Pentair IC40 User's Manual
Contents
1. 57 kg 125 bs 48 kg 105 bs 9kg 11 kg 20 Ibs 25 Ibs 53 m3 14 000 159 kg 350 Ibs 145 kg 320 Ibs 134 kg 295 122 kg 270 Ibs 104 kg 230 Ibs 91 kg 104 kg 200 Ibs 230 Ibs 79 kg 175 lbs 68 kg 77 kg 150 Ibs 170 Ibs 2000 ppm 39 kg 45 kg 54 kg 63 kg 68 kg 77 kg 86 kg 93 kg 100 kg 109 kg 116 kg pp 85 Ibs 100 Ibs 120 Ibs 140 Ibs 150 Ibs 170 190 Ibs 205 Ibs 220 Ibs 240 Ibs 255 Ibs 54 kg 59 kg 66 kg 73 kg 76 kg 110 Ibs 120 Ib 130 Ibs 145 Ibs 160 Ibs 168 Ibs S 14 kg 30 Ibs bs b b b 60 m3 16 000 181 kg 400 Ibs 168 kg 370 Ibs 154 kg 340 Ibs 136 kg 300 Ibs 120 kg 265 Ibs 14 kg 30 Ibs 91 kg 200 Ibs Pool Size gallons 68 m3 76 m3 18 000 20 000 204 kg 450 Ibs 188 kg 415 Ibs 209 kg 460 Ibs 191 kg 420 Ibs 154 kg 340 Ibs 172 kg 380 Ibs 150 kg 330 b 132 kg 290 Ib 113 kg 250 Ib 86 kg 95 kg 190 Ibs 210 Ib b S 118 kg S S S S S 260 Ibs 102 kg 225 Ibs 50 kg 18 kg 40 Ibs 18 kg 40 Ibs NOTE Add salt as required to maintain 3000 ppm concentration IMPORTANT Add 1 25 Ib 0 57 kg of Stabilizer per 50 Ib 22 7 kg of Salt IntelliChlor Installation and User s Guide 8 m3 22 000 249 kg 550 Ibs 231 kg 510 Ibs 209 kg 460 Ibs 191 kg 420 Ibs 163 kg2. 0 50 Ibs 0 60 Ibs 0 66 Ibs 0 75 0 80 Ibs 0 90 Ibs 1 00 Ibs 1 10 Ibs 1 20 0 kg 0 kg 0 kg 0 kg 0 kg 0 0 Ibs 0 0Ibs 0 0 Ibs 0 0 Ibs 0 0 Ibs NOTE Add 1 25 Ib 0 57 kg Chlorine Stabilizer to the pool every time 50 Ib 22 7 kg of Salt is added to the pool The Stabilizer reading should be maintained at 75 PPM 5 Ibs g bs bs g bs bs bs bs 40 PPM 1 3 kg 1 6 kg 1 8 kg 2 kg 2 4 kg 2 6 kg 2 9 kg 3 1 kg 3 4 kg 3 7 kg es Ibs 2 90 Ibs 3 50 Ibs 4 00 Ibs 4 60 Ibs 5 25 Ibs 5 80 Ibs 6 40 Ibs 6 90 Ibs 7 58 Ibs 8 20 Ibs i 2 8 kg 50 PPM 1kg 1 1 kg 1 3 kg 1 5 kg 1 7 kg 1 9 kg 2kg 2 2 kg 2 4 kg 2 6 kg 6 25 Ibs 2 00 Ibs 2 50 Ibs 2 90 Ibs 3 30 Ibs 3 75 Ibs 4 10 Ibs 4 60 Ibs 4 90 Ibs 5 40 Ibs 5 80 Ibs g F bs bs g bs bs 0 kg 0 kg 0 kg 0 kg 0 kg NM 0 0 lbs 0 0lbs O0lbs 0 0Ibs 0 0 lbs IntelliChlor Installation and User s Guide 16 Pool Water Preparation Determining Pool Size m3 of Water in Your Pool e Rectangular Pools Length x width meters x average depth x 1000 e Circular Pools Diameter x diameter x average depth x 785 Oval Pools Length x width meters x average depth x 893 e Sloping Sides Multiply total m3 by 0 85 m3 capacity Determining Pool Size Gallons of Water in Your Pool e Rectangular Pools Length x width x average depth x 7 5 e Circular Pools
3. Pentair Water Pool and Spa IntelliChlor Electronic Chlorine Generator Model IC20 IC40 Installation and User s Guide LISTED OZ Patents pending CE IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS 2006 Pentair Water Pool and Spa Inc All rights reserved This document is subject to change without notice 1620 Hawkins Ave Sanford NC 27330 919 566 8000 10951 West Los Angeles Ave Moorpark CA 93021 805 553 5000 Trademarks and disclaimers IntelliChlor IntelliTouch EasyTouch and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa Inc Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products Pentair Water Pool and Spa Inc disclaims proprietary interest in marks and names of others P N 520589 Rev D 04 28 2006 Contents IntelliGMIOF OVES W ais 1 FOU ce T 1 INTSIIGMIOF model S EE 2 Electrolytic Cell Controle tise feasze EUER 3 IntelliGhlor Power Cente vv cisn szeesissvasecaecbeesineesasiien i etes saan dene ab reme ze tuba ties eeepc rd tian dca a repara DEED 3 y cBIL ult 3 Loop PlUMbING B Bio zT EIE ETE alti ehadbede eines tered ene en 4 IntelliChlor Plumbing Dia granis ises seinieni ana ea a aa a eaaa O E ERA ES 4 Section 1 IntelliChlor Cont
4. 8 A M to 5 P M Phone 800 831 7133 Fax 805 530 0194 Web sites visit www pentairpool com and www staritepool com IntelliChlor Installation and User s Guide IntelliChlor Overview The IntelliChlor salt chlorinator uses a process known as electrolysis to produce Sodium Hypochlorite liquid chlorine from a low concentration of salt added to the pool water Hypochlorite kills bacteria oxidizes organic material and kills algae then reverts back to salt IntelliChlor then reuses the salt and the process starts over again The IntelliChlor system is comprised of the Power Center and Electrolytic Cell Features e Superior design combines cell and control panel as one assembly e Cell blades are made from a titanium metal base and coated with precious metal Ruthenium oxide e Cell blades are capable of lasting in excess of 10 000 hours e The cell assembly can be installed horizontally or vertically Separate Power Center mounts to wall at equipment pad for easy AC wiring e Easily serviced e Electronics run cool for long reliable life e Cell hours meter reports current usage to determine how many hours remain e C40 model produces up to 1 40 Ibs of chlorine per day The IC20 model produces 70 Ibs per day e Salt level bar graph shows the amount of salt in pool e Red and green LED indicators show system status for power water flow and cell status e MORE and LESS output buttons control how much chlorine is pr
5. Diameter x diameter x average depth x 5 9 e Oval Pools Length x width x average depth x 6 7 e Sloping Sides Multiply total gallons by 0 85 gallon capacity caution Never use dry acid to adjust pH in arid geographic areas with excessive evaporation and minimal dilution of pool water with fresh water A buildup of byproducts can damage the electrolytic cell IntelliChlor Pass Through Cell After new pool construction has been completed in order to prevent debris from entering the IntelliChlor cell assembly it is recommended that the IntelliChlor pass through cell P N 520588 be installed before installing the IntelliChlor cell After the pool system has flushed the debris from the pipes remove the pass through cell and install the IntelliChlor cell Selecting Model Size IntelliChlor Model IC20 Chlorine Production 0 70 Ib 317 gm per 24 hour period Residential Pools One unit per 57 m3 up to 20 000 gallons pool year round use One unit per 66 m3 up to 17 500 gallons pool winterized IntelliChlor Installation and User s Guide IntelliChlor Model IC40 Chlorine Production 1 40 Ib 635 gm per 24 hour period Residential Pools One unit per 114 m3 up to 40 000 gallons pool year round use One unit per 132 m3 up to 35 000 gallons pool winterized 17 Section 4 Installation This section describes how to install the IntelliChlor electrolytic cell assembly into the pool plumbing system Also in
6. Stabilizer Cyanuric Acid Test pool water stabilizer cyanuric acid level using a test kit or by having a water sample tested by a pool professional Maintain ideal range of 50 75 PPM Follow your pool professional s recommendations 5 Calcium Hardness Test pool water for calcium hardness level using test kit or by having a water sample tested by a pool professional If necessary adjust according to your pool professional s recommendations APSP standard of 200 400 PPM is recommended 6 Metals Test It is recommended that the pool water be tested periodically for the presence of metals such as copper iron and manganese These metals should not be present in the pool water If those metals are present contact the your pool professional Cell Usage Hours Meter IntelliChlor provides a built in cell usage hours meter that reports how many hours IntelliChlor has been operating The cell is designed to operate for approximately 10 000 hours before replacement is needed or roughly five years of average use To access the system status mode 1 Press and hold the MORE button for three seconds until the lights scroll across the unit 2 One of the five Output LED indicators 20 40 60 80 and 100 will be lit indicating the hours of usage The Output LEDs are as follows e 2000 hours 20 LED on 4000 hours 4096 LED on e 6000 hours 60 LED on e 8000 hours 80 LED on e 10 000 hours 100 LED on Electrolytic Cell Clea
