Monarch Industries Chloromatic ESR 160

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Summary

Installation Instructions

Installing the Power Supply

Instructions for mounting and positioning the power supply unit for the Chloromatic system.

Connecting the Electrolytic Cell

Details on correctly connecting the electrolytic cell to the power supply unit.

Chloromatic ESR System Operation

System Overview and Indicators

Explanation of Cell Output, LED indicators, and the warning system for the ESR system.

Chloromatic ESC System Operation

Special Features for ESR and ESC Series

System Control Operation

Details how the System Control adjusts cell operating time and its settings.

Low Salinity Indicator and Winter Mode

Maintenance of Electrolytic Cell

Day to Day Operation

Salt Levels

Minimum required salt levels for system operation and preventing cell damage.

The Chloromatic® Salt Water Pool System is an advanced sanitizing system for pools and spas, designed to provide a natural solution for water treatment. This system utilizes an electrolytic cell to convert salt in the pool water into chlorine, ensuring clean and sanitized water without the need for traditional chlorine tablets or liquid. The manual covers the ESR and ESC series, detailing their installation, operation, and maintenance.

Function Description

The Chloromatic® system generates chlorine from salt dissolved in the pool water through an electrolytic process. This eliminates the need for manual addition of chlorine, offering a more consistent and automated sanitization method. The system is designed to be user-friendly, with electronic controls and warning systems to ensure optimal performance and safety.

Important Technical Specifications

Salt Levels:

ESR Systems: Minimum 40kg per 10,000 litres (0.4%), not to exceed 7000 ppm.
ESC Systems: Minimum 30kg per 10,000 litres (0.3%), not to exceed 6000 ppm.
Low salt levels (below 4000 ppm for ESR, 3000 ppm for ESC) can damage the electrolytic cell and void the warranty.

Chlorine Production:

The system produces pure 100% chlorine.
Production rates vary by model:
- ESR 110: 11.0 grams/hour (100%), 16.9 grams/hour (65% equivalent)
- ESR 160 / ESC 16: 16.0 grams/hour (100%), 24.6 grams/hour (65% equivalent)
- ESR 200: 20.0 grams/hour (100%), 30.8 grams/hour (65% equivalent)
- ESR 240 / ESC 24: 24.0 grams/hour (100%), 36.9 grams/hour (65% equivalent)
- ESR 300: 30.0 grams/hour (100%), 46.2 grams/hour (65% equivalent)
- ESC 48: 48.0 grams/hour (100%), 73.8 grams/hour (65% equivalent)

Power Supply:

The power supply unit should be mounted vertically on a post or wall, 1.5 meters above ground level and within one meter of filter equipment.
Australian Standards require it to be located within 3 meters of the pool water.
It must be plugged into a suitable weatherproof outlet.
The power outlet on the bottom of the Power Supply is dedicated to the POOL PUMP ONLY. Using a double adaptor for more than one pump can cause overload and void the warranty.
The unit is fitted with a 3 Amp fuse.

Electrolytic Cell:

The cell housing should be installed to ensure water flows through the cell head end, in accordance with the arrow on the housing, for correct flow sensor operation.
The cell is designed for easy removal and cleaning.
Replacement cells must be genuine Chloromatic® parts to ensure compatibility and warranty validity.

pH and Total Alkalinity:

Fibreglass pools: pH 7.0 to 7.4
Other pools: pH 7.2 to 7.6
Total Alkalinity: 80 - 150 ppm

Stabiliser (Cyanuric Acid):

Maintain at 30 - 50 mg/l (ppm).
Do not exceed 100 ppm.
Initial addition rate: 500 grams per 10,000 litres of water.

Usage Features

Control Panel Layout:

Digital LED Display: Shows cell output as a percentage (around 100% for sanitiser production, 85% in Winter Mode).
Operation LEDs: Two LEDs (Green/Red) indicate system status and potential faults.
Stand-By Indicator: Illuminates during initial start-up or when the cell is off.
Flow Indicator: Illuminates if there is a water flow problem or gas detected in the cell housing.
Winter Switch: Activates Winter Mode.
Winter Mode Indicator: Illuminates when Winter Mode is active.
System Control: A dial to vary the cell's operating time during the filtration cycle (from MIN/OFF to MAX/ON in 10% steps).
Time Clock (Optional): Allows setting operating times by pushing small pins forward or backward. Pre-set for 8 hours/day.
ON-OFF-AUTO Switch (Time Clock):
- ON: Overrides time clock, filtration system on.
- OFF: Overrides time clock, filtration system off.
- AUTO: Filtration system switches on and off automatically according to set times.
Pool Light Switch (Optional): Controls the pool light if a light transformer is installed.

