DAVEY COMM1000 Commercial Salt Water Chlorinators Instruction Manual

DAVEY COMM1000 Commercial Salt Water Chlorinators

Product Information

• Specifications
  • Models: COMM500, COMM1000

Product Usage Instructions

• IMPORTANT NOTICE
  • Please refer to the product information updates for any updates or scan the QR code provided.
  • Pass these instructions on to the operator of the equipment.
• IMPORTANT SAFETY INSTRUCTIONS
  • When installing and using this electrical equipment, always follow these basic safety precautions:
  • Read and follow all instructions.
  • WARNING: Do not permit children to use this product unless closely supervised at all times to reduce the risk of injury.
  • WARNING: Risk of Electric Shock. Connect only to a circuit protected by a Ground-Fault circuit interrupter (GFCI) or Residual Current Device (RCD). Contact a qualified electrician if you cannot verify the circuit protection. Do not bury or coil the supply cord.
  • The unit must be connected only to a supply circuit that is protected by a ground fault.
  • This unit is to be installed following these installation instructions, local Electrical Codes, and the requirements of the authority having jurisdiction.
  • The chlorinator must be positioned downstream of all pool equipment including pumps, heaters, filters, cleaners, etc. If an Ozone generator is installed, the injection point MUST be installed after the cell.
  • WARNING: Replace the damaged cord immediately to reduce the risk of electric shock.
  • CAUTION: Install a power supply at least 10 feet (3m) from the inside walls of the pool to reduce the risk of electric shock.
  • CAUTION: Ensure the green/yellow earthing conductor of the supply cord is connected to the earth to reduce the risk of electric shock.
  • WARNING: Do not energize or operate the unit if the enclosure or cell housing is damaged or improperly assembled.
  • To reduce the risk of injury, only permit people who have read these instructions to use this product.
  • CAUTION: Do not use this device with bromide products.
  • SAVE THESE INSTRUCTIONS.
• FACTORS THAT WILL IMPROVE THE PERFORMANCE & LIFE OF YOUR SALTWATER CHLORINATOR COMMON TERMS
  • Algae: Microscopic forms of plant life that enter the pool by rain, wind, and dust. There are numerous varieties – some are free-floating while others grow on walls and in cracks, and they come in different colors. Some are more resistant to chemical treatment than others.
• FAQ
  • Q: Can I use this device with bromide products?
  • A: No, it is not recommended to use this device with bromide products.

IMPORTANT SAFETY INSTRUCTIONS

IMPORTANT NOTICE IMPORTANT SAFETY INSTRUCTIONS

WHEN INSTALLING AND USING THIS ELECTRICAL EQUIPMENT, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED, INCLUDING THE FOLLOWING:

1. READ AND FOLLOW ALL INSTRUCTIONS
2. WARNING – To reduce the risk of injury, do not permit children to use this product unless they are closely supervised at all times.
3. WARNING – Risk of Electric Shock. Connect only to a circuit protected by a Ground-Fault circuit interrupter (GFCI) or Residual Current Device (RCD). Contact a qualified electrician if you cannot verify that the circuit is protected by a GFCI or RCD. Do not bury or coil the supply cord.
4. The unit must be connected only to a supply circuit that is protected by a ground-fault circuit interrupter (GFCI). Such a GFCI should be provided by the installer and should be tested on a routine basis. To test the GFCI, push the test button. The GFCI should interrupt power. Push the reset button. Power should be restored. If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI interrupts power to the unit without the test button being pushed, a ground current is flowing, indicating the possibility of an electric shock. Do not use this unit. Disconnect the unit and have the problem corrected by a qualified service representative before using it.
5. This unit is to be installed following these installation instructions and any local Electrical Codes and the requirements of the authority having jurisdiction.
6. The chlorinator must be positioned downstream of all pool equipment including pumps, heaters, filters, cleaners, and so on. Note: If an Ozone generator is installed the injection point MUST be installed after the cell.
7. WARNING – To reduce the risk of electric shock, replace the damaged cord immediately.
8. CAUTION – To reduce the risk of electric shock, install a power supply at least 10 feet (3m) from the inside walls of the pool.
9. CAUTION – To reduce the risk of electric shock, ensure the green/yellow earthing conductor of the supply cord is connected to the earth.
10. WARNING – Do not energize or operate the unit if the enclosure or cell housing is damaged or improperly assembled.
11. To reduce the risk of injury, only permit people who have read these instructions to use this product.
12. CAUTION – Do not use this device with bromide products.
13. SAVE THESE INSTRUCTIONS

WARNING: This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they don’t play with the appliance. This appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons to avoid a hazard.

