ZODIAC DuoClear installation Guide

Installation and Operator’s Manual

Complete Inground Pool Sanitizing System

To the Builder: LEAVE THIS MANUAL WITH POOL OWNER
To the Pool Owner: SAVE THIS MANUAL

SAFETY INSTRUCTIONS

Keep these instructions in a handy location

Please take a moment to read through the entire manual before installing the new chlorinator. The
chlorinator must be installed and operated as specified.

IMPORTANT SAFETY INSTRUCTIONS.
READ AND FOLLOW ALL INSTRUCTIONS.
SAVE ALL INSTRUCTIONS.

ELECTRICAL HAZARD

•To reduce risk of electrical shock

-Make sure all power to pool equipment area is off prior to any installation or removal of DuoClear
system components.

- Replace damaged power pack cord immediately.

- Do not bury cord. Locate cord to minimize abuse from lawn mowers, hedge trimmers and other
equipment.

•Severe shock or injury will likely occur as a result of a drill or drill cord coming in contact with water.
Never allow electric drill or cord to come in contact with water. Only plug drill into a Class A (5
Milliampere Trip) protected Ground Fault Circuit Interrupter (GFCI) in accordance with the National
Electrical Code Section 680 (USA only). Please see your drill owner’s manual for further safety
precautions.

• Install the power pack at least 10 feet from the inside walls of a pool to prevent any possibility of the
unit coming in contact with water.

•Your DuoClear system has been designed with an electronic flow sensor. This device automatically
switches the chlorinator ‘OFF’ when the water through the cell stops.To prevent vessel damage and
personal injury, do not in any way interfere with this system which has been designed for your protection.

CHEMICAL USE HAZARD

•To avoid personal injury when working with pool chemicals, always wear rubber gloves and eye
protection and work in a well-ventilated area. Use caution when choosing a location to open and use
chemicals as they may damage any surface in which they come in contact.

• The addition of certain chemicals can reduce the effectiveness of chlorine. Always make sure that proper
residual chlorine levels are maintained to avoid personal injury.

• This product manufactures chlorine. Individuals with any type of chlorine sensitivity should take the
appropriate precautions to avoid injury or illness.

WARNING

Failure to heed the following warnings can result in
permanent injury, electrocution or drowning.

!

SAFETY INSTRUCTIONS

• Chlorinator must be installed and operated as specified.

• Scratching or bending plates in vessel housing can reduce vessel life.

•Power to the DuoClear system should be turned off before unplugging the vessel connectors to prevent
cell damage and low voltage sparks.

•Keep the electrode terminals protected with a light coating of silicone grease to allow for a positive
electric connection. Use of any other type of grease may damage the terminal seals and ‘o’ rings. Do not
immerse these terminals in acid wash solution, and avoid accidental contact with salt water.

•Water above the temperature of 104 degrees F (40 degrees C) flowing through the vessel can cause
plastic vessel to discolor.

•Power pack must not be installed directly above any other heat source such as filter, pump or heater. It
must be at least 1.0 Ft. (300 mm) from the ground to allow free circulation of air around it. It must not
be installed in a closed box. If the power pack is to be installed on a post, then it must be centrally
positioned on a flat panel of suitable waterproof material at least 10 inches (240mm) wide and 18 inches
(440mm) high.

• Check the cell frequently to prevent the accumulation of pool debris that for any reason may have by­passed the pool filter.

CAUTION

Failure to heed the following warnings could cause
damage to pool equipment or personal injury.

!

EQUIPMENT WATER PRESSURE HAZARD

•Always turn pump off prior to installing or removing any DuoClear system. Your pump/filter system is
operated under pressure and the pressure must be released before you begin work. Please see your
pump/filter owner’s manual for further instructions.

•To avoid vessel damage, water pressure in the vessel must not exceed 45 psi.

PREVENT CHILD INJURY AND DROWNING

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

• Do not let anyone, especially small children, sit, step, lean, or climb on any equipment installed as part of
your pool’s operational system. Unless otherwise stated,ALL components of your pool's operational
system should be located at least 3 feet from the pool so children cannot use the equipment to gain
access and be injured or drown.

Renowned worldwide for the quality and reliability of its
products in the aeronautical and marine sectors, Zodiac has
now brought its expertise to swimming pools, to bring you a
full range of pools, automatic pool cleaners and water
treatment systems.

Backed by Nature

2

®

and Clearwater®technology, expertise
and experience, Zodiac brings you the reassurance of top
quality equipment in terms of both design and
performance.

A real guarantee of efficiency and peace of mind!

MASTERING THE ELEMENTS

Dear Pool Owner,

Congratulations on purchasing a Zodiac DuoClear™Complete Inground Pool
Sanitizing System. DuoClear will help you and your family to benefit from greater
enjoyment of your pool.

There are two major advantages in owning a DuoClear system. First you will find
that the pool will be easier to maintain, secondly you will notice the clarity and feel
the softness of the water.

Please take the time to read through your DuoClear Owner’s Manual. It is set out
in such a way that you can see the simple steps to keep your pool in pristine
condition.

This owner’s manual will provide you with useful information on how to operate
the DuoClear system most efficiently and help you to understand more about the
maintenance of your pool. Your local pool shop can also be helpful in a more
detailed explanation in the care of your pool and assist you with any questions or
problems.

