ChlorKing NEXGEN100 Installation, Operation And Maintenance Manual
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ChlorKing NEXGEN100 Installation, Operation And Maintenance Manual

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NEXGEN100 and 100R
Installation, Operation, and
Maintenance Manual
04/11/2019
NEXGEN100R Installation
Page 1 of 41

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  • Page 1 NEXGEN100 and 100R Installation, Operation, and Maintenance Manual 04/11/2019 NEXGEN100R Installation Page 1 of 41...

  • Page 2: Table Of Contents

    Routine Maintenance Cell Cleaning Procedure 5.0 WARRANTY INFORMATION Note: This manual is subject to change at any time based on system improvements, design changes, authorized modifications or new information. Please consult ChlorKing for the latest revision. Manufacturer: ChlorKing Inc 2935 Northeast Parkway...

  • Page 3: Description

    SECTION 1 DESCRIPTION 1.1 GENERAL INFORMATION The NEXGEN system is an on-site sodium hypochlorite generator designed for commercial swimming pool applications. The NEXGEN is capable of producing up to 120 pounds of equivalent chlorine per day. The system manufactures bleach continuously from a salt concentration of 5000ppm to 7000ppm and uses the water from the pool as a raw material.

  • Page 4: Principals Of Operation

    1.2 PRINCIPALS OF OPERATION Production Tank Assembly The production tank assembly consists of a polyethylene tank, four external electrolytic cells, a circulation pump and heat exchanger. Pool water from the pool return line is fed into the production tank. The circulation pump circulates water through the electrolytic cells and heat exchanger.

  • Page 5: Specifications, Certifications, And Sizing Guidelines

    CSA Standard C22.2 #218.1 PRMA Reg. No. 33004 Sizing guidelines Chlorinator sizing must comply with local codes. Please contact your local health department for specific requirements or contact your local ChlorKing representative for assistance. 04/11/2019 NEXGEN100R Installation Page 5 of 41...
  • Page 6 MINIMUM SPACE REQUIREMENTS FOR NEXGEN100: 04/11/2019 NEXGEN100R Installation Page 6 of 41...
  • Page 7 MINIMUM SPACE REQUIREMENTS FOR NEXGEN100R: 04/11/2019 NEXGEN100R Installation Page 7 of 41...

  • Page 8: Installation

    ANY SERVICING OF THIS EQUIPMENT MUST BE DONE WITH THE UNIT FULLY OFF AND DISCONNECTED FROM THE POWER SOURCE AND ALL PRESSURE BLED FROM THE LIQUID LINES. WARNING CHLORKING® SYSTEMS ARE INTENDED TO BE INSTALLED ACCORDING  TO ALL LOCAL AND NATIONAL REGULATIONS.
  • Page 9  ONLY A CERTIFIED TECHNICIAN MAY INSTALL AND SERVICE THE CHLORKING® NEXGEN SYSTEM.  MODIFYING THE CHLORKING® NEXGEN SYSTEM IN ANY WAY MAY CAUSE BODILY INJURY AND WILL VOID THE WARRANTY.  DO NOT ALLOW CHILDREN OR ANYONE NOT CAPABLE TO OPERATE THE CHLORKING®...

  • Page 10: Plan Ahead

    CHLORKING ® SYSTEMES SONT DESTINES A ETRE INSTALLES SELON TOUS LES REGLEMENTS LOCAUX ET NATIONAUX. CONNECTER LE MONTAGE DE L'ÉQUIPEMENT SUR UN CIRCUIT  PROTÉGÉ PAR UN DISJONCTEUR DE FUITE À LA TERRE. SEUL UN TECHNICIEN CERTIFIE PEUT INSTALLER ET ENTRETENIR LE ...

  • Page 11: Power Supply Electrical Connections

    VOLTAGE AND CURRENT. ENSURE THAT POWER IS LINKED TO THE MAIN PUMP POWER SOURCE FOR THE 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.

  • Page 12: Plumbing Connections

    25 PSI at the venturi outlet. Install the booster pump in the supply line to the venturi. Consult ChlorKing 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.
  • Page 13 The pressure connection should provide a minimum of 5 psi when the pool pump is on and pressure should be less than 3 psi when the pool pumps are off. Contact ChlorKing for installations that do not meet these specifications. 04/11/2019...

  • Page 14: Saturated Salt Feeder Installation

    2.9 SATURATED SALT FEEDER INSTALLATION Place the Saturated Salt Feeder tanks in an easy to access location. The large tank will need access for adding salt on a continuous basis. Saturated Salt Feeder Float Tank Install the Stenner Pump pickup in the large 55 gallon Saturated Salt tank. Connect the Saturated Salt Feeder tank to the float tank with the supplied valve.

  • Page 15: Plumbing The Overflow

    Plumb the peristaltic pump suction lines (there are two) with the #5 hoses to the salt outlets on the Saturated Salt Feeder with the 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 (there are two).

  • Page 16: Preparing The Ph Neutral System

    3 inch pipe for the vent. The vent pipe should not be longer than 100 feet. (Consult ChlorKing if longer runs are required). Keep the opening clear and protected from water or debris with the use of a hood or bend. Do not use screens or louvres at the vent outlet.

  • Page 17: Operation

    SECTION 3 OPERATION 3.1 START-UP PROCEDURES AND CHECKS Check that all components are mounted securely. Check that all plumbing is secure and tight. Check that all plumbing and electrical connections are connected in the proper place. Ensure that all system isolation valves installed during installation are open. Fill the Saturated Salt Feeder with pure rock or pellet salt.

