Intermatic IPURE PE25K120V User manual

This manual must be given to the homeowner to ensure warranty coverage.

When installing and operating this Product and other associated equipment, basic safety precautions should

always be followed, including the following:

1. DO NOT OPEN THE GENERATOR BOX – NOT A SERVICABLE UNIT

2. READ AND FOLLOW ALL INSTRUCTIONS

3. Disconnect all AC power before installation.

4. WARNING – To reduce the risk of injury, do not permit children to use this product.

5. This Control must be installed by a qualified electrician, according to National and Local Electrical Codes.

6. The Control Box must be mounted vertically on a flat surface and a minimum of 5 ft (1.5m) horizontal

distance (or more, if local codes require) from the pool/spa

IMPORTANT SAFETY INSTRUCTIONS

READ, FOLLOW AND SAVE THIS INSTRUCTION MANUAL

Intermatic Incorporated, 7777 Winn Road, Spring Grove, IL 60081

Questions concerning your Salt Chlorine Generator? Call 321-274-0059 or 815-675-7000

The Natural Way To Purify Your Pool or Spa

PE25K120V

PE25K240V 25,000 gallons

40,000 gallons

PE40K120V

PE40K240V

Section 1. General Information 1

Section 2. Important Safety Information 1

Section 3. Installation Instructions 2

3.1 General Information 2

3.2 Plumbing Your System 3

3.3 Installing the Cell 4

3.4 Installing the Flow Sensor 5

3.5 Mounting the Control Box 5

3.6 Wiring the Control Box 7

3.7 Wiring the Flow Sensor 8

Section 4. Startup Instructions 8

4.1 Before Adding Salt 8

4.2 Adding Salt 9

4.3 Acceptable & Unacceptable Salts 9

4.4 Salinity Demand Table 10

4.5 Calculating the Size of the Pool 10

Section 5. Operating Instructions 11

5.1 Chlorinator Specifics 11

5.2 Filtration 11

5.3 Sanitation/Oxidation 11

5.4 Basic Operation 11

5.5 Winterizing 12

5.6 Spring Startup 12

5.7 Controls 13

-Red Light 13

-Power Meter 13

-On/Off Light 13

-Flow Light 13

-Salinity Indicator 14

-Power Switch 14

Section 6. Maintenance / Cleaning 15

6.1 Cell Maintenance 15

6.2 Cell Cleaning 15

-Cleaning with optional cleaning cap 15

-Cleaning without optional cleaning cap 16

6.3 Understanding the chemistry 17

6.4 Calculating Saturation Index 19

Section 7. Troubleshooting 20

Section 8. Warranty & Registration 24

Table Of Contents OCT 2006

Page 1

Section 1. General Information

Congratulations on the purchase of your new Salt Chlorine Generator. Your

purchase will minimize the efforts needed to maintain your pool and maximize your

enjoyment for many years. Before installation or operation, please read these

instructions carefully. This manual contains easy to follow step-by-step procedures

to properly install and operate your system. A little time spent understanding your

system and its parts will assure successful, trouble-free installation and usage.

When working around your pool, please take care to avoid hazards such as

electrical wires and chemicals. CAUTION! Safety comes first!

Section 2. Important Safety Instructions

WARNING

DANGER

READ AND FOLLOW ALL INSTRUCTIONS

All electrical work must be performed by a licensed electrician and conform to all national, state,

and local codes. When installing and using this electrical equipment, basic safety precautions should

always be followed, including the following:

DO NOT OPEN THE GENERATOR BOX – NOT A SERVICABLE UNIT

DISCONNECT ALL AC POWER BEFORE INSTALLATION

WARNING

To reduce the risk of injury, do not permit children to use this product.

WARNING

The Control Box must be mounted vertically on a flat surface and a minimum of 5 ft (1.5m)

horizontal distance (or more, if local codes require) from the pool/spa.

WARNING

The power cable must be hardwired to the time clock so that the system cannot operate without

the pump.