7. Center After the cell installation is completed connect the power cable to the Power Center e Align the four pins of the cell power cord connector with the socket on the bottom of the Power Center and insert the connector Turn the round socket nut until it locks the connector in place E hA Connector socket nut To cell assembly IntelliChlor Installation and User s Guide 19 Connecting the Power Center to an IntelliTouch or EasyTouch System To operate IntelliChlor with the IntelliTouch or EasyTouch system connect a four wire cable from the IntelliChlor Power Center to the IntelliTouch or EasyTouch load center An alternate connection can be made by splicing anywhere along the four wire connection that connects the IntelliTouch or EasyTouch indoor control panel to the load center Note For IntelliChlor operating instructions using the IntelliTouch system see the IntelliTouch User s Guide P N 520102 or for the EasyTouch system see the EasyTouch User s Guide P N 520584 To connect IntelliChlor Power Center four wire cable to the IntelliTouch or EasyTouch load center 1 Remove the cover screw securing the Power Center cover Remove the cover 2 Run a UL approved four conductor cable 22 AWG from the IntelliChlor Power Center to the Load Center The preferred wire color scheme is red yellow green and black Remove the cover screw securing the Power Center cover Remove the cover Remove one of the k
8. FLASHING mi ed life e Red Water temperature is below 52 F cell is shut off to extend GREEN good flow warranty D Flow ko RAA e Green flashing Cell is bad may have calcium buildup time to clean although it is still producing chlorine Sanitizer Output e Green Cell is good and producing chlorine 20 40 60 80 100 e Blank Cell is off and not producing chlorine It may be in an Min Mox off period of the sanitizing cycle and will return on shortly m hd e e e Life The cell is designed to operate for approximately 10 000 hours Loss uo before replacement is needed or approximately five years of average use e be e Green flash The cell is over 10 000 hours of life replace soon Boost f e Green The cell is under 10 000 hours of life good Press poles simultaneously for 24 hour 100 output Flow This light indicates water is flowing through the cell to produce Conforms to chlorine Oe UL STD 1081 e Red Insufficient water flow through the cell no chlorine will be produced e Green Sufficient water to produce chlorine IntelliChlor Installation and User s Guide Operator Control Panel continued Sanitizer Output LED Indicators The five LED indicators display as a bar graph to show in 20 increments the amount of time the chlorine is produced per hour In BOOST mode these LEDs scroll in a pattern Note If no LEDs are lit the output is set to 0 and is not producing chlorine e 0 NoLEDs on indicate no chlorin
9. Hawkins Ave Sanford NC 27330 10951 W Los Angeles Ave Moorpark CA 93021 Phone 800 831 7133 Fax 800 284 4151 Pentair Water Pool and Spa P N 520589 Rev D
10. art process Pentair Water warrants its products as follows Limited Warranty Pentair Water warrants its products to be free from defects in material and or workmanship for a period of three 3 years or 8 000 hours parts only from the original date of installation Exceptions that could result in denial of a warranty claim 1 Damage caused by careless handling improper repackaging or shipping 2 Damage due to misapplication misuse abuse or failure to operate equipment as specified in the owners manual 3 Damage caused by failure to install products as specified in the owners manual 4 Damage due to unauthorized product modifications or alterations or failure to use Pentair Water original replacement parts 5 Damage caused by negligence or failure to properly maintain products as specified in the owners manual 6 Damage caused by failure to maintain water chemistry in conformity with the standards of the swimming pool industry for any length of time 7 Damage caused by water scaling freezing or other conditions causing inadequate water circulation 8 Accidental damage fire acts of God or other circumstances outside the control of Pentair Water e This warranty extends to the original retail owner only beginning on the date of installation and is not enforceable by any other party Proof of purchase and or date of installation will be required to execute a warranty claim Original owner agrees to repay all shipping ch
11. from 20 to 100 Refer to More and Less Output Buttons on page 6 Note Check Chlorine Level on a regular basis and adjust IntelliChlor accordingly CAUTION Before attempting to operate IntelliChlor refer to Recommendations and General Cautions on page 8 and Pool Water Preparation on page 17 Also do not adjust Chlorine production above 20 until it is certain that salt has been dissolved in pool Operating without salt will result in the unit turning off and lighting the ADD SALT light on the salt display No chlorine will be produced until salt is added to the pool If you use a Pool Pump Timer The Association of Pool and Spa Professionals APSP recommends that all water in a residential pool pass through the filtration system at least once every 12 hours referred to as pool water turnover However many factors have an effect on actual pump and filter system run times Pool size source of water direct sun light indoor outdoor screened unscreened filtration system cold or hot weather swimmer load rain organic debris algae etc are all factors which contribute to either more or less pool pump and filter system run times Because of these differences it is extremely difficult to set an initial run time starting point for the pool pump and chlorinating system Try initially setting the pool pump timer to 12 hours It will take a few days to achieve the correct amount of pool pump operating time When IntelliChlor i
12. kg Table 3 Approximate Amount of Chlorine Stabilizer Cyanuric Acid Needed to Obtain 75 PPM Pool Size gallons Stabilizer 13 m3 Level 38 m3 45 m3 53 m3 60 m3 68 m3 76 m3 83 m3 91 m3 98 m3 106 m3 30 000 Before 10 000 12 000 14 000 16 000 18 000 20 000 22 000 24 000 26 000 28 000 Addition 8 5 kg 0 00 PPM 2 8 kg 3 4 kg 4 kg 4 5 kg 5 kg 5 7 kg 6 2 kg 6 8 kg 7 4 kg 7 9 kg 18 75 Ibs f 6 25 Ibs 7 50 Ibs 8 75 Ibs 10 0 Ibs 11 25Ib 12 5 Ibs 13 75 Ibs 15 0 Ibs 16 3 Ibs 17 5 7 4 kg 10 PPM 2 5 kg 2 9 kg 3 5 kg 3 9 kg 4 4 kg 5kg 5 4 kg 5 8 kg 6 3 kg 6 9 k 16 25 Ibs 5 40 Ibs 6 50 Ibs 7 60 Ibs 8 60 Ibs 9 75 10 8 Ibs 11 90 Ibs 12 9 lbs 14 0 Ibs 15 2 6 2 kg 20 PPM 2kg 2 5 kg 2 9 kg 3 3 kg 3 7 kg 4 1 kg 4 5 kg 4 9 kg 5 4 kg 5 8 k 13 75 lbs 4 60 Ibs 5 50 Ibs 6 40 Ibs 7 30 Ibs 8 25 9 20 Ibs 10 0 Ibs 10 9 Ibs 11 9 Ibs 12 8 i 5 3 kg 30 PPM 1 7 kg 2kg 2 4 kg 2 7 kg 3kg 3 4 kg 3 7 kg 4kg 4 4 kg 4 8 kg 11 75 Ibs 3 75 Ibs 4 50 Ibs 5 25 Ibs 6 00 Ibs 6 75 7 50 Ibs 8 25 Ibs 9 00 Ibs 9 75 Ibs 10 5 g 1 7k 60 PPM 0 5 kg 0 7 kg 0 8 kg 1 kg 1 kg 1 1 kg 1 2 kg 1 4 kg 1 5 kg 1 6k 3 75 Ibs 1 25 Ibs 1 50 Ibs 1 75 Ibs 2 00 Ibs 2 25 2 50 Ibs 2 75 Ibs 3 00 Ibs 3 25 Ibs 3 50 j 0 6 kg 70 PPM 0 2 kg 0 2 kg 0 3 kg 0 3 kg 0 3 kg 0 4 kg 0 4 kg 0 4 kg 0 5 kg 0 5k 1 25 Ibs 0 40 Ibs
13. through the low voltage raceway in the Load Center to the Personality board Strip back the cable conductors 1 4 in Insert the wires into the screw terminals provided in the kit Secure the wires with the screws Make sure to match the color coding of the wires Red 15 Yellow DT Green DT and GND Black Insert the cable plug onto either of the COM PORTS J7 or J8 connectors located on the left side of the Personality board When the connection has been completed close the control panel into its original position and secure it with the two retaining screws Close the load center front door Fasten the two spring latches Restore AC power to the system Retaining screws GAS NTeKERETURNVLVR vvB IHERTER VRLVE RCTURTORS le 6 Personality ud board r AND i ONLY 7 COM ports z z E COM PORTS Le USE EITHER IT ETT iw OR BOTH SCHEELS Outdoor Control m Panel Personality board BLK D enD INDOOR CONTROL Connector J7 or J8 GRN YEL 4 DATA RED amp H5 vc AND OR RF TRANSCEIVER AND OR i 10 SPA SIDE REM Q J Personality Board Route wire from IntelliChlor into conduit knockout up through raceway to Personality board IntelliTouch Load Center IntelliChlor Installation and User s Guide 21 Connecting IntelliChlor to an EasyTouch System To connect the four wire ca
14. 360 Ibs 145 kg 320 Ibs 125 kg 275 Ibs 104 kg 230 Ibs 20 kg 45 Ibs 91 m3 24 000 272 kg 600 Ibs 249 kg 550 Ibs 229 kg 505 Ibs 209 kg 460 Ibs 181 kg 400 Ibs 159 kg 350 Ibs 136 kg 300 Ibs 113 kg 250 Ibs 98 m3 26 000 272 kg 600 Ibs 247 kg 545 Ibs 225 kg 495 Ibs 195 kg 430 Ibs 172 kg 380 Ibs 147 kg 325 Ibs 125 kg 275 Ibs 48 kg 106 m3 28 000 318 kg 700 Ibs 293 kg 645 Ibs 268 kg 590 Ibs 240 kg 530 Ibs 209 kg 460 Ibs 186 kg 410 Ibs 159 kg 350 Ibs 134 kg 295lbs 50 kg 105 Ibs 110 Ibs 27 kg 60 Ibs 113 m3 30 000 340 kg 750 Ibs 313 kg 690 Ibs 259 kg 570 Ibs 225 kg 495 Ibs 197 kg 435 Ibs 170 375 Ibs 143 kg 315 Ibs 82 kg 180 Ibs 54 kg 120 Ibs 27 kg 60 Ibs 15 Table 2 Approximate Pounds kg of Salt Needed to Maintain 3 000 PPM Salt concentration Salt addition required Salt concentration Salt addition required before addition per 1000 gallon pool capacity before addition per 1000 gallon pool capacity 0 ppm 25 6 Ibs 11 6 kg 1500 ppm 12 8 Ibs 5 8 kg 300 ppm 23 5 Ibs 10 7 kg 1800 ppm 10 7 Ibs 4 8 kg 500 ppm 21 4 Ibs 9 7 kg 2000 ppm 8 5 Ibs 3 9 kg 800 ppm 19 2 Ibs 8 7 kg 2300 ppm 6 4 Ibs 2 9 kg 1000 ppm 17 1 Ibs 7 8 kg 2500 ppm 4 2 Ibs 1 9 kg 1300 ppm 15 Ibs 6 8 kg 2800 ppm 2 2 Ibs 1