  • Page 18: Touch-Screen Icon Explanations

    3.3 TOUCH SCREEN ICON EXPLANATIONS This icon is displayed if the system is turned off. This icon is displayed if the system is waiting for a signal from an external controller. This icon is displayed if cell cleaning mode has been selected. This icon will be displayed until the cell cleaning process is complete.

  • Page 19: Using The Touchscreen

    3.4 USING THE TOUCHSCREEN Home Screen Below is the HOME screen that will be displayed any time the NEXGEN is operating normally. Process Pool Feed Tank Indicator Temperature On/Off Indicator On/Off Button Electrolytic Process Cell Volts Tank pH Process Menu Button Electrolytic Tank Salt Cell Amps...
  • Page 20 Turning the NEXGEN On or Off To turn 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. On/Off Indicator On/Off Switch The Menu...
  • Page 21 The Service Screen Press MENU then SERVICE to access the SERVICE screen. The service screen has the option to view the current state of the system OUTPUTS, the current state of the system INPUTS, to manually TEST system outputs, to view or set system SETPOINTS, and to view recorded data.
  • Page 22 View System Analog Inputs Press MENU then SERVICE then INPUTS then ANALOG INPUTS to display 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.
  • Page 23 System Tests Note: Selecting the TEST screen will turn the NEXGEN system off. Press MENU then SERVICE then TEST to view the test screen. Press NEXT for the second TEST screen. The following components can be manually operated for testing from these screens.
  • Page 24 Viewing or Changing Set-points Press MENU then SERVICE then SETPOINT to access the set-point screen. From this screen the SALT SETPOINT, PH SETPOINT, and MINIMUM SALINITY can be adjusted. The factory default is 7000 for salt, 7.4 for pH, and 100 for minimum salinity. Accessing the Recorded Event Log Press MENU then SERVICE then RECORD to access the event log screen.
  • Page 25 Accessing Graphs Press MENU then SERVICE then GRAPHS to access the graphs screen. From this screen process temperature and process 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.

  • Page 26: Maintenance

    SECTION 4 MAINTENANCE 4.1 ROUTINE MAINTENANCE Daily Confirm system operation with a visual inspection. Check the salt concentration on the display. Check the amps as displayed on the 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.
  • Page 27 Note: Sulfuric acid and dry acid (sodium bisulfate) are not recommended for cell cleaning. Under some conditions the electrolytic cell can be damaged. WARNING Read all cautions and directions provided with the muriatic acid used. Always add acid to water. Use only with adequate ventilation. If strong odor is noticed, STOP, ventilation is inadequate.
  • Page 28 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 Valve marked 3. Close the Product Flow Adjustment Valve marked 4.
  • Page 29 When the tank has emptied, TANK EMPTY will be displayed. Press NEXT to continue. STEP 3 – Close the Cell Output Valve marked 8 and the Pump Isolation Valve 7. Valve 8 Press NEXT to continue. Cell Output Valve Valve 7 Pump Isolation Valve...
  • Page 30 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. STEP 5 – Open the Acid Wash Inlet and Outlet Valves. Press NEXT to continue. Acid Wash Outlet Valve Acid Wash...
  • Page 31 STEP 6 – Open both Acid Wash Valves marked A on the Acid Wash assembly. Press NEXT to continue. Open Acid Wash Valve A Open Acid Wash Valve A STEP 7 – Close both Acid Wash Valves marked B on the Acid Wash assembly. Press NEXT to continue.
  • Page 32 STEP 8 – Plug the Acid Wash Assembly into the Special Power Connector. Press NEXT to continue. 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.
  • Page 33 STEP 10 – Open both Acid Wash Valves marked B on the Acid Wash assembly. Press NEXT to continue. Open Acid Open Acid Wash Wash Valve B Valve B STEP 11 – Close both Acid Wash Valves marked A on the Acid Wash assembly. Press NEXT to continue.
  • Page 34 STEP 12 – Press the blue “Press to Drain” button. 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.
  • Page 35 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. 04/11/2019 NEXGEN100R Installation Page 35 of 41...
  • Page 36 STEP 17 – Open Cell Output Valve marked 8 and the Pump Isolation Valve marked 7. Press NEXT to continue. Valve 8 Cell Output Valve Valve 7 Pump Isolation Valve 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.
  • Page 37 STEP 19 – Open Tank Fill Valve marked 3. Press NEXT to continue. Valve 3 Tank Fill Valve STEP 20 – This step will fill the tank and determine the current system pH. 04/11/2019 NEXGEN100R Installation Page 37 of 41...
  • Page 38 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. Valve 4 Production Flow Valve STEP 22 – Cell cleaning is finished. Press NEXT to continue. 04/11/2019 NEXGEN100R Installation Page 38 of 41...
  • Page 39 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. 04/11/2019 NEXGEN100R Installation Page 39 of 41...

  • Page 40: Warranty Information

    SECTION 5 WARRANTY INFORMATION ChlorKing® NEXGEN system carries a limited 3-year warranty 1. 3-year warranty on assembly of the system. 2. 1 year on all electrical items, cell tubes, and production tanks. 3. 2 years pro-rated monthly, on titanium electrodes. (Year 1 is warranted fully, thereafter pro-rated warranty applies, applicable over the full 2-year period.
  • Page 41 04/11/2019 NEXGEN100R Installation Page 41 of 41...

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