Don’t forget that your DuoClear system is backed by a comprehensive warranty.
The DuoClear warranty is an expression of the confidence that Zodiac Pool Care,
Inc. has in its products, and is your assurance of prompt and expert after-sales
service by professional technicians. If you require any additional information talk to
your pool professional, or telephone Zodiac Pool Care, Inc. at 1-888-537-6657.

Due to constant developments and improvements, specifications may change
without notice.

INDEX

1

Page

DuoClear Product Specifications ..................................................................2

DuoClear System Installation.........................................................................3

The DuoClear System.....................................................................................5

DuoClear Operation........................................................................................6

Control Panel Function Features ...................................................................7

Using the Control Panel Operating Functions.............................................9

DuoClear Maintenance ................................................................................11

Operating Hints .............................................................................................14

Salt:When & How To Add.............................................................................16

Salt Chart .......................................................................................................17

Stabilizer Chart .............................................................................................18

Some Tips On Water Chemistry..................................................................19

Tr oubleshooting .............................................................................................21

Caution............................................................................................................26

WARRANTY INFORMATION .....................................................................27

WARRANTY CARD ......................................................................................29

DUOCLEAR™PRODUCT SPECIFICATIONS

2

Salt Level: 4000 ppm

Maximum salt level: 13,000 ppm

Minimum flow rate: 12 gallons/minute

Plumbing: 2" Schedule 40 PVC

Maximum water temperature

through the cell:

104˚ F

Maximum operating pressure: 45 psi

Power requirements: 220 – 240 VAC

2 amp draw

Vessel dimensions: 8 1/4" x 3" x 3 1/4"

Power pack dimensions: 7 5/8" x 14 3/4" x 4 7/8"

Electrode warranty: 3 years limited

Power pack warranty: 3 years limited

The DuoClear system should be installed

on residential pools only.

Salt level in your Duoclear pool should

never exceed 13,000 ppm.

DUOCLEAR™SYSTEM INSTALLATION

3

The Zodiac DuoClear Inground Pool Sanitizing System must be installed by a
qualified swimming pool professional or certified electrician. If you need assistance
in finding a qualified installer, please contact our technical service department at 1­888-537-6657.

PLUMBING THE SANITIZING SYSTEM

Your DuoClear Inground Pool Sanitizing System must be plumbed level, ports down
as the last piece of pool equipment on the return line and located within 6’ of the
power pack. There are no height restrictions or requirements.

It can only be plumbed one way. The inlet and outlet are labeled. (The
inlet side is the side with the DuoClear Nature2cartridge, the outlet side is the
side with the chlorinating electrode.)

The ports in the bottom of the sanitizing system are 2" slip ports. PVC reducing
bushings may be used to reduce the port size. Any standard PVC cement may be
used. Allow adequate drying time before pressurizing the system.

DO NOT INSTALL AN ISOLATION VALVE ON THE DISCHARGE SIDE OF THE
SANITIZING SYSTEM. If a valve is required, due to a flooded plumbing situation,
use a one-way check valve. If the sanitizer is plumbed on by-pass, install the isolation
valve on the inlet side only.

The DuoClear Sanitizing System is available in three different sizes to sanitize pools
up to 45,000 gallons. Do not use multiple units in one pool.

INSTALLING THE POWER PACK

The power pack must be located a minimum of 10 feet from the inside wall of the
pool. Use the anchors provided to mount the bracket onto the wall. If the power
pack is to be mounted onto a post, a waterproof backing of at least 14" wide X 13"
high must be used. Do not enclose the power pack in any box. Do not install it
above any heat source. Hang the power pack on the bracket. If wiring to a controller,
consult the controller manual for additional instructions.

The power pack is 220-240 VAC ONLY. It wires to the load side of a pool timer or
the pump circuit of a controller so that when the pool pump comes on the

DUOCLEAR™SYSTEM INSTALLATION

4

DuoClear Inground Pool Sanitizing System comes on. The green ground wire must
be attached to the grounding screw or grounding bar.

Please insure the electrode cap is firmly pressed onto the electrode connectors.

When the pump and filtration system is running, water that has passed through the
pool filter is then passed through the DuoClear system.

By using the DuoClear System, you only need to maintain a chlorine level of 0.5 - 1.0
parts per million (PPM) to keep your pool sanitized.

IMPORTANT

To ensure your DuoClear system works at maximum efficiency, regularly check and
maintain the water chemistry of your pool.

Figure 1

THE DUOCLEAR™SYSTEM

5

HOW YOUR DUOCLEAR WORKS

In simple, non-technical terms, the chlorine, silver and copper combination destroys
bacteria and algae, and in doing this the chlorine reverts back to the dissolved salt
ion, chloride.

Every day, when your DuoClear and the filtration system are switched on, dust and
debris are trapped by the filter, and your DuoClear sanitizes the water to make it
sparkling clear.

IMPORTANT

To ensure your DuoClear system works at maximum efficiency, regularly check and
maintain the water chemistry of your pool.

Preferred Water Chemistry Readings

Ideal Salt concentration 4,000 ppm

pH 7.4 to 7.8

Chlorine stabilizer (Cyanuric acid) 40 to 80 ppm
(Up to 100ppm in tropical climates)

Total alkalinity 80 to 150 ppm

Calcium hardness 200 to 400 ppm

Free chlorine 0.5 to 1.0 ppm

DUOCLEAR™OPERATION

6

DUOCLEAR START UP PROCESS

Before starting up the DuoClear system you must add the required
amount of salt for your sized pool. (See chart on page 17).

