The BLUEWORKS BLH Series is an electronic chlorine generator designed for automatic pool and spa sanitation. It operates by converting a low concentration of salt (sodium chloride) in the pool water into free chlorine through electrolysis, effectively killing bacteria and algae. The system is suitable for average residential swimming pools up to 40,000 gallons (150,000 liters).
Important Cautions and Safety Instructions:
- The total working hours for the T-Cell should not exceed 8 hours per day.
- If using a variable speed pump for 24 hours a day, adjust chlorine output to 25-30%.
- If the pump runs for 10 hours per day, adjust chlorine output between 60-80%.
- Always disconnect AC power during installation.
- Do not permit children to use this product.
- A green-colored screw inside the wiring compartment must be connected to ground using a continuous copper wire.
- The system includes one bonding lug (two for Canadian models) on the external surface. Connect the local common bonding grid to these terminals with an insulated or bare copper conductor (not smaller than 8 AWG US/6 AWG Canada).
- All field-installed metal components within 10 feet (3 meters) of the pool, spa, or hot tub must be bonded to the equipment grounding bus with copper conductors (not smaller than 8 AWG US/6 AWG Canada).
Water Chemistry:
Maintaining proper water chemistry is crucial for the BLH system. This includes pH, alkaline content, and calcium levels. The BLH specifically requires proper levels of salt and stabilizer.
- Ideal Chemical Levels:
- Salt: 3000 to 4000 ppm (3400 ppm optimal)
- Free chlorine: 1.0 to 3.0 ppm
- pH: 7.2 to 7.6
- Cyanuric Acid (Stabilizer): 50 to 100 ppm
- Total Alkalinity: 80 to 120 ppm
- Calcium Hardness: 200 to 400 ppm
- Metals: 0 ppm
- Saturation Index: -0.2 to 0.2 (indicates water balance; below -0.2 is corrosive, above +0.2 causes scaling/staining).
- Salt Level: A low salt level reduces efficiency and chlorine production. Excessively high salt levels will cause the BLH to shut down.
- Type of Salt: Use only 99% pure sodium chloride (NaCl), available as food seasoning or water softener salt. Do not use rock salt, salt with more than 1% yellow prussiate of soda, anti-caking additives, or iodized salt.
- Adding Salt: Turn on the filter pump. For in-ground pools, add salt directly into the shallow end. For above-ground pools with main drains, add in front of the return jet and run the filter pump for 24 hours with suction from the main drain. For above-ground pools without main drains, add directly into the pool and brush to speed dissolution.
- Important: Do not add salt directly to skimmers or main drains, as this can shut down or shorten the cell's life due to high salt concentration and reduced flow. If added incorrectly, turn off the BLH for 24 hours while the pump and filter continue to run.
- Salt Evaporation: Salt does not evaporate. To lower salt concentration, partially drain the pool and refill with fresh water.
- Stabilizer (Cyanuric Acid): Essential for maintaining chlorine levels. Refer to the provided charts for calculating the amount of salt and stabilizer needed based on pool size and current levels.
- Polymers: It is advised to use poly algaecide (30% or 60% concentration) on saltwater sanitizing systems. Application rate is 1 quart of Poly30 (or 1½ quart of Poly60) per 15,000 gallons (60,000 liters) of pool water per month, applied directly in front of the return jet.
Controls:
- Main Switch:
- AUTO: Normal operation, produces chlorine according to the "Desired Level %" setting.
- SUPER CHLORINATE: For high bather load, heavy rainfall, or cloudy water. Electronically "shocks" the water for 24 hours (filter pump must be on). Return to AUTO after the period.
- OFF: Prevents the electrolytic cell from energizing, stopping chlorine generation. Not for servicing; turn off power at the circuit breaker for servicing.
- Desired Output Level Control: Adjusts chlorine output from 5% to 100% capacity. Start high and adjust downward over a few days to find the ideal setting.
- Indicator LEDs:
- POWER: Solid when BLH has input power.
- GENERATING: Solid during normal operation. Flashing when pool water is too hot or cold to operate.
- SUPER CHLORINATE: Solid during Super Chlorination.
- REMOTE CONTROLLED: Indicates control by a remote system.
- NO FLOW: Solid when flow switch detects no flow and BLH is not generating chlorine. Flashing indicates flow restored, with a 60-second delay before generation resumes.
- CHECK SALT: Flashing when salt level is low (below 2500ppm), generating at low efficiency. Solid when salt level is too low and BLH has shut down.