15. Chlorine TSU e 13 What Type of Satti BC D 13 How Much Salt to B yc H RO 13 How to Add Salt tothe POOL t tpe de cit EY tasa ceno duets ea dob Lnd ranae sta cea ethene deuce 14 Pool Walter PIeparatlOr 5 oue acostu ipo Leere irse pe pee SE eL Br se espe e Sees Minsawhcuee Pc xus cL aeein uet esu Penne RE pta RD 16 Determining Pool Size m3 of Water in Your Pool ssssssssssssseeeeeeeneeenn nennen nennen nennen enn 16 Determining Pool Size Gallons of Water in Your Pool essssseeeeeeeeneeeneeenn nennen 16 IntelliChlor Pass Through Cells eid runt mte ea a t te en ven gh Rated E che eet aden Eee at aad 16 Selecting Model Size e pM 16 S ction 4 DAS TAU i tect acai ct M 17 Iit CODtents oot n amd E 17 FRREQUITE oro e T 17 Installing the Cell Assembly sssssesseeseeeeenennneeennnenennennennnnnnnnnnnnn nen rnns innen nennen nennen nennen enn 18 Connecting the Cell Power Cable to the Power Center sssssssssseseeeeeeeneeeeeneenennnn nennen 18 Connecting IntelliChlor to an IntelliTouch System ssssssssseseeseeeeeeeennenenn enne 19 Connecting IntelliChlor to an Easy Touch System srira aani a aaa 21 Section NI ie m 22 Table 1
16. LOW IntelliChlor Installation and User s Guide Section 1 IntelliChlor Control Panel This section describes the IntelliChlor control panel status LEDs and the More Less and Boost On Off control buttons Salt Level Status LEDs The salt level is checked daily and is displayed on this section of the unit Pentair Water Pool and Spa e Green Good salt The water salt level is above 2900 ppm the cell will produce chlorine Flash green Salt is above 4200 ppm Chlorine is being produced but the pool water may be corrosive to l Il Chl TM other pool equipment Water needs to be drained and refilled one nte I or foot at a time until the salt level is lowered chlorine generator e Yellow Low salt The water salt level is between 2500 ppm and 2900 ppm salt should be added to the pool The cell will continue to produce chlorine but will be at a reduced level Salt L PPM a eve e Red Very low salt The water salt level has fallen below 2500 3900 7 Good CREEN good sot parts per million ppm The cell will not produce chlorine until FLASHING IR dd ai additional salt is added 2900 Add veuow bini iet Status LEDs 5e Low wo 9 Pwr Shows the condition of the system Status ae er GREEN ood e Red An error is occurring in the system Service is needed Oo Pwr RED ce e Green The system is operational and ready GREEN d Cell FLASHING Den Cell This light is on if the cell is producing chlorine o Life CREEN
17. MP Output 22 39 VDC Q 6 AMPS maximum from the Power Center Chlorine 0 70 Ib 24 hour 317 gm 24 Hour Water flow 15 gallons per minute minimum 105 gallons per minute maximum Maximum pressure 75 psi IntelliChlor Model IC40 Input 90 130 VAC 50 60 Hz 220 Watts 2 AMP or 220 240 VAC 50 60 Hz 220 Watts 1 AMP Output 22 39 VDC Q 6 AMPS maximum from the Power Center Chlorine 1 40 Ib 24 Hour 635 gm 24 Hour Water flow 15 gallons per minute minimum 105 gallons per minute maximum Maximum pressure 75 psi IMPORTANT When using IntelliChlor with an IntelliTouch system it is recommended to wire the Power Center to the pump side of the relay located in the IntelliTouch Load Center This method does not require a ground fault circuit interrupter GFCI to protect the circuit POOL PUMP TIMER IN 40V WIRI Circuit Breaker Panel POWER CENTER 240 VAC 50 60 Hz Transformer leads YELLOW VIOLET su Back WHITE 20 Amp 2Pole GFCI 220 VAC Basic System Wiring POOL PUMP TIMER 110V WIRING Circuit Breaker Panel POWER CENTER 110 VAC 50 60 Hz Transformer 20 Amp 2Pole GFCI 110 VAC Basic System Wiring IntelliChlor Installation and User s Guide LIMITED WARRANTY Pentair Water Pool and Spa Inc Pentair Water manufactures its products with the highest standards of workmanship using the best materials available through state of the
18. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW PENTAIR WATER DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Procedure for Obtaining Performance In order to obtain the benefits of this warranty the consumer who made the original retail purchase must contact the Pentair Water Technical Service Department upon discovery of the defect but in no event later than the expiration date of the warranty period provided in this warranty Upon receipt of this communication Pentair Water will promptly notify the customer of the address to which the defective item may be shipped The customer shall then ship the item freight prepaid to the address indicated together with a RETURN GOODS AUTHORIZATION form obtained from Technical Service and a brief description of the problems encountered Unauthorized returns will not be accepted Freight must be prepaid by customer Warranties or Representations by Others No dealer or other person has any authority to make any warranties or representations concerning Pentair Water or its products Accordingly Pentair Water is not responsible for any such warranties or representations Other Rights This warranty gives you specific legal rights and you may also have other rights which vary from state to state This warranty supersedes all previous publications PENTAIR WATER POOL AND SPA INC 1620
19. Troubleshooting Inteli Chlor resisaer nna aaa p aE A nnns nnns 22 Table 2 Troubleshooting the Power Center sssssssssssessssseeeeeeeee nennen a aa e ia a a ae ae 23 Electrical Specifications and 110 VAC and 220 VAC Wiring sssssssseeeeeeeeenmeennnnns 24 IntelliChlor Installation and User s Guide IMPORTANT SAFETY PRECAUTIONS SAVE THESE INSTRUCTIONS RA Important Notice Attention Installer This manual contains important information about the installation operation and safe use of this product This information should be given to the owner and or operator of this equipment When installing and using this electrical equipment basic safety precautions should always be followed including the following A WARNING IMPORTANT SAFETY INSTRUCTIONS PERTAINING TO A e RISK OF FIRE ELECTRIC SHOCK OR INJURY TO PERSONS READ AND TN FOLLOW ALL INSTRUCTIONS S Before installing this product read and follow all warning notices and instructions which are included Failure to follow safety warnings and instructions can result in severe injury death or property damage Call 800 831 7133 for additional free copies of these instructions A WARNING To reduce the risk of injury do not permit children to use this product unless they are closely supervised at all times A WARNING When mixing acid with water ALWAYS ADD ACID TO WATER NEVER ADD WATER TO ACID A WARNING To reduce the risk of injury service
20. arges to Pentair Water Pool and Spa Inc e Warranties by others Some products incorporate components manufactured by other manufacturers Some of these provide warranties in addition to the warranty provided herein In all such cases a copy of that warranty will be provided with the product To the extent protection provided under any such third party warranty exceeds the Limited Warranty provided herein the Customer will have to look to that manufacturer for the additional warranty protection Warranty Obligations of Pentair Water Should a defect in workmanship and or material in any item covered by this warranty become evident during the term of the warranty then upon the consumer following the procedures set forth below Pentair Water will at its option repair or replace such item or part at its own cost and expense Pentair Water is not however responsible under this warranty for any cost of shipping or transportation of the equipment or parts thereof to or from the Technical Service Department Also Pentair Water is not liable for any loss of time inconvenience incidental expenses such as telephone calls labor or material charges incurred in connection with the removal or replacement of the equipment or any other incidental or consequential damages PLEASE NOTE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you No Other Warranties
