TECHNICAL GUIDE

NEX-GEN 20

NEX-GEN Troubleshooting Guide 2/10/2014 1

 Table of Contents

Using this manual 3

Event Troubleshooting 4
CURRENT ADJUSTMENT IS REQUIRED 4
pH CALIBRATED 4
SWITCH OFF IN NEX-GEN 4
CLEAN MODE 5
HEAT SINK OVERTEMP ATTEMPTING TO COOL HEAT SINK 5
LOW WATER LEVEL ATTEMPTING TO FILL TANK 5
LOW pH ATTEMPTING TO CORRCT pH 5
WAITING FOR ORP 1 SIGNAL 5
WAITING FOR ORP 2 SIGNAL 8
FAILURE BOOSTER PUMP SWITCH 11
BOOSTER PUMP FLOW FAILURE 12
CIRCULATION FLOW SWITCH FAILURE 21
CIRCULATION PUMP NO/LOW FLOW 22
FAN SWITCH FAILURE 31
FAN FLOW FAILURE 32
WAITING FOR POOL PUMP 40
VALVE 1 DID NOT RESPOND 47
VALVE 2 DID NOT RESPOND 69
VALVES 1 & 2 DID OPEN 80
INSUFFIECIENT WATER TO TANK 80
TANK FILL TIMED OUT 82
LOW SALT 83
TANK TEMP LOW 95
TANK TEMP HIGH 95
LOW LEVEL SWITCH FAILURE 95
ACID WASH SW FAILURE 96
LOW pH ALARM 99

NEX-GEN Troubleshooting Guide 2/10/2014 2

 Using This Manual

The NEX-GEN system monitors all aspects of its operation and will display information,
events, faults and alarms on an EVENT screen. This allows the operator to determine
system performance, monitor current and past conditions, and troubleshoot abnormal system
operation. This manual was designed to troubleshoot the NEX-GEN system using the
information displayed on the EVENT screen of the touch-screen. A list of EVENTS is
accompanied by a description of the EVENT and a section on troubleshooting the EVENT.

READ AND FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

WHEN TROUBLESHOOTING AND REPAIRING THIS EQUIPMENT, KEEP SAFETY
CONSIDERATIONS FOREMOST. USE PROPER TOOLS, PROTECTIVE CLOTHING,
AND EYE PROTECTION WHEN WORKING ON OR INSTALLING THE EQUIPMENT.
FOLLOW THE INSTRUCTIONS IN THIS MANUAL AND TAKE ANY ADDITIONAL
SAFETY MEASURES APPROPRIATE. BE EXTREMELY CAREFUL IN THE PRESENCE
OF HAZARDOUS SUBSTANCES AND LIVE ELECTRICAL CIRCUITS.
THE PERSONNEL RESPONSIBLE FOR TROUBLESHOOTING AND REPAIR OF THIS
EQUIPMENT MUST BE FULLY FAMILIAR WITH THE CONTENTS OF THIS MANUAL.

WARNING

 ONLY A CERTIFIED TECHNICIAN MAY INSTALL AND SERVICE THE

CHLORKING® NEX-GEN SYSTEM.
 MODIFYING THE CHLORKING® NEX-GEN SYSTEM IN ANY WAY MAY CAUSE
BODILY INJURY AND WILL VOID THE WARRANTY.
 ONLY REPLACE COMPONENTS WITH THOSE SPECIFIED BY THE
MANUFACTURER.
 ALL BOXES ON THE CHLORKING® NEX-GEN SYSTEM CONTAIN HIGH
VOLTAGE COMPONENTS.

Note: This manual is subject to change at any time based on system improvements,
design changes, authorized modifications or new information. Please consult ChlorKing
for the latest revision.

Manufacturer:
ChlorKing Inc
6767 Peachtree Industrial Blvd.
Norcross, GA 30092
1-800-536-8180

NEX-GEN Troubleshooting Guide 2/10/2014 3

 EVENT TROUBLESHOOTING

EVENTS displayed in BLACK are current EVENTS that need to be addressed or cleared.

EVENTS displayed in GREEN are cleared. GREEN events are visible only as a record of what has
happened in the past.

CURRENT ADJUSTMENT IS REQUIRED

This event must be cleared by adjusting the current level the first time the system is
operated. This event is cleared at the factory and will not normally be encountered in the
field. In the event a replacement touch screen or software update has been done, this event
may need to be cleared. Call ChlorKing at 800-536-8180 for the Current Adjustment
Procedure.

pH CALIBRATED

This event is cleared at the factory prior to delivery of equipment and not normally required in
the field. In the event that a replacement pH probe has been installed, pH calibration may be
required. Call ChlorKing at 800-536-8180 for pH Calibration Procedure.

SWITCH OFF IN NEX-GEN

This EVENT will automatically clear when the NEX-GEN is turned on. To turn the NEX-GEN
on, press and hold the on/off switch until the ON indicator is displayed.

On/Off
Indicator

On/Off
Switch

NEX-GEN Troubleshooting Guide 2/10/2014 4

CLEAN MODE

This event will be displayed any time a user has selected CLEAN CELLS from the service menu.
Once the cell cleaning process has been completed, CLEAN MODE will automatically clear. In the
event of a fault during cell cleaning, cell cleaning can be finished manually (call ChlorKing at 800-
536-8180 for instructions on operating clean mode from the test screen) or CLEAN MODE can be
manually cleared (for instructions on clearing a CLEAN MODE event, call ChlorKing at 800-536-
8180).

HEATSINK OVERTEMP ATTEMPTING TO COOL HEAT SINK

This event is displayed any time the water cooled heat-sink found inside of the control cabinet has
exceeded 170° F. If this event is displayed the heat-sink is currently above 170° F and chlorine
production will stop until the heat-sink temperature has fallen below the 170° set-point. When the
heat-sink cools to less than 170° F system operation will automatically resume and this event will
clear.

LOW WATER LEVEL ATTEMPTING TO FILL TANK

This event is displayed if the water level in the production tank falls below the salt sensor for more
than 30 seconds. If the water level recovers to a level above the salt sensor within 1 hour, the
system will resume normal operation.

LOW pH ATTEMPTING TO CORRECT pH

This event is displayed if pH drops below 6.0. The system will flush the production tank with pool
water for up to 1 hour in an attempt to bring pH above 6.0. Once pH is above 6.0 the system
operation will resume.

WAITING FOR ORP 1 SIGNAL

This EVENT will automatically clear when the NEX-GEN has received a signal from an
external source asking for chorine to be fed to a body of water. If the EVENT does not clear,
the pool 1 icon is not active and the NEX-GEN system does not start to produce chorine
when an external source is active, perform the following steps.

1. Check that 120 VAC is available at the blue power cord on the NEX-GEN control box.

If 120 VAC is available, go to the next step.

If 120 VAC is not available, check the external source for faults.

NEX-GEN Troubleshooting Guide 2/10/2014 5

 2. With a volt meter set the AC volt scale, check for 120 VAC across terminal block 1,
terminals 1 and 2.

If 120 VAC is measured, go to the next step.

If 120 VAC is not measured, repair or replace the blue cord.

Pool 1
Relay,
Terminal 8 Power
Supply
Negative
Pool 1
Relay,
Terminals
13 and 14

Terminal
Block 1,
Terminals
1 and 2

3. Check for 120 VAC across pool 1 relay terminals 13 and 14.

If 120 VAC is measured, go to the next step.

If 120 VAC is not measured, repair or replace the wires from terminal block 1,
terminals 1 and 2 to pool 1 relay terminals 13 and 14.

