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Aquacal Pool Pilot 75003 User's Manual

1. 40 TESTING THE FLOW SWITCH CLEANING THE FILTER SCREEN AND CLEANING THE BYPASS VALVE nennen 4 SAUDI 4 REMOVAL OP THE SUPER G EISE 4 veo VR EUR cus Me pe ves dee er une vende 4 VISUAL INSPECTION OF THE SUPER vae euet e ger dud e a uer e EYED Rebate coe seeds ERES rev ed UR 42 IVPANUAT CLEANING OF THE SUPERO PLE tuv aetna eaten amends 42 INSTALLATION OF THE SUPERG 56 42 POOL CHEMISTRY CONTROL MAINTENANCE AND 43 HELPFUL HIN Oe ss 43 REMOVA D ls eho td aaah 43 E SI gos a sale Wastes 43 GIA So Bs he cr ee Re E 43 TROUBEESHOOTING GUIDE 44 49 DDLANDARD DISPBEAYS Do ap 44 47 OTHER
2. Pee 4 DHEOPRISESOUTEET et dh M AI Ati er M A cae ast ae 4 MANTOLDEEOW REQUIREMENT mido Partt eem ceti LL Si 4 POMPEAUXIDIAR Y RELAY INPUT OUIP UT tud etum tede a 4 AGENCY APPRONABS aL M a Mm iU M CL aL 4 FOR 75001 POOL CHEMISTRY CONTROLLER UNIT PH ACID FEED PUMP AND TANK AC INPUT 4 LOW Input POW 4 EIOS C LM M 4 PREPARING THE POOL WACDBBR bet di sue pesada 5 CALCULATA VOLUME E oec suce cM ELLE EM TT COUR I D DE 5 EU scu Ed M M I PP Ar RUT DIM te CT ECL S 5 HOW TO ADD SALT OR REMOVE S ALT cues e Eva bate asd esae UV Pad UNA E e 5 SEE Emi MEC THET M M
3. 34 PROGRAMMING POOL VOLUME state nee 34 PROGRAMMING D VPs tete tue aia Me b naa 34 PROGRAMMING 34 PROGRAMMING SET RELAY FUNCTION PUMP CONTROL 34 PROGRAMMING SELECT REMOTE ELECTRONIC CONTROLLER INTERFACE 2 enne nen 35 PROGRAMMING SYSTEM cen ncaa ee clea ee aeons 35 PH CONTROL AND TOTAL CONTROL MENUS tes ts M EP neck ater 35 BOOTA Dt CO I E D DE TO HET MEA E E 35 PEINE A ram EM D EMEN I MM EI M IM I M E M MM ER MM MD MM EI 35 BESET ACID M ITER 35 ENABLES DIS ABER ACID Duaci Ue esa uberius ated E 35 TOTAL CONTROL MENUS 5 2 Metz ode 36 SEPPITOVEREBBDS ULM E MeL 36 snis gn eer e 36 NON uS De ce 36 CAEIBRAUEINGOPEL seis sea
4. 5 SALT ADDITION CHART 6 BASIC WATER CHEMISTRY RET 7 SATURATION INDE 5 D C 9 OS TTS AON soe 9 BEFORE INSTALLING THE 75003 POOL PILOT DIGITAL SYSTEM ccccccsscccscccssccescccsccesccesccesccesscusccusccesseesceesccecseesceusccesseeusseusess 9 WHATIS INCLUDE D ic 9 WHATS NOT INCLUDED 9 gt eco EE MM LL 10 8 55 Carta m 10 INSTALLATION STEPS m P 10 PLUMBING THE MANIFOLD ASSEMBLY csccseccsscssccsccsccsccsccsscescesccsscescessccscesccsscescessesscessesscsscescesscescessesees 11 MOUNTING THE 75003 DIGITAL CONTROL etoile eo te eve Me orbe eie abe 12 CONNECTIONS
5. 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Calibrate pH is displayed then press SELECT the pH sensor measurement will be displayed 3 Press A V to match a reliable pH test result then press SELECT 4 Press A or V until End menu mode 15 displayed then press SELECT Enable Disable ORP Used to temporarily enable or disable the ORP control system thus disabling the chlorine generation 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Enable ORP or Disable ORP is displayed then press SELECT if Enable ORP then the ORP sensor is disabled press SELECT to enable the ORP sensor if Disable ORP then the ORP sensor is enabled press SELECT to disable the ORP sensor 3 Press Aor V until menu mode 15 displayed then press SELECT Set ORP overfeed Range No ORP overfeed 120 minutes in 5 minute increments Used to stop the chlorine and acid feed if the ORP set point is not reached in the user programmed time 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until ORP overfeed is displayed then press SELECT No overfeed is the factory setting 3 Press A or V to the desired overfeed time setting then press SELECT 4 Press Aor V until End menu mode is displayed then press SELECT 36 PROGRAMMING AND OPE