21. be found at the pool return line The higher level at the pool return line indicates IntelliChlor is producing chlorine 2 pH Level Test Test the pH level of your pool with a test kit If necessary adjust according to your pool professional s recommendations APSP standard of 7 2 7 8 is recommended Note Never use dry acid to adjust pH in arid geographic areas with excessive evaporation and minimal dilution of pool water with fresh water A buildup of byproducts can damage the electrolytic cell Monthly Service To ensure that the correct chemical balance is maintained in your pool it is important to perform the following recommended salt and pool water tests every month 1 Salt Level Test Check salt display lights on the unit and check that the green GOOD light is on e Ifthe yellow ADD Salt light is on see page 5 add salt by following the procedures and charts described on page 14 and 15 e If salt level does not rise after 24 hours see Troubleshooting page 22 e If the red LOW salt light is on no chlorine will be produced until salt is added to the pool see charts beginning on page 14 2 Pool Water Sample Take water sample to local pool store for testing IntelliChlor Installation and User s Guide 10 Monthly Service Continued 3 Total Alkalinity Test Test pool water for total alkalinity with a test kit Adjust according to your pool professional s recommendations 80 120 PPM APSP Standard 4
22. ble from the IntelliChlor Power Center see page 19 to the motherboard located in the Easy Touch load center A waARNING Switch OFF main system power to the load center before making any connections Unlatch the load center enclosure door spring latches and open the door 2 Loosen the two retaining screws from the control panel 3 Lower down the control panel on its hinges to access the motherboard located behind the control panel 4 Route the four conductor cable up through the low voltage raceway in the load center to the motherboard 5 Strip back the cable conductors in Insert the wires into the screw terminals provided in the kit Secure the wires with the screws Make sure to match the color coding of the wires Red 15 Yellow DT Green DT and GND Black 6 Insert the connector on the COM PORT J20 screw terminal on the motherboard 7 When the connection is completed close the control panel and secure it with the two retaining Screws 8 Close the load center front door Fasten the two spring latches Retaining screws Control Panel O00099 O00009 hen SPA SIDE REMOTE 1 TEMP SENSORS lee KoA VEL RN qr Gi O o O 6 v iS4 SPA SIDE REMOTE COMPORT kan J20 IntelliFlo RF Transceiver EasyTouch Motherboard Route wire from IntelliChl
23. cell is being Super Chlorinated When IntelliChlor is used on pools the pool water sparkles and does not burn the eyes because of the absence of Chloramines Note On initial start up of a pool it is best to Super Chlorinate from an outside source i e use a shock treatment available at your local pool supplier 6 pH produced by IntelliChlor is close to Neutral pH However other factors usually cause the pH of the pool water to rise Therefore the pH in a pool chlorinated by IntelliChlor tends to stabilize at approximately 7 8 This is within APSP standards If the pool pH rises above 7 8 have a pool professional test to see if other factors such as high Calcium Hardness or Total Alkalinity are the cause and then balance accordingly 7 Total Dissolved Solids TDS Adding salt to pool water will raise the TDS level While this does not adversely affect the pool water chemistry or clarity the pool water professional testing for TDS must be made aware salt has been added for the IntelliChlor system The individual performing the TDS test will then subtract the salinity level to arrive at the correct TDS level See Table 3 page 15 8 New Pool Water A recently filled or newly refinished pool may contain undesirable matter This undesirable matter could interfere with IntelliChlor s ability to chlorinate properly Make sure the water is tested by a pool professional and properly balanced before turning on IntelliChlor Optimum Pool Water Condi
24. cluded are connection instructions for IntelliTouch and EasyTouch systems Before installing review the IntelliChlor kit contents and required tools Note For Power Center installation instructions see the IntelliChlor Power Center Installation Guide P N 520590 Note Salt is not provided For details about the type of salt to use see What type of salt to use on page 13 Kit Contents One electrolytic cell Two cell union with two o rings User s Guide this manual Required Tools Tape measure Phillips and flathead screwdriver Pliers Hacksaw An NSF approved all purpose PVC CPVC ABS cleaner primer An NSF approved all purpose PVC CPVC ABS cement A waRNING When using electrical products basic precautions should always be followed including the following Q S DANGER RISK OF ELECTRIC SHOCK WHICH CAN RESULT IN SERIOUS INJURY OR DEATH Before attempting installation of service ensure that all power to the circuit supplying power to the system is disconnected turned off at the circuit breaker It is recommended but not mandatory that the IntelliChlor Power Center be connected to a circuit protected by a ground fault circuit interrupter GFCI Grounding earth bonding is required The unit should be installed by a qualified service person and grounded Install to allow access to cell buttons and power center Read Safety Precautions and Important Instructions page ii and iii Before attem
25. e gallon of tap water in a plastic bucket A warnine Note The IntelliChlor acid cleaning kit P N Working with muriatic acid can be dangerous 520670 provides a cap for the IntelliChlor When cleaning elements always wear rubber unit to allow acid to be poured into the gloves and eye protection Always add acid to lyti il pl l i water do not add water to acid Always work ina electrolytic cell plates for cleaning well ventilated area Splashing or spilling acid can cause severe personal injury and or property damage d Place the cell vertically in a five gallon bucket Pour the acid solution as described above into the cell until the blades are just covered Allow the acid solution to bubble and to clean the blades The acid should only be contained in the cell and not around it A foaming action will begin which is caused by scale calcium carbonate being dissolved from the plates If rigorous foaming action does not begin the cell does not need to be cleaned STOP THE CLEANING PROCESS go on to step d Otherwise allow the cell to remain in the solution until the foaming has stopped However do not leave in acid for more than 1 2 hour Excessive Acid Washing will damage electrolytic cell e Remove the cell from the bucket and place in an empty five gallon bucket Rinse the cell thoroughly with clean tap water and inspect If deposits are still visible immerse the cell again in the solution for further clean
26. e produced IntelliChlor is off e 20 Produces chlorine 20 of the hour 12 minutes on 48 minutes off 40 Produces chlorine 40 of the hour 24 minutes on 36 minutes off 60 Produces chlorine 60 of the hour 36 minutes on 24 minutes off 80 Produces chlorine 80 of the hour 48 minutes on 12 minutes off 10096 Produces chlorine 10096 of the hour 59 minutes on 1 minute off e e o o Note If connected to an IntelliTouch EasyTouch system these lights may slowly flash when the output is set to a value not exactly 20 40 60 80 or 100 Example 21 output setting from the IntelliTouch EasyTouch will flash the 20 light More and Less Output Buttons The More and Less buttons control the sanitizing cycle as displayed by the sanitizer output display bar graph Slide the panel cover up to access the More Less and Boost On Off buttons Note When connected to an IntelliTouch system the Less and More buttons are disabled and IntelliChlor Sanitizer Output is controlled from the IntelliTouch Indoor Control Panel More Increases the time the cell produces chlorine in 2096 increments Example The Sanitizer Output display is showing 20 Pressing the More button will turn off the 20 light and turn on the 40 light The unit will now produce chlorine 4096 of an hour Less Decreases the time the cell produces chlorine in 2096 increments Example The Sanitizer Output display is showing 40 Pressing the Less button will turn off the 40 ligh
