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Summary of Contents for Hayward NEXGENph NEXGEN50SMR
- Page 1 NEXGENph On-Site Chlorine Generator Models covered in this manual: NEXGEN50SMR NEXGEN100SMR 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. 10/18/2023 NEXGEN50 and 100R Installation Page 2 of 60...
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Page 3: Table Of Contents
Table of Contents DESCRIPTION ..........................4 GENERAL INFORMATION ....................4 PRINCIPALS OF OPERATION ..................5 SPECIFICATIONS, CERTIFICATIONS, AND SIZING GUIDELINES ....... 6 INSTALLATION ..........................9 UNPACKING ........................9 STORAGE ......................... 9 SAFETY CONSIDERATIONS ................... 9 PLAN AHEAD ......................... 11 ADDITIONAL PARTS REQUIRED FOR INSTALLATION ..........11 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. Depending on the model, the NEXGEN can produce 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 5: Principals Of Operation
PRINCIPALS OF OPERATION Production Tank Assembly The production tank assembly consists of a polyethylene tank, 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 6: Specifications, Certifications, And Sizing Guidelines
SPECIFICATIONS, CERTIFICATIONS, AND SIZING GUIDELINES Max Sodium NEXGEN Model Hypochlorite Electrical Requirements VOLTS AMPS FLOW Production* 208-240V, single phase, NEXGEN50SMR Up to 60 lbs/day 17 - 23 2.5 GPM 60A, 50/60Hz 208-240V, single phase, NEXGEN100SMR Up to 120 lbs/day 17 - 23 5 GPM 100A, 50/60Hz Additional 120-volt connection to a chemical feed controller or 120V outlet @ 1 amp... - Page 7 MINIMUM SPACE REQUIREMENTS FOR NEXGEN50: 10/18/2023 NEXGEN50 and 100R Installation Page 7 of 60...
- Page 8 MINIMUM SPACE REQUIREMENTS FOR NEXGEN100: 10/18/2023 NEXGEN50 and 100R Installation Page 8 of 60...
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Page 9: 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 10 CONNECT THE EQUIPMENT ASSEMBLY TO A CIRCUIT PROTECTED BY A GROUND-FAULT CIRCUIT-INTERRUPTER. 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. ...
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Page 11: Plan Ahead
MISE EN GARDE 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 12: Power Supply Electrical Connections
Container specified for 31.4% muriatic acid solution along with the necessary chemical Pure rock or pellet salt for the Saturated Salt Feeder 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 VOLTAGE AND CURRENT. -
Page 13: Bonding
BONDING Connect a minimum 8awg bonding wire to the bonding lug on the bottom of the electrical enclosure. PLUMBING CONNECTIONS Hydrogen Vent to outside atmosphere ChlorKing Salt NEX-GEN 50 SM Tank NEX-GEN Pump Acid Plumbing Layout Overflow pressure Tank Field Installation switch. -
Page 14: Booster Pump
PLUMBING THE CHEMICAL METERING VENTURI It is important that the Chemical Metering Venturi is plumbed correctly, or the system will not function properly, and the warranty will be void. The chemical metering venturi injector requires a pressure differential across the venturi to achieve the rated chemical flow. - Page 15 PLUMBING Plumb the inlet of the venturi to the booster pump which is connected to the return line of the pool after all other pool components such as heaters etc. NEXGEN50: Use a minimum of 2” inch PVC pipe for this connection. NEXGEN100: Use a minimum of 3”...