FACTORS THAT WILL IMPROVE THE PERFORMANCE & LIFE OF YOUR SALTWATER CHLORINATOR PLEASE READ THIS BEFORE OPERATING YOUR CHLORINATOR.

MAINTAIN THE RECOMMENDED SALT LEVELS:

• SALT LEVELS: 3,000 – 36,000ppm (mg/L)
• Run the chlorinator at the salt levels stated within this document and on the product to ensure optimum sanitizer output and cell life.
• Operating this device at low salt levels will damage the cell and reduce its life.
• The chlorinator will not run at full output and the control panel will display red LED indicator warnings when the salt levels are low.
• If no action is taken to rectify the salt levels, damage to the cell may result which will not be covered under warranty.

MONITOR & MAINTAIN YOUR CHLORINATOR CELL:

• To keep your saltwater chlorinator in the best possible condition, regular monitoring of the electrolytic cell is recommended. The ‘Cell’ is the clear plastic housing containing the metal plates.
• During the chlorination process, a white powdery Calcium scale may naturally build up on the titanium plates in the cell. Monitor the cell to prevent excessive scale build up. Excessive scale build-up will cause damage to your cell, and dramatically reduce its efficiency and lifespan.
• The control panel displays red LED indicator warnings when the cell requires cleaning.
• If the Calcium scale builds up please clean the cell, following the cleaning instructions provided on page 18.
• NEVER : Use concentrated acid to clean your cell.
• NEVER: Leave cell in cleaning solution for extended periods
• NEVER: Use metal implements, scourers or brushes to clean your cell.

BALANCED POOL WATER CHEMISTRY:

• Salt levels MUST be maintained at 3,000 – 36,000ppm (mg/L) for optimum performance and lifespan.
• Calcium Hardness levels MUST be kept to the ideal range of 200ppm – 275ppm (mg/L) (for concrete and tiled pools) and 100-225ppm (mg/L) (for inert surfaces) to prevent excessive scale build up and damage to equipment.
• pH levels MUST be kept between 7.2 and 7.6 to prevent damage to equipment and pool surfaces and to obtain optimum sanitizer effectiveness.
• Total alkalinity and stabilizer levels must also be kept in an ideal range. Please refer to the day-to-day operation section on pages 18 and 19 for more information.

COMMON TERMS

• Algae are Microscopic forms of plant life that enter the pool through rain, wind, and dust. There are numerous varieties – some are free-floating whilst others grow on walls and in cracks and come in different colors. Some are more resistant to chemical treatment than others.
• Bacteria The germs that contaminate your pool. Introduced by swimmers, dust, rain storms, and other elements.
• Balanced water The correct ratio of mineral content and pH level that prevents pool water from being corrosive or scale forming.
• Compounds formed when chlorine combines with nitrogen from urine, perspiration, etc. Chloramines cause eye and skin irritation, as well as unpleasant odors.
• Chlorine demand The chlorine is required to destroy germs, algae, and other contaminants in the pool.
• Chlorine residual The amount of chlorine remaining after chlorine demand has been satisfied. This is the reading obtained with your test kit.
• Cyanuric acid is Also known as a stabilizer or conditioner. It reduces the dissipation of chlorine by direct sunlight.
• Liquid acid Chemicals are used to reduce the pH and total alkalinity in the pool water, and for cleaning Sanitiser cells.
• ppm An abbreviation for Parts Per Million the accepted measurement of chemical concentration in swimming pool water (1 ppm = 1 mg/L).

YOUR NEW SYSTEM

Packing list

• a. Power supply;
• b. Electrolytic cell;
• c. Securing brackets and fasteners;
• d. 4 x cell/pipe adaptors (2 pair);
• e. 2 x cell adaptor union nuts;
• f. Key for front door panel;
• g. Waterproofing boot for data connection
• h. Flow switch
• i. Flow switch circuit cable

Appropriate details for all these items are contained in the following Installation and Operating Instructions. Read these in their entirety before switching on the EcoMatic. If you are uncertain as to any of these Installation and Operating Instructions, please contact your Davey dealer, or the appropriate Davey office as listed on the back of this document.