27. ell chamber and are activated upon start up of the system and or every eight hours of running Upon start up the salt sensor flashes for two minutes to indicate it is in analysis mode then determines the salt level and displays it Control Panel status LEDs Clear sliding cover MORE and LESS output buttons IntelliChlor Cell Assembly IntelliChlor Installation and User s Guide IntelliChlor Power Center The Power Center converts AC electrical current to a low voltage DC current which is required by the cell to perform the electrolysis The power supply is connected with the pool circulation pump electrical source so that the electrolytic cell only operates when the pool pump is on The enclosure can be mounted vertically on the wall up to 15 feet away from the cell controller The Power Center contains the transformer fuse connector to the cell and the 110 VAC and 220 VAC wiring configuration with the 36 VDC output cable to the cell controller A fuse holder is mounted on the bottom of this enclosure for additional protection There are no other controls or lights on the unit For more information about the Power Center see the IntelliChlor Power Center Installation Guide P N 520590 IMPORTANT Before plugging or unplugging the IntelliChlor cell to the Power Center first switch off the AC power to the Power Center either by switching off the filter pump or setting the associated circuit breaker to OFF Power Cen
28. h a solid LED If the salinity is below 2400 ppm the salt display will light the red ADD SALT indicator and the CELL light will go blank indicating there is not enough salt in the pool for chlorine to be produced Set the Sanitizer Output to 60 by pressing the MORE or LESS button page 6 After 24 hours use a reliable test kit to test the pool water for free active chlorine The ideal range to maintain is 1 3 PPM If the chlorine content of the pool water is too low increase chlorine production by pressing the MORE button If the chlorine content of the water is too high decrease chlorine production by pressing the LESS button Due to a varying chlorine demand of pool water it may take a few days to determine the correct pool operating time and chlorine production percentage setting for your pool Continue adjusting as necessary allowing 24 hours between adjustments until the chlorine content of the pool is stabilized at 1 3 PPM Operating in winter The unit turns off in water temperatures of 52 F and below and will not produce chlorine This feature extends the life of the cell See Winterizing page 11 Recommendations After new pool construction has been completed before installing the IntelliChlor cell install the IntelliChlor pass through cell P N 520588 to remove debris from the pipes Read and keep the manual in a safe place Increase Chlorine Production before party time and return to normal afterwards Increa
29. has a self cleaning cycle which reverses the cell polarity reducing calcium buildup This feature turns the cell on and off at regular intervals to prevent calcium and scale buildup and further maximizes cell life The electrolytic cell contains the control electronics and bipolar electrodes that perform the electrolysis and produce chlorine when energized with DC current Chlorine is generated as pool water containing salt passes through the cell The chlorine production can be varied by either adjusting the sanitizer output level on the cell or by varying the number of hours IntelliChlor is on each day IntelliChlor automatically cleans the Cell electrodes once every few hours This does not interrupt the production of Chlorine The cell also contains a mechanical flow sensor to ensure the proper amount of water is passing through the cell to allow chlorination to occur The cell automatically measures the water salinity and temperature and displays on the top of the cell using lights The cell includes a 15 ft UL approved four conductor 16 gauge cable for connection to the Power Center e Flow Sensor A cell flow sensor assures that there will always be adequate water flow through the cell no matter how it is plumbed Temperature Sensor To protect the unit from operation and potential damage when the temperature of the water falls below 52 F the temperature sensor switches the unit off e Salt Sensor Two salt sensor probes extend into the c
30. hlor Installation and User s Guide Declaration of Conformity We declare under our sole responsibility that the product identified in this declaration and to which this declaration relates are in conformity with the protection requirements of Council Directive 89 336 EEC and standards IP33 e Standard EN60335 1 2001 EN60529 e Standard EN6100 3 2 2000 EN6100 3 3 1995 A1 2001 e Standard EN 55014 2 1997 A1 2001 EN 55014 1 2000 A1 A2 2002 Manufacturer Pentair Water Pool and Spa Inc 1620 Hawkins Ave Sanford NC 27330 10951 West Los Angeles Ave Moorpark CA 93021 Installation Steps Summary The recommended IntelliChlor installation steps are Review Chemistry You Need to Know page 11 Review this important information Review Optimum Pool Water Conditions page 12 Review NSPI standards information 6 Review Pool Water Preparation page 16 Review this important information o Installing the cell into the plumbing system Connecting the cell to the Power Center page 17 21 Installing the cell into the pool plumbing system Cabling the cell to the Power Center and connecting IntelliChlor to an IntelliTouch or Easy Touch system o Operating and Maintaining IntelliChlor page 7 and 9 Operating and maintenance information for IntelliChlor Technical Support Contact Technical Support at Sanford North Carolina 8 A M to 5 P M Phone 800 831 7133 Fax 919 566 8920 Moorpark California
31. ine is destroyed by the UV radiation from the sun within 2 hours Chlorine stabilizer should be maintained between 50 75 PPM See Table 3 page 15 IntelliChlor Installation and User s Guide 12 Chemistry You Need to Know Continued 2 Nitrates can cause extremely high chlorine demands and will deplete chlorine from your swimming pool In some cases Nitrates may even lower your chlorine levels to zero The local pool professional can test for Nitrates Make sure Nitrates are not present in your pool 3 Metals some metals can cause loss of chlorine Also metals can stain your pool Have the local pool professional check for metals and recommend methods of removal 4 Chloramines should not be present in pool water When organic materials combine with Free Chlorine Chloramines are formed This ties up the Free Chlorine in your pool and does not allow the chlorine in your pool to disinfect Chloramines also cloud pool water and burn the eyes Super Chlorinate shock to remove Chloramines at the initial startup of the pool 5 Super Chlorination Shocking burns out the organic material that has combined with chlorine This frees the chlorine for sanitizing This is accomplished by raising the chlorine level quickly and dramatically When the chlorine level is raised to 5 to 15 PPM the pool water is said to have been Super Chlorinated shocked As pool water is continuously passed through the electrolytic cell all pool water inside the
32. ing Additional acid may need to be added to the solution f Rinse the cell again with clean tap water and inspect If clean replace the cell and resume normal operation g Ifthe acid wash procedure is necessary it is recommended that a sample of pool water be analyzed by an authorized IntelliChlor service representative for excessive hardness and or improper water balance h Ifno scale or debris deposits are observed in the cell after two bimonthly inspections it is not necessary to continue bimonthly inspections However due to possible changes in pool water chemistry and filtering effectiveness it is recommended that the cell be removed for inspection at least twice a year i Insert the IntelliChlor cell cable plug into the Power Center connector then restore AC power to the Power Center Winterizing Very little chlorine is needed in cold water Below 52 Fahrenheit chlorine production is stopped the unit will not produce chlorine This low temperature cut off extends the life of the cell If preventative measures are not taken freezing water may cause severe damage to the cell Prevent freeze damage to the cell by running the pool pump continuously or winterize the pool by draining water from pump filter and all intake and return lines Remove the cell clean and store it Chemistry You Need to Know 1 Chlorine Stabilizer cyanuric acid is needed in outdoor pools to maintain proper levels of chlorine Most unstable chlor
