This guide shows you how to install a Crystal Pure Salt Chlorine Generator (SCG).The Crystal Pure Salt Chlorine Generator (SCG) automatically sanitizes your in-ground pool by converting the low concentration level of salt in your pool into free chlorine through electrolysis. Note: This guide is intended to give you a visual reference to supplement the Crystal Pure owner's manual, not replace it. Make sure you read and understand your owner's manual before installing your unit.
1. COLLECT TOOLS REQUIRED - To install an Crystal Pure SCG you will need the following tools / materials:
- philips head screwdriver
- flat head screwdriver
- power drill
- 3/16" carbide drill bit
- 1/4" x1-1/4" hex head concrete anchors
- felt pen marker
- digital multimeter
- 1/2" mpt terminal adapter
- 12-3 AWG cable
- electrical; conduit
- electrical junction box
- heavy cutting pliers
- wire strippers
- wire connectors
- 8 AWG bonding wire
- copper split bolt
- tape measure
- PVC primer and glue
- hack saw
- file
- pvc connectors
- salt
- salt water test strips
2. BALANCE POOL WATER - Make sure your pool water is balanced before installing the Crystal Pure SCG. Note: If the pool does not have new water, add one quart of metal remover and one quart of a non-copper based algaecide to the pool.
3. POSITION CRYSTAL PURE CONTROL BOX - Locate an area on the wall near the equipment for the Crystal Pure Control Box. The control box must be mounted a minimum of 5' horizontal distance (or more, if local codes require) from the pool/spa. Locate the Control Box close to the pump and Crystal Pure Cell. Keep in mind that the 15' cable of the salt cell, which will be installed on the return line, must be able to reach the control box. Note: It is important not to block the four sides of the Control Box. DO NOT mount the Control Box inside a panel or a tight enclosed area.
4. MARK FOR MOUNTING SCREWS - Mark the locations for the four mounting screws. The Control BOX is designed to mount vertically on a flat surface with the knockouts facing downward.
5. DRILL MOUNTING HOLES - Drill four holes where the mounting screws will be installed. Note: We used a special 3/16" carbide drill bit to drill into the concrete wall.
6. MOUNT CONTROL BOX - Install screws (or other hardware appropriate for the mounting surface) through the four mounting holes at the bottom and the top of the Crystal Pure SCG. Note: We used 1/4" x 1-1/4" hex head, concrete anchors. Hex head anchors are recommended for better traction when installing into the concrete.
7. PREPARE FOR WIRING POWER - The Crystal Pure SCG must be tied into the timer circuit going to the pump so that when the pump is shut off, the SCG also shuts off. One way to do this is to insert a power junction box between the timer and the pump. Power that was coming from the timer and going directly to the pump will now come into one side of the box and exit out the other side through two ports; one going to the pump and one going to the SCG. When wiring, be sure to follow local and NEC/CEC electrical codes. CONTACT A PROFESSIONAL ELECTRICTIAN IF YOU ARE UNCOMFORTABLE WORKING WITH POWER. Incorrect wiring can cause dangerous shocks and may void your warranty.
8. TURN OFF POWER TO TIMER - Before wiring you should check the output power level at the timer going to your pump. It will be either 120VAC or 240VAC. In preparation for measuring your power, TURN OFF THE POWER TO THE TIMER BOX. There should be a circuit breaker before the timer box where the power can be turned off.
9. REMOVE TIMER COVER - With POWER OFF, remove the cover over the screw connectors inside the timer box.
10. VIEW TIMER WIRING - This picture shows the wiring inside the timer box. Three wires come in from the left of the box. Two are labeled INPUT and one GROUND. There are 5 terminals in the timer box. The left-most labeled "A" is not used. The other four are labeled 1 to 4. The INPUT wires are connected to 1 and 3. The OUTPUT wires to 2 and 4.The OUTPUT wires are currently wired to the pump. The GROUND WIRES SHOULD BE ATTACHED TO THE GROUND SCREW JUST ABOVE TERMINAL "A". IT IS WRONGLY SHOWN IN THE CURRENT PICTURE AS GOING TO "A". Note: The timer pictured is an Intermatic 220v T104 timer. Please refer to your timer's manual for guidance.