Power supply with door closed

Power supply control panel

Electrolytic cell and housing

INSTALLATION

Choosing a site

• Installation must be done in accordance with any local regulations. When deciding on a position for the unit, take care to allow for the cable lengths available.
• The power supply and electrolytic cell are very heavy.
• Allow for this during installation. If any components are dropped, damage will occur.
• The electrolytic cell can be plumbed in using 80mm (3”), or 50mm (2”) size PVC pressure pipe.
• The power supply box should be wall mounted using the brackets provided which are designed for masonry bolts/wall plugs.
• The brackets provide a gap between the back of the unit and the wall for enough air flow.
• The power supply box should be mounted approximately 1.2 – 1.5m (4ft – 5ft) above ground level and at least 1.5m (5ft) away from the pool.

Sample installation diagram

Pipe connections

• Ensure EcoMatic cell housing is installed with sufficient clearance from all walls, to be easily removed should service be necessary.
• NOTE: If a heater is installed, Davey recommends installing it on a bypass such that water above 30°C (86°F) does not pass through the cell.

Cell power connection

• Push cell sockets (female) from the end of the cell lead onto the plugs (male) on the cell as illustrated below ensuring correct color configuration.
• Once attached, tighten nut on the cell socket to ensure a tight fit. Overheating of connection may occur otherwise.

Installing flow switch

Locate a suitable position to install the flow switch. The flow switch should be installed on a straight section of pipe with a minimum of 5 pipe diameters, in either direction, between the flow switch and any pumps, valves, or fittings. This will ensure that the paddle is exposed to non-turbulent flow and giving a steady and stable response. The flow switch can be installed in vertical or horizontal pipes, either on the side or on the top of the pipe.

The flow switch should not be mounted on the underside of horizontal pipes.

Once a suitable location is selected, drill a 32mm (1¼”) diameter hole in the pipe.

Place the o-ring in the groove on the inside face of the top half of the pipe clamp.

The flow switch should not be mounted on the underside of horizontal pipes.

Position the lower half of the pipe clamp onto the pipe and secure with the fasteners provided. Tighten sufficiently to prevent leakage.

Apply Teflon tape to the thread on the flow switch and screw the flow switch into the pipe clamp. Tighten the flow switch using the spanner flats on the body. Avoid tightening the switch via the electrical enclosure as this can damage the switch.

Alignment of the switch is critical to correct operation. The switch should be in line with the pipe and the flow arrow in the direction of flow. Remove the lid on the electrical enclosure and insert the wires into the cable entry. Connect the wires to the terminals labeled “COMM” and “NO”.

Fit the lid onto the electrical enclosure and secure via the screw. Disconnect the gas sensor from the cell.

Remove the brass connector from the white wire on the cell cable. Strip the white wire and attach to the brown wire from the flow switch via the supplied crimp.

Fit the brass connector on the lead from the flow switch onto the gas sensor on the cell.

Mains power connection

• The power supply has a power cord attached to the bottom panel.
• The power cord should be connected to mains power using the correct sized male plug or by hardwiring straight into the control box.
• The earth must be connected.
• The GPO (General Purpose Outlet) / pool equipment control box, to which the unit is connected should be protected by a Residual Current Device (RCD Safety Switch), see local electrical regulations.
• The electrical supply to the unit should be interlocked to the main pump(s). That is, if the main pump(s) are not operational, power is turned off.

External control connection

• The external control feature is a means of controlling the EcoMatic chlorinator’s output from an external controller.
• This can take the form of a timer, residual chlorine controller, or ORP monitor.
• The production LED’s will light up to show that the external controller has the cell power turned ON.
• The external control input requires normally open (NO), voltage-free contacts, where open contacts signal the chlorinator output is OFF and closed contacts signal the chlorinator output is ON.
• The external controller’s output is connected to the terminals located at the base of the chlorinator as shown on page 6.

OPERATION

Start-up procedure

• Ensure water flow through cell housing is above recommendations, see page 21.
• The production indicator is a meter made up of a bar of five LEDs in the middle of the control panel.
• Normal cell operation is indicated by five green LEDs being on.
• The unit is fitted with an electronic control and warning system. This regulates the output of the Unit to a preset maximum.
• The warning system consists of an OPERATION LED which will glow Red to indicate possible faults with the Unit or damaging operating conditions.
• Once the salt level in the pool is correct the unit may be switched ON. The OPERATION LED will be green, and no cell output will be seen for approx. 120 seconds, this allows the pump and filter to prime and the cell housing to fill with water.
• After this start-up delay, the bar meter should light up showing all five LEDs.
• At this point the OPERATION LED should be green; if it is red it indicates that there is a problem and please refer to the table below.