33. l in pool Observe Salt Display lights See Salt Level water Status LEDs page 5 DEED High nitrate level Contact Pool Professional Metals present in pool water Contact Pool Professional New pool water or not shocked properly upon Super Chlorinate Pool See Start up startup Installation page 8 Clogged or dirty cell Remove cell for inspection Clean if necessary See Electrolytic Cell Cleaning page 10 IntelliChlor Installation and User s Guide 23 Table 1 Troubleshooting Continued Red ADD salt light is Pool water needs salt No chlorine is being Add salt as described on pages 13 14 and on produced 15 Yellow LOW salt light is Not enough salt in pool Add salt to pool to achieve 3200 ppm to 3500 on Heavy Rainfall ppm See page 13 14 and 15 Leak in pool Green GOOD salt light Too much salt in pool May cause corrosion on Dilute pool water by draining some water then is flashing other pool equipment filling with fresh water PWR light is red Call for service Unit requires attention Cell light is red Water is below 52 F The water temperature must be above 52 F to produce chlorine Cell light does not Chlorine Production set to 00 Adjust CHLORINE PRODUCTION to desired come on percentage Insufficient water flow Cell is plugged with Remove obstruction and or clean cell See debris pump has lost prime page 10 Prime pump if necessary Salt level below 2500 ppm Add salt as described on
34. les Operation is subject to the following two conditions 1 this device may not cause interference and 2 this device must accept any interference including interference that may cause undesired operation of the device Interference Statement This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radio TV technician for help Note Modifications not expressly approved by the party responsible for FCC compliance could void the user s authority to operate the device IntelliC
35. nator and pool pump will switch on and off together IntelliChlor Installation and User s Guide IMPORTANT SAFETY PRECAUTIONS SAVE THESE INSTRUCTIONS A CAUTION Use of chemicals other than those recommended may be hazardous Follow the Chemical Manufacturer s Instructions A CAUTION To reduce the risk of electric shock install IntelliChlor cell at least 5 feet from the inside wall of the pool A CAUTION Install the IntelliChlor unit a minimum of two 2 feet from the heater outlet A CAUTION It is recommended to install a Pentair 2 CHECK VALVE P N 263042 between the input side of the IntelliChlor cell and the main heater output pipe A CAUTION A solid copper bonding conductor not smaller than No 8 AWG 8 4 mm should be connected from the accessible wire connector on the unit to all metal parts of the swimming pool spa or hot tub structure and to all electrical equipment metal conduit and metal piping within 5 feet 1 5 m of the inside walls of a swimming pool spa or hot tub when the unit is installed within 5 feet of the inside walls of the swimming pool spa or hot tub Canada Industry Canada IC This device complies with RSS210 of Industry Canada 1999 FCC Standard 47 CFR Part 15 Subpart C Section 15 247 This version is limited to chapter 1 to chapter 11 by specified firmware controlled in the U S A Federal Communications Commission FCC This device complies with Part 15 of the FCC Ru
36. ning 1 Automatic Cleaning This unit has an automatic cell cleaning feature Cell Reversing that removes scale deposits from the electrolytic cell Note Automatic Cleaning does not interrupt Chlorine Production Scale is a white crusty deposit that forms in excessively hard water or from pool water that is out of balance and in a scaling condition If the cell shows excessive scaling you need to perform an acid wash cleaning Proceed to Acid Wash Cleaning Step 2 2 Acid Wash Cleaning If the electrolytic cell has a tendency to scale it is recommended that every two months the cell be removed and inspected for scale formation and or debris Some filters allow debris to pass through to the cell possibly lodging between the plates in the cell A small amount of scale formation is normal If by looking through the cell it is observed that there is excessive scale formation between the plates or debris is present the cell must be cleaned as follows a Use a high pressure jet of water from a garden hose If the cell cannot be reasonably cleaned in this manner acid cleaning is necessary IntelliChlor Installation and User s Guide 11 Electrolytic Cell Cleaning Continued b To acid clean the cell Disconnect the IntelliClor cell communication cable from the cell Remove the AC power from the Power Center either by switching off the filter pump or setting the associated circuit breaker to OFF c Mix one quart of muriatic acid with on
37. nockouts from the underside of the Power Center Route the four conductor cable up through the lower hole DAM Bow Strip back the cable conductors 1 4 in Insert the wires into the screw terminals provided in the kit Secure the wires with the screws Make sure to match the color coding of the wires Red 15 Yellow DT Green DT and GND Black Plug the screw terminal onto the four pins located on the Power Center board 8 Reinstall the cover and secure with the cover screw 9 Proceed to Connecting IntelliChlor to an IntelliTouch System on page 20 or Connecting IntelliChlor to an EasyTouch System on page 21 Screw terminal Screw terminal pin outs Conduit knockout IntelliChlor Power Center cover removed IntelliChlor Installation and User s Guide 20 Connecting IntelliChlor to an IntelliTouch System To connect the four wire cable communication from the IntelliChlor Power Center see page 19 to the Personality board located in the IntelliTouch load center A WARNING Switch OFF main system power to the Load Center before making any connections 1 2 3 Unlatch the load center enclosure door spring latches and open the door Loosen the two retaining screws from the Outdoor Control Panel Lower down the Outdoor Control Panel on its hinges to access the Personality board located behind the Outdoor Control Panel Route the four conductor cable up
38. oduced e BOOST cycle sets the unit to maximum chlorine output for 24 hours e Cell lifetime is tracked with at a glance green LED indicators e UL listed to UL1081 standards for swimming pool chlorinators IntelliChlor models The IntelliChlor salt chlorinator system models are PC 100 P N 520556 Power Center Kit e C20Cell P N 520554 Designed for pools up to 20 000 U S gallons 75 liters this cell will produce approximately 0 70 pounds of chlorine per 24 hour period This cell uses two terminal blades and five bi polar blades making this system more cost competitive e IC 40 Cell P N 520555 Designed for pools up to 40 000 U S gallons 151 liters the cell will produce approximately 1 40 pounds of chlorine per 24 hour period This cell uses three terminal blades and ten bi polar blades five on each side of the center terminal blade This will supply more than enough chlorine for almost any residential and many smaller commercial pools e ntelliChlor pass through cell P N 520588 For new pool start up IntelliChlor Installation and User s Guide Electrolytic Cell Controller The electrolytic cell controller includes a control panel with buttons and LED indicators to fully control and produce chlorine The cell controller measures the water temperature and salt level to optimally produce chlorine If the salt level is too low red on salt display the cell is turned off until salt is added to the pool The controller
39. on about high salt levels see Troubleshooting on page 22 IntelliChlor Installation and User s Guide 14 How to Add Salt to the Pool CAUTION Do not operate IntelliChlor with newly poured pool plaster salt damage can occur Wait at least 1 MONTH to allow new pool plaster to cure before operating IntelliChlor 1 Switch on the pump to circulate the pool water Determine the amount of salt from the following charts Slowly pour in the salt around the outer perimeter of the pool for quick and even distribution To avoid clogging the filter or damaging power supply and pump do not add salt through the skimmer or surge tank Brush the pool bottom and allow water to circulate for 24 hours to dissolve completely After 24 hours verify correct salt reading Switch on IntelliChlor and set to desired sanitizer output level for example 60 Table 1 Approximate Pounds kg of Salt Needed to Obtain 3 000 PPM in Pool Salt Conc Before Addition 27kg 32 kg 39 kg 45 kg 2250 ppm co Ibs 70 Ibs 85 Ibs 100 Ibs 9500 ppm 18k9 23ko 27 kg 29 kg 32 36 kg 41 kg 45 kg PPM 40 Ibs 50 Ibs 60 Ibs 65 Ibs 70 Ibs 80 Ibs 90 Ibs 100 Ib 23 kg 23 kg 50 Ibs 50 Ibs 2700 ppm 38 m3 45 m3 10 000 12 000 113 kg 250 136 kg 300 Ibs 86 kg 190 bs 104 kg 230 Ibs 91 kg 200 Ibs 79 kg 175 Ibs 68 kg 150 Ibs 59 kg 130 Ibs 75 kg 165 bs 66 kg 145 bs