- HIGH SALT: Solid when salt level is too high, BLH has shut down. Dilute pool water with fresh water.
- INSPECT CELL: Flashing indicates reduced cell efficiency or scheduled inspection. Press diagnostic button for 3 seconds to stop flashing. Solid indicates greatly reduced cell efficiency and BLH stopped chlorine production. Inspect, clean, or replace.
- Salt Display: Shows current salt concentration in ppm. Push "diagnostic" button once to switch to grams per liter. With temperature displayed, move main switch from AUTO to SUPER CHLORINATE to AUTO to switch between Fahrenheit and Celsius.
- Diagnostic Displays: Sequential pushes of the "diagnostic" button show:
- Pool temperature (Fahrenheit or Celsius)
- Cell voltage (21.0-27.0V generating, 16-25V otherwise)
- Cell current (2.50-7.80A generating, 0A otherwise)
- Desired Output % (0%-100%)
- Instant salinity (-XXXX ppm or -X.XX grams/Liter)
- Product name sent to pool automation control display
- Software revision level
- Cell type
The display reverts to default salt display after 8 pushes or 30 seconds of inactivity.
Operation:
- The BLH will not produce chlorine at temperatures below 50°F. Manual chlorination is required if water is colder.
Maintenance Features:
- Cell Inspection: Remove and visually inspect the cell every 3 months (or after approximately 500 hours of operation). Press the diagnostic button for 3 seconds to reset the 500-hour timer after inspection/cleaning.
- Self-Cleaning Feature: The electrolytic cell has a self-cleaning feature to maintain optimum efficiency.
- Cleaning the Cell:
- Turn off power to the BLH.
- Inspect for scale (light-colored crusty or flaky deposits) or debris.
- If no deposits, reinstall.
- If deposits are visible, flush with a high-pressure garden hose. If not successful, use a plastic or wood tool to scrape deposits. Do not use a metal scraper.
- Persistent buildup indicates high calcium levels in the pool water.
- Mild Acid Washing (Severe Cases Only):
- Turn off power to BLH.
- Remove the cell from piping.
- In a clean plastic container, mix a 4:1 solution of water to muriatic acid. Always pour acid into water, never water into acid. Wear protective glasses, clothing, and chemical-resistant gloves.
- The solution level should just reach the top of the cell, not submerging the wire harness compartment.
- Soak for 5 minutes, then rinse with a high-pressure garden hose.
- Repeat if deposits are still visible.
- Replace cell and inspect periodically.
- Winterizing: The electrolytic cell and flow detection switch can be damaged by freezing water. Drain all water from the pump, filter, and lines in areas with freezing temperatures. The electronic control can withstand winter weather and does not need to be removed.
- Spring Start-up: Do not turn on the BLH until pool water chemistry is balanced.
Installation:
- Installation must comply with Local and NEC electrical codes.
- Mounting the BLH Control: Mount vertically on a flat surface, minimum 5 ft (2 meters) horizontally from the pool/spa. Ensure knockouts face downward. Do not block the four sides of the control unit, as it acts as a heat sink. Do not mount in a panel or tightly enclosed space.
- Plumbing: The cell and flow switch are plumbed in the return line to the pool, after all other pool equipment (filter, heater, solar, etc.). The kit includes components for 2" (51mm) rigid PVC piping (in-ground pools) and 1 1/2-1 1/4" (38-32mm) flexible hose connections (above-ground pools).
- Flow Switch: Ensure the arrow on the flow switch points in the direction of water flow.
- Electrolytic Cell: Install using provided unions, tightening by hand for a watertight seal. For pool/spa combination systems with spillover, use configurations #2 or #3 to allow chlorination during spillover while preventing over-chlorination when operating the spa only.
- Wiring:
- Turn off power at the circuit breaker.
- Follow Local and NEC electrical codes.
- The BLH must be properly grounded and bonded.
- Input Power for Stand-alone Operation: Wire the BLH to the LOAD SIDE of the filter pump timer so it is only powered when the pump is running. Refer to the wiring label and diagrams for correct connections. The BLH is shipped with configuration jumpers in a separate bag; install them for the desired voltage before powering on.
- Canadian Models: Connect to a circuit protected by a class A ground fault interrupter. Connect the GROUND wire to the green ground screw terminal inside the enclosure.