4. With a volt meter set on the DC scale, check for 24 VDC from power supply negative
to the blue wire on pool 1 relay, terminal 8.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured repair or replace the blue wires from the power supply
positive connection to pool relay 1, terminal 8.

NEX-GEN Troubleshooting Guide 2/10/2014 6

 5. With a volt meter set on the DC scale, check for 24 VDC from power supply negative
to the blue wire on pool 1 relay, terminal 12.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured replace pool 1 relay.

Pool I1
Relay 1,
Terminal 5

Pool 1 Power
Relay, Supply
Terminal 12 Negative

6. Check for 24 VDC from power supply negative to the blue wire on pool 1 relay,
terminal 9.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured repair or replace the blue wire from pool relay 1, terminal 9
to pool relay 1, terminal 12.

7. Check for 24 VDC from power supply negative to the white wire on pool 1 relay,
terminal 5.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured replace pool relay 1.

8. Check for 24 VDC from power supply negative to the white wire I1.

If 24 VDC is measured, replace the micro controller.

If 24 VDC is not measured repair or replace the wire from pool relay 1, terminal 5 to I1.

NEX-GEN Troubleshooting Guide 2/10/2014 7

 WAITING FOR ORP 2 SIGNAL

If the NEX-GEN is equipped to feed multiple bodies of water, this EVENT will clear when the
NEX-GEN has received a signal from an additional external source asking for an additional
body of water to be fed chlorine. If the EVENT does not clear, the pool 2 icon is not active
and the NEX-GEN system does not start to produce chorine when an external source is
active, perform the following steps.

1. Check for 120 VAC across terminal block 3, terminal 10 and terminal block 4, terminal
1.

If 120 VAC is measured, go to the next step.

If 120 VAC is not measured, troubleshoot the external source that supplies the 120
VAC.

Terminal
Block 3,
Terminal 10

Terminal
Block 4,
Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 8

 2. Check for 120 VAC across pool 2 relay, terminal 13 and terminal 14.

If 120 VAC is measured, go to the next step.

If 120 VAC is not measured, repair or replace the wires from terminal block 3, terminal
10 and terminal block 4, terminal 1 to pool 2 relay terminals 13 and 14.

Pool 2
Relay, Power
Terminal 8 Supply
Negative

Pool 2 Pool 2
Relay, Relay,
Terminal 14 Terminal 13

Pool 2
Relay,
Terminal 12

3. Check for 24 VDC from power supply negative to pool 2 relay, terminal 8.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, repair or replace the wire from power supply positive to
pool 2 relay, terminal 8.

4. Check for 24 VDC from power supply negative to pool 2 relay, terminal 12.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, replace pool 2 relay.

NEX-GEN Troubleshooting Guide 2/10/2014 9

 5. Check for 24 VDC from power supply negative to pool 2 relay, terminal 9.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, repair or replace the wire from pool 2 relay, terminal 12 to
9.
I2
Pool 2
Relay,
Terminal 5

Power
Supply
Negative

Pool 2
Relay,
Terminal 9

6. Check for 24 VDC from power supply negative to pool 2 relay, terminal 5.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, replace pool 2 relay.

7. Check for 24 VDC from power supply negative to microcontroller terminal I2.

If 24 VDC is measured, replace the micro controller.

If 24 VDC is not measured repair or replace the wire from pool 2 relay, terminal 5 to I2.

NEX-GEN Troubleshooting Guide 2/10/2014 10

FAILURE BOOSTER PUMP SWITCH

This EVENT is displayed if the booster pump is off and the booster pump flow switch indicates the
booster pump is on. When this occurs, the system will shut down and will require the EVENT to be
acknowledged and cleared before the system will resume operation. If the EVENT cannot be
cleared troubleshoot as follows.

1. Ensure that there is no flow across the venturi with the booster pump off.

If no flow is present, go to the next step.

If flow is present, correct the installation. See page 11 of the Installation Manual for
plumbing guidelines.

2. Look through the clear T and check that the flow switch blade is not up against the reed
switch.

If the blade is not against the reed switch, go to the next step.

If the blade is against the reed switch, replace the flow switch.

Clear T

Blade Reed
Switch

NEX-GEN Troubleshooting Guide 2/10/2014 11

 3. Check for 24 VDC across power supply negative and the microcontroller I3.

If 24 VDC is measured, replace the flow switch.

If 24 VDC is not measured, replace the microcontroller.

Power
Supply I3
Negative

BOOSTER PUMP FLOW FAILURE

This EVENT is displayed if the booster pump is on and the booster pump flow switch is off. When
this occurs, the system will shut down and will require the event to be acknowledged and cleared
before the system will resume operation. If the EVENT cannot be cleared troubleshoot as follows.

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST to
pull up the test screen. Select and press the BOOSTER PUMP button.

If the booster pump starts, go to Troubleshoot Booster Pump Flow Failure –

Booster Pump is Running.

If the booster pump does not start, go to Troubleshoot Booster Pump Flow Failure –
Booster Pump is Not Running
.

NEX-GEN Troubleshooting Guide 2/10/2014 12

Troubleshoot Booster Pump Flow Failure – Booster Pump is Running

1. Ensure that there is adequate water available to the booster pump and no restrictions
back to the return line.

If there are no restrictions, go to the next step.

If restrictions are present correct them.

2. Look through the clear T and check that the flow switch blade is pressed up against the
reed switch.

If the blade is pressed against the reed switch, go to the next step.

If the blade is not pressed up against the reed switch, replace the booster pump.

Clear T

Blade Reed
Switch

NEX-GEN Troubleshooting Guide 2/10/2014 13

 3. Check for 24 VDC across power supply negative and the blue wire at terminal block 2,
terminal 1.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, repair or replace the blue wire between power supply positive
and terminal block 2, terminal 1.

4. Check for 24 VDC across power supply negative and the white wire at terminal block 2,
terminal 2.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, replace the flow switch.

5. Check for 24 VDC across power supply negative and the white wire at microcontroller I3.

If 24 VDC is measured, replace the microcontroller.

If 24 VDC is not measured, repair or replace the white wire from terminal block 2, terminal
2 to microcontroller I3.
I3

Power
Supply
Negative
Terminal
Block 2,
Terminal 1

Terminal
Block 2,
Terminal 2

NEX-GEN Troubleshooting Guide 2/10/2014 14

Troubleshoot Booster Pump Flow Failure – Booster Pump is Not Running

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST
to pull up the test screen. Select and press the BOOSTER PUMP button. The
booster pump output will be energized for 40 minutes in order to troubleshoot the
circuit.

2. Check the state of the booster pump circuit breaker.

If the breaker is not tripped, go to the next step.

If the breaker is tripped, reset the circuit breaker.

3. Check for 208/240 VAC across the power supply L connection and the booster
pump contactor coil red wire.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the red wire from the incoming
terminal block to the booster pump contactor coil.

Power
Supply L
Connection

Booster
Pump
Circuit
Breaker

Booster Pump
Contactor Coil
Red Wire

Incoming
Terminal
Block Red
NEX-GEN Troubleshooting Guide Wire
2/10/2014 15
 4. Check for 208/240 VAC across the microcontroller output C and the booster pump
contactor coil red wire.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the black jumper wires from power
supply L and microcontroller output C connections.

Microcontroller
Output C

Booster Pump
Contactor Coil
Red Wire

NEX-GEN Troubleshooting Guide 2/10/2014 16

 5. Check for 208/240 VAC across the microcontroller output 8 (08) and the booster
pump contactor coil red wire. Be sure the booster pump is still energized from step
1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the microcontroller.