6. 95 F 13 C 35 C As temperatures fall lower than 75 F 24 C the unit will activate a high purifier lock out and may not allow purifier adjustments up to 100 This prevents the unit from overdriving the cell under cold temperatures which can cause premature cell wear At 55 F 13 C or colder the unit will adjust to a fixed 1 output to prevent the over chlorination and premature cell failure during cooler temperatures At 95 F 35 C or warmer the unit will adjust up to 100 of the normal purifier setting to prevent under chlorination during warmer temperatures The Temperature Compensation feature is not needed and is therefore automatically disabled when the Pool Pilot Digital model 75003 1s installed as a part of the Digital TC Total Control System in conjunction with AutoPilot s Pool Chemistry Controller 75001 Patented Automatic Flow Bypass Manifold Assembly The manifold is connected into the pool plumbing Water from the pool is circulated though the manifold by the circulation filter pump The manifold s four key components are the strainer screen Tri Sensor SuperCell and bypass flow valve The strainer screen prevents debris in the water from entering the Tri Sensor or SuperCell and requires periodic inspection and cleaning Tri Sensor The Tri Sensor provides data from electronic sensors to the Control SuperCell Unit for monitoring water flow water temperature and salt level through the cell The
7. tondeuse cate aco ie ten 30 PEST POO RIOT ROGR AND sean iced Bienes e d 31 ETOP PROGRA ctam MM ELM IM EIL ML DM 31 S LEET LANGUAGE PROGRAM 4 3 32 UNT PROGRAM iacet eR etn ee eer 32 SELEC TEMPERATURE PROGRA Morosin te tase a 5 32 SELECT 12 24 HOUR CLOCK PROGRAM 32 SET TIME OP DAY PROGRAM tem erat 32 PROGRAMMING PUMP OPERATING FIMES 225 tes 32 DOT STIINGEORCERBEVBRSE etta E 33 PROGRAMMING REVERSE DIME 52525 reo eet edlen editio ded named cun 33 BNABDETDISABEEISENIOTE S oni eet e D M M M 33 REPLACE CELL RESET AMPERE HOUR COUNTER cccccscccsscccscccsscccsccessceesccescsecseescseseseesssesesesseesesessseeseees 33 SET PRIME sd EUH IRR DO 33 TABLE OF CONTENTS SAET CATABRA TION one tae iol PD M 34 ADJUSTING TEMPERA TURE DISPIOA eie d rosa amete
8. Diluting will reduce salt and CYA Check and adjust as needed Low CYA Add cyanuric acid 1 1b 5000 gallons increases CYA 25 ppm High CYA Partially drain and refill pool with fresh water to dilute Diluting will reduce salt Check and adjust as needed Excessively high chlorine levels can cause premature cell failure and corrosion damage to pool fixtures and equipment Always follow the instructions on the manufacturer s label whenever adding chemicals to your pool PREPARING THE POOL WATER Saturation Index SI The Saturation Index is a formula used to predict the calcium carbonate saturation of water that is whether your water will precipitate dissolve or be in equilibrium with calcium carbonate Your water is properly balanced if the SI is 0 0 3 If your SI is greater than 0 3 scaling and staining will occur If your SI is less than 0 3 then the water is corrosive to metallic fixtures and aggressive to plaster surfaces and vinyl liners A high or low SI can cause premature damage to the cell equipment or pool finish As a general rule higher concentrations of calcium total dissolved solids pH and alkalinity all promote a greater tendency for scale Scaling potential also increases with increasing temperature Use the chart below to determine your overall water balance Test your water for pH water temperature Calcium Hardness Total Alkalinity and Salt Level and use the equivalent Factors TF C
9. Slide the plastic cover back over the metal BNC connector once installed Or twist the lock knob counterclockwise and slide down to remove Electrical Connections Connecting the 75001 Pool Chemistry Controller Turn off power before making any electrical connections The 75001 Pool Chemistry Controller is provided with an attached interface cable similar to a telephone cable which plugs directly to the base of the 75003 Pool Pilot Digital Control unit where indicated in the diagram below 75001 Pool Chemistry Controller Terminal This allows communication between the Pool Chemistry Control unit and the Digital Control unit 9 75001 Pool Chemistry Controller Terminal L From 75001 Pool Chemistry Controller Lug 7 5008 e Relay Terminal 75003 Digital Control Panel Base Plate 19 INSTALLATION PH Installation Connecting the pH Acid Feed Pump Turn off power before making any electrical connections The electrical instructions will depend on the Set Relay 1 configuration of the Pool Pilot Digital 75003 see pg 34 One Speed or Two Speed Pump Digital is controlling the main circulation pump Note The AC Power Source voltage and the Stenner Acid Feed Pump voltage must match one another Auxiliary Relay Kit 75008 is required complete mounting and wiring instructions are included with the kit 1 Mount the 75008 Auxiliary Relay box the proper distances between the Con