Low electrical conductivity

• As the salt concentration in the water is diluted, the water’s conductivity drops.
• This will be shown on the control panel by a reduction from 5 working green LEDs of the production display, to 4.
• This may reduce further to 3 etc. A low salt level (or low electrical conductivity to be more accurate) can also be created by cold water, a calcified salt cell, or a cell that’s starting to wear.

MODBUS physical interface

• This product implements the MODBUS RTU protocol standard over an RS485 interface.
• The RS485 interface is accessible via the RJ45 connector on the bottom of the power supply unit.
• Pin connections follow the official guidelines of the Modbus Organisation.
• Pin connections as follows, colour codes used for standard T-568A and T-568B varieties of network cable are included for reference.

RJ45 PINOUT

The RJ45 interface of your ECOMATIC COMM series chlorinator is designed to maintain ingress protection performance when used with the included sealing boot over an un-booted RJ45 plug.

MODBUS register specification

The product consists of holding registers which can be read (using MODBUS function 3) as below:

2=reverse)
3| Run Current| How much current is running through the cell (mA)
4| V1| The voltage on one side of the cell cable at PCBA (mV)
5| V2| The voltage on the other side of the cell cable at PCBA (mV)
6| Bridge Temp| The temperature in the high current area of PCBA (°C)
7| Micro Temp| The temperature in the logic control area of PCBA (°C)
8| Pot Position| Position of output control knob (0 – 1024)
9| DIPS| PCBA DIPs setting (b0 = DIP1; b1 = DIP2; b2 = DIP3; b3 = DIP4)
10| ORP| Whether ORP input is triggered (0=false; 1=true)
11| TDS| Calculated TDS (PPM)
---|---|---
12| Current Warnings/Faults| 0x00 = none;

0x01 = low conductivity warning; 0x02 = high conductivity warning; 0x80 = flow switch shut-down; 0x81 = low conductivity shut-down; 0x82 = over-current shut- down;

0x83 = bridge temperature shut-down; 0x84 = micro temperature shut-down; 0x85 = unexpected fault shut-down;

13| Time to Clear| Time before fault is cleared and re-start attempted (s)
14| Set Current| What the unit is pre-set to regulate current to when at 100% (mA)
15| Target Current| What current the unit is currently regulating towards (allowing for faults, ramping up/down at start-up/shut-down) (mA)
16| Duty| Calculated duty based on Pot Position (% time on in 10 min block)
17| Rise/Fall| MSB is time (s) of start-up ramp; LSB is time (s) of shut-down ramp
18| Reverse Time| How long the reversal period of the cell is (minutes)
19| Uptime LSBs| Lowest 16-bits of uptime (time unit has been powered in minutes)
20| Runtime LSBs| Lowest 16-bits of runtime (time cell has been active in minutes)
21| Uptime and Runtime MSBs| MSB is Uptime MSB (total 24-bit) LSB is Runtime MSB (total 24-bit)
22| Microcontroller ID| ID number of embedded micro-controller
23| Microcontroller Revision| Revision number of embedded micro- controller
24| Software Version| Software Version
 |  |
102| Serial Number| Unique serial number

The following registers have write access (using MODBUS function 6) available: –

Shorter reversal times mean less opportunity for scale build-up but reduce plate life.

Longer reversal times mean more opportunity for scale build-up but increase plate life.

The default is 480 minutes (8 hours)

| 240 – 720

MAINTENANCE

The power supply

• Little maintenance is typically required, however the wall to which the unit is installed must be sprayed (not the unit itself) periodically with a good surface type insect repellent, since penetration by insects may cause damage which is not covered by your warranty.

The electrolytic cell

• The EcoMatic COMM system uses a reverse polarity cleaning system to clean the cell and reduce operational maintenance.
• In ideal conditions reverse polarity systems will require little or no manual cleaning, however in areas with hard water (high calcium hardness), reverse polarity systems may require occasional manual cleaning.
• Calcium and other minerals are deposited on the cell plates as electrolysis takes place.
• This build-up will interfere with the flow of electrical current and water in the cell and thus lower sanitizer production.