Microcontroller
Output 08

Booster Pump
Contactor Coil
Red Wire

NEX-GEN Troubleshooting Guide 2/10/2014 17

 6. Check for 208/240 VAC across the booster pump contactor coil black wire and the
booster pump contactor coil red wire. Be sure the booster pump is still energized
from step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the wire from the microcontroller
output 8 (08) and the booster pump contactor coil black wire.

Booster Pump
Contactor
Input Black Booster Pump
Wire Contactor
Input Red
Wire

Booster Pump
Booster Pump Contactor Coil
Contactor Coil Red Wire
Black Wire

7. Check for 208/240 VAC across the booster pump contactor input black wire and
the booster pump contactor input red wire. Be sure the booster pump is still
energized from step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the circuit breaker.

NEX-GEN Troubleshooting Guide 2/10/2014 18

 8. Check for 208/240 VAC across the booster pump contactor output black wire and
the booster pump contactor output red wire. Be sure the booster pump is still
energized from step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the contactor.

Booster Pump
Contactor
Booster Pump Output Red
Contactor Wire
Output Black
Wire

NEX-GEN Troubleshooting Guide 2/10/2014 19

 9. Check for 208/240 VAC across terminal block 6, terminals 9 and 10. Be sure the
booster pump is still energized from step 1.

If 208/240 VAC is present, repair or replace the booster pump.

If 208/240 VAC is not present, repair or replace the wiring between the contactor
and terminal block 6, terminals 9 and 10.

Terminal Terminal
Block 6, Block 6,
Terminal Terminal 10
9

NEX-GEN Troubleshooting Guide 2/10/2014 20

CIRCULATION FLOW SWITCH FAILURE

This EVENT is displayed if the circulation pump is off and the circulation pump flow switch indicates
the circulation pump is on. When this occurs, the system will shut down and will require the EVENT
to be acknowledged and cleared before the system will resume operation. If the EVENT cannot be
cleared troubleshoot as follows.

1. Look through the clear T and check that the flow switch blade is not up against the reed
switch.

If the blade is not against the reed switch, go to the next step.

If the blade is against the reed switch, replace the flow switch.

Clear T

Blade

Reed
Switch

NEX-GEN Troubleshooting Guide 2/10/2014 21

 2. Check for 24 VDC across power supply negative and the microcontroller I4.

If 24 VDC is measured, replace the flow switch.

If 24 VDC is not measured, replace the microcontroller.

Power
Supply I4
Negative

CIRCULATION PUMP NO/LOW FLOW

This event is displayed if the circulation pump is on and the circulation pump flow switch is off.
When this occurs, the system will shut down and will require the event to be acknowledged and
cleared before the system will resume operation. If the EVENT cannot be cleared troubleshoot as
follows.

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST to
pull up the test screen. Select and press the CIRCULATION PUMP button.

If the circulation pump starts, go to Troubleshoot Circulation Pump Flow Failure –

Circulation Pump is Running.

If the circulation pump does not start, go to Troubleshoot Circulation Pump Flow Failure –
Circulation Pump is Not Running

NEX-GEN Troubleshooting Guide 2/10/2014 22

Troubleshoot Circulation Pump Flow Failure – Circulation Pump is Running

1. Ensure that there is adequate water in the production tank and that water is available to
the circulation pump and no restrictions from valve 7 and 8 are present.

If there are no restrictions and the production tank is full of water, go to the next step.

If restrictions are present or no water is present, correct these conditions.

2. Look through the clear T and check that the flow switch blade is pressed up against the
reed switch.

If the blade is pressed against the reed switch, go to the next step.

If the blade is not pressed up against the reed switch, replace the circulation pump.

Clear T

Blade

Reed
Switch

NEX-GEN Troubleshooting Guide 2/10/2014 23

 3. Check for 24 VDC across power supply negative and the blue wire at terminal block 2,
terminal 3.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, repair or replace the blue wire between power supply positive
and terminal block 2, terminal 3.

4. Check for 24 VDC across power supply negative and the white wire at terminal block 2,
terminal 4.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, replace the flow switch.

5. Check for 24 VDC across power supply negative and the white wire at microcontroller I4.

If 24 VDC is measured, replace the microcontroller.

If 24 VDC is not measured, repair or replace the white wire from terminal block 2, terminal
4 to microcontroller I4.

Power
Supply
Negative

Blue Wire
Terminal
Block 2,
Terminal 3

NEX-GEN Troubleshooting Guide 2/10/2014 24

Troubleshoot Circulation Pump Flow Failure – Circulation Pump is Not Running

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST
to pull up the test screen. Select and press the CIRCULATION PUMP button. The
circulation pump output will be energized for 1 minute in order to troubleshoot the
circuit. Restart the circulation pump for each test if necessary.

2. Check the state of the circulation pump circuit breaker.

If the breaker is not tripped, go to the next step.

If the breaker is tripped, reset the circuit breaker.

3. Check for 208/240 VAC across the power supply L connection and the circulation
pump contactor coil red wire.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the red wire from the incoming
terminal block to the circulation pump contactor coil.

Power
Supply L
Connection

Circulation
Pump Circuit
Breaker

Circulation
Pump
Contactor Coil
Red Wire

Incoming
Terminal
Block Red
NEX-GEN Troubleshooting Guide 2/10/2014
Wire 25
 4. Check for 208/240 VAC across the microcontroller output 6 (06) and the circulation
pump contactor coil red wire.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the black jumper wires from power
supply L and microcontroller output 6 (O6) connections.

Microcontroller
Output 6 (O6)

Circulation Pump
Contactor Coil
Red Wire

NEX-GEN Troubleshooting Guide 2/10/2014 26

 5. Check for 208/240 VAC across the microcontroller output (O6) and the circulation
pump contactor coil red wire. Be sure the circulation pump is still energized from
step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the microcontroller.

Microcontroller
Output 6 (O6)

Circulation Pump
Contactor Coil Red
Wire

NEX-GEN Troubleshooting Guide 2/10/2014 27

 6. Check for 208/240 VAC across the circulation pump contactor coil black wire and
the circulation pump contactor coil red wire. Be sure the circulation pump is still
energized from step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the wire from the microcontroller
output 6 (O6) and the circulation pump contactor coil black wire.

Circulation
Pump
Contactor Input Circulation
Black Wire Pump
Contactor Input
Red Wire

Circulation Pump Circulation

Contactor Coil Pump Contactor
Black Wire Coil Red Wire

7. Check for 208/240 VAC across the circulation pump contactor input black wire and
the circulation pump contactor input red wire. Be sure the circulation pump is still
energized from step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the circuit breaker.

NEX-GEN Troubleshooting Guide 2/10/2014 28

 8. Check for 208/240 VAC across the circulation pump contactor output black wire
and the circulation pump contactor output red wire. Be sure the circulation pump is
still energized from step 1.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the contactor.

Circulation
Pump Contactor
Circulation Output Red
Pump Contactor Wire
Output Black
Wire

NEX-GEN Troubleshooting Guide 2/10/2014 29

 9. Check for 208/240 VAC across terminal block 6, terminals 7 and 8. Be sure the
circulation pump is still energized from step 1.

If 208/240 VAC is present, repair or replace the circulation pump.

If 208/240 VAC is not present, repair or replace the wiring between the contactor
and terminal block 6, terminals 7 and 8.