10. Error Acid off stopped due to Turn the control valves to the correct position to allow water flow Check Flow insufficient water flow through the manifold If a suction type vacuum cleaner is used then clean if clogged Check and clean the skimmer basket Check and clean the pump basket Check and clean or backwash the main circulation filter Clean the manifold screen of trash or debris Testing the Flow Switch Cleaning the Filter Screen and Cleaning the Bypass Valve see pg 41 Verify that the Tri Sensor cable is plugged in Plug it in using care to orient it correctly before inserting it Warning Read warning instructions and see illustrations in Connecting the Tri Sensor Cable on pg 15 Clean the SuperCell if plugged with debris or calcium scale See the sections under SuperCell on pgs 41 42 for directions on removing inspecting and cleaning Check for air in the manifold by loosening the top union on the cell to see if air or water comes out If air comes out then there may be a vacuum side leak or the pump may be undersized Check for leak at pump basket O ring leaking valve or fitting If the pump is a 2 speed pump is it on low speed The low speed may not create enough flow for the manifold Chlorine generation has Add salt as indicated on the Digital display to bring the salt level up to stopped because the salt 3000 ppm 3 0 g l level is below 1900 ppm which is too low The salt level is between 2000 2400 ppm
11. INSTALLATION Low voltage wiring Connecting the SuperCell Cable 1 The SuperCell cable connector is keyed and must be aligned to connect properly Line up the cell cord and plug into the cell cord connector located on the bottom right of the Pool Pilot Digital base plate 2 The other end of the SuperCell cable may have a red weather plug located in one of the holes The SuperCell will have either 2 or 3 electrical terminals the SuperCell has 3 electrical contact terminals then the red weather plug should be removed and discarded e Align the cable and terminals and connect them together e the SuperCell has 2 electrical contact terminals then the red weather plug will seal the unused contact in the cable Position the SuperCell plug so that the two open holes align with the two mating terminals and connect them together Connecting the Tri Sensor Cable The Tri Sensor Cable is 12 feet 3 4m long and connects the Tri Sensor Assembly to the Pool Pilot Digital Both ends are keyed and must be aligned to connect properly e Connect the white 6 pin connector to the mating plug located on the base of the Pool Pilot Digital e Remove the black dust cap that covers the electrical connector on the Tri Sensor Assembly located near the top of the Manifold Assembly e Carefully align the black 6 pin connector to the mating plug located on the Tri Sensor Assembly The cable connector has a slot that will align with the slot on the
12. chlorine and acid feed operation if there is a loss of flow for a user programmed time period No prime protect 1s the factory setting Caution Damage to equipment caused by a loss of prime to the pump system is not covered under warranty The prime protection feature is designed to assist in preventing damage However conditions beyond the control of the Digital Control System may still allow damage to occur 1 Press MENU press or V until Maintenance menu or Installer menu is displayed then press SELECT 2 Press Aor V until Set prime protect is displayed then press SELECT 3 Press A or V to adjust to the desired length of time before