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Page 16: 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 17: Plumbing The Production Tank Overflow
the Saturated Salt Feeder water supply to the fitting on the chemical metering assembly using ½ inch tubing. Note: The NEXGEN50 has one salt pump and the NEXGEN100 has two salt pumps. PLUMBING THE PRODUCTION 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. -
Page 18: 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 from the end of the pH probe. Re-install the probe. Plumb the suction port of the peristaltic pump with the #2 hose to a container (not supplied with the NEXGEN) specified for muriatic acid solutions. -
Page 19: Installing A Second Pool With Nexgen
INSTALLING A SECOND POOL WITH NEXGEN 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. CHLORPDSAC40 CHLORVFS CHLORPDS5 DIMENSIONS CHLORVFS L 16”... -
Page 20: 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 CHLORVFS Up to 1.3 GPM 30 PSI 30 GPM 1-1/2 inch 1/2 inch 1/2 inch CHLORPDS5 Up to .12 GPM 25 PSI... - Page 21 VENTURI and VENTURI FEED SYSTEM INSTALLATION (VFS) The venturi injector requires 30 GPM 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 22 VENTURI and VENTURI FEED SYSTEM 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 23 VENTURI and VENTURI FEED SYSTEM 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 24 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 25 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 26 PUMP DOSING SYSTEM INSTALLATION CONTINUED Connect a 6 conductor 18awg SJTOW or SOOW cable (not supplied) from the CHLORPDS to the NEXGEN. CHLORPDS5 CO NNECTION DIAGRAM FOR NEXGEN50 and 100 CHLORPDS5 NEXGEN 50 & 100 Control Box CHLORPDSAC40A CONNECTION DIAGRAM FOR NEXGEN50 and 100 CHLORPDSAC40A NEXGEN 50 &...
- Page 27 PUMP DOSING SYSTEM 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 28 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 W a r n i n g www.chlorking.com / 800.536.8180 ET L I n t er t e c h...
- Page 29 One Additional Pool CHLORPDSAC40A 10/18/2023 NEXGEN50 and 100R Installation Page 29 of 60...
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Page 30: 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 31: 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 32 Adjustment for the NEXGEN100 Flow Control Adjust the flow through the flow meter for the following production rates: Valve 4 5 GPM = 120 pounds of chlorine production per day 4.4 GPM = 105 pounds of chlorine production per day 3.7 GPM = 114 pounds of chlorine production per day 1.7 GPM = 98 Pounds of chlorine production per day NOTE...
- Page 33 3.4 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 34 3.5 USING THE TOUCHSCREEN Home Screen This is the HOME screen that will be displayed any time the NEXGEN is operating normally. Date & Date & Time Time On/Off Indicator Output in On/Off Salinity in Tank Button Flow through Venturi pH in Tank Menu Button...
- Page 35 The Service Screen Press MENU then SERVICE to access the SERVICE screen. The Dealer Screen Press MENU then SERVICE then DEALER to access the Dealer screen. The Dealer screen will display Cell VOLTS and AMPS. The NEXGEN 60 and NEXGEN80 will display two bars on CELL DC VOLTS and CELL DC AMPS.
- Page 36 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 37 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 input number on the PLC.
- Page 38 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 output number on the PLC. System Tests Note: Selecting the TEST screen will turn the NEXGEN system off.
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- Page 40 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 41 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.
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Page 42: 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 43 10/18/2023 NEXGEN50 and 100R Installation Page 43 of 60...
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- Page 45 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.
- Page 46 Step 4. Wait 30 seconds and mark the water level on tank. Note: should be about 6in from the top of the tank. Step 5. Allow booster pump to run for five minutes. Step 6. Ensure there is no change in the water level in the tank.
- Page 47 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 48 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 49 Cell Connectors from STEP 15 HEADER CONNECTION CELL CONNECTORS REVERSE BOX 16. Visual Inspection of Control Box Connections Turn the NEXGEN off and disconnect all sources of power. Inspect the components and wiring for signs of heat damage, melted insulation, or loose connections.