Terminal Terminal
Block 6, Block 6,
Terminal Terminal 8
7

NEX-GEN Troubleshooting Guide 2/10/2014 30

FAN SWITCH FAILURE

This EVENT is displayed if the fan flow switch is indicating a fan that is on when the fan is off.
When this occurs, the system will shut down and will require the EVENT to be acknowledged and
cleared before the system will resume operation. If the EVENT cannot be cleared troubleshoot as
follows.

1. Look through the clear Y and check that the fan flow switch blade is in the down position
and that the reed switch is not making contact.

If the blade is in the down position with no reed switch contact, go to the next step.

If the blade is in the up position with reed switch contact, replace the fan flow switch.

Switch in
Down
Position

Reed
Switch No
Contact

Reed
Switch
Contact

Switch in
Up
Position

NEX-GEN Troubleshooting Guide 2/10/2014 31

 2. Check for 24 VDC from the power supply negative connection to the I5 connection
on the microcontroller.

If 24 VDC is measured, replace the fan flow switch.

If 24 VDC is not measured, replace the microcontroller.

I5

Power
Supply
Negative

FAN FLOW FAILURE

This EVENT is displayed if the fan should be on and fan flow switch is off. When this occurs, the
system will shut down and will require the EVENT to be acknowledged and cleared before the
system will resume operation. If the EVENT cannot be cleared troubleshoot as follows.

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST
then NEXT to pull up the test screen for the fan motor. Select and press the FAN
MOTOR button.

If the fan motor starts, go to Troubleshoot Fan Flow Failure – Fan is Running.

If the fan does not start, go to Troubleshoot Fan Flow Failure – Fan is Not Running

NEX-GEN Troubleshooting Guide 2/10/2014 32

Troubleshoot Fan Flow Failure – Fan is Running

1. Look through the clear Y and check that the fan flow switch blade is in the up position and
that the reed switch is making contact.

If the blade is in the up position with the reed switch making contact, go to the next step.

If the blade is in the down position with no reed switch contact, replace the fan flow
switch.

Switch in
Down
Position

Reed
Switch No
Contact

Reed
Switch
Contact

Switch in
Up
Position

NEX-GEN Troubleshooting Guide 2/10/2014 33

 2. Check for 24 VDC from the power supply negative connection to the blue wire on
terminal block 2, terminal 5.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, repair or replace the blue wire from power supply positive to
terminal block 2, terminal 5.

3. Check for 24 VDC from the power supply negative connection to the white wire on
terminal block 2, terminal 6.

If 24 VDC is measured, go to the next step.

If 24 VDC is not measured, replace the fan flow switch.

Power
Power Supply
Supply Negative
Positive

Terminal
Block 2,
Terminal 5

Terminal
Block 2,
Terminal 6

NEX-GEN Troubleshooting Guide 2/10/2014 34

 4. Check for 24 VDC from the power supply negative connection to the I5 connection
on the microcontroller.

If 24 VDC is measured, replace the microcontroller.

If 24 VDC is not measured, replace the white wire from terminal block 2, terminal 6 to
microcontroller I5.

I5

Power
Supply
Negative

Troubleshoot Fan Flow Failure – Fan is Not Running

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST
then NEXT to pull up the test screen. Select and press the FAN MOTOR button.
The fan motor output will be energized for 1 minute in order to troubleshoot the
circuit. Restart the fan motor for each test if necessary.

NEX-GEN Troubleshooting Guide 2/10/2014 35

 2. Check for 208/240 VAC across the power supply L connection and the red wire on
fan relay terminal 14.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the red wire from the incoming
terminal block to the fan relay terminal 14.

Power
Supply L
Connection

Fan Relay
Terminal 14

Incoming
Terminal
Block

NEX-GEN Troubleshooting Guide 2/10/2014 36

 3. Check for 208/240 VAC across the microcontroller connection O1 input and the red
wire on fan relay terminal 14.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the black wire from the power
supply L connection to the microcontroller O1 connection.

4. Check for 208/240 VAC across the microcontroller connection O1 output and the
red wire on fan relay terminal 14. Be sure to repeat step 1 if it has been more than
1 minute since the fan was last started.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, replace the microcontroller.

5. Check for 208/240 VAC across the fan relay terminal 13 and the red wire on fan
relay terminal 14. Be sure to repeat step 1 if it has been more than 1 minute since
the fan was last started.

If 208/240 VAC is present, go to the next step.

If 208/240 VAC is not present, repair or replace the black wire from the
microcontroller O1 output to the fan relay terminal 13.

O1 Input

O1 Output

Fan Relay Fan Relay

Terminal 14 Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 37

 6. Check for 24 VDC across the power supply negative connection and the blue wire
on bottom of the fan fuse.

If 24 VDC is present, go to the next step.

If 24 VDC is not present, repair or replace the blue wire from the power supply
positive to the bottom of the fan fuse.

7. Check for 24 VDC across the fan relay terminal 12 and the blue wire on the bottom
of the fan fuse.

If 24 VDC is present, go to the next step.

If 24 VDC is not present, repair or replace the white wire from the power supply
negative connection to the fan relay terminal 12.

8. Check for 24 VDC across the fan relay terminal 12 and the blue wire at the top of
the fan fuse.

If 24 VDC is present, go to the next step.

If 24 VDC is not present, replace the fan fuse.

Power
Supply
Negative

Blue Wire
Top of Fan Fan Relay
Fuse Terminal 12

Fan Fuse

NEX-GEN Troubleshooting Guide 2/10/2014 38

 9. Check for 24 VDC across the fan relay terminal 12 and the blue wire at the fan
relay terminal 9.

If 24 VDC is present, go to the next step.

If 24 VDC is not present, repair or replace the wire between the fan fuse and the
fan relay terminal 9.

10. Check for 24 VDC across the fan relay terminal 5 and 8. Be sure to repeat step 1 if
it has been more than 1 minute since the fan was last started.

If 24 VDC is present, replace the fan.

If 24 VDC is not present, replace the fan relay.

Blue Wire
Fan Relay
Terminal 9
Fan Relay
Terminal 12

Fan Relay Fan Relay

Terminal 5 Terminal 8

NEX-GEN Troubleshooting Guide 2/10/2014 39

WAITING FOR POOL PUMP

This EVENT is displayed if the pool circulation system is not circulating water. Once the pool
circulation system is restarted the system will resume normal operation and the EVENT will clear. If
the EVENT will not clear troubleshoot as follows.

1. Check that the pool circulation system is operating.

If the pool circulation system is operating go to the next step.

If the pool circulation system is not operating, correct that condition.

2. Check that the pressure switch is connected to the pool circulation system and any
isolation valves used during installation are open. Check that water pressure is
available at the Pressure Switch Connection.

If water pressure is available, go to the next step.

If water pressure is not available, correct that condition.

Pressure
Switch
Connection

3. Turn the power to the system off. Pull the safety boot back from the pressure switch.
Check for continuity across the 2 electrical connections on the pressure switch with
the pool circulation system operating. Continuity should be present.

If continuity is present, go to the next step.

If continuity is not present, replace the pressure switch.

NEX-GEN Troubleshooting Guide 2/10/2014 40

 4. Connect a voltmeter set on a DC scale capable of reading 24 VDC to the power
supply negative terminal and I6.

If 24 VDC is available replace the micro controller.

If 24 VDC is not available go to the next step.

Power I6
Supply
Negative

NEX-GEN Troubleshooting Guide 2/10/2014 41

 5. Connect the voltmeter to the power supply negative terminal and the white wire on the
pressure switch.

If 24 VDC is available, repair or replace the white wire from the pressure switch to the
micro controller I6.