NOTE:

We r ecommend waiting 2-4 weeks before adding salt to a newly

plastered pool.

1. Install the complete DuoClear system.

2. Follow “Start-Up” instructions in your DuoClear Cartridge Owner’s Manual.

3. Set the output level to maximum.

4. Press the “

Nature2Reset” button to activate the cartridge timer, which will

let you know when to replace the DuoClear Nature2cartridge.

5. After four days of running the system 24 hours a day or fourteen days of
running the system 6 hours a day, gradually reduce the system to maintain the
chlorine level at about 0.5 ppm.

NOTE: Minimum run time 6 hours per day.

The system has a set of four lights which indicate the life of the DuoClear Nature

2

cartridge. The “Start up” lights are 2 green and 1 yellow. Over six months the 2
green lights and yellow light gradually go out, and then a red light begins to flash.
When this red light flashes you must replace the DuoClear Nature2cartridge.

(If
the cartridge is not replaced promptly the pool will not be sanitized
properly by the chlorination alone, even at full output.)

The daily chlorine production of the DuoClear is controlled by the number of
hours the DuoClear and filtration system is ON, as well as the setting of the
chlorine output control.

CONTROL PANEL FUNCTION FEATURES

7

The “

Chlorine Output” (6) controls the amount of chlorine generated by the
electrode. Next to it are 6 indicator lights, (See power panel illustration above)
1 yellow (minimum output) and 5 green indicator lights (1). Maximum chlorine
output is achieved when all lights are on.

Activating the “Super Chlorinate” (7) function increases the chlorine output beyond
the “6 lights on” level, for the next 24 hours of active running time. This is used when
the pool needs extra sanitation after heavy rain, hot weather or heavy bather loads.
The adjacent green indicator light (2) will be on when this function is operating.

“

Add Salt” (3) indicator – green or yellow light

“No Flow” (4) indicator – red light – chlorine production stopped until proper
flow is resumed

“

ON/OFF” (8) button switches the DuoClear system ON and OFF. Operation of

the ON/OFF button will not change the pool timer settings.

The “

Nature2Reset” (9) button is used only at start-up of your new system, or
whenever the DuoClear Nature2cartridge is replaced.

6

7

8

9

1

2

3

4

5

Figure 2

CONTROL PANEL FUNCTION FEATURES

8

DuoClear is designed to require minimum operator maintenance once it is set.
The reverse polarity technology minimizes scaling of your salt water electrode.

Power to unit is controlled by your pool timer or a controller.

The chlorinator functions may only be set when the filtration system is operating.

To use the Super Chlorinate mode effectively, the full filtration system must be run
continuously for 24 hours.

BACKUP BATTERY

DuoClear is fitted with a long life rechargeable battery. If the power is removed, it
will retain the Time-Switch settings, Output power settings, Super Chlorinate
settings, and the Nature2indicator settings.

USING THE CONTROL PANEL OPERATING FUNCTIONS

9

Setting the “Chlorine Output”(1)

Chlorine production is controlled by both the number of hours your pool pump
runs and by controlling the “Chlorine Output” (1). Repeated pushing of the
“Chlorine Output” (6) button increases the chlorine production one step at a time
and the number of “Chlorine Output” indicator lights showing, until maximum is
reached (one yellow and five green lights). An extra push of the “Chlorine Output”
button resets the output to minimum – one yellow light.

NOTE: This setting does not show the actual chlorine reading in the pool. Use of a
test kit is required to confirm the Free Chlorine reading of the pool water. (Or
take a water sample to your pool shop for testing.)

During polarity reversal the yellow light flashes.The yellow (minimum output) light
will flash for a few minutes when the electrode polarity reverses (Self cleaning
function) indicating no output during this time.

“Super Chlorinate” (2)

The Super Chlorinate (2) function is used to rapidly add chlorine to the pool.
When pressed, the chlorine output settings are temporarily over-ridden and the
chlorinator is set to run for approx. 24 hours at increased chlorine production.
A green light will indicate this is functioning. To disable, press the Super Chlorinate
(7) button a second time and the light will go off. Normal output settings resume at
the conclusion of the pre-set Super Chlorinate period. (See Troubleshooting parts B
& C for details regarding when the Super Chlorinate function should be used.)

“Add Salt” (3)

The “Add Salt” light may come on at any salt level between 3000 ppm and 4000 ppm
depending on mains voltage and water temperature. This is not a fault but a
precaution to ensure the salt level is never too low. (See ”Salt:When And How To
Add”.)

NOTE: Operating the DuoClear system at reduced salt levels may shorten the life
of the cell.

USING THE CONTROL PANEL OPERATING FUNCTIONS

10

“No Flow” (4)

The “No Flow” light will come on if there is insufficient water flow in the cell,
usually caused by the pump not running or the filter needing to be cleaned. The
“Chlorine Output” function will turn off at this time. (See “Troubleshooting”.)
“Chlorine Output” indicator lights will also turn off at this time.

“DuoClear Nature2Cartridge” Indicator Lights (5)

A series of 4 lights indicate life of the DuoClear Nature2Cartridge. When the
DuoClear Nature2Cartridge is first installed and started the “Reset” (9) button
should be pressed and the Nature2Cartridge (5) will display 3 indicator lights - 2
green, 1 yellow. As the timer counts down, the 2 green lights, then the yellow light
will progressively go out to bring a red light on and flashing. This indicates the
DuoClear Nature2cartridge needs to be replaced. The DuoClear Nature

2

cartridge has a six month life.