prime protect activates then press SELECT 4 Press Aor V until End menu mode is displayed then press SELECT 33 PROGRAMMING AND OPERATION MENUS For the Installer Menu press and hold SELECT button for approximately 13 seconds to access this feature Calibrating the salt sensor Note The unit has been calibrated at the factory and should not need further adjustments In the event that the salt display does not match on site test results follow these steps 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Calibrate salt is displayed then press SELECT 3 Press Aor V until the number on the display matches the accurately measured pool sample then press SELECT The maximum adjustment is 1000 ppm 1 0 g
13. which is low Purifier OFF Add Salt xxx Ibs Warning Add Salt xxx Ibs Add salt as indicated on the Digital display to bring the salt level up to 3000 ppm 3 0 g l Purifier OFF Add Salt xxx Ibs or Warning Add Salt xxx Ibs No Error Displays Added salt as indicated by the Pool Pilot but salt level still shows low Salt level on display does not match pool store or salt test strip The pool volume has not been set up in the Installer Menu and is higher than the factory default of 15 000 gallons 56 000 liters The salt sensor in the Tri Sensor may be dirty The Salt display may need to be calibrated The test may have been faulty or the salt strips may be old or damaged Have your salt level re checked at your local pool store If the discrepancy is more than 400 ppm 4 mg l then contact AutoPilot Systems If the Tri Sensor salt blades are clean then the salt sensor may need to be re calibrated TROUBLESHOOTING GUIDE Message on Problem Typical Solution Display Warning Check Clean Cell Conductivity of the water is reduced and is usually caused by Low salt cold water or a Scaled cell Check the salt level and adjust to 3000 ppm 3 0 g l or verify salt calibration For water temperatures below 65 F 18 3 C increase salt to 3500 ppm 3 5 g l Remove and inspect the cell for white calcium scale Follow the instructions on pgs 41 42 to clean the cell Increase salt level to 3500 ppm
14. 000 25 000 30 000 35 000 40 000 ppm g 4 000 8 000 18 000 38 000 56 000 76 000 94 000 114 000 132 000 152 000 25 50 125 250 376 501 626 751 876 1 002 11 23 57 114 170 227 284 341 398 454 250 23 46 115 230 344 459 574 689 803 918 0 25 10 21 52 104 156 208 260 312 364 416 500 21 42 104 209 313 417 522 626 730 835 0 50 9 19 47 95 142 189 237 284 331 379 750 19 38 94 188 282 376 470 563 657 751 0 75 9 17 43 85 128 170 213 256 298 341 1 0 8 15 38 76 114 151 189 227 265 303 1 25 7 13 33 6 99 133 166 199 232 265 1 5 6 11 28 57 85 114 142 170 199 227 1 75 5 9 24 47 71 95 118 142 166 189 2 0 4 8 19 38 57 76 95 114 133 151 d 2 25 3 6 14 28 43 57 71 85 99 114 2 500 4 8 21 42 63 83 104 125 3 000 3 0 Ideal 3 500 OK for Pool Pilot Operation This is typically the maximum salt level desired by most pool 3 5 owners operators since most people can taste salt levels above this Greater than 3 500 OK for Pool Pilot Operation but greater than 6000 ppm can cause corrosion to metallic objects If lower salt level is desired partially drain and refill with fresh water PREPARING THE POOL WATER Basic Water Chemistry Your Pool Pilot Digital is designed to produce chlo
15. ON DITIONS ce eran TOTAL CON FROL AND PH LDISPIEAYS deem D SUM dr a ane a 46 49 vi SYSTEM OVERVIEW System Overview Although the Pool Pilot is easy to use it is important to read through the manual before attempting to operate the unit The Pool Pilot Digital 75003 is a salt chlorination system for pool or spa purification which is designed to operate in the following configurations e Purifier standard mode manually adjusted purifier output See pg 27 for system operation and programming e Purifier and pH Control optional mode standard purifier mode operating in conjunction with the optional pH Acid Feed Pump and Tank System 75004 75005 75006 75007 which is manually programmed for daily pH control This mode will require 75008 Auxiliary Relay Kit when using the Digital Set Relay 1 to control the main circulation pump See pg 28 for system operation and programming e Total Control optional mode utilizing the optional 75001 Pool Chemistry Controller for automatic daily adjustments of purifier and pH based upon user programmed settings See pg 28 for system operation and programming The Pool Pilot has a digital interface that allows the unit to be operated through a Jandy Aqualink RS versions I and K only Polaris EOS or Pentair IntelliTouch electronic remote panel located i