If 24 VDC is not available, go to the next step.

Power
Supply
Negative

Pressure
Switch
White
Wire

NEX-GEN Troubleshooting Guide 2/10/2014 42

 6. Connect the voltmeter to the power supply negative terminal and the blue wire on the
pressure switch.

If 24 VDC is available, replace the pressure switch.

If 24 VDC is not available, go to the next step.

Power
Supply
Negative

Pressure
Switch
Blue Wire

NEX-GEN Troubleshooting Guide 2/10/2014 43

 7. Connect the voltmeter to the power supply negative terminal and the blue wire on the
current/voltage sensor.

If 24 VDC is available, repair or replace the blue wire from the current/voltage sensor
to the pressure switch.

If 24 VDC is not available, go to the next step.

Power
Supply
Negative

Current/
Voltage
Sensor
Blue Wire

NEX-GEN Troubleshooting Guide 2/10/2014 44

 8. Connect the voltmeter to the power supply negative terminal and the blue wire on
terminal block 1, screw 5.

If 24 VDC is available repair or replace the blue wire from the current voltage sensor
to terminal block 1, terminal 5.

If 24 VDC is not available go to the next step.

Power
Supply
Negative

Terminal
Block 1,
Terminal 5
blue wire

NEX-GEN Troubleshooting Guide 2/10/2014 45

 9. Connect the voltmeter to the power supply negative terminal and the blue wire on pool
1 relay upper left screw.

If 24 VDC is available, repair or replace the blue wire from terminal block 1, terminal 5
to pool 1 relay upper left screw.

If 24 VDC is not available go to the next step.

Pool 1 Power
Relay Supply Power
Upper Left Positive Supply
Terminal Negative

Pool 2
Relay
Upper Left
Terminal

10. Connect the voltmeter to the power supply negative terminal and the blue wire on pool
2 relay upper left screw.

If 24 VDC is available, repair or replace the blue wire from pool 1relay to pool 2 relay.

If 24 VDC is not available go to the next step.

11. Connect the voltmeter to the power supply negative terminal and the blue wire on
power supply positive terminal.

If 24 VDC is available, repair or replace the blue wire from pool 2 relay to the power
supply.

If 24 VDC is not available replace the power supply.

If the problem is not resolved, call ChlorKing at 800-536-8180 for assistance.

NEX-GEN Troubleshooting Guide 2/10/2014 46

VALVE 1 DID NOT RESPOND

This EVENT is displayed if VALVE 1 does not respond to an open or close command but VALVE 2
has responded to its command. When this occurs the system will shut down unless VALVE 2 has
responded to an open command and will require the EVENT to be acknowledged and cleared
before the system will resume operation. If the EVENT cannot be cleared troubleshoot as follows.

1. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST
then NEXT to pull up the test screen for valve 1. This will turn the NEX-GEN off and
valve 1 should close and display a green dot next to the word CLOSED on the display.

If valve 1 closed and a green dot appeared next to the word CLOSED on the screen,
go to the next step.

If valve 1 closed but a green dot did not appear next to the word CLOSED on the
screen, go to Troubleshoot Valve 1 Did Not Respond – Feedback Circuit Close.

If valve 1 does not close, go to Troubleshoot Valve 1 Did Not Respond - Close.

Valve 1

NEX-GEN Troubleshooting Guide 2/10/2014 47

 2. From the Touch Screen on the NEX-GEN, press VALVE 1. Valve 1 should open and
a green dot should appear next to the word OPEN on the screen.

If valve 1 opened and a green dot appeared next to the word OPEN on the screen,
valve 1 is working as designed.

If valve 1 opened but a green dot did not appear next to the word OPEN on the
screen, go to Troubleshoot Valve 1 Did Not Respond – Feedback Circuit Open.

If valve 1 does not open, go to Troubleshoot Valve 1 Did Not Respond - Open.

NEX-GEN Troubleshooting Guide 2/10/2014 48

Troubleshoot Valve 1 Did Not Respond – Feedback Circuit – Open

1. With valve 1 in the open position check for 24 VDC from the power supply negative
terminal to the blue wire on terminal block 2, terminal 9.

If 24 VDC is available, go to the next step.

If 24 VDC is not available repair or replace the blue wire from power supply positive to
terminal block 2, terminal 9.

2. With valve 1 in the open position check for 24 VDC from the power supply negative
terminal to terminal block 3, terminal 1.

If 24 VDC is available, go to the next step.

If 24 VDC is not available replace valve 1.

Power
Supply
Negative

Terminal
Block 2,
Terminal 9

Terminal
Block 3,
Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 49

 3. With valve 1 in the open position check for 24 VDC from the power supply negative
terminal to microcontroller terminal I8.

If 24 VDC is available, replace the microcontroller.

If 24 VDC is not available repair or replace the white wire from terminal block 3,
terminal 1 to microcontroller terminal I8.

Power I8
Supply
Negative

Terminal
Block 2,
Terminal 9

Terminal
Block 3,
Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 50

Troubleshoot Valve 1 Did Not Respond – Feedback Circuit – Close

1. With valve 1 in the closed position check for 24 VDC from the power supply negative
terminal to the blue wire on terminal block 2, terminal 9.

If 24 VDC is available, go to the next step.

If 24 VDC is not available repair or replace the blue wire from power supply positive to
terminal block 2, terminal 9.

2. With valve 1 in the closed position check for 24 VDC from the power supply negative
terminal to terminal block 2, terminal 10.

If 24 VDC is available, go to the next step.

If 24 VDC is not available replace valve 1.

Power
Supply
Negative

Terminal
Block 2,
Terminal 9

Terminal
Block 2,
Terminal 10

NEX-GEN Troubleshooting Guide 2/10/2014 51

 3. With valve 1 in the closed position check for 24 VDC from the power supply negative
terminal to microcontroller terminal I7.

If 24 VDC is available, replace the microcontroller.

If 24 VDC is not available repair or replace the white wire from terminal block 2,
terminal 10 to microcontroller terminal I8.

Power I7
Supply
Negative

Terminal
Block 2,
Terminal 9

Terminal
Block 2,
Terminal 10

NEX-GEN Troubleshooting Guide 2/10/2014 52

 Troubleshoot Valve 1 Did Not Respond – Closed

1. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire on the incoming terminal block.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the red wire from terminal block 6,
terminal 1 to the incoming terminal block.

Black Wire
Incoming
Terminal Block

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 53

 2. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at the bottom of the valve 1 fuse.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the black wire from the top of the main
fuse to the bottom of the valve 1 fuse.

Bottom of
Valve 1
Fuse

Top of
Main
Fuse

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 54

 3. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at the top of the valve 1 fuse.

If 240 VAC is available, go to the next step.

If 240 VAC is not available replace valve 1 fuse.

Top of
Valve 1
Fuse

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 55

 4. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at valve 1 relay, terminal 9.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the wire from the top of valve 1 fuse to
valve 1 relay, terminal 9.

Valve 1
Relay
Terminal 9

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 56

 5. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at valve 1 relay, terminal 1.

If 240 VAC is available, go to the next step.

If 240 VAC is not available replace valve 1 relay.

Valve 1
Relay
Terminal 1

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 57

 6. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire on terminal block 5, terminal 2.

If 240 VAC is available, replace valve 1.

If 240 VAC is not available repair or replace the wire from valve 1 relay terminal 1 to
terminal block 5, terminal 2.