All Lights OFF

If all the lights are OFF it indicates that the DuoClear system is turned off. Check
to see if the pool time clock is ON or OFF, or if the mains power is disconnected.

DUOCLEAR™MAINTENANCE

11

Replacing the DuoClear Cartridge

A DuoClear cartridge lasts six months under normal operating conditions and
should be replaced as soon as the DuoClear Nature2Cartridge life indicator light
turns RED and flashes.

NOTE: Always turn pump off prior to installing or
removing any DuoClear system. Your pump/filter system
is operated under pressure and pressure must be
released before you begin. Open the air relief valve on
your pool filter to release the pressure in the system.

To r eplace the cartridge:

1. Turn off the pool pump and release the

pressure in the system.

2. If appropriate, close any valves between the

filter and pool to prevent draining the pool.

3. Unscrew the cartridge retaining ring and

remove the cartridge.

4. Install the new cartridge and insure the O-ring is seated and lightly coated with

silicone lubricant.Tighten the cartridge retaining ring.

5. Press the “Nature2Reset” button (9) on the power pack so that the three

indicator lights (5) ( 2 green and 1 yellow) are on.

6. Open any valves that were closed to isolate the DuoClear vessel.

7. Restart your pool’s pump and filtration system. Check for leaks.

8. Follow the DuoClear cartridge start up procedures in the DuoClear Cartridge

Owner’s Manual.

NOTE: As the DuoClear system requires sufficient residual silver in the system to
sanitize effectively with the low chlorine levels, the pool will not be sanitized
sufficiently if the DuoClear system is operated without replacing the DuoClear
Nature2cartridge when indicated.

Figure 3

DUOCLEAR™MAINTENANCE

12

How to clean your electrode cell

Depending upon water chemistry, occasional
manual cell cleaning may be necessary.

1. Switch off the filter pump and

chlorinator, close necessary valves.

NOTE: Always turn pump off prior to installing
or removing any DuoClear system. Your
pump/filter system is operated under pressure
and pressure must be released before you begin.
Open the air relief valve on your pool filter to
release the pressure in the system.

2. Unplug the Electrode connector from

the DuoClear vessel.

3. Unscrew the Electrode retaining ring and

remove the Electrode.

4. Look down into the Electrode bundle to

see if there is scale on the plates.

NOTE:

To avoid personal injury when
working with pool chemicals, always wear
rubber gloves and eye protection and work in
a well ventilated area. Use caution when
choosing a location to open and use chemicals
as they may damage any surface into which
they come in contact.

5

.Mix cleaning solution in a suitable plastic vessel by adding one (1) part of Hydrochloric

(muriatic) acid to ten (10) parts water. Note:To avoid splash, always ADD

MURIATIC ACID TO WATER rather than water to muriatic acid. Solutions
stronger than 1:10 will damage electrode and void warranty. Submerge only

the plate of the electrode in the cleaning solution. See Figure 4. Allow the cleaning
solution to dissolve the calcium deposits for approximately 5 minutes.

During

electrode

cleaning, only

immerse this

portion of

electrode

Figure 4

DUOCLEAR™MAINTENANCE

13

6. Repeat the procedure if necessary.Take care to avoid splashing the electrode terminals

and other equipment with the acidic cleaning solution.Wash down any spills with
plenty of fresh water. To neurtralize acid cleaning solution, add baking soda (foaming
will occur).

7. Rinse the electrode in clean water and reinstall the electrode into the vessel. Insure the

O-ring is seated properly and coated lightly with silicone lubricant.

8. Replace the electrical connectors after drying and smearing lightly with silicone grease.

9. Reset valves and switches.Turn pump and chlorinator on.

10. Confirm chlorine output and settings on the power pack.

Your DuoClear system has been designed with an electronic flow sensor.This
device automatically switches the chlorinator “OFF” when water through the
cell stops.To prevent cell damage and personal injury, do not in any way
interfere with this system that has been designed for your protection.

Damage caused by insects

The case of the DuoClear power pack has small vents to allow internal
components to remain cool in hot weather. Sometimes small insects may enter the
case of the power pack, and this can cause damage to the internal electrical
components.To avoid this, spray some insect repellent on surfaces around the
power pack while the power is off.

OPERATING HINTS

14

A. Filtration and chlorination system operating periods

Run your filtration and chlorination system for at least 6 to 8 hours per day in the
swimming season.

During very hot weather it might be necessary to run the system for around 10 hours
per day, but during winter if no bathing occurs, it is only necessary to run the filtration
system for around 4 hours per day.

B. Chlorine output settings

Commence operation of the DuoClear at maximum output.Add salt to the pool if
the ‘Add Salt’ light is showing. Please see page 17 salt chart for proper salt addition.

C.Free (residual) chlorine reading

The free chlorine residual in the pool as measured by test strips, test kits or pool
shop should be around 0.5 – 1.0 ppm. Increasing the daily operating period of the
system increases the free chlorine reading, and a shorter operating period reduces
the chlorine reading.

Likewise, operating the system at maximum output will produce a higher
chlorine reading.

D. Chlorine stabilizer (Cyanuric acid) level

Make sure that the water has a satisfactory level of chlorine stabilizer (Cyanuric
acid) reading between 40 – 80 ppm. (You need to take a water sample to your pool
shop to measure this.) Chlorine stabilizer helps to keep a satisfactory free chlorine
reading in hot sunny climates.

