloride NaCl Coarse Grain Example For a 350 Gallon Spa Divide 350 Gal by 100 Gallons then multiply answer by 2 5 Cups 350 100 3 5 x 2 5 8 75 Cups 99 Pure Sodium Bromide NaBr Fine Grain Example For a 1 326 Liter Spa Divide 1 326 Liters by 379 Liters then multiply answer by 4 0 Cups 1 326 379 3 5 x 4 0 14 Cups Simply pour the recommended amount of salt directly into the spa water to
10. power source that turns on amp off when the spas continuous 24 hour circulating pump turns on amp off ChlorMaker should only operate when water is circulating through the cell Make sure the SPA is protect ed with a GFI protected circuit Please see product layout and wiring diagram below Wiring Diagram Power Supply VAC Input Connections PRODUCT LAYOUT I Brown amp Blue Wire to 110 or 220 3 amp 4 Wire Spa Power m 110 VAC Spa Power on es 110 VAC Black Low Voltage 5SVdc 110 220VAC in Blue__y Common White ChlorMaker Controller Power Supply 1 5 by 3 75 Ground Green 3 Wire 220 VAC Spa Power 1u 110 VAC1 Black Bue 110 VAC2 Red Ground Green 24 Hour Pump gm 4 Wire 220 VAC Spa Power Bown 110 VAC1 Black e o 110 VAC2 Red Common White Ground Green 1 Prepare Spa For Installation Shut down main power to spa and drain water completely Open access panel to the spa exposing the spas plumbing and spa pack Open the access panel to the spa pack 2 Find Power Supply Location ChlorMaker s power supply needs be fastened to a cool dry location where water will not splash on it Use the supplied screws to fasten power supply to spa compartment 3 Find Pump Connection Locate the spas pump connection inside the spas power pack Many spa packs have special connectors It may be necessary to cut and splice ChlorMaker s power supply cable to make the connection When routing the wire
11. s make sure they are protected from sharp edges in the spa cavity or spa pack Refer to Diagram 1 for wiring layout DIAGRAM 1 Power Supply Spa Pack 24 Hour Pump Find 24 Circulation Plumbing Locate the continuous 24 Hour circulating pump and the 3 4 inch tub bing connected to the pump The ChlorMaker cell should be installed on the OUTPUT side of the pump The tube will need to be cut and reconnected to the ChlorMaker cell Refer to DIAGRAM 2 Item B Additional tubing may be needed if the existing tube is not long enough or is hard to access Additional tubing is avail able at most hardware stores The location of the cell should have no obstructions at the cable end of the cell to allow for cell removal replacement and cleaning Fasten ChlorMaker Cell Find a location near the OUTPUT side of the continuous 24 Hour circu lating pump where the tube can be cut and reconnected to the cell The location should be visible to allow for inspection of the titanium plates through the clear part of the cell The location should also have no obstructions at the cable end of the cell to allow for removal of the cell plates if plate cleaning is needed Mount the cell using the two supplied brackets shown in DIAGRAM 2 Item A Cell Orientation The cell must be mounted vertically to prevent chlorine gas from being trapped in the cell Connect Tubing To Cell Cut the existing tube and reconnect the ends to the two 3 4 inch barb fit ting
12. s on the cell Use the supplied clamps at B to securely fasten the tube to the barbs on the cell Note that some water will spill from the cut tube even though the spa has been drained or shut off E DIAGRAM 2 ha B out 2 24 Hour Pump A ia 10 Mounting The Control Panel Find a location in the spa skirting that will give easy access to the spa cabinet amp spa pack Drill a 3 4 Hole to allow the Control Panel cables to run through Use silicone caulking to seal the hole once the cables are run through Use the provided mounting screws to securely fasten the control panel to the spa skirting making sure the control panel completely covers the 3 4 inch hole Control Panel Connections Connect the control panel cell cable to the ChlorMaker Cell This cable will be identified with black tape near the connection end Connect the control panel power supply cable to the black power supply CAUTION Do not turn spa power on until the spa has been refilled with water and salt has fully dissolved Refer to DIAGRAM 3 Spa Skirt DIAGRAM 3 Control Panel Side View Refill Spa amp Add Salt Recheck all plumbing connections to make sure all are tight Refill soa with water and pour dissolve the recommended amount of salt in the water See Salt Requirement Section Please make sure the salt is fully dissolved before proceeding to the next step Turn Spa Power ON When ChlorMaker is turned on the LED Lights will al