It is essential to inspect the cell regularly and clean when necessary. The rate at which deposits will form on the plates differs with each pool and can be influenced by the following:

• Calcium hardness of the water;
• Water temperature;
• pH control;
• Water which has been chlorinated with calcium hypochlorite for an extended period
• Calcium in the plaster surfaces of a concrete pool.

These conditions can vary a lot. Check the cell at least weekly, to begin with to see if any deposits appear on the plates. You will then be able to determine the cleaning cycle necessary for your pool (obviously more in summer). The intervals between cleaning could get longer to the point where cleaning is only necessary a couple of times each year. One exception is the use of bore water or groundwater, in which case cleaning may need to be as frequent as once a week. If the cell remains dormant for a period, or there is evidence of rust within the cell or on the cell plates, an acid wash clean of the cell is required before use of the sanitizing system (please refer to next section – How to clean your EcoMatic COMM cell). The life of EcoMatic COMM electrolytic cells will vary substantially from one installation to another due to variations in operating time, water quality and composition, and system and cell maintenance. Please ensure that when a cell replacement is necessary you use the correct genuine EcoMatic COMM replacement cell to match your system.

How to clean

How to clean your EcoMatic COMM cell

• First, turn off the power, then disconnect the cell from the power supply unit. In some installations such as above-ground pools, it may be necessary to isolate the cell housing in the plumbing and de-pressurize the pipework.
• Then, remove from the cell housing from the pool return line by undoing the unions.
• Take care not to lose the o-rings and always make sure the pump and EcoMatic power supply is turned off.
• Always wear personal protective clothing such as rubber gloves and glasses while cleaning your cell. Inspect the cell for obvious damage. If damage is present, consult your place of purchase, or the nearest Davey representative from the back page of this manual.

Method 1:

• Add 1 part (28% strength) Hydrochloric Acid (Muriatic Acid) to 10 parts water in a suitable container.
• The cell should be placed on a surface that allows it to be placed upside-down to form a U shape.
• The solution can then be poured into the up-turned cell. Take care when doing this as the solution can foam and create a spill which must be cleaned up by dilution.
• When clean, the cell should be rinsed thoroughly with water and the connections should be dried carefully to avoid connector corrosion. It should not take longer than a few minutes to clean.
• If it does, the cell should be cleaned more frequently. Return the cell to its position and re-connect it.

Method 2:

• As an alternative, an approved commercial cell cleaning solution can be used several times effectively.
• Frequent cleaning of cells is required in areas with water containing high iron content.

WARNING: Never add water to acid. Always add acid to water

• The weak acid solution can be stored in a safe place (where children cannot access it) and re-used several times before becoming ineffective (saving having to make the solution each time).
• Avoid getting the acid solution on your skin or in your eyes.
• If you accidentally do so, wash off immediately with fresh water (or use the pool/spa water).
• Please do not hesitate to contact your EcoMatic dealer for any assistance regarding ‘cell’ cleaning.

Day-to-day operation

Stabilizer:

• Measure the stabilizer level using an appropriate test kit.
• It should be between 25 and 50 ppm (mg/L). Follow the directions for adding it or load it directly into the pool pump inlets.
• If there is some stabilizer present, but it is below 30 ppm (mg/L), add 20 ppm (mg/L) to the pool and re-measure the level once it has dissolved.
• Then add enough to make up the 50ppm (mg/L). The amount of stabilizer to add is calculated as follows:
• A 50m3 (13,200 gallons) pool has 30ppm (mg/L) stabiliser present. Adding 1kg (35 ounces) will raise to 50ppm (mg/L).

IMPORTANT:

• The stabiliser is for use in outdoor pools only.
• It is used to reduce the loss of chlorine due to the effect of sunlight.
• It should not be used in indoor pools as it may adversely affect pool chlorine demand. Stabiliser is very slow to dissolve and if loaded into the pump inlets it can sit in the filters for several days.
• If the filters are backwashed, they will be lost. Monitor the stabilizer after backwashing.
• Outdoor pool using an ORP controller, should have stabilizer levels maintained between 15-25ppm (mg/L).

pH and Total Alkalinity: A correct pH level must be maintained to prevent problems such as black spots, staining, cloudy water, etc. An incorrect pH level can damage the pool. Correct pH levels are as follows:

• Concrete & tiled – 7.4 to 7.6
• Inert surfaces – 7.2 to 7.4

If you allow the pH level to rise to 8.0 or above the chlorine required could be as much as three times the normal amount and can cause increased cell scaling. To lower the pH add Hydrochloric (Muriatic) acid. To raise the pH level add Sodium Bicarbonate, or Soda Ash. Total Alkalinity should not be confused with pH, although the two are closely related. The correct Total Alkalinity buffers the pool water against rapid changes in pH and prevents what is known as pH ‘bounce’ where the pH value rises and falls sharply. It is measured in ppm; the ideal range is 80-120ppm (mg/L) for concrete or tiled pools and 125-250ppm (mg/L) for other surfaces or refer to your pool professional. You should use a test kit that includes a test for Total Alkalinity. Low Total Alkalinity can cause unstable pH levels – i.e. An inability to keep the pH constant may cause staining, etching and corrosion of metals. High Total Alkalinity will cause constantly high pH levels. To lower, add Hydrochloric Acid (a little at a time). To raise, add Sodium Bicarbonate.

Salt levels:

• Salt levels MUST be maintained at 3,000 – 36,000ppm (mg/L) for optimum performance and lifespan.
• Operating the unit with too little salt in the pool will cause damage to your cell. Salt is the essential element by which your unit operates.
• Low salt means low chlorine production.
• This simple rule governs the total operation of your EcoMatic and insufficient salt WILL damage your cell.
• Salt is NOT consumed in the process of producing chlorine or by evaporation.
• Salt is only lost through dilution, backwashing, splash-out, overflow, or by leakage from the pool or plumbing.
• Rain also dilutes the salt centration in your pool, therefore salt levels should be checked after heavy rainfall.
• Colder water lowers the conductivity of the pool water.
• This will reduce the unit output and turn the Operation LED red.
• If this occurs extra salt should be added or damage to the cell will result.
• If the water temperature is below 15°C (59°F), it is suggested the EcoMatic unit be switched off.

WARNING: Low salt levels will destroy the coating on the plates and will void all Warranty.

• The EcoMatic unit has a built-in warning system to minimize damage resulting from insufficient salt levels, however, the ultimate responsibility is on the owner to ensure adequate salt levels are maintained all year round.
• The EcoMatic will show a low salt alarm at a salt concentration of ~ 3,000 (mg/L).
• The system will continue to operate, but the display will show an orange operation LED, and less than 5 green LEDs on the “production bar meter”.
• At a salt concentration of ~ 2,500ppm, the EcoMatic will enter a “low salt cut-out”. At this point, the EcoMatic will stop operating.
• If the low salt alarm or low salt cut-out is triggered, raising the salt concentration back to within range will automatically clear the alarms.

Chlorine production

• The EcoMatic unit must be run daily to generate enough chlorine to sanitize the pool.
• If the level is too low either longer running times are required, or the system control needs to be adjusted higher.
• Harsh local conditions such as traffic pollution or windborne dust require different running times, in which case seek advice from your pool shop.
• Without enough filtration/chlorination, your pool will never function correctly.
• Always run the filtration system when swimming in the pool.
• In some cases, you may find your chlorine level to be too high.
• To determine if this is the case, run your chlorinator for the suggested times/chlorine production level and test your pool water on the morning after the operation.
• If your chlorine test shows a high level of chlorine, either the running times can be reduced slightly, or the system control can be turned down (anti–clockwise).
• Test your chlorine level again the following morning at around the same time.
• If your chlorine level is still high, repeat the above process until the correct level is attained.

Super Chlorination:

• Periodically, especially during extremely hot conditions, it may be necessary to boost the amount of chlorine in your pool to maintain absolute sanitation of the water.
• This can be achieved by adding either liquid or granulated chlorine.
• If granulated chlorine is added, the cell must be checked regularly, since the additives from this product may clog the electrodes.
• Alternatively, extend the running time of your EcoMatic.

TECHNICAL SPECIFICATIONS

Power consumption typical @ 230V: COMM 500 @ ~4500ppm (mg/L) COMM 1000 @ ~4500ppm (mg/L)

Efficiency improves with increased salinity

| 250W

500W

Maximum input current (AC):

COMM 500

COMM 1000

| 1.6 Amps

3.0 Amps

Fuse type:

COMM 500/1000

| 5.0 Amps slow blow
Output to cell (DC):

COMM 500

COMM 1000

| 22 – 24V, 9 Amps

24 – 26V, 19 Amps

Chlorine gas output:

COMM 500

COMM 1000

| 50g/h (1.2kg/day, 2.65lbs/d) @ 5,000ppm (mg/L) @ 25°C (77°F) 100g/h (2.4kg/day, 5.29lbs/d) @ 5,000ppm (mg/L) @ 25°C (77°F)
Operating salt range:| 3,000-36,000ppm (mg/L)
---|---
Ideal salt range:| 4,500-6,000ppm (mg/L)
Low salt alarm:| ~ 3,000ppm (mg/L)
Low salt cut-out:| ~ 2,500ppm (mg/L)
Cooling:| Passive – product must be mounted on a flat vertical surface using the supplied mounting kit to ensure adequate ventilation
Electrolytic cell type:| Coated Titanium, reverse polarity
Maximum water temperature (in cell):| 45°C, or 113°F

Keep water below 30°C, or 86°F for chlorine effectiveness

Minimum recommended water temperature (in cell):| ****

15°C, or 59°F

Minimum flow (through cell):

COMM 500

COMM 1000

| ****

170L/min, 45USG/min, or 10.2m3/h 235L/min, 62USG/min, or 14.1m3/h

Head loss @ 400L/min

COMM 500

COMM 1000

| ****

5.1kPa, 0.74psi 5.7kPa, 0.83psi

Pipe connections:| 3″/ 80mm, or 2″ / 50mm with adaptors
Approvals:| EN60335-1, EN62233, EN61000-6-3, EN61000-3-2, EN61000-3-3, EN61000-4-2, EN61000-4-4, EN61000-4-5,

EN61000-4-6, EN61000-4-11, EN55014-2, IPX4, UL 1081 and CSA C22.2 No.218.1

Dimensions of power supply enclosure

 | Height| Width| Depth| Mounting| Weight
COMM 500| COMM 1000

Inches

| ****

15.7

| ****

11.8

| ****

5.9

| 4 holes

W: 13.4

H: 12.8

| ****

28.7lb

| ****

28.7lb

Millimeters

| ****

400

| ****

300

| ****

150

| 4 holes

W: 340

H: 326

| ****

13kg

| ****

13kg

Dimensions of electrolytic cell housing

 | ****

Height

| ****

Width

| ****

Depth

| Inlet/outlet

(actual ID)

| Plumbing holes

(from center to center)

| Weight
COMM 500| COMM 1000
Inches| 8.1| 16.3| 5.0| 3.5| 11.8| 6lb| 8lb
Millimeters| 206| 415| 127| 89| 300| 2.7kg| 3.6kg

NOTE:

• In certain installations, these minimum flow rates may be insufficient to fill the cell housing with water.
• In these cases, the flow must be increased to ensure that the cell plate surfaces are completely immersed.
• Otherwise, damage will occur, and decreased cell life will result.

GENERAL INFORMATION

Pool water chemistry instructions

POOL WATER BALANCE| ****

Free Chlorine ppm (mg/L)

| ****

pH

| Total Alkalinity TA ppm (mg/L)| Calcium Hardness ppm (mg/L)| Stabiliser – Cyanuric Acid ppm (mg/L)| Recommended salt Levels ppm (mg/L)
---|---|---|---|---|---|---
Ideal reading

/ range

| 1.5 – 3| Concrete & tiled pools 7.4-7.6

Other surfaces 7.2-7.4

| 80 – 150| Concrete & tiled pools 200-275

Other surfaces 100-225

| 25-50 (15-25 if used with an ORP controller) Not to be used in indoor pools.| Depends on model (see page 4)
To increase| Increase the output of sanitizer. Add chlorine.

Increase filtration time.

| Add Soda Ash (Sodium Carbonate)| Add Buffer (Sodium Bicarbonate)| Add Calcium Chloride| Add Cyanuric Acid| Add salt
To decrease| Decrease output of sanitizer. Decrease filtration time.| Add Hydrochloric Acid| Add Hydrochloric Acid or Dry Acid| Partially drain & refill the pool with lower-hardness water to Dilute| Partially drain & refill the pool to dilute| Partially drain & refill the pool to dilute
Frequency of testing| Weekly| Weekly| Weekly| Weekly| Regularly| Regularly

SPARE PARTS

TROUBLESHOOTING

•  System control dial set below MAX. The cell is turned off. (Refer to operations on page 14)

5 LEDs| Green| •  System operating normally
Less than 5 LEDs| Orange| •  Salt level could be low. Get tested by your pool shop, or service technician.

•  Cell is calcified. Clean cell.