OPERATING HINTS

15

E. pH readings

It is ABSOLUTELY ESSENTIAL that the pH of the pool be maintained in the range
of 7.4 – 7.8. Regularly test or ask your pool shop to test the pH level. The
effectiveness of chlorine as a sanitizer is significantly reduced as the pH rises. At a
pH of 8.0, most all of the chlorine being added to the pool is wasted, and it will be
almost impossible to maintain a satisfactory free chlorine reading.

F. Regular maintenance checks

WEEKLY:

•Test the free chlorine.

•Test the pH of the water. Adjust if necessary.

•Test the pressure gauge on the pool filter to see if backwashing is necessary.

MONTHLY:

•Test the salt concentration of the pool (see “Salt:When And How To Add”).

•Test the total alkalinity. Adjust if necessary.

•Test the chlorine stabilizer reading. Adjust if necessary.

• Remove any debris that may have passed through the filter and lodged in the

Electrode.Take care not to scratch or bend the Electrode (see “DuoClear
Maintenance”).

SALT:WHEN AND HOW TO ADD

16

When to add salt

Add salt when indicated on the control panel.The light marked ‘Add Salt’ functions
automatically when extra salt is needed. Note that the ‘Add Salt’ light may switch on at any salt
level between 3000 and 4000 ppm, depending upon the water temperature and mains voltage
(see note).This is not a fault but a precaution to ensure that the salt level is never too low.

The salt concentration should normally be around 4000 ppm, but should never be allowed
to fall below 3000 ppm, as this can reduce the life of the cell electrodes.

Salt is not lost through evaporation. Salt is lost with the water splashed out of the pool or
during backwash. Adding fresh water or rainfall to the pool dilutes the salt concentration.
Adding salt may be needed from time to time to maintain an optimum salt level.

NOTE: Even if the salt concentration is around 4000 ppm, the ‘Add Salt’ light may switch
ON if the water temperature drops below 65˚ or mains supply voltage is too low. In this
situation, it may not be possible to set the Chlorine Output to maximum. Addition of
more salt to the pool will allow the Chlorine Output to reach maximum settings.

How much to add

Use a salt test strip to determine the salt level in pool water prior to adding any salt.
Capture water from elbow depth in a container, then use a test strip in this water sample.
Previous regular usage of sodium hypochlorite (liquid chlorine) creates residual salt within
the pool and may bring your salt level close to the required 4000 ppm concentration. Only

99.5% pure refined, non-iodized salt (sodium chloride) should be used with the DuoClear
system. Do not use salt containing yellow prussate as it may stain the plaster finish of the
pool. Add enough salt to obtain a 4000 ppm concentration.

- In a pool of approximately 13,200 gallons, one (1) 50 lb. bag of salt will increase the
salt concentration by 500 ppm.

- In a NEW pool (where there is no salt residual) of approximately 13,200 gallons,
eight (8) 50 lb bags of salt are required to reach a 4000 ppm concentration.

- Refer to ‘Salt Chart’ on page 17.

IMPORTANT: To avoid damage to your DuoClear system, never allow
salt level to exceed 13,000 ppm.

How to add salt

Evenly disperse the proper amount of salt around the perimeter of the pool. Run filter for 4-6
hours. Allow 24 hours for salt to fully dissolve. If the ADD SALT light is on after 24 hours, test salt
level and add necessary salt to obtain at 4000 ppm concentration. Even if the salt level is maintained
at 4000 ppm, but water temperature drops below 65˚ F, the ADD SALT may come on. This is not
cause for concern. For further assistance, consult your pool professional or call 1-888-537-6657.

Note: Do not add salt to the skimmer box.

SALT CHART

17

Adding Salt to Your Pool

Pounds and (KG) of salt needed to raise lev

el to 4000 PPM

STABILIZER CHART

18

Adding Stabilizer to Your Pool

Pounds and (KG) of stabilizer (Cyanuric Acid)

needed to raise le

vel to 80 PPM

The above chart is for general reference only. The recommended stabilizer reading
is between 40-100 ppm and will vary dependent on geographic climate.Warm,
sunny climates will require a stabilizer reading at the higher end of the given range.
Consult your local pool professional for your optimum level. Always add stabilizer
according to manufacturer’s instructions.

SOME TIPS ON WATER CHEMISTRY

19

pH is very important

Do not confuse pH with total alkalinity. pH is a simple numerical scale which
expresses the acid/alkaline balance of the water. A pH value of 7.0 denotes
neutrality, i.e. neither acid nor alkaline. High pH values (i.e. above 7.0) denote
alkaline conditions. Low pH values (below 7.0) denote acidic conditions.

How to adjust pH

A pH range of 7.4 – 7.8 is ideal for maximum comfort and chlorine efficacy. Always
adjust total alkalinity before adjusting pH.

Low pH (acidic water) leads to stinging eyes and corrosion of open metal fittings. Raise the
pH by adding sodium bicarbonate or soda ash. Consult your pool professional regarding
which chemical is best for your situation and the proper amount to use. Check the pH
after 4 hours of circulation, adjusting as necessary to achieve the proper range.

High pH (alkaline water) leads to clouding of the water and reduces the amount of active
chlorine.This means algae and germs can grow. Lower the pH by adding muriatic acid to
the pool water.The acid demand indicated by your 4-in-1 test kit will show the amount of
acid to use.

