Hayward ClorKing NEXGEN Series Installation, Operation, Maintenance And Parts Manual

On-site chlorine generator

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NEXGENph On-Site Chlorine Generator

Installation, Operation, Maintenance, and Parts Manual

Models covered in this manual:

NEXGEN20, NEXGEN20R

NEXGEN40, NEXGEN40R

NEXGEN60, NEXGEN60R

NEXGEN80, NEXGEN80R

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Summary of Contents for Hayward ClorKing NEXGEN Series

Page 1 NEXGENph On-Site Chlorine Generator Models covered in this manual: NEXGEN20, NEXGEN20R NEXGEN40, NEXGEN40R NEXGEN60, NEXGEN60R NEXGEN80, NEXGEN80R Installation, Operation, Maintenance, and Parts Manual...
Page 2 Manufacturer: ChlorKing 2935 Northeast Parkway Atlanta, GA 30360 1-800-536-8180 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. NEXGEN Installation Manual Page 2 of 61 April 2024...
Page 3: Table Of Contents
TABLE OF CONTENTS DESCRIPTION ..........................4 GENERAL INFORMATION ............... 4 PRINCIPALS OF OPERATION ..............5 SPECIFICATIONS ..................6 INSTALLATION .......................... 11 UNPACKING ................... 11 STORAGE ....................11 SAFETY CONSIDERATIONS ..............11 PLAN AHEAD ..................13 ADDITIONAL PARTS REQUIRED FOR INSTALLATION ....... 13 POWER SUPPLY ELECTRICAL CONNECTIONS .........
Page 4: Description
DESCRIPTION GENERAL INFORMATION The NEXGEN system is an on-site sodium hypochlorite generator designed for commercial swimming pool applications. With the appropriate accessories, the NEXGEN is capable of independently chlorinating up to six bodies of water. Depending on your model, the NEXGEN linear power supply can produce up to 96 pounds of equivalent chlorine per day.
Page 5: Principals Of Operation
PRINCIPALS OF OPERATION Production Tank Assembly The production tank assembly consists of a polyethylene tank, an external electrolytic cell, 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 cell and heat exchanger.
Page 6: Specifications
SPECIFICATIONS Max Sodium NEXGEN Hypochlorite Electrical Ratings Breaker Size Power Supply Fuse Model Production* 240-volt single phase NEXGEN20 Up to 24 lbs/day 240V, 39.88A, 60Hz 40 amp RK5 class fuse @ 50 amps 240-volt single phase NEXGEN20R Up to 24 lbs/day 240V, 39.88A, 60Hz 40 amp RK5 class fuse @ 50 amps...
Page 7 NEXGEN 20 AND NEXGEN 20R DEMENSIONS NEXGEN Installation Manual Page 7 of 61 April 2024...
Page 8 NEXGEN 40 AND NEXGEN 40R DEMENSIONS NEXGEN Installation Manual Page 8 of 61 April 2024...
Page 9 NEXGEN 60 AND NEXGEN 60R DEMENSION NEXGEN Installation Manual Page 9 of 61 April 2024...
Page 10 NEXGEN 80 AND NEXGEN 80R DEMENSIONS NEXGEN Installation Manual Page 10 of 61 April 2024...
Page 11: Installation
INSTALLATION UNPACKING Units are shipped from the factory. In the event of damages during shipping, it is the responsibility of the customer to notify the carrier immediately and to file a damage claim. Open the crate carefully and examine all material inside. STORAGE When storing units, use the original packaging and store under a shelter to protect the contents from weather.
Page 12  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 13: 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 14: Power Supply Electrical Connections
POWER SUPPLY ELECTRICAL CONNECTIONS WARNING DO NOT FORGET TO CONNECT THE EARTH TERMINALS AND THE EQUIPMENT BONDING WIRE. THE ELECTRICAL SUPPLY MUST MATCH THE SYSTEM RATED CURRENT. ENSURE THAT POWER IS LINKED TO THE MAIN PUMP POWER SOURCE FOR THE POOL TO ENSURE THAT YOUR CHLORKING®...
Page 15 Connect the blue control cord to a chemical feed controller or for manual operation, into a 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.
Page 16: Plumbing Connections
PLUMBING CONNECTIONS NEXGEN Installation Manual Page 16 of 61 April 2024...
Page 17 PLUMBING THE CHEMICAL METERING VENTURI It is important that the Chemical Metering Venturi is plumbed with the correct size plumbing and booster pump, or the system will not function properly. The chemical metering venturi injector requires a pressure differential across the venturi to achieve the rated chemical flow.
Page 18: Saturated Salt Feeder Installation
PLUMBING THE PRESSURE SWITCH Pressure Switch Connection Connect the pressure switch to the return line with ¼ tubing (not supplied) and the ¼ inch valve supplied. 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.
Page 19: Plumbing The Production Tank Overflow
Plumb the SALT 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 labeled Salt Tank Feed Valve using ½...