- Bonding: A lug for bonding is attached to the bottom of the BLH enclosure. Bond the BLH with an 8 AWG copper wire (6 AWG Canada) to the pool bonding system.
- Electrolytic Cell and Flow Switch: Cables have connectors that plug into the BLH for easy attachment/removal. The flow switch plugs into a connector on the outer bottom of the enclosure.
- Input Power for Goldline, Pentair, and Polaris Controllers: Wire the BLH directly to 120/240VAC power (not through a timer or relay). These controllers use a 4-wire connection to communicate with the BLH and can be wired up to 500' apart using outdoor-rated 4-conductor cable. Refer to manufacturer instructions and wiring diagrams. Only one "primary" BLH unit; additional units must be configured as "secondary."
Troubleshooting:
- "Power" LED not on: Check 120/240 VAC input power, jumper settings, and input voltage with a voltmeter. Check the 20-amp mini ATO fuse on the circuit board.
- "Generating" LED flashing: Pool water temperature is too high or low. Override by switching to SUPER CHLORINATE for the remainder of the pump cycle or 24 hours.
- "No Flow" LED solid or flashing: Check flow switch connection, wire damage, and ensure at least 12" of straight pipe before the switch. Verify arrows on the flow switch point in the direction of flow. If flashing, flow is established and BLH will turn on within 1 minute.
- "Check Salt" LED illuminated or flashing: Check salt level. If low, add salt per chart. Have salt level professionally checked before adding large quantities.
- "High Salt" LED illuminated: Check salt level. If too high, lower by draining and refilling with fresh water.
- "Inspect Cell" LED flashing: Inspect and clean cell. Press diagnostic button for 3 seconds to stop flashing.
- "Inspect Cell" LED illuminated: Remove and inspect cell for scaling. Clean if scaled. If still illuminated after cleaning and proper salt levels, the cell may be depleted and needs replacement.
- Possible causes of low or no chlorine:
- BLH main switch in OFF position.
- Desired output % level setting too low.
- Low stabilizer (Cyanuric Acid) levels.
- Filter pump off or running time too short (8 hours recommended for average pools).
- Salt level too low (below 2500 ppm, Low Salt LED on).
- Salt level too high (High Salt LED on).
- Low pH (oxidizes chlorine quickly). Adjust pH.
- Warm pool water (increases chlorine demand). Increase desired level or filter run time.
- Cold water (below 50F) can stop generation (Generating LED flashing).
- Excessive scaling on cell.
- High level of phosphates in pool water.
- Some yellow algae treatments can deplete free chlorine rapidly. Manually shock if indicated.
- "PCB" displayed and all 4 LED lights illuminated: Indicates a possible printed circuit board fault. Call for service.
Warranty:
- Residential Use: One (1) or Two (2) year limited warranty for defects in materials and workmanship under normal use. Proof of purchase required. Non-transferable.
- One-year schedule: 100% coverage in year one.
- Two-year schedule: 100% coverage in year one, 100% coverage in year two.
- Commercial Use:
- One-year residential warranty corresponds to 2 months commercial use.
- Two-year residential warranty corresponds to 1 year commercial use.
- Terms of Sale: 30-day refund for unwanted items if returned in perfect new condition with original packaging.
- Exclusions: O-Rings, rubber gaskets, electrical fuses, circuit-breaker components (normal wear items). Product discoloration or cosmetic damage. Problems from improper pool chemistry, improper installation, negligence, improper maintenance, improper service, unauthorized modifications, non-genuine parts, misapplication, misuse, abuse, overuse (over 10 hours/day cell lifetime), failure to operate as specified, tampering, accident, fire, flood, freezing, lightning, insects, natural elements, over-tightening threaded components, excessive pressure/stress, or material/workmanship by others during installation.
- Liability is limited to repair or replacement of defective items/parts. No implied warranties of merchantability or fitness for a particular purpose.
- The manufacturer/agents/installers are not liable for consequential, special, or incidental damages, personal injury, property damage, or loss of equipment.
- Warranty valid only in the United States. Disputes settled by binding arbitration in Mecklenburg County, NC.
- During full coverage warranty, all replacements, repairs, and labor costs are covered. Customer is responsible for shipping to/from the warranty center.
- Contact: Phone: 1-888-909-0457 / Email: Support@blueworkspool.com. Hours: Monday-Thursday 9:30am-4:30pm (EST), Friday 9:30am-3:30pm (EST). Closed Saturday & Sunday.
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