40. or into conduit knockout up through raceway to motherboard EasyTouch Load Center IntelliChlor Installation and User s Guide 22 Section 5 Troubleshooting Usethe following troubleshooting information to resolve possible problems with the IntelliChlor system Note Switch power off to unit before to attempting service or repair Always remove AC power to Power Center when plugging or unplugging the IntelliChlor cell into the Power Center Table 1 Troubleshooting Problem Possible Cause Corrective Action Low or no chlorine Low stabilizer cyanuric acid level in pool Add stabilizer to maintain 50 75 PPM per water pool professional s recommendations See Stabilizer Chart Table 3 page 15 Insufficient operating hours of the Chlorinator Increase the Chlorinator operating time per unit day See page 6 CHLORINE PRODUCTION percentage set too Increase chlorine production by pressing the low or off at 096 MORE button See page 6 Recent increases in weather temperature Increase chlorine production by pressing the without increasing the chlorine production of MORE button See page 6 your unit Temporary loss of chlorine due to heavy Set Boost mode and allow to run for 24 organic load rain leaves fertilizer or heavy hours Recheck If still too low super bather load recent party or pets using pool chlorinate with outside source Take pool water sample to pool professional Low less than 2500 ppm salt leve
41. pages 13 14 and 15 CELL light is flashing Cell has calcium build up and requires Refer to Maintenance Procedure for acid green cleaning wash cleaning See User Maintenance on page 9 LIFE light is flashing Cell life has achieved 10 000 hours life is Prolong cell life by keeping salt at GREEN green limited level and minimize BOOST modes Flow light is red Pump fails to provide sufficient water flow Check for correct operation of the pump i e loss of pump prime or clogged strainer baskets Closed valves Check and correct all valve alignments Dirty filter Follow filter cleaning procedures Obstruction in the Chlorinator cell Remove cell for inspection Follow cleaning procedures See Electrolytic Cell Cleaning on page 10 IntelliChlor unit does Fuse in Power Center is open Replace AC fuse located at bottom of Power not have green power Center light No AC power to Power Center Verify time clock is providing 110 VAC or 220 VAC to Power Center when active Transformer leads not wired correctly in Power Verify transformer leads wired to AC source by Center referring to wiring diagram decal on inside of Power Center cover IntelliChlor Installation and User s Guide 24 System Specifications 110 VAC and 220 VAC Wiring Circuit Protection Two pole 20 AMP device at the electrical panel IntelliChlor Model IC20 Input 90 130 VAC 50 60 Hz 220 Watts 2 AMP or 220 240 VAC 50 60 Hz 220 Watts 1 A
42. play will return to the sanitizer output display Pressing the Less button within five seconds will now light the 20 LED light indicating it is now at two hour self clean cycle Wait five seconds and this mode will end returning to the sanitizer output display IntelliChlor Installation and User s Guide Section 2 Operating IntelliChlor This section describes the start up procedure and operating instructions for IntelliChlor Initial Start up Period For the first 30 days of cell operation the self cleaning cycle will be set to two hours After 30 days has elapsed the unit will automatically set itself to four hour self cleaning cycle This feature will clean the cell more often on a new pool installation then go to a more standard self cleaning cycle for longer cell life Operation Use of an external Pool Pump Timer is not required IntelliChlor is designed to supply a sufficient amount of chlorine to sanitize pool water on a daily basis If IntelliChlor is operated 24 hours a day at 100 more chlorine would be generated than would be needed by most pools 1 3 PPM IntelliChlor has its own internal timer which cycles the electrolytic cell on and off depending on what percent the Chlorine Production is set For instance at 100 the cell works all the time When set at 80 the cell is allowed to rest 20 of the time prolonging cell life In order to fine tune IntelliChlor to any size pool just increase or decrease the Chlorine Production
43. pting any electrical wiring be sure to read and follow Safety Instructions Wiring should only be performed by a qualified professional Install the IntelliChlor unit a minimum of two 2 feet from the heater outlet Pipe couplings Schedule 80 maximum pressure 150 psi at 70 F Note Operate unit with minimum flow of 20 gpm For high flow applications use a bypass loop IntelliChlor Installation and User s Guide 18 Installing the Cell Assembly Install the IntelliChlor cell assembly no closer than three 3 feet from the heater outlet if used For more information see plumbing diagrams on page 3 and 4 Note After new pool construction has been completed in order to prevent debris from entering the IntelliChlor cell assembly it is recommended that the IntelliChlor pass through cell P N 520588 be installed before installing the IntelliChlor cell After the pool system has flushed the debris from the pipes remove the pass through cell and install the IntelliChlor cell Note Pipe couplings Schedule 80 maximum pressure 75 psi to 70 F Coupling Coupling To install the cell 1 Using PCV glue mount the PVC couplings to the plumbing pipe Allow the glue to dry 2 Mount the cell to allow access to the control panel Install the cell onto the couplings Ensure the O rings are seated properly 3 Switch on the pump and visually inspect for leaks around the couplings Connecting the Cell Power Cable to the Power
44. rol Pan el crearon anon an iri ruan nnnm auus nar ae nakaasa a niaaa 5 Salt Level Status LEDS eT HE Em 5 Status LEDS ce 5 Sanitizer Output LED Indicators sssssssssesesseeeeenee inanan iaraa ekrid 6 Mor and Less Output Buttons rsisi siinne asada Fea eel De RR EL e EENAA TEEN aatar 6 Self Cleaning reverse sssssssssssssesseseeeesen nennen enne nennen nennen enn tnts erstes eae sentes ener rns enne 6 Section 2 Operating IntelliChlQt ocerene cereo rre one bata cte tnn a nonu cesannceceseabsedseeunecectanseeceeate 7 Initial Startup Period geiko a eee A a A E E 7 Operationer enan a e epee eee ters peer MEE II IL 7 Startup Procedure Super Chloririation 12 crei e nei rro prn ta ein REFER onder 8 Pole DOWN acs oes CERE 8 Operating IN Tou n ed eis inde ed ees 8 FRECOMIMOMOALIOMS eR ER 8 General CAUTIONS Em 8 Section 3 User MaintenaLrice ueenn irse ntn ro rata nin ec ve cnasnecesxeciseuscnanuececxssuervecstusecnaxeccardecs 9 Bremer E 9 lucrum 9 Monthly Serni Esisi V EEA aa 9 Cell Sage Hours icr EE 10 Electrolytic Cell Cleaning Es 10 WV UMS NZI AG T 11 Chemistry You Needto KNOW ooa coi tru tee obese De sedi ta cages sapaceet suse OI auper exco Eaa 11 Optimum Pool Water Conditions 2 eie inet i tr ub Dritte epe n uat tre doen 12
45. s wired with a pool pump timer results will vary greatly from one pool installation to the next so this should be discussed with either the pool builder or your pool professional The key points are e Operate the pool pump at least the minimum time needed for good filtration e The pool pump timer can reduce energy consumption Note Exception For Cold Weather Operation The unit turns off in water temperatures of 52 F and below and will not produce chlorine This feature extends the life of the cell IntelliChlor Installation and User s Guide Startup Procedure Super Chlorination Shocking Super Chlorination is recommended before pool startup Start out with clean pool water from the beginning IntelliChlor will build up a sufficient level of chlorine for sanitation in several hours However if pool water has a high demand from the start up IntelliChlor will not be able to produce enough chlorine to reach break point chlorination So it is best to super chlorinate from an outside source at the time of pool startup Then wait until the chlorine level has returned to 1 to 3 PPM before turning on IntelliChlor Apply power Switch on the pool pump switch or pool pump timer The IntelliChlor control panel green PWR power LED light should be on The salt display will scroll all three LEDs for two minutes indicating that it has not checked the salt level yet After two minutes the salt will be checked and its level will be displayed wit