Operation Modes:

Start-Up Delay: Approximately 30 seconds after switching on, allowing the pump and filter to prime.
System Control Adjustment: Varies the percentage of time the cell operates during the filtration cycle (e.g., 60% setting for a 5-hour cycle means 3 hours of cell operation). The cell turns on and off multiple times per hour to adjust to water conditions.
Winter Mode:
- Should be activated when pool water temperature drops.
- Alters the Low Salinity Indicator setting.
- Reduces cell output by approximately 15%.
- Not recommended for use during swimming season as it reduces sanitiser output and can lead to premature cell failure.

ESC System Specific Features:

Polarity Indicator: A ± symbol appears before the cell output display to indicate positive or negative polarity, which alternates automatically.
System Control Flash: When adjusting the System Control, the cell output display flashes the control setting for a few seconds before returning to show cell output.
Electronic Self Cleaning: Patented system that automatically cleans the cell, reducing the need for manual cleaning unless extreme water conditions are present.
Pump Cut-Out: A protective interlock system that cuts off power to the pool pump if no water flows through the cell housing, preventing the pump motor from burning out.

Chlorine Production & Running Times:

Summer: Approximately 8 hours per day, preferably in two periods (e.g., 6:00-8:00 am and 5:00-11:00 pm). Nighttime operation is preferred due to rapid chlorine dissipation in sunlight.
Winter: Approximately 4 to 6 hours per day.
Running times may need to be extended (10-14 hours/day) during extremely hot weather or heavy bathing loads.
Always run the filter when swimming.
If chlorine levels are too high, reduce running times or adjust the System Control anti-clockwise.

Super-Chlorination:

To boost chlorine levels during hot conditions or heavy use, add liquid or granulated chlorine, or extend the Chloromatic® running time.
If using granulated chlorine, regularly check the cell as additives can clog electrodes.

Maintenance Features

Power Supply Maintenance:

Minimal maintenance required, mainly replacing blown 3 Amp fuses.
Periodically spray the wall or post (not the unit itself) with insect repellent to prevent insect penetration and damage, which is not covered by warranty.
The back of the unit is designed as a heat sink and may become very hot, which is normal.

Electrolytic Cell Maintenance:

Regular Inspection: Inspect the cell regularly (at least weekly initially) for scale or blue/green soapy substances.
Cleaning Frequency: Cleaning frequency depends on water conditions (calcium hardness, water temperature, pH control, use of calcium hypochlorite, concrete pool plaster). ESC systems with self-cleaning generally require less frequent cleaning.
Cleaning Methods:
- Method 1 (Acid Solution): Mix 1 part Hydrochloric Acid with 5 parts water. Immerse the cell in this solution for a few minutes. If build-up is not excessive, a jet of running water can also be used.
- Method 2 (Commercial Cleaner): Use an approved commercial cell cleaning solution.
Cell Replacement: Electrolytic cells wear out over time. Use genuine Chloromatic® replacement cells that match your system model. ESC48 cells may require earlier replacement than ESC24 models due to increased output.

Water Chemistry Maintenance:

Stabiliser: Essential for retaining chlorine. Maintain 30-50 ppm. Add 500 grams per 10,000 litres by placing it in a stocking in front of the return jet.
pH: Maintain 7.0-7.4 for fibreglass pools, 7.2-7.6 for other pools. Use Hydrochloric Acid to lower pH, and Sodium Bicarbonate or Soda Ash to raise pH.
Total Alkalinity: Maintain 80-150 ppm. Use Hydrochloric Acid to lower, and Sodium Bicarbonate to raise.
Salt Levels: Crucial for cell operation. Maintain 4000 ppm for ESR and 3000 ppm for ESC systems. Low salt levels will damage the cell and void the warranty. Salt is lost through backwashing, splash-out, overflow, or leaks, not evaporation or consumption. Check levels during winter due to rain dilution.

Troubleshooting:

The manual provides a troubleshooting guide for "No Chlorine Production" and "Low Chlorine Production," covering issues like power supply, fuse, dirty cell, filter, gas sensor, running times, winter mode, stabiliser, pH, and salt levels.

Warranty Information:

During the warranty period, a call-out fee applies for technician visits outside company premises, unless the unit is returned to the distributor for repair.
Warranty does not cover services for issues not covered by warranty; labor charges will apply.
Commercial or semi-commercial installations have a 12-month warranty on both power supply and cells, provided the system runs no more than an average of 8 hours per day.
Using non-genuine Chloromatic® replacement parts will void the warranty and can damage the unit's electronics.