If your pH remains inconsistent, check your total alkalinity.

Total alkalinity affects pH

To tal alkalinity is a measure of the alkaline chemicals in your pool water (e.g. bicarbonates,
carbonates, and hydroxides). It can be thought of as the buffering system necessary to
control pH. Low alkalinity can allow pH to fluctuate or drift rapidly in one direction. The
pH will be difficult to maintain and staining of pool surfaces may occur when total alkalinity
is too low.

Total alkalinity should be in the range of 80 – 120 ppm. Total alkalinity is often confused
with pH.They are related by distinct.

To raise total alkalinity, add pH buffer (sodium bicarbonate) at the rate shown in the
manufacturer’s instructions to achieve a reading in the 80 – 120 ppm range. 1.5 lbs. of
sodium bicarbonate raises 10,000 gallons of pool water by 10 ppm.

SOME TIPS ON WATER CHEMISTRY

20

To lower the total alkalinity, use muriatic acid. The acid demand chart in your 4-in-1 test
kit will indicate the necessary amount to add. Adjust as needed until the reading (taken at
least 24 hours later) is in the 80 – 120 ppm range. When total alkalinity is correct, you
may need to adjust pH.

Use of algaecides and phosphate removers

Algaecides may be used in conjunction with a DuoClear system but are usually not
necessary. Only use ammonia based poly-quat algaecides. Do not use copper or silver
based algeacides.

Phosphate removers may also be used in conjunction with a DuoClear system and, as with
other systems, may be helpful in high phosphate regions where algae growth can be a
problem. Phosphates enter the water from a variety of sources such as fertilizer, soaps and
run off. High phosphate levels will cause chlorine destruction. Contact your local pool
professional for phosphate testing and information regarding the presence of phosphates in
your local area. Always follow manufacturer’s instructions for treatment.

The chlorine residual level and silver and copper level automatically contributed by a
DuoClear system is the best defense against algae and is usually all that is necessary. If algae is
observed however, brush spot thoroughly, adjust pH, super-chlorinate with your DuoClear
system or manually shock pool water with either liquid or granular chlorine. A chlorine
residual should be measurable within 24 hours. If not, repeat shock treatment (see pages 21 –
22 for additional water balance instructions). After shocking, check to ensure that the
DuoClear system is maintaining a residual chlorine level to prevent future algae growth. With
extreme algae conditions, manually shocking the pool is the best option.

Note: Overuse of algaecides can lead to a reduction in chlorine residual because
algaecides can negatively react with the chlorine produced by the DuoClear system.When
using algaecides, always follow manufacturer's instructions and adjust the output of the
DuoClear system to maintain a residual chlorine level.

Use of sequestering agents

In some areas the total hardness of your source water may be unusually high. High total
hardness can contribute to scale formation in the pool. Sequestering agents will help keep
minerals in solution and under some conditions can prevent this from happening. Consult
your pool professional about the use of a sequestering agent.

TROUBLESHOOTING

21

Problem A – Water looks clean but no chlorine residual reading

To test for chlorine residual, switch on the filtration system and adjust the DuoClear

system to maximum output.After a few hours take a water sample from the pool.Test this

water with your test kit. Chlorine residual should measure between 1 and 3 ppm.

REMEDY:

• Adjust total alkalinity to 80 – 120 ppm.

• Adjust the pH within the range 7.4 – 7.8.

•Make sure your electrode is clean.

• Adjust cyanuric acid levels to 40 – 80 ppm.

• Increase the setting of the output control.

• Increase the running time of the filter and chlorinator. Make sure that the filter is
clean and functioning properly.

•Add salt if indicated by ‘Add Salt’ light.

• Manually shock pool.

Use chlorine stabilizer (cyanuric acid) to protect chlorine
residual.

This chemical acts as a sun-screen for chlorine and prevents chlorine from being too quickly
destroyed by the sun. Chlorine stabilizer is essential to prolong the life of chlorine in the
pool water. It should be added following the manufacturer’s instructions to achieve a level of
40 – 100 ppm depending on geographical climate. Refer to stabilizer chart on page 18.

TROUBLESHOOTING

22

Problem B – Pool green and no chlorine reading

Chlorine is still considered the most effective way of destroying algae and bacteria in your
pool water. A chlorine residual of 0.5 to 1.0 ppm is appropriate with the DuoClear system.
Higher chlorine levels are required to destroy an algae build-up.

REMEDY:
Superchlorinate or manually shock the pool. This will raise the chlorine residual to a very
high level for a short period of time, and reduce chlorine demand.

Manually shock with chlorine or oxidizing agents:

i) Backwash the filter.

ii) Adjust the pH to within the range 7.4 – 7.8 (See “Some Tips on Water Chemistry” on

pages 19 – 20).

iii) Add 1.0 lb. granular chlorine or 1.0 gallon liquid chlorine or 1.0 lb. non-chlorine

oxidizer per 10,000 gallons of water.

iv) After shock dosing, re-adjust the pH to within the range of 7.4 – 7.8 and check the

chlorine level before using the pool. The chlorine residual should be 1 – 3 ppm.

v) Set DuoClear to Super Chlorinate.

vi) Run the pool pump for 24 hours.

