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Summary of Contents for ChlorKing NEXGEN60
- Page 1 NEXGEN60 and 60R Installation, Operation, and Maintenance Manual 04/11/2022 NEXGEN60 InstallationRev1 Page 1 of 42...
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Page 2: Table Of Contents
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
24 hours a day or controlled by any pool controller. “R” models are reverse polarity for reduced maintenance. The basic components of the NEX-GEN are outlined below. Production Power Tank Supply and Control Box Chemical Metering Dilution 04/11/2022 NEXGEN60 InstallationRev1 Page 3 of 42... -
Page 4: Principals Of Operation
The power supply provides the current to the electrolytic cells to produce the rated amount of sodium hypochlorite. The power supply houses all the safety features to prevent system operation in the event of a malfunction. 04/11/2022 NEXGEN60 InstallationRev1 Page 4 of 42... -
Page 5: Specifications, Certifications, And Sizing Guidelines
120 volt connection to a chemical feed controller or 120 volt outlet @1 amp Internal System Fusing Power Supply NEXGEN60 and 60R – 2 x 60 amp RK5 class fuse Circulation Pump – 10 amp internal circuit breaker Chemical Metering / Control – 12 amp internal circuit breaker Certifications NEXGEN60 and NEXGEN60R are certified for indoor installation. - Page 6 MINIMUM SPACE REQUIREMENTS FOR NEXGEN60 04/11/2022 NEXGEN60 InstallationRev1 Page 6 of 42...
- Page 7 MINIMUM SPACE REQUIREMENTS FOR NEXGEN60R 04/11/2022 NEXGEN60 InstallationRev1 Page 7 of 42...
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Page 8: Installation
FROM THE LIQUID LINES. WARNING CHLORKING® SYSTEMS ARE INTENDED TO BE INSTALLED ACCORDING TO ALL LOCAL AND NATIONAL REGULATIONS. CONNECT THE EQUIPMENT ASSEMBLY TO A CIRCUIT PROTECTED BY A GROUND-FAULT CIRCUIT-INTERRUPTER. 04/11/2022 NEXGEN60 InstallationRev1 Page 8 of 42... - Page 9 LE CONTENU DE CE MANUEL. AUCUNE OPÉRATION DE MAINTENANCE DE CET ÉQUIPEMENT DOIT ÊTRE FAITE AVEC L'UNITÉ ENTIÈREMENT ÉTEINT ET DÉBRANCHÉE DE L'ÉLECTRICITÉ ET TOUTE LA PRESSION SAIGNÉ À PARTIR DES LIGNES DE LIQUIDES. MISE EN GARDE 04/11/2022 NEXGEN60 InstallationRev1 Page 9 of 42...
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Page 10: Plan Ahead
PVC 90’s, 45’s, couplings and saddles or adapters for the return line size encountered 3 inch PVC pipe, 90’s, 45’s and couplings for the hydrogen vent Anchors and mounting hardware Container specified for muriatic acid solutions 04/11/2022 NEXGEN60 InstallationRev1 Page 10 of 42... -
Page 11: Power Supply Electrical Connections
240 VAC L1, L2 and ground. Ensure that the electrical service is protected by a circuit interrupter and is rated for the model NEXGEN that is installed. 240 VAC 240 VAC Ground L1 and L2 L1 and L2 04/11/2022 NEXGEN60 InstallationRev1 Page 11 of 42... -
Page 12: Bonding
120V electrical outlet protected by a ground fault circuit interrupter. Blue Controller Cord Bonding Lugs 2.7 BONDING Connect a minimum 8awg bonding wire to the bonding lug on the bottom of the electrical enclosure. 04/11/2022 NEXGEN60 InstallationRev1 Page 12 of 42... -
Page 13: 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 14 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. 04/11/2022...
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Page 15: Saturated Salt Feeder Installation
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 ½ inch tubing. 04/11/2022 NEXGEN60 InstallationRev1 Page 15 of 42... - Page 16 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 16 of 42...
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Page 17: 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 18: Operation
7000 ppm salt concentration and 3.3 GPM. Adjustments in excess of 3.3 gallons per minute will not produce more chlorine. Adjustments in excess of 3.3 gallons per minute will consume excess salt. 04/11/2022 NEXGEN60 InstallationRev1 Page 18 of 42... -
Page 19: Touch-Screen Icon Explanations
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, pressing it will stop the beeping sound. 04/11/2022 NEXGEN60 InstallationRev1 Page 19 of 42... -
Page 20: Using The Touchscreen
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 Level 04/11/2022 NEXGEN60 InstallationRev1 Page 20 of 42... - Page 21 The NEXGEN may take several minutes to completely turn on or off. On/Off Indicator On/Off Switch The Menu Press the MENU button to access the HOME, SERVICE and EVENTS buttons. Menu Button 04/11/2022 NEXGEN60 InstallationRev1 Page 21 of 42...
- Page 22 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 indicates the actual input number on the PLC. 04/11/2022 NEXGEN60 InstallationRev1 Page 22 of 42...
- Page 23 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 23 of 42...
- Page 24 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 test) 04/11/2022 NEXGEN60 InstallationRev1 Page 24 of 42...
- Page 25 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 that has occurred by date and order. 04/11/2022 NEXGEN60 InstallationRev1 Page 25 of 42...
- Page 26 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 26 of 42...
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Page 27: Maintenance
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 instructions for cleaning the cells. 04/11/2022 NEXGEN60 InstallationRev1 Page 27 of 42... - Page 28 It is important that 25 gallons of fluid is used. The cleaning process will not work properly if less fluid is used. Fill to 25 gallon mark Press NEXT to continue. 04/11/2022 NEXGEN60 InstallationRev1 Page 28 of 42...
- Page 29 Tank Fill Valve 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 29 of 42...
- Page 30 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. Acid Wash Press NEXT to continue. Outlet Valve Acid Wash Inlet Valve 04/11/2022 NEXGEN60 InstallationRev1 Page 30 of 42...
- Page 31 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 Inlet Valve 04/11/2022 NEXGEN60 InstallationRev1 Page 31 of 42...
- Page 32 Open Acid Wash Valve A STEP 7 – Close both Acid Wash Valves marked B on the Acid Wash assembly. Press NEXT to continue. Close Acid Close Acid Wash Wash Valve B Valve B 04/11/2022 NEXGEN60 InstallationRev1 Page 32 of 42...
- Page 33 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 33 of 42...
- Page 34 Valve B Valve B STEP 11 – Close both Acid Wash Valves marked A on the Acid Wash assembly. Press NEXT to continue. Close Acid Wash Valve A Close Acid Wash Valve A 04/11/2022 NEXGEN60 InstallationRev1 Page 34 of 42...
- Page 35 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 Outlet Valve Close Acid Wash Inlet Valve 04/11/2022 NEXGEN60 InstallationRev1 Page 35 of 42...
- Page 36 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 36 of 42...
- Page 37 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 37 of 42...
- Page 38 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 38 of 42...
- Page 39 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 39 of 42...
- Page 40 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. 04/11/2022 NEXGEN60 InstallationRev1 Page 40 of 42...
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Page 41: Warranty Information
ChlorKing® accepts no responsibility and is not liable for any extended warranties or variations to this warranty offered by re-sellers of ChlorKing® systems. 04/11/2022 NEXGEN60 InstallationRev1 Page 41 of 42... - Page 42 04/11/2022 NEXGEN60 InstallationRev1 Page 42 of 42...
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