Terminal
Block 5,
Terminal 2

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 58

Troubleshoot Valve 1 Did Not Respond - Open

1. Check for 240 VAC across the red wire on valve 1 relay, terminal 14 and the black
wire on the incoming terminal block.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the red wire from valve 1 relay terminal 14
to the incoming terminal block.

Red Wire Valve

1 Relay,
Terminal 14

Black Wire
Incoming
Terminal
Block

NEX-GEN Troubleshooting Guide 2/10/2014 59

 2. Check for 240 VAC across the red wire on valve 1 relay, terminal 14 and the black
wire at microcontroller output 4 (O4) left side.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the wire from power supply terminal L to
microcontroller terminal O4.

O4

Power
Supply
Terminal L

Red Wire Valve

1 Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 60

 3. From the touch screen on the NEX-GEN press VALVE 1. Valve 1 will stay energized
in the open position for 1 minute. Check for 240 VAC across the red wire on valve 1
relay, terminal 14 and the black wire at microcontroller output 4 (O4) right side.

If 240 VAC is available, go to the next step.

If 240 VAC is not available replace the microcontroller.

O4

Red Wire Valve

1 Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 61

 4. Be sure valve 1 is still energized in the open position for this test. Check for 240 VAC
across the red wire on valve 1 relay, terminal 14 and the black wire at valve 1 relay,
terminal 13.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the black wire from microcontroller
terminal O4 to valve 1 relay, terminal 13.

O4

Valve 1 Relay,
Terminal 13 Red Wire Valve
1 Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 62

 5. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire on the incoming terminal block.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the red wire from terminal block 6,
terminal 1 to the incoming terminal block.

Black Wire
Incoming
Terminal Block

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 63

 6. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at the bottom of the valve 1 fuse.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the black wire from the top of the main
fuse to the bottom of the valve 1 fuse.

Bottom of
Valve 1
Fuse

Top of
Main
Fuse

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 64

 7. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at the top of the valve 1 fuse.

If 240 VAC is available, go to the next step.

If 240 VAC is not available replace valve 1 fuse.

Top of
Valve 1
Fuse

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 65

 8. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire at valve 1 relay, terminal 9.

If 240 VAC is available, go to the next step.

If 240 VAC is not available repair or replace the wire from the top of valve 1 fuse to
valve 1 relay, terminal 9.

Valve 1
Relay
Terminal 9

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 66

 9. Be sure the output for valve 1 is energized as outlined in step 3. Check for 240 VAC
across the red wire on terminal block 6, terminal 1 and the black wire at valve 1 relay,
terminal 5.

If 240 VAC is available, go to the next step.

If 240 VAC is not available replace valve 1 relay.

Valve 1
Relay
Terminal 5

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 67

 10. Check for 240 VAC across the red wire on terminal block 6, terminal 1 and the black
wire on terminal block 5, terminal 1.

If 240 VAC is available, replace valve 1.

If 240 VAC is not available repair or replace the wire from valve 1 relay terminal 5 to
terminal block 5, terminal 1.

Terminal
Block 5,
Terminal 2

Red Wire
Terminal Bock
6, Terminal 1

NEX-GEN Troubleshooting Guide 2/10/2014 68

VALVE 2 DID NOT RESPOND

The opening or closing of valve 2 is controlled by an external device; however the valve is
monitored by the NEX-GEN. This EVENT is displayed if VALVE 2 does not respond to an open or
close command but VALVE 1 has responded to its command. When this occurs the system will
shut down unless VALVE 1 has responded to an open command and will require the EVENT to be
acknowledged and cleared before the system will resume operation. If the EVENT cannot be
cleared troubleshoot as follows.

1. Confirm that the external devise is calling for pool 2 to feed. From the Touch Screen
on the NEX-GEN, select MENU then SERVICE then TEST then NEXT to pull up the
test screen for valve 2. This will turn the NEX-GEN off and valve 2 should close and
display a green dot next to the word CLOSED on the display.

If valve 2 closed and a green dot appeared next to the word CLOSED on the screen,
go to the next step.

If valve 2 closed but a green dot did not appear next to the word CLOSED on the
screen, go to Troubleshoot Valve 2 Did Not Respond – Feedback Circuit Close.

If valve 2 does not close, troubleshoot the external control device for valve 2.

2. Confirm that the external devise is calling for pool 2 to feed. From the Touch Screen
on the NEX-GEN, press VALVE 2. Valve 2 should open and a green dot should
appear next to the word OPEN on the screen.

If valve 2 opened and a green dot appeared next to the word OPEN on the screen,
valve 2 is working as designed.

If valve 2 opened but a green dot did not appear next to the word OPEN on the
screen, go to Troubleshoot Valve 2 Did Not Respond – Feedback Circuit Open.

If valve 2 does not open, go to Troubleshoot Valve 2 Did Not Respond - Open.

NEX-GEN Troubleshooting Guide 2/10/2014 69

 Troubleshoot Valve 2 Did Not Respond – Feedback Circuit – Open

1. With valve 2 in the open position check for 24 VDC from the power supply negative
terminal to the blue/red wire on terminal block 2, terminal 9.

If 24 VDC is available, go to the next step.

If 24 VDC is not available repair or replace the blue wire from power supply positive to
terminal block 2, terminal 9.

Power
Supply
Negative

Terminal
Block 2,
Terminal 9

NEX-GEN Troubleshooting Guide 2/10/2014 70

 2. With valve 2 in the open position check for 24 VDC from the power supply negative
terminal to the red wire on terminal block 4, terminal 4.

If 24 VDC is available, go to the next step.

If 24 VDC is not available repair or replace the red wire from terminal block 2, terminal
9 to terminal block 4, terminal 4.

Power
Supply
Negative

Terminal
Block 4,
Terminal 4

NEX-GEN Troubleshooting Guide 2/10/2014 71

 3. With valve 2 in the open position check for 24 VDC from the power supply negative
terminal to the orange wire on terminal block 4, terminal 3.

If 24 VDC is available, go to the next step.

If 24 VDC is not available troubleshoot the external control device for valve 2.

Power
Supply
Negative

Terminal
Block 4,
Terminal 3

NEX-GEN Troubleshooting Guide 2/10/2014 72

 4. With valve 2 in the open position check for 24 VDC from the power supply negative
terminal to the orange wire on terminal IA or the microcontroller.

If 24 VDC is available, replace the microcontroller.

If 24 VDC is not available repair or replace the orange wire from terminal block 4,
terminal 3 to microcontroller terminal IA.

Power
Supply IA
Negative

Terminal
Block 4,
Terminal 3

NEX-GEN Troubleshooting Guide 2/10/2014 73

 Troubleshoot Valve 2 Did Not Respond – Feedback Circuit – Closed

1. With valve 2 in the closed position check for 24 VDC from the power supply negative
terminal to the blue/red wire on terminal block 2, terminal 9.

If 24 VDC is available, go to the next step.

If 24 VDC is not available repair or replace the blue wire from power supply positive to
terminal block 2, terminal 9.

Power
Supply
Negative

Terminal
Block 2,
Terminal 9

NEX-GEN Troubleshooting Guide 2/10/2014 74

 2. With valve 2 in the closed position check for 24 VDC from the power supply negative
terminal to the red wire on terminal block 4, terminal 4.

If 24 VDC is available, go to the next step.

If 24 VDC is not available repair or replace the red wire from terminal block 2, terminal
9 to terminal block 4, terminal 4.

Power
Supply
Negative

Terminal
Block 4,
Terminal 4

NEX-GEN Troubleshooting Guide 2/10/2014 75

 3. With valve 2 in the open position check for 24 VDC from the power supply negative
terminal to the green wire on terminal block 4, terminal 2.