16. and discarded Align the cable and terminals and connect them together An illustration of the cable is in Connecting the SuperCell Cable on pg 15 If the SuperCell has two 2 electrical contact terminals then the red weather plug will seal the unused contact in the cable Position the SuperCell plug so that the two open holes align with the two mating terminals and connect them together e Turn on the system e Check for leaks and proper operation of the system 42 SYSTEM MAINTENANCE Pool Chemistry Controller Sensor Maintenance Warning The sensors are very delicate devices They must be handled with care and protected at all times Take care not to scratch or break the glass tip Helpful Hints Do not allow the sensor tip to dry out for more than one hour or damage to life or accuracy may occur e The sensor tips must always be kept wet when in use or storage The sensors are threaded into the Flow Cell using Teflon tape It is not recommended to use any dope compound or glue to install the sensors e Save the cap box and packaging that the sensors came in for storage Do not over tighten the sensors into the flow cell as the flow cell housing may be damaged by this e sensors require 24 hours to stabilize when first installed Any calibration should be done after this point Removal The ORP and pH sensors are connected to the 75001 Pool Chemistry Controller electronic processor unit using BNC conn
17. chlorine and acid feed if the pH set point is not reached in the user programmed time 1 Press MENU press or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until pH overfeed is displayed then press SELECT No pH overfeed 15 the factory setting 3 Press A or V to the desired overfeed time setting then press SELECT 4 Press V until End menu mode 1s displayed then press SELECT Set pH min Used to set the lower limit of pH adjustment before a warning message is displayed 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Set pH min is displayed then press SELECT 6 5 is the factory setting 3 Press A or V to the desired pH min setting then press SELECT 4 Press V until End menu mode 1s displayed then press SELECT Set pH max Used to set the upper limit of pH adjustment before a warning message is displayed Note For safety reasons acid will not feed when measured above the programmed pH max Press MENU press or V until Maintenance menu 15 displayed then press SELECT Press A or V until Set pH max 1s displayed then press SELECT 8 0 1s the factory setting Press or V to the desired pH max setting then press SELECT Press or V until End menu mode is displayed then press SELECT p BE Calibrate pH Used to match the pH display of the Digital to the results of a reliable pH test kit
18. dace ou n M as oc ce MM EM M LCD 36 ENABDE DISABEE CORP aiit ui 36 Rr cT 36 PLECTRONIC CONTROLEER OPERATION 37 ADJUSTING AND SUPERCHLORINATING THE POOL PILOT THROUGH THE ELECTRONIC CONTROLLER CONTROL 37 PROGRAMMING THE POOL PILOT DIGITAL FOR AN ELECTRONIC CONTROLLER 1 37 ELECTRONIC CONTROLLER DISPLAYS CHECK POOL ee Dvd CE DER oru buds 37 VE MAINIENANC E wi sec 38 WINTER bem SRM 38 DPRBEZEPROTEC TION PROGRA M Det Mes ML SPEED PP A Ee 38 hue nuc at M 38 MS OC A AND RATING E Lus M ba ease a enews aaa sa UA P ena aeons 39 TRIE SENS ORIN S ISIN 40 REMOVING INSPECTING CLEANING THE