In Canada and some other regions, local codes require the unit be connected only to a circuit

that is protected by a ground-fault circuit-interrupter (GFCI). The installer should provide this

GFCI requirement. The GFCI should be tested on a regular basis by pushing the test button. If

the GFCI fails to operate correctly, there is ground current flowing indicating the possibility of

an electric shock. Do not use this unit. Disconnect unit and have a qualified professional correct

the problem before using.

CAUTION

SAVE THESE INSTRUCTIONS

WARNING

A Build-up of flammable fumes can result in a hazardous condition if the Cell is allowed to

operate without flow. This machine must be operated only with an approved in-line flow sensor.

The flow Sensor must be installed between the last piece of apparatus and the Cell, upstream of

the Cell.

CAUTION

DANGER

ALWAYS ADD ACID TO WATER, NEVER WATER TO ACID

Section 3. Installation Instructions

Section 3.1 General Information: The system comes in three sections, the Control

Box, cell and Flow Sensor. They are manufactured from the latest corrosion resistant

materials to give you years of trouble free use, and installing them in the most sheltered

position from sun and water will protect them from extreme weather conditions for years

to come.

Safety Measures

1. Only operate the system with an approved flow sensor.

2. See safety measures and warnings on page 2 of this manual.

Additional Materials Required

1. PVC solvent cement and priming fluid

2. Hacksaw or pipe cutters

3. Screwdrivers

4. Drill

5. Teflon Tape (a.k.a. Plumber’s Tape)

6. Silicone Sealant (DO NOT USE silicone glue or petroleum jelly).

7. Pipe adaptors (i.e. reducer couplings) if needed for systems with 1 ½ inch plumbing.

Page 2

Page 3

Section 3.2 Plumbing Your System

MODEL CONFIRMATION: Confirm you have the

correct model for your pool size by checking the model

number on the cell:

•PE25K < 25,000 gallons (100,000 liters)

•PE40K < 40,000 gallons (150,000 liters)

Page 4

Section 3.3 Installing the Cell

NOTE

Lay out equipment pieces to be sure there is enough pipe space between the last piece of apparatus and

the tees in the return line to fit the Flow Sensor and the Cell. A Vertical Installation may be used to save

space.

1. The Cell and Flow Sensor must be installed

downstream from the filter and heating

devices but before any tees in the return

line. The Cell may be installed horizontally

or vertically so long as the Cell is pointed in

the direction of flow and is installed

immediately after the enclosed Flow Sensor

(see diagram above).

2. Approximately 15 inches (~380 mm) of available pipe length will be needed for horizontal

installations of the Flow Sensor and Cell. Vertical installations can be made to take less space.

3. On the pipe where the cell will be installed, mark two lines 11 3/4 inches (300mm) apart and cut out

using hacksaw or pipe cutters.

4. Unscrew and remove the barrel unions (i.e. barrel nuts and slip connections) from either end of the

Cell. Thread one of the barrel nuts over the pipe and glue its slip connection to the cut pipe.

5. Hold up the Cell with the second union to gauge the proper distance before threading the second nut

and gluing the second slip.

6. After the glue had sufficient drying time, place the Cell with the o-rings into the opening between

the two ends of the pipe and tighten the unions making sure that the Cell is installed with the arrow

pointing in the same direction as the flow (i.e. water should enter from the side with the blue cap).

Flow direction

Section 3.4 Installing the Flow Sensor

1. Install the Flow Sensor between the last piece of apparatus and the Cell (if installed after the Cell,

damage to the sensor may result). When possible, install on a horizontal pipe.

2. Mark two lines on the pipe 3inches (~76 mm) apart and cut with a hacksaw or pipe cutters.

3. Clean and glue the “T” connector (included) to the pipe making sure that the threaded end with the

sensor is on the topside of the pipe.

4. Be sure the arrow on the top of the Flow Sensor is pointing in the direction of flow, and that no glue

touches the paddle inside the sensor as it may cause it to jam.

Page 5

Flow direction

Section 3.5 Mounting the Control Box

1. It’s important to identify and understand the

purpose of each cord at the bottom of your

Control Box. Please refer to the picture for cord

identification and application prior to mounting:

BONDING – Bonding is recommended and may

be required by local code. The bonding lug is

found on the bottom of the Control Box.