TROUBLESHOOTING

23

Problem C – Chlorine odor

CAUSE: Presence of excess chloramines.
Surprisingly, the problem here is not too much chlorine as many imagine. Chloramines
form by the bonding of chlorine with amines from sweat and other sources.These
chloramines can create a chlorine odor and can also cause eye and skin irritation. Free
chlorine does not smell (up to 10 ppm concentration).

REMEDY:
Same as problem B.

Problem D – Slimy walls of pool or spa

CAUSE: Combined algae and bacteria growth.

REMEDY:
Brush down the affected walls and follow remedy for problem B, manually shocking pool.

Problem E – Eye and/or skin irritation

CAUSE: Incorrect pH.

REMEDY:
Adjust total alkalinity, to the proper range 80 – 120 ppm. Then adjust the pH to within the range

7.4 – 7.8 (See “Some Tips on Water Chemistry” on pages 19 – 20).

Prob

lem F – Scale formation on pool equipment

To clean the deposit (scale) from the electrode plates, see DuoClear Maintenance section.

CAUSE 1: Incorrect pH and hard water.

REMEDY:
Adjust total alkalinity, to the proper range 80 – 120 ppm. Then adjust the pH to within the range

7.4 – 7.8 (See “Some Tips on Water Chemistry” on pages 19 – 20).

CAUSE 2: High total hardness or high phosphate levels.

REMEDY:
Dilute pool with fresh water. Consult your pool professional regarding use of a phosphate
remover or sequestering agent.

TROUBLESHOOTING

24

Problem G – Chlorine Output will not reach maximum - Add Salt
light may also be on

CAUSE 1: Low incoming voltage.

REMEDY:
Confirm DuoClear system is wired to a 220 – 240 VAC source. If incoming voltage is less
than 220 VAC due to location (rural areas for example), raising the salt level will compensate.

CAUSE 2: Salt level below 4000 ppm or water temperature is below 65˚ F.

REMEDY:
Add salt. (See “Salt:When and How to Add”)

CAUSE 3: Electrode is reversing polarity (self clean).

REMEDY:
If the cell is reversing, the yellow light on the Chlorine Output indicator will flash. Wait
approximately three minutes and the output should return to normal.

CAUSE 4: Electrodes may be damaged.

REMEDY:
Replace electrode.The electrode must be replaced with the same model or the
chlorinator will not function correctly. Call Zodiac Pool Care, Inc. for further instructions
(see page 27).

CAUSE 5: Electronics malfunctioning.

REMEDY:
Call Zodiac Pool Care, Inc. for further instructions.

Problem H – No Flow light on

CAUSE 1: Insufficient water flow through the cell.

REMEDY:
Ensure sufficient water flow through chlorinator cell. Verify that the filter pump is on. Flow
may be restricted if the filter needs backwashing.

CAUSE 2: Sensor disconnected. Sensor cap loose.

REMEDY:
Insure that electrode cap is tightly connected. Call Zodiac Pool Care, Inc. if problem continues.

TROUBLESHOOTING

25

Problem I – Chlorinator stops working, all lights OFF

CAUSE 1: Unit turned off.

REMEDY:
Push ON/OFF button. A yellow light in the Chlorine Output indicator window is present when
the unit is “ON”.

CAUSE 2: Mains power removed or blown fuse.

REMEDY:
Check mains power source and fuse.

CAUSE 3: Component failure within power pack.

REMEDY:
Call Zodiac Pool Care, Inc. 1-888-537-6657.

Resetting the Fuse

Turn off all power to the DuoClear power pack.The resettable fuse is located above the powercord in
the middle of the DuoClear power pack unit. If the fuse is blown (popped with white area exposed),
push to reset. Restore power to unit. If fuse continues to trip contact Zodiac Pool Care, Inc.

Mains power supply

Your DuoClear system must be connected and properly grounded to the electrical power source.

Problem J – Chlorine level is too high

CAUSE 1: Chlorinator is manufacturing too much chlorine.

REMEDY 1:
Use the output button to reduce setting. Retest chlorine daily until proper level is attained.

REMEDY 2:
Manually turn chlorinator off. The DuoClear uses a smart switch that turns the chlorinator on
automatically with each pump cycle.

REMEDY 3:
If chlorine output at lowest setting consistently provides for excessive chlorine levels, decrease
pump operation to 6 hours daily. If chlorine output at lowest setting is still excessive the
DuoClear unit is oversized for the pool.

Any type of electrical troubleshooting should be handled by a
qualified pool professional or certified electrician.

CAUTION

26

Failure to adhere to the following could invalidate your warranty and
damage pool equipment:

1. DuoClear must be installed and operated as specified.

2. Your DuoClear has been fitted with an electronic flow sensor.This device
automatically switches the chlorinator ‘OFF’ when the water through the
DuoClear housing stops. Do not in any way interfere with this system which has
been fitted for your protection.

3. Do not scratch or bend the electrode in the housing.

4. Power to the DuoClear should be turned off before unplugging the electrode
connectors.

5. Keep the electrode terminals protected with a light smear of silicone grease.
Use of other than silicone grease may damage the terminal seals and ‘O’ rings.
Do not immerse these terminals in acid wash solution, and avoid accidental
contact with salt water.

6. Water above the temperature of 104˚ F must not flow through the DuoClear
vessel.

7. Water pressure in the DuoClear vessel must not exceed 45 psi (DuoClear
Vessel Housing)

8. Check the electrode housing frequently to prevent the accumulation of pool
debris that for any reason may have by-passed the pool filter.