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Page 50: 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 51: Parts Guide
PARTS GUIDE 10/18/2023 NEXGEN50 and 100R Installation Page 51 of 60... - Page 52 ITEM NO. MODEL PART NUMBER DESCRIPTION QTY. 1 ALL PUMPSF2220 PUMP STENNER FIXED #2 HOSE 220 VAC (HOSE ‐ UCCP202) 1 2A 50 PUMPSF5220 PUMP STENNER FIXED #5 HOSE 220 VAC (HOSE ‐ MCCP205) 1 2B 100 PUMPSF5220 PUMP STENNER FIXED #5 HOSE 220 VAC (HOSE ‐MCCP205) 2 3A 50 PUMPFT7 PUMP 3/4 HP MAG DRIVE CIRCULATION 1 3B 100 PUMPFT10 PUMP 3/4 HP MAG DRIVE CIRCULATION 1 4 ALL FSKHARWIL2MSCNOT FLOW SWITCH HARWIL 2 1 5A 50 20157 STRAINER 1 5B ...
- Page 53 ITEM NO. MODEL PART NUMBER DESCRIPTION QTY. 21 ALL CKPH PH MODULE 0‐10 VOLTS 1 22 ALL 3273070 DINRAIL TERMINAL BLOCK 7 RED 2 23 ALL 3273090 DINRAIL TERMINAL BLOCK 13 BLU 1 24 ALL 3273088 DINRAIL TERMINAL BLOCK 13 GY 1 25 ALL 3273080 DINRAIL TERMINAL BLOCK BLK 2 26 ALL 27E895 RELAY SOCKET DIN RAIL DPDT 7 27 ALL 88981103 EM4 LOCAL B26 24VDC GLOSSY BLA 1 28 ...
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- Page 55 ITEM MODEL PART NUMBER DESCRIPTION QTY. NO. 44A 50 SU192RPNEXGEN REVERSING BOX 2 44B 100 SU19240RNEXGEN REVERSING BOX 4 45* ALL KITFLOATSWITCH FLOAT SWITCH MINI HORIZONTAL KYNAR (NOT SHOWN) 1 46 ALL BLOWERXGEN24VDC BLOWER ASSEMBLY XGEN 24VDC 1 47 ALL KITAIRFLOWSENSORYR3T KIT AIRFLOW SENSOR 1 48 ALL KIT BLOWERXGEN24VDC BLOWER 24VDC (SHIPS W/ 10’ B11802 18AWG + 318‐2PG‐330) 1 49 ALL CH8X80 CELL HOUSING 1 PER STACK ...
- Page 56 ITEM MODEL PART NUMBER DESCRIPTION QTY. NO. 54 ALL PHXT pH PROBE 1 55 ALL 10‐12‐8‐K‐PG JACO KYNAR MALE 1/2 TUBE X 1/2 NPT 2 56A 50 KIT2670A FLOAT VALVE ASSY. 1 56B 100 KIT2680A FLOAT VALVE ASSY. 1 58A 50 3523CNEX2040 TANK LID CH40NEX 1 58B 100 3523CX80 TANK LID CH80X 1 58A 50 GSKTTANKLID 3.8' LID GASKET 1 ...
- Page 57 ITEM PART NUMBER DESCRIPTION QTY. NO. 74 SSFEEDER55S SALT FEEDER 55G SINGLE TANK (INCLUDES ALL PARTS SHOWN) 1 75 FLOAT ASSEMBLY FLOAT VALVE ASSEMBLY 1 76 10‐6‐8‐K‐PG JACO 3/8" X 1/2" PP MALE CONNECTOR 2 77 LV050MTV PP VALVE MICRO 1/2 FPT X 1/2 MNP 1 78 PP011624W PP MALE CONNECTOR 1/2 TUBE X 1/2 NPT 1 79 ST114 STENNER PUMP STRAINER PICK UP 1 80 TF100 PVC BULKHEAD UNION 1 TXT 1 81 CFVSI‐010 STRAINER 1" 1 82 8172V‐002 PVC BULKHEAD UNION 1/4 TXT 1 ...
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Page 58: 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. - Page 59 10/18/2023 NEXGEN50 and 100R Installation Page 59 of 60...
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