POWER CORD – Hardwire the power cable to

the time clock as indicated in the section titled

“Wiring the Control Box”. Check label on side of

Control Box for the proper voltage specification

of your system (i.e. 120v or 240v)

FLOW SENSOR – The flow switch MUST BE

connected to the Control Box in order for the

system to work properly. Ensure proper flow

switch operation once installed.

CELL CONNECTORS – Connect the two black

wires from the Control Box to the two metal studs

on the sides of the Cell and tighten firmly with a

screwdriver by hand. See “Wiring the Control

Box” for further instructions.

Page 6

Section 3.5 Mounting the Control Box (Continued)

2. The Control Box must be mounted vertically on a flat surface and a minimum of 5 ft (1.5m)

horizontal distance (or more, if local codes require) from the pool/spa.

3. Locate a position for your Control Box within 10 ft (~3 meters) of where the Cell will be installed

and within 2 ft of the power supply to ensure enough wire is available.

All four sides of Control Box

must have air ventilation for

proper heat dissipation.

4. Because the box acts as a heat sink dispersing heat from

inside the box, do not block the four sides of the Control

Box. Do Not mount the system inside a panel or tight

enclosed area.

WARNING

5. Secure the hanging rack on the wall using the enclosed

screws and anchors. 1/4” (8mm) drill bit should be used for

the anchor holes.

6. Hang the Control Box on the mounted hanging rack.

7. Hardwire the power cable to the time clock as

indicated in the wiring instructions below.

*Check the label on the side of the Control Box

for the proper voltage specification on your

system (i.e. 120v or 240v).

8. Do not extend the cable leading to the cell. This

decreases the system’s efficiency and will void

warranty coverage. Please contact the

manufacturer for installations demanding a

longer cell cable.

Section 3.6 Wiring the Control Box

1. Attach the green ground wire to the grounding lug or bar.

2. Connect the black Load wire from the chlorine generator to

Load 1 of the time clock.

3. If wiring a 240 Volt generator, connect the third wire to Load 2

of the time clock. If wiring a 120 Volt generator, connect the

third wire to the Neutral lug or bar on the timer (see label on the

left side of the Control Box to confirm voltage).

4. Bonding is recommended and may be required by local code.

The bonding lug is found on the bottom of the Control Box.

Page 7

Check whether your chlorine generator operates on 120 volts or 240 volts (see label on the left

side of the Control Box), and be sure to wire the system accordingly. It is critical to wire the

chlorine generator in such a way that it can only operate when the pump is operating (i.e. load

side). See instructions below for details.

CAUTION

5. Connect the two black wires from the Control Box to the two metal

studs on the sides of the Cell. These wires are interchangeable.

6. Tighten firmly by hand, with a screwdriver. To avoid damage to the

screws, DO NOT use a power screwdriver.

7. Push the plastic terminal covers up to cover the terminal connection

until they click into place. This will ensure a watertight connection.

Section 3.7 Wiring the Flow Sensor

Section 4. Startup Instructions

NOTE

Flow Sensor wires are interchangeable. You

must have flow sensor connected in order for

the Salt Chlorine Generator system to

work properly.

Section 4.1 Before Adding Salt

Balance the chemicals

See the section titled “Understanding the Chemistry” for recommended water balance. Also, add 1

quart of metal remover and 1 quart of non-copper based algaecide to the pool, according to the

manufacturers instructions. This will ensure that the transition to the Natural Generator system will be

quick and trouble-free.

Measure existing salt in your pool.

Years of liquid chlorine use may cause the salt reading to be higher due to residual salt.

New Pools

Wait 10-14 days, or longer if specified by the pool builder, for plaster to cure before adding salt or

operating the I-Pure Salt Chlorine Generator.

Biguanide Pools

If installing on a pool using Biguanide sanitizers, all Biguanides must be removed before system startup.

Page 8

Flow Sensor

1. Find the two 18 AWG wires with the ¼” Quick connect

terminals from the Cell cable and push them on their

respective connectors on the Flow Sensor. These wires

are interchangeable.

This manual suits for next models

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