•  Water temperature low < 25ºC (77ºF). Add salt to compensate or heat water. Maintain salt level between recommended levels. (See page 4).

Off| Red| •  Insufficient flow. Check pump & pipes for damage or blockage and ensure that all valves to and from the pump are open;

•   Check flow switch connecting and working;

•   Gas sensor not connected to the cell.

•  Salt level too low and cell has turned off.

Davey Warranty

Davey Water Products Pty Ltd (Davey) warrants all products sold will be (under normal use and service) free of defects in material and workmanship for a minimum period of one (1) year from the date of original purchase by the customer as marked on the invoice, for specific warranty periods for all Davey products visit daveywater.com.
This warranty does not cover normal wear and tear or apply to a product that has:

• been subject to misuse, neglect, negligence, damage or accident
• been used, operated, or maintained other than by Davey’s instructions
• not been installed by the Installation Instructions or by suitably qualified personnel
• been modified or altered from original specifications or in any way not approved by Davey
• had repairs attempted or made by other than Davey or its authorized dealers
• been subject to abnormal conditions such as incorrect voltage supply, lightning or high voltage spikes, or damages from electrolytic action, cavitation, sand, corrosive, saline or abrasive liquids,

The Davey warranty does not cover the replacement of any product consumables or defects in products and components that have been supplied to Davey by third parties (however Davey will provide reasonable assistance to obtain the benefit of any third-party warranty).
To make a warranty claim:

• If the product is suspected of being defective, stop using it and contact the original place of purchase. Alternatively, phone Davey Customer Service or send a letter to Davey as per the contact details below
• Provide evidence or proof of the date of the original purchase
• If requested, return the product and/or provide further information concerning the claim. Returning the product to the place of purchase is at your cost and is your responsibility.
• The warranty claim will be assessed by Davey based on their product knowledge and reasonable judgment and will be accepted if:
  • a relevant defect is found
  • the warranty claim is made during the relevant warranty period; and
  • none of the excluded conditions listed above apply
• The customer will be notified of the warranty decision in writing and if found to be invalid the customer must organise the collection of the product at their expense or authorize its disposal.

If the claim is found to be valid Davey will, at its option, repair or replace the product free of charge. The Davey warranty is in addition to rights provided by local consumer law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. For any internet-connected products, the consumer is responsible for ensuring a stable internet connection. In the event of a network failure the consumer will need to address the concern with the service provider. The use of an App is not a substitute for the User’s vigilance in ensuring the product is working to expectation. Use of a Smart Product App is at the User’s own risk. To the fullest extent permitted by law Davey disclaims any warranties regarding the accuracy, completeness, or reliability of App data. Davey is not responsible for any direct or indirect loss, damage, or costs to the User arising from its reliance on internet connectivity. The User indemnifies Davey against any claims or legal actions from them or others relying on internet connectivity or App data in this regard. Products presented for repair may be replaced by refurbished products of the same type rather than being repaired. Refurbished parts may be used to repair the products. The repair of your products may result in the loss of any user- generated data. Please ensure that you have made a copy of any data saved on your products. To the fullest extent permitted by law or statute, Davey shall not be liable for any loss of profits or any consequential, indirect or special loss, damage or injury of any kind whatsoever arising directly or indirectly from Davey products. This limitation does not apply to any liability of Davey for failure to comply with a consumer guarantee applicable to your Davey product under local laws and does not affect any rights or remedies that may be available to you under local laws. For a complete list of Davey Dealers visit our website (daveywater.com) or call:

CONTACT

• Davey Water Products Pty Ltd ABN 18 066 327 517
• daveywater.com.

AUSTRALIA

• Head Office
• 6 Lakeview Drive,
• Scoresby, Australia 3179
• Ph: 1300 232 839
• Fax: 1300 369 119
• Email: sales@davey.com.au.

NEW ZEALAND

• 7 Rockridge Avenue,
• Penrose. Auckland 1061
• Ph: 0800 654 333
• Fax: 0800 654 334
• Email: sales@dwp.co.nz.

® Davey is a trademark of Davey Water Products Pty Ltd. © Davey Water Products Pty Ltd 2023. P/N 401751-15

• Models:
  • COMM500,
  • COMM1000
• Please refer to https://qr.daveywater.com/67. JH for any product information updates, or simply scan this QR code.

Please pass these instructions on to the operator of this equipment.

References

• Home - Davey Network
• 67JH
• 67JH

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