11. MEASURE POWER - To measure your voltage level, TURN ON POWER back on at circuit breaker. Set your digital multimeter to 300 VAC and place the meter's probes on the OUTPUT terminals, 2 and 4. It does not matter which probe is placed on which terminal. Be careful not to let the probes short out between two adjacent terminals. The meter should read close to 240VAC if your power is 240VAC - 120VAC if the timer is using 120VAC.
12. TURN OFF POWER / REPLACE COVER - Switch off power at the breaker and replace the timer electrical cover.
13. MOUNT JUNCTION BOX - Place an electrical junction box on the wall between the timer and the pump. Use the same drill bit and hex screws used to mount the Control Box above. This junction box can be purchased at any hardware store.
14. WIRE INPUT TO BOX -With the POWER OFF, cut into the existing power line to the pump. Leave an extra 5" to 6" of wire length on the input side of the box (from timer) to make connections inside the box. You may have to insert a new wire and conduit between the junction box and the pump if the resulting length to the pump is now too short.
15. GLUE CONDUIT TO BOX - Glue the conduit from the Timer to the input side of the Junction Box.
16. VIEW INPUT POWER -This picture shows the result of wiring from the Timer to the Junction Box.
17. WIRE POWER TO PUMP - On the output side of the Junction Box, connect wire and conduit from one of the two output ports to the Pump. As stated above, you may have to provide new wire and conduit to the Pump is the old wiring is now too short.
18. REMOVE SCG COVER - Open the Crystal Pure SCG Control Box and remove the two screws that secure the blue cover panel. Remove the blue cover panel.
19. INSERT MPT ADAPTER IN SCG - The SCG comes with a cord grommet in the bottom of the Control Box. For a better seal, replace the grommet provided with a 1/2" MPT terminal adapter and secure it with a ring.
20. WIRE POWER TO SCG - Connect wire and conduit between the second output port of the Junction Box and the power port of the SCG.
21. VIEW JUMPER CONFIGURATION - As shown here, the jumper configuration for 240V input power is to connect terminal 2 to terminal 3. This is the default configuration shipped out from the factory.
22. CONNECT WIRE LEADS TO SCG TERMINAL - The power cable coming into the SCG should be opened about 6" to release the three wires in the cable: two sheathed power wires and one bare ground wire. Strip 1" off the end of the two power wires and attach the black wire to terminal 1 and the white or red wire to terminal 4. Connect the ground wire to the ground screw at the back of the Control Box.
23. VIEW OPTIONAL 120V INSTRUCTIONS - This diagram shows how the jumpers are changed to configure the SCG for 120V source power. The 120V configuration uses two jumpers between terminals 1 and 2 and terminals 3 and 4. These jumpers are provided with the SCG package usually taped to the inside cover of the Control Box. The power wires are connected the same as for 240V.
24. CONNECT WIRE INSIDE JUNCTION BOX - Now go back to the Junction box. You will have three sets of wires: one set from the timer; one set going to the pump; and one set going to the SCG. Gather the three black wires and connect them with a wire wing nut. Gather and connect the white or red wires. And gather and connect the bare ground wires.
25. SCREW ON JUNCTION BOX COVER - When you buy a junction box, it will come with a cover plate and gasket. Screw this cover plate and gasket onto the top of the junction box to seal out critters and weather.
26. CONNECT BONDING WIRE TO SCG - Use 8 AWG bonding wire to ground the SCG to your pool's grounding grid. Connect one end of the wire to the grounding lug underneath the Control Box. Note: This bonding wire is installed in addition to your normal grounding process (green wire). You need both per code.
27. CONNECT BONDING WIRE TO PUMP BOND - Connect the other end to the bonding wire on your pump that already connects to the pool's grounding grid. The simplest way to connect the two wires is to use a copper split bolt shown here. If the pump's bonding wire is insulated, scrape an inch clear so that the two bonding wires are bare where they join.
28. VIEW PLUMBING LAYOUT - The next steps will illustrate how to install the Crystal Pure SCG salt cell and flow switch on the return line. They will need to be installed after (downstream) all the pool equipment (filter, heater, etc.). For most installations, we recommend installing the flow switch after (downstream) of the cell. The flow switch can be installed before or after the cell but there must be 12" of straight pipe before the flow switch. The cell counts as 12" of straight pipe if installed directly before the flow switch. See your owner's manual for other options.