Page 20: Preparing The Ph Neutral System
PREPARING THE pH NEUTRAL SYSTEM Before use, remove the pH probe from the top of the production tank and remove the cover. Confirm the crown from the end of the pH probe is removed. Install the probe in the port located on top of the production tank. Plumb the suction port of the ACID pump with the #1 or #2 hose to a container (not supplied with the NEXGEN) specified for muriatic acid solutions.
Page 21: Installing An Optional Second Pool With Nexgen
INSTALLING AN OPTIONAL SECOND POOL WITH NEXGEN This equipment is purchased separately and may not be part of your installation. The NEXGEN comes equipped to feed a second pool with the addition of a Venturi Feed System (VFS) or a Pump Dosing System (PDS). These items are purchased separately.
Page 22: Electrical Requirements
GENERAL SPECIFICATIONS FOR SECOND POOL EQUIPMENT Chemical Inlet/Outlet Minimum Sodium Feed Model Rated Diameter Water Flow Hypochlorite Diameter Designation Pressure Rate across Dose Rate Venturi Venturi 1/2 inch CHLORVFS Up to 1.3 GPM 30 PSI 30 GPM 1-1/2 inch CHLORPDS5 Up to .12 GPM 25 PSI 1/2 inch...
Page 23 OPTIONAL VENTURI and VENTURI FEED SYSTEM INSTALLATION (VFS) The venturi injector requires 30GPM of filtered water to function on pools with up to 25 PSI in the return line. Consult ChlorKing for rates necessary for higher pressures. Use an appropriately sized booster pump to achieve this flow. The venturi should be plumbed as the last component before the water returns to the pool.
Page 24 OPTIONAL VFS INSTALLATION CONTINUED The Venturi Feed System’s black power cord plugs into a 15a outlet. The blue control cord plugs into a chemical feed controller. The Venturi Feed System Control box is equipped with a contactor rated for 240 Vac and 30a capable of controlling the booster pump for the venturi.
Page 25 OPTIONAL VFS INSTALLATION CONTINUED Confirm that the Chemical Feed Valve is open, and the Service Valve is closed. Open the chemical flow control valve all the way. Activate the valve by plugging the blue cord into an outlet or by activating the feed function on the chemical feed controller. Ensure that the flow meter will flow more than the desired flow rate of product.
Page 26 One Additional Pool VFS Diagram ChlorKing NEX-GEN 6 Conductor Chemical cord from NEXGEN Feed Controller Blue Control Cord 110 VAC W a r n i n g www.chlorking.com / 800.536.8180 ET L I nt e r t ec h Feed from NEXGEN Tank 208-240 Volt Feed...
Page 27 OPTIONAL PUMP DOSING SYSTEM INSTALLATION (PDS) Locate a space on the wall in the pump room that will accommodate the dimensions of the CHLORPDS. Install in an easy to access location. Using a level, mark where the panel will be located. On a concrete wall installation, mark the wall (using a dot) where the first concrete anchor hole will be drilled.
Page 28 OPTIONAL PDS INSTALLATION CONTINUED Connect a 6 conductor 18awg SJTOW or SOOW cable (not supplied) from the CHLORPDS to the NEXGEN. CHLORPDS5 CONNECTION DIAGRAM FOR NEXGEN10, 20, 40, AND 80 CHLORPDS5 NEXGEN Control Box CHLORPDSAC40A CONNECTION DIAGRAM FOR NEXGEN10, 20, 40, AND 80 CHLORPDSAC40A NEXGEN Control Box NEXGEN Installation Manual...
Page 29 OPTIONAL PDS INSTALLATION CONTINUED Activate the CHLORPDS by plugging the blue cord into an outlet or by activating the feed function on a chemical feed controller. FLOW RATE INFORMATION The total flow through the NEXGEN plus the CHLORPDS assembly cannot exceed the total rated flow of the NEXGEN.
Page 30 One Additional Pool CHLORPDS5 Legend BLACK - Power Cord 110VAC BLUE - Control Cord ChlorKing PURPLE - 6 Conductor Cord NEX-GEN 6 Conductor Chemical cord from NEXGEN Feed Controller Pump Dosing System Blue Control Cord Wa r n i n g www.chlorking.com / 800.536.8180 ET L I n t er t e c h...
Page 31 One Additional Pool CHLORPDSAC40A NEXGEN Installation Manual Page 31 of 61 April 2024...
Page 32: Operation
OPERATION START-UP WATER CHEMISTRY ChlorKing® NEXGEN systems operate by electrolyzing sodium chloride (salt) that has been added to machine into sodium hypochlorite (liquid chlorine). Use standard industry test kit, confirm the pool water is balanced within the following range before turning your ChlorKing® system on: Note: Sulfuric acid is not recommended for use in pools with electrolytic cells.
Page 33: Start-Up Procedures And Checks
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 34: Touch Screen Icon Explanations
2.4 GPM = 48 pounds of chlorine production per day 1.8 GPM = 39 pounds of chlorine production per day 1.44 GPM = 42 pounds of chlorine production per day .64 GPM = 36 pounds of chlorine production per day NOTE 48.0 pounds is achieved at 7000 ppm salt concentration and 2.4 GPM.