13. t due to improper installation product abuse misuse negligence or improper maintenance of the system pool or spa The warranty does not cover any loss or damage to the spa spa components users or anything outside the system due to system failure Purchas er assume all responsibility for using the system This warranty does not apply to any costs repairs services damages claims or losses for all of the following Service calls to correct the installation of the product or to explain the usage of the system to the buyer repairs necessitated by use other than normal home use damage resulting from misuse unintended use unforeseen use non pool or spa use abuse accidents alterations improper installation or corrective work necessitated by repairs made by anyone other than an authorized service technician THE FOREGOING WARRANTIES ARE CONTINGENT ON THE PROPER USE OF THE SYSTEM IN ACCOR DANCE WITH THESE INSTRUCTIONS AND SPECIFICATIONS AND SHALL NOT APPLY TO ANY SYSTEM THAT HAS BEEN REPAIRED OR MODIFIED BY PERSONS OTHER THAN THE MANUFACTURER THE EXPRESS WARRANTIES SET FORTH IN THIS AGREEMENT ARE IN LIEU OF ALL OTHER WARRAN TIES EXPRESS OR IMPLIED MANUFACTURER HEREBY SPECIFICALLY DISCLAIMS ANY OTHER REPRE SENTATIONS OR WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRAN TIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT WILL MANUFACTURER S LIABILITY FOR ANY CLAIM WHETHER IN CONTRACT TORT OR
14. ternate flashing 11 times indicat ing the unit has power and is getting ready to make chlorine After the 11th flash ChlorMaker will be off in stand by for 11 seconds After the 11 second pause ChlorMaker will begin the chlorine generation process SELECTING THE RIGHT POWER LEVEL Selecting the right power level requires some testing and adjustment There are many factors that affect the sanitizing needs of a spa such as Frequency of spa use number of people if there is an Ozone Generator spa temperature last drain and refill etc However after the testing and adjustment period ChlorMaker will take care of your sanitation needs day after day As a starting point please program ChlorMaker and set the power level to the general recommendations shown in the chart below Power ChlorMaker Level Spa Gallons Less than 200 6 400 500 Test the Chlorine Level with test strips after 1 to 2 days When testing the best readings are always done about an hour after restarting ChlorMaker by simply turning the dial up 1 power level wait a few seconds then turn the dial back down to its original setting If the chlorine level is LOW increase the power level by one level If the chlo rine level is HIGH decrease the power level by one level Wait a day or so after this initial adjustment re test and repeat as necessary until a consistent chlorine residual has been achieved If the chlorine level is VERY high or VERY low adjust by 2 levels as
15. with ChlorMaker to prevent additional water from draining Note The grey spacer at the end of the cell plates may come lose during this procedure If so simply and firmly reinstall the grey spacer as needed Place the cell plates in a glass of white vinegar for about 30 minutes to remove any and all scale build up Do not scrap plates with any foreign objects Rinse plates clean with fresh water Reverse the steps above Reinstall cell plates tighten Hex Nut Use Teflon Tape on threads to create a water tight seal Plug water tight black connect into cell housing and turn main spa power back on to complete the cleaning process LIMITED WARRANTY Models This warranty applies to ChlorMaker models referenced as System ControlOMatic Inc Warrants the system to be free of all defects in material and workmanship for one 1 year from the original purchase date The system includes the power supply unit cable electronics and electrolytic genera tor for residential use only The product must be installed properly and used in accordance with this manual and all applicable local codes and regulations This warranty is not transferable In no event shall ControlOMatic Inc be liable for consequential damages for breach of this warranty Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply The warranty does not cover any loss or damage to the produc
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