If 24 VDC is available, go to the next step.

If 24 VDC is not available troubleshoot the external control device for valve 2.

Power
Supply
Negative

Terminal
Block 4,
Terminal 2

NEX-GEN Troubleshooting Guide 2/10/2014 76

 4. With valve 2 in the open position check for 24 VDC from the power supply negative
terminal to the green wire on terminal I9 or the microcontroller.

If 24 VDC is available, replace the microcontroller.

If 24 VDC is not available repair or replace the orange wire from terminal block 4,
terminal 3 to microcontroller terminal IA.

Power
Supply I9
Negative

Terminal
Block 4,
Terminal 2

NEX-GEN Troubleshooting Guide 2/10/2014 77

Troubleshoot Valve 2 Did Not Respond – Open

1. Confirm that an external devise is calling for pool 2 to feed and that the EVENT
WAITING FOR ORP 2 is green.

If the EVENT WAITING FOR ORP 2 is green, go to the next step.

If the EVENT WAITING FOR ORP 2 is black, go to WAITING FOR ORP 2

troubleshooting.

2. Check for 120 VAC across Pool 2 relay terminal 14 and microcontroller terminal O5.

If 120 VAC is available, go to the next step.

If 120 VAC is not available, repair or replace the white wire from pool 2 relay, terminal
13 to microcontroller terminal O5.

O5
Pool 2
Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 78

 3. Check for 120 VAC across Pool 2 relay terminal 14 and microcontroller terminal O5
purple wire.

If 120 VAC is available, go to the next step.

If 120 VAC is not available, repair or replace the microcontroller.

O5
Pool 2
Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 79

 4. Check for 120 VAC across Pool 2 relay terminal 14 and terminal block 4, terminal 5.

If 120 VAC is available, troubleshoot the external device controlling pool 2.

If 120 VAC is not available, repair or replace the purple wire from microcontroller
terminal 5 to terminal block 4, terminal 5.

Pool 2
Relay,
Terminal 14

O5

NEX-GEN Troubleshooting Guide 2/10/2014 80

VALVES 1 & 2 DID NOT OPEN

This EVENT is displayed if VALVE 1 or VALVE 2 did not responded to an open command and both
valves are closed. When this occurs, the system will shut down and will require the EVENT to be
acknowledged and cleared before the system will resume operation. If the EVENT cannot be
cleared troubleshoot using the steps in Valve 1 Did Not Respond or Valve 2 Did Not Respond
depending on which valve is not responding.

INSUFFICIENT WATER TO TANK

This EVENT is displayed if the water level in the production tank falls below the salt sensor for more
than 30 seconds five times in 1 hour. When this occurs, the system will shut down and will require
the EVENT to be acknowledged and cleared before the system will resume operation. If the
EVENT cannot be cleared troubleshoot as follows.

1. Check Valve 3, Tank Fill Valve to make sure it is all the way open.

If Valve 3 is open, go to the next step.

If Valve 3 is not all the way open, correct this.

Valve 3

NEX-GEN Troubleshooting Guide 2/10/2014 81

 2. Check the float inside the production tank for mechanical damage or obstructions and
repair or replace the float.

TANK FILL TIMED OUT

This EVENT is displayed if the water level in the production tank is below the salt sensor for more
than 1 hour with the booster pump running. When this occurs, the system will shut down and will
require the EVENT to be acknowledged and cleared before the system will resume operation. If the
EVENT cannot be cleared troubleshoot as follows.

1. Check Valve 3, Tank Fill Valve to make sure it is all the way open.

If Valve 3 is open, go to the next step.

If Valve 3 is not all the way open, open Valve 3.

Valve 3

2. Check the float inside the production tank for mechanical damage or obstructions and
repair or replace the float.

NEX-GEN Troubleshooting Guide 2/10/2014 82

LOW SALT

This EVENT is displayed if the salt concentration in the production tank falls below 3000 PPM or if
the salt concentration set-point cannot be reached in 15 minutes. When this occurs, the system will
shut down and will require the EVENT to be acknowledged and cleared before the system will
resume operation. If the EVENT cannot be cleared troubleshoot as follows.

1. Check that the Saturated Salt Feeder is full of rock or pellet salt. Only use rock or
pellet salt in the ChlorKing Saturated Salt Feeder. Fine salt can clog the suction of the
feeder. The Saturated Salt Feeder may require cleaning at regular intervals to remove
debris introduced with the salt.

If the Saturated Salt Feeder is full of rock or pellet salt, go to the next step.

If the Saturated Salt Feeder is not full or has the wrong type of salt, add or replace salt
as necessary.

2. Check that the Saturated Salt Feeder float tank has a source of water and is
approximately ¼ full of water.

If the Saturated Salt Feeder has a source of water, go to the next step.

If the Saturated Salt Feeder has no water, correct this condition. See the NEX-GEN
Installation and Operating Manual for details on Saturated Salt Feeder installation and
operation.

3. Check that the peristaltic salt pump is plugged in, turned on, and the suction and
discharge lines are connected to the Saturated Salt Feeder and NEX-GEN.

If all of the above conditions check OK, go to the

next step.

If any of the above conditions are not OK, correct

them.

4. Check that the peristaltic pump head is not

collapsed and that the #5 hose is in good
condition. The #5 hose will require replacement at
regular intervals.

If the above items check OK, go to the next step.

If the above items are not OK, correct them.

Information on servicing Stenner peristaltic pumps Salt Pump

NEX-GEN Troubleshooting Guide 2/10/2014 83

 can be found in the Stenner Pump Installation and Maintenance Manual.
5. From the Touch Screen on the NEX-GEN, select MENU then SERVICE then TEST to
pull up the test screen. Select and press the SALT PUMP button. The salt pump will
operate for 1 minute.

If the salt pump runs, replace all salt pump tubing and the injection check valve.

I the salt pump does not run, go to the next step.

6. Unplug the salt pump from the electrical plug and check for 208/240 VAC at the plug.
Be sure to restart the salt pump outlined in step 5 if it has been more than 1 minute
since it was last started.

If 208/2040 VAC is available at the plug, replace the salt pump.

If 208/240 is not available, go to the next step.

NEX-GEN Troubleshooting Guide 2/10/2014 84

 7. Check for 208/240 VAC from the black wire on the incoming terminal block to the red
wire on salt relay, terminal 14.

If 208/240 is available, go to the next step.

If 208/240 is not available, repair or replace the red wire from the incoming terminal
block to the salt relay, terminal 14.

Red Wire Salt

Relay,
Terminal 14

Black Wire Incoming

Terminal Block
NEX-GEN Troubleshooting Guide 2/10/2014 85
 8. Check for 208/240 VAC from the black wire at output 2, left side connection to the red
wire on salt relay, terminal 14.

If 208/240 is available, go to the next step.

If 208/240 is not available, repair or replace the wire from the power supply L terminal
to output 2, left side connection.

Black Wire
Output 2, left
Power side connection
Supply
Terminal L

Red Wire Salt

Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 86

 9. Check for 208/240 VAC from the black wire at output 2, right side connection to the
red wire on salt relay, terminal 14. Be sure to restart the salt pump outlined in step 5 if
it has been more than 1 minute since it was last started.

If 208/240 is available, go to the next step.

If 208/240 is not available, output 2 of the microcontroller is bad. Replace the

microcontroller.