Page 35 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. This icon indicates a failure during the acid wash sequence for cell maintenance.
Page 36: Using The Touchscreen
USING THE TOUCHSCREEN Home Screen Date & Date & Time Time On/Off Indicator Output in Percent On/Off Salinity in Tank Button Flow through Venturi pH in Tank Menu Button Active Status Turning the NEXGEN On or Off To turn the system on or off, press the ON/OFF button until the desired ON/OFF indicator is displayed.
Page 37 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 38 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 indicates the actual input number on the PLC.
Page 39 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. System Tests Note: Selecting the TEST screen will turn the NEXGEN system off.
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Page 41 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, ACID FEED TIME, and MINIMUM SALINITY can be adjusted. The factory default is 5000 for salt, 7.4 for pH, and 60 seconds for feed time.
Page 42 Accessing Graphs Press MENU then SERVICE then GRAPHS to access the graphs screen. From this screen process temperature, process 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.
Page 43: Maintenance
MAINTENANCE ROUTINE MAINTENANCE Daily Confirm system operation with a visual inspection. Confirm the OUTPUT is at 100% on the NEXGEN touchscreen. Confirm the salt concentration is at setpoint on the NEXGEN touchscreen. Confirm appropriate flow displayed on the flow sensor. Address any EVENTS on the NEXGEN touchscreen.
Page 44 NEXGEN Installation Manual Page 44 of 61 April 2024...
Page 45 NEXGEN Installation Manual Page 45 of 61 April 2024...
Page 46 CONTINUED SECTION 4 MAINTENANCE GUIDANCE 1. Wipe down the NEXGEN Completely The NEXGEN should be wiped down to prevent premature or unnecessary component failure or skid degradation. Using a lint free cloth and a mild soap solution, wipe the NEXGEN down from top to bottom. This will also assist the operator with any leak identification addressed in the next maintenance item.
Page 47 Step 8. Adjust Valve 4 back to original flow on flowmeter. Step 9. Push home on the touchscreen. 5. Inspect Cells for Calcium, Acid Wash as Needed Visually inspect the electrolytic cell through the cell tube for calcium buildup on or in between the plates and on the headers.
Page 48 7. Clean Inlet Strainer The Inlet strainer is in place to capture minor debris that passed through the filter. The screen is cleaned by closing Valve 3 and unscrewing the black housing. Rinse the screen and reinstall. 8. Inspect the Venting Line The NEXGEN vent is installed with PVC that may be dry fit, glued, or have a union.
Page 49 11. Clean pH Probe Carefully remove the pH probe and inspect the bulb. Clean the pH probe with a mild acid, vinegar, or CLR and a soft bristle brush. Ensure the protective crown has been removed. Replace the pH probe carefully to avoid damage and ensure the wire is not under stress or kinked.
Page 50 15. Inspect Cell Connections Visually inspect the header connections, the cell connectors, and the connections at the reverse box. Clean, repair, or replace any damaged or corroded connectors. Record DC amps and volts. CELL CONNECTORS REVERSE BOX HEADER CONNECTION 16. Visual Inspection of Control Box Connections Turn the NEXGEN off and disconnect all sources of power.
Page 51: Cell Cleaning Procedure
CELL CLEANING PROCEDURE Note: This process will take approximately 60 minutes and cannot be interrupted once begun. Ensure you have time to complete before beginning. Press MENU then SERVICE then CLEAN CELLS to Access on screen instructions for cleaning the cells. Review QR code instructional video for support.
Page 52: Parts Guide
PARTS GUIDE The following pages contain the parts guide for forward and reverse polarity NEXGEN Models 20, 40, 60, and 80. NEXGEN Installation Manual Page 52 of 61 April 2024...
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Page 59: Accessories
ACCESSORIES PART NUMBER COMPONENT DESCRIPTION The ChlorKing® 5000 TDS Controller CHLORKING5000TDS-WV TDS Controller automates the process of controlling Total Dissolved Solids (TDS). The ChlorKing® 5000 HHS is a handheld, CHLORKING 5000 HHS Salt Meter digital toroidal salt tester. The booster pump is required for NEXGEN operation and is sold separately.
Page 60: Warranty Information
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.
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