46. salt supplier e Avoid using salt with anti caking agents sodium ferrocyanide also known as YPS or yellow prussiate of soda that could cause some discoloration of fittings and surface finishes in pool e Water conditioning salt pellets are compressed forms of evaporated salt and may be used but will take longer to dissolve e Do not use calcium chloride as a source of salt Use sodium chloride only e Do not use Rock salt insoluble impurities mixed with the rock salt can shorten the life of the unit How Much Salt to Use Use the Table 1 chart page 15 to determine how much salt will be needed Most pools contain some salt depending on the water source and chemicals used for sanitizing If IntelliChlor has not been wired and turned on yet a hand held meter calibrated for NaCl salt can be used to determine the existing salt concentration of the water If IntelliChlor is wired in connected use it to determine the salinity Turn on the filter pump to allow IntelliChlor to switch on The salt display will flash the last known salt status light for two minutes while it analyzes the water then will turn solid This solid light indicates the salt status of the pool e 3000 to 3500 ppm of salt is recommended for optimum water conditions e Low salt concentration below 2400 ppm will cause the unit to turn off e High salt concentration above 6000 ppm may cause corrosion damage to pool fixtures Note For more troubleshooting informati
47. se Chlorine Production when temperature goes up Increase Chlorine Production when number of guests goes up Use Stabilizer Cyanuric Acid to Stabilize Chlorine in Pool Take Pool water sample to Pool Professional once per month General Cautions Do not get fertilizer in your pool Fertilizers contain nitrates which cause a high chlorine demand on pool water Never use dry acid to adjust pH in arid geographic areas with excessive evaporation and minimal dilution of pool water with fresh water A buildup of byproducts can damage the electrolytic cell Do not add any pool water balancing chemicals including salt unless IntelliChlor is switched off Do not let Chlorine Stabilizer drop below 50 PPM IntelliChlor Installation and User s Guide Section 3 User Maintenance This section describes how to maintain the IntelliChlor chlorination system Daily service None is needed Weekly service Chlorine Test Test pool water chlorine level with a reliable test kit Maintain ideal range by adjusting IntelliChlor chlorine production rate See More and Less Output Buttons on page 6 e Chlorine is 1 3 PPM Note Above 3 0 PPM of chlorine may cause corrosion of pool metals and possibly cause damage to associated pool equipment Note It is recommended that chlorine test samples be taken from two places one at the pool return line the other well away from the pool return line Compare the samples A higher level should
48. should only be attempted by a qualified Pool Service Professional A WARNING Do not operate electrolytic cell without proper flow or water circulation A build up of flammable gases will result in hazardous conditions AA A CAUTION This chlorinator is for use with permanently installed pools and may also be used with hot tubs and spas if so marked Do not use with storable pools A permanently installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage A storable pool is constructed so that it is capable of being readily disassembled for storage and reassembled to its original integrity A CAUTION When using IntelliChlor with an IntelliTouch system it is recommended to wire the IntelliChlor Power Center to the pump side of the relay located in the IntelliTouch Load Center This wiring method does not require a ground fault circuit interrupter GFCI to protect the circuit A green colored terminal or a wire connector marked Q GR Ground or Grounding is provided within the terminal compartment in the Power Center transformer enclosure To reduce risk of electric shock connect this terminal or connector to the grounding terminal of your electric service or supply panel with a conductor equivalent in size to the circuit conductors supplying this equipment The power supply must be interconnected with pool pump motor power source This insures the IntelliChlor chlori
49. t and turn on the 20 light The unit will now produce chlorine 20 of the hour Boost On Off Press and hold both the More and Less buttons together to activate Boost mode Boost mode sets the sanitizer output to run 100 for 24 hours straight If the time clock switches off the pump cycle then switches power back on the next day Boost mode will continue until 24 hours has elapsed or Boost mode is canceled by the user The Sanitizer Output display will show a pattern LED display to indicate Boost mode To exit Boost mode press and hold both the More and Less buttons Self Cleaning reverse The unit has a self cleaning feature that reduces scale buildup on the cell blades The self cleaning cycle tends to reduce cell life so less often is better however it is important to minimize the scale buildup on the blades The cycle can be every 2 4 6 8 or 10 hours It is factory set to two hours for the first 30 days of operation then automatically switches to four hours To change the self cleaning cycle press and hold the Less button for three seconds The sanitizer output display will now correspond to the self clean cycle Pressing More or Less button will change this setting Example The self clean cycle is set to four hours and needs to be two hours Press and hold the Less button for three seconds The sanitizer output will blank then light up the 4096 LED light only indicating four hours If no button is pressed for five seconds the dis
50. ter Model PC 100 System Diagram The following diagram shows the IntelliChlor system functionality It is recommended to install a two inch check valve between the input side of the IntelliChlor cell and the main heater output pipe Pool pump and Power Center MUST Power Conter Pentair two inch Check be wired to switch E ON Valve recommended on and switch off P N 263042 24 Hour together Pool Pump Timer N or Switch i 5 mm m RAM a S E Heater 4 115 230 VAC Decem Electrical Supply To Drain Backwash IntelliChlor Installation and User s Guide Loop Plumbing Diagram The IntelliChlor will operate in water flow rates from 15 gallons per minute up to 110 gallons per minute the limit of 2 plumbing For flow rates over 80 gallons per minute it is recommend that you use a bypass loop shown below for best chlorine production Installations with flow rates over 80 gallons per minute are those that have in floor cleaning systems or boost pumps These systems should use a bypass loop with the IntelliChlor JO YOI 94U J i T N J L Flow in Valve Flow out n IntelliChlor Plumbing Diagram Plumb the IntelliChlor cell AFTER the filter and heater If installed on a pool spa combination system the plumb the IntelliChlor cell BEFORE the pool spa return valve to allow proper chlorination of both the pool and spa See diagram below gt WATER F
51. tions In accordance with the Association of Pool and Spa Professionals APSP standards it is recommended that the following water balance conditions be maintained on an on going basis to protect the pool finish and equipment and ensure the pleasing appearance of the water IntelliChlor is warranted to operate properly only if these conditions are met Free Chlorine 2 0 3 0 PPM Above 3 0 PPM may cause corrosion of pool metals Combined Chlorine Chloramines None Super Chlorinate to remove all Chloramines PH 7 2 7 8 USE MURIATIC ACID to lower pH and Soda Ash to raise pH Chlorine Stabilizer Cyanuric Acid 50 75 PPM Total Alkalinity 80 120 PPM Calcium Hardness 150 400 PPM Metals Copper Iron Manganese None Nitrates None IntelliChlor Installation and User s Guide 13 Chlorine Testing It is recommended that chlorine test samples be taken from two places Compare the samples A higher level should be found at the pool return line The higher level at the pool return line indicates IntelliChlor is producing chlorine Take chlorine test samples e At the pool return line e 18 inches 457 mm below the surface and well away from the pool return line What Type of Salt to Use The purer the salt the better the life and performance of the electrolytic cell Use a salt that is at least 99 8 pure NaCl sodium chloride The preferred salt is an evaporated granulated food quality non iodized salt Consult your
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