Black Wire
Output 2, right
side connection

Red Wire Salt

Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 87

 10. Check for 208/240 VAC from the black wire at the salt relay, terminal 13 to the red
wire on salt relay, terminal 14. Be sure to restart the salt pump outlined in step 5 if it
has been more than 1 minute since it was last started.

If 208/240 is available, go to the next step.

If 208/240 is not available, repair or replace the wire from output 2, right side
connection to the salt relay, terminal 13.

Black Wire Salt

Relay,
Terminal 13

Red Wire Salt

Relay,
Terminal 14

NEX-GEN Troubleshooting Guide 2/10/2014 88

 11. Check for 208/240 VAC from the black wire at the incoming terminal block to the red
wire on terminal block 6, terminal 3.

If 208/240 is available, go to the next step.

If 208/240 is not available, repair or replace the wire from terminal block 6, terminal 3
to the red wire on the incoming terminal block.

Black Wire Red Wire

Incoming Terminal Block
Terminal Block 6, Terminal 3
NEX-GEN Troubleshooting Guide 2/10/2014 89
 12. Check for 208/240 VAC from the black wire at the bottom of the salt fuse to the red
wire on terminal block 6, terminal 3.

If 208/240 is available, go to the next step.

If 208/240 is not available, repair or replace the wire from the incoming terminal block
to the bottom of the salt fuse.

Black Wire
Bottom of Salt
Fuse

Black Wire
Incoming
Terminal Block

Red Wire
Terminal Block
6, Terminal 3
NEX-GEN Troubleshooting Guide 2/10/2014 90
 13. Check for 208/240 VAC from the black wire at the top of the salt fuse to the red wire
on terminal block 6, terminal 3.

If 208/240 is available, go to the next step.

If 208/240 is not available, replace the salt fuse.

Black Wire
Top of Salt
Fuse

Red Wire
Terminal Block
6, Terminal 3

NEX-GEN Troubleshooting Guide 2/10/2014 91

 14. Check for 208/240 VAC from the black wire at terminal 9 on the salt relay to the red
wire on terminal block 6, terminal 3.

If 208/240 is available, go to the next step.

If 208/240 is not available, repair or replace the wire from the top of the salt fuse to the
terminal 9 on the salt relay.

Terminal 9
Salt Relay

Red Wire
Terminal Block
6, Terminal 3
NEX-GEN Troubleshooting Guide 2/10/2014 92
 15. Check for 208/240 VAC from the black wire at terminal 5 on the salt relay to the red
wire on terminal block 6, terminal 3. Be sure to restart the salt pump outlined in step 5
if it has been more than 1 minute since it was last started.

If 208/240 is available, go to the next step.

If 208/240 is not available, replace the salt relay.

Terminal 5
Salt Relay

Red Wire
Terminal Block
6, Terminal 3
NEX-GEN Troubleshooting Guide 2/10/2014 93
 16. Check for 208/240 VAC from the black wire at terminal block 6, terminal 2 to the red
wire on terminal block 6, terminal 3. Be sure to restart the salt pump outlined in step 5
if it has been more than 1 minute since it was last started.

If 208/240 is available, the problem has been resolved.

If 208/240 is not available, repair or replace the wire from the salt relay terminal 5 to
terminal block 6, terminal 2.

Red Wire
Black Wire Terminal Block
Terminal Block 6, Terminal 3
6, Terminal 2

NEX-GEN Troubleshooting Guide 2/10/2014 94

TANK TEMP LOW

This EVENT is displayed if the water temperature in the production tank is below 40° F or if the
water temperature is between 40° F and 59° F and the system has operated for 1 hour in attempt to
raise the water temperature. The NEX-GEN system is not designed to operate in temperatures
below 59° F. When this occurs, the system will shut down and will require the EVENT to be
acknowledged and cleared before the system will resume operation.

TANK TEMP HIGH

This EVENT is displayed if the water temperature in the production tank is above 110° F. The
system will shut down and attempt to cool the water for 1 hour to a temperature below 110° F.
Once the water has cooled to a temperature below 110° F, the system will automatically restart. In
the event that the water does not cool to a temperature below 110° F in 1 hour, the system will shut
down and will require the EVENT to be acknowledged and cleared before the system will resume
operation.

LOW LEVEL SWITCH LEVEL FAILURE

This EVENT is displayed if the salt sensor indicates the production tank is full and the low level
switch indicates the production tank is empty. When this occurs, the system will shut down and will
require the EVENT to be acknowledged and cleared before the system will resume operation. If the
EVENT cannot be cleared troubleshoot as follows.

1. Check for 24 VDC from the power supply negative to terminal block 1, terminal 5.

If 24 VDC is available, go to the next step.

If 24 VDC is not available, repair or replace the blue wire from power supply positive to
terminal block 1, terminal 5.

Power
Supply
Negative

Terminal
Block 1,
Terminal 5

NEX-GEN Troubleshooting Guide 2/10/2014 95

 2. Check for 24 VDC from the power supply negative to terminal block 1, terminal 4.

If 24 VDC is available, replace the low level switch.

If 24 VDC is not available, go to the next step.

Terminal Power IF
Block 1, Supply
Terminal 4 Negative

3. Check for 24 VDC from the power supply negative to microcontroller terminal IF.

If 24 VDC is not available, replace the microcontroller.

NEX-GEN Troubleshooting Guide 2/10/2014 96

ACID WASH SW FAILURE

This event is displayed if the salt sensor indicates the production tank is full and the acid wash
switch indicates the system is empty. This event will not stop system production however the cell
cleaning procedure will not function. If the EVENT cannot be cleared troubleshoot as follows.

1. Check for 24 VDC from the power supply negative to terminal block 3, terminal 7.

If 24 VDC is available, go to the next step.

If 24 VDC is not available, repair or replace the blue wire from power supply positive to
terminal block 3, terminal 7.

Power
Supply
Negative

Terminal
Block 3,
Terminal 7

NEX-GEN Troubleshooting Guide 2/10/2014 97

 2. Check for 24 VDC from the power supply negative to terminal block 3, terminal 9.

If 24 VDC is available, replace the acid wash switch.

If 24 VDC is not available, go to the next step.

Power IG
Supply
Negative

Terminal
Block 3,
Terminal 9

3. Check for 24 VDC from the power supply negative to microcontroller terminal IG.

If 24 VDC is not available, replace the microcontroller.

NEX-GEN Troubleshooting Guide 2/10/2014 98

LOW pH ALARM

This EVENT will be displayed if the system pH is below 6.0 for more than 1 hour. When this occurs,
the system will shut down and will require the EVENT to be acknowledged and cleared before the
system will resume operation. The Low pH Alarm EVENT will only become active after the system
has flushed the production tank for 1 hour under the Low pH EVENT.

1. Acknowledge and clear the event to force the system into Low pH flushing. During
flushing verify that Tank Fill Valve 3 is open, Flow Adjust Valve 4 is adjusted properly,
Actuated Feed Valve 1 is open, and the Flow Meter has fluid being drawn though it.

If the above items are verified to be correct, go to the next step.

If the above items are not correct, correct them and allow the system to flush for 1
hour.

Flow
Adjust
Valve 4

Tank Fill Flow

Valve 3 Meter

Actuated
Feed
Valve 1

NEX-GEN Troubleshooting Guide 2/10/2014 99

 2. Verify that the supply water to the NEX-GEN has a pH greater than 6.0.

If the supply water has a pH greater than 6.0, replace the pH probe.

If the supply water has a pH less than 6.0, correct the water supply.

NEX-GEN Troubleshooting Guide 2/10/2014 100