9. Power pack must not be installed directly above any other heat source such as
filter pump or heater. It must be at least 1 foot from the ground to allow free
circulation of air around it. It must not be enclosed in a closed box. As for all
electronic equipment the power pack life will be increased if it is mounted in a
shady spot and not in direct sunlight.

WARRANTY

27

The limited warranties contained within this document are the only warranties given with
your DuoClear system and supersede any prior warranties. All other warranties, expressed
or implied, including the implied warranty of merchantability or the implied warranty of fitness
for a particular purpose are hereby disclaimed. Our sole obligation under this warranty, and
the purchaser’s sole remedy, is limited to the repair or replacement of the DuoClear, or one
of its parts. This DuoClear Limited Warranty applies to the original owner only.

VESSEL AND ELECTRODE WARRANTY

•The manufacturer warrants this DuoClear system to be free of defects in materials and

workmanship for a period of one (1) year from the date of purchase*.

• In addition to the one (1) year warranty, the manufacturer further warrants the power

pack for an additional two (2) year period (parts only) **.

• In addition to the one (1) year warranty, the manufacturer further warrants on a pro-

rated basis the electrode (parts only)**. (In the second year the electrode will be
replaced for a payment of 33% of current list price; in the third year the cell electrode
will be replaced for a payment of 66% of the current list price.)

* If no proof of purchase date is supplied, the warranty period begins on the date of
manufacturer as encoded on the product.

** The cost of field service calls and/or freight cost to return goods for repair are not
covered by this warranty after the one (1) year unconditional period has expired.

EXCLUSIONS FROM WARRANTY

The DuoClear system is designed for residential use only and any commercial application
voids all warranty. If the unit is used in any application other than as an ingound swimming
pool sanitizing system, the purchaser and/or end-user releases the manufacturer from any
and all claims related to the use of the DuoClear system and agrees to indemnify the
manufacturer from any claims related to improper or non-authorized use.

This warranty does not cover problems arising from whole or in part from purchaser’s or
user’s negligence, misuse or abuse, improper maintenance or installation, accident, improper
application, failure to follow all safety instructions or precautions, Acts of God, abnormal
weather conditions, damage from plants or animals, and improper use of chemicals.

This warranty specifically excludes all incidental or consequential damages, except where
state law requires them to be paid. This warranty gives you specific rights. You may have
other rights that vary from state to state.

TO SUBMIT A CLAIM

Report claims to Zodiac Pool Care, Inc. by calling 1-888-537-6657. Only the original
purchaser may submit a claim under this limited warranty. All claims must be accompanied
by an original purchase receipt.

For more information consult your pool care professional or call 1-888-537-6657.

Due to constant developments and improvements, specifications may change without notice.

ZODIAC POOL CARE, INC.

2028 NW 25th Avenue

Pompano Beach, Florida 33069

1-888-537-6657

www.zodiacpoolcare.com

RECORD YOUR ZODIAC DUOCLEAR SYSTEM PURCHASE DETAILS HERE:

Model No.:

❑

DuoClear 25

❑

DuoClear 35

❑

DuoClear 45

Date of Purchase ___________________________________________________________________________________

Purchased From ____________________________________________________________________________________

City ________________________________________________________State ____________ Zip Code ____________

Warranty No:

DCL Please quote this number when you contact us.

IMPORTANT – MAIL THE WARRANTY REGISTRATION TODAY

W173301

IMPORTANT - MAIL TODAY

This certificate must be completed and returned within 14 days of date of purchase.
I certify that my Zodiac DuoClear (Model Number) ___________ was purchased on:______________________________________

Day Month Year

and that I have read and understand the terms of the Zodiac DuoClear limited warranty provided by Zodiac Pool Care, Inc.

______________________________________________________

Serial No. W Customer Signature Date

Consumer Name: ____________________________________________________________________________________________

Address:____________________________________________________________________________________________________

City: __________________________________________________________ State: ______________ Zip Code:______________

Telephone Number: H ( ____ ) __________________________________ Email: ______________________________________

W( ____ ) __________________________________ Mobile: ______________________________________

Purchased From: Name: ______________________________________________________________________________________

Address: ____________________________________________________________________________________

City: ________________________________________ State: ______________ Zip Code: ____________

Shape of Pool

❑ Rectangle ❑ Kidney ❑ Other Pool Size ______________________ My pool is ____________years old

Type of Pool ❑ Vinyl ❑ Fiberglass ❑ Plaster ❑ Paint ❑ Other ______________________________________________

ZODIAC DuoClear is ❑ my first sanitation system ❑ replaces a ______________________________________

I have an automatic pool cleaner ❑ yes ❑ No ❑ Brand/Model ____________________________________

I heard about DuoClear from ❑ Pool Supply Store ❑ Pool Builder ❑ Advertisements ❑ Friend

Complete Inground Pool Sanitizing System

First Middle Last

WARRANTY CERTIFICATE

Zodiac Pool Care, Inc.

1-888-537-6657

RETURN

TODAY

TO SECURE YOUR

LIMITED WARRANTY

Complete Inground Pool Sanitizing System

DUOCLEAR WARRANTY
ZODIAC POOL CARE INC
2028 NW 25TH AVE
POMPANO BEACH FL 33069-9906

BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 36 POMPANO BEACH, FL

POSTAGE WILL BE PAID BY ADDRESSEE

W173301