29. CONNECT FLOW SWITCH TO SCG CELL - Connect the salt cell and flow switch by gluing a short piece of 2" diameter schedule 40 pipes between the two. Make sure the arrow of the flow switch is pointing in the direction of the flow of the water. Gluing is a two-step process. First, apply a thin but even coat of purple primer on each surface to be joined: the outside of the pipe and the inside of the union/flow switch. After the primer has dried, apply a thin even coat of glue to both surfaces. Immediately push the pipe all the way into the union/flow switch and twist 1/4 turn to spread the glue. Hold the pipe in place for 30 seconds until the glue sets. Note: If you haven't glued PVC pipe together before, have someone who can help you with the first couple of connections. It is an unforgiving process.
30. REMOVE PIPE SECTION - Measure the total length of the salt cell and flow switch. With that measurement, find the correct spot in the return line (after the equipment) and cut out the properly measured section of pvc pipe. Keep in mind that the section of pipe removed should be approximately 2-1/2" shorter than the length of the switch and cell. This takes into consideration that some of the pvc plumbing will slip into the flow switch and salt cell.
31. INSERT SCG CELL AND FLOW SWITCH - Glue the salt cell and flow switch into the section of return line that was removed above.This installation was in a tight fit and required extra elbows. All installation will be different and most will have more space in the section to be cut out and replaced.
32. PLUG IN FLOW SWITCH - Plug the cable from the flow switch into the jack located at the bottom of the Crystal Pure Control Box.
33. PLUG-IN THE CELL CABLE - Plug the cable from the SCG salt cell into the Crystal Pure Control Box.
34. REPLACE SCG COVER - Reinstall the blue cover panel onto the Crystal Pure Control Box.
35. TURN POWER ON - Turn on the power to the timer box.
36. CHECK FOR LEAKS - Check around the SCG collars for leaks. Tighten collars if required but do not overtighten.
37. CHECK "POWER" LED - Check the "POWER" LED. With the power on and the Main Switch at the OFF position, the "POWER" LED should be illuminated.
38. CHECK "NO FLOW" LED - Check the "NO FLOW" LED. If it is illuminated, the water flow pressure has not reached operational level. After the system is fully primed, the light should go off.
39. ENSURE MAIN SWITCH IS '"OFF" - Make sure that SCG cell is "OFF" by sliding the Main Switch to "OFF". The SCG LEDs and display will still be operational, but the SCG cell will stop generating chlorine and the pump will still be on to circulate water in the pool.
40. CHECK SALT LEVEL - The next steps will involve adding the salt to the pool. Using a saltwater test strip, measure the current salt level of your pool. For the Crystal Pure SCG, the ideal level is 2700-3400 ppm (3200 ppm is optimal). If the level is low, determine the number of gallons in your pool and add salt according to the Salt Table located in the owner's manual. For example, if your pool has 15,000 gallons of water and your current salt level is 0, you need to add 427 lbs of salt.
41. BUY SALT - It is important to use only sodium chloride (NaCl) salt that is greater than 99% pure. This is common food quality salt or water softener salt and is usually available in 40-80 pound bags. DO NOT use rock salt, salt with yellow prussiate of soda, salt with anti-caking additives, or iodized salt.
42. ADD SALT TO POOL - While the pump is running, walk around the pool and pour in the salt. Brush the salt around to speed up the dissolving process. Run the pump for 24 hours with the suction coming from the main drain (use pool vac if there is no main drain) to allow the salt to evenly disperse. Note: For new plaster pools, wait 10-14 days before adding salt. This allows the plaster to cure.
43. START GENERATING CHLORINE - After the salt has dissolved and the salt level is between 2700-3400 ppm, move the power switch on the Crystal Pure Control Box to the "AUTO" position to start generating chlorine. The "GENERATING" LED will flash for about a minute while the system is settling, then the LED should go to steady on. If the system is operating correctly, two lights will now be illuminated; the "POWER" LED and the "GENERATING" LED.
44. SET INITIAL OUTPUT LEVEL - Adjust the "DESIRED OUTPUT %" dial to 50%. Test the chlorine level every few days and adjust the dial up or down accordingly. It usually takes 2-3 adjustments to find the ideal setting for your pool/spa and after that, it should only take minor, infrequent adjustments.
45. MONITOR SCG OUTPUT - Monitor the Crystal Pure SCG system over the next couple of weeks to make sure it is operating correctly.
If you have any other questions about pool and spa products please do let us know - we are here to help!