19. is recommended to replace the acid feed lines including the Stenner feed tube annually Reinstall all equipment removed for winterizing Follow the start up instructions for filling acid tank and priming acid pump see pg 23 steps 9 11 38 SYSTEM MAINTENANCE Fuse Location and Ratings Follow the instructions on pg 12 for Mounting the Control Unit to access the fuses on the internal circuit boards 1 Turn off the power from the circuit breaker i DAN GER Before servicing this unit Main Power Board Fuse Specification 250 Vac 6 amps Main AC Power Fuse 250 Vac 3 amps Control Panel Circuit Board Fuse 250 Vac 20 amps Cell Fuse 250 Vac amp PCC Fuse Total Control Interface Board 838 Fuse Specification 250 Vac 1 amps AC Input Power Fuse 250 Vac 1 amps 12V Feeder Power Fuse 39 SYSTEM MAINTENANCE Tri Sensor Assembly Tri Sensor Assembly 909 1 5 Cable Ordered S tel The Tri Sensor Assembly is used to measure water Ordered flow salt level and water temperature salt Sensor Blades When the water flow reaches a minimum flow rate of Flow Paddle 20 gpm 76 L m the flow paddle magnet closes a micro switch that is monitored by the Control Unit Temperature Sensor Post Note The use of high strength magnet devices in the Tri Sensor O Ring 19028 close proximity of the Tri Sensor can cause the flow switch to function incorrectly The Control U
20. is displayed then press SELECT 2 Press Aor V until Select units is displayed then press SELECT English units is the factory setting 3 Press A or V until desired measurement English units gallons and pounds or Metric units liters and kilograms 15 displayed then press SELECT 4 Press V until End menu mode 15 displayed then press SELECT Programming the temperature measurement unit for the display Allows for personal preference temperature display 1 Press MENU press or V until Owner or Installer Menu is displayed then press SELECT 2 Press Aor V until Temperature unit is displayed then press SELECT Fahrenheit 1s the factory setting 3 Press A or V until desired measurement unit Fahrenheit or Celsius 1s displayed then press SELECT 4 Press Aor V until End menu mode is displayed then press SELECT Programming the time format to 12 24 hour clock for the display Allows for personal preference time clock display Press MENU press A or V until Owner or Installer Menu 1s displayed then press SELECT 2 Press Aor V until 12 24 hour clock is displayed then press SELECT 12 hour is the factory setting 3 Press A or V until desired time format 12 hour 24 hour 15 displayed then press SELECT 4 Press Aor V until End menu mode 15 displayed then press SELECT Programming the time of day Allows for changes to the time of day displays for time z
21. is displayed then press SELECT Factory setting is SC 48 3 Press A or V until the correct SuperCell type is displayed SC 36 SC 48 SC 60 CC 15 then press SELECT 4 Press Aor V until End menu mode 15 displayed then press SELECT Changing the output cell power level See recommendations on pg 29 for when to change cell power Factory setting is Cell Power 2 1 Press MENU press or V until Installer menu 1s displayed then press and hold SELECT for 13 seconds 2 Press Aor V until Set cell power is displayed then press SELECT 3 Press A or V until desired level Cell power 1 2 or 3 is displayed then press SELECT 4 Press Aor V until End menu mode 15 displayed then press SELECT Programming the Set relay 1 function Used when the Digital is used to control the main circulation pump or pH acid feed pump 1 Press MENU press or V until Installer menu 1s displayed then press and hold SELECT for 13 seconds 2 Press Aor V until Set Relay 1 is displayed then press SELECT Relay not used is the factory setting 3 The display will show the current configuration Relay not used pump is controlled by an external time clock controller or switch One speed single speed pump is wired and programmed to the Digital Two speed two speed pump is wired and programmed to the Digital Acid pump only when the main pump is not controlled by the Digital and the pH control option is installed 4 Pres
22. low voltage connections High voltage connections will be made for providing the direct input power to it Additional high voltage connections may be made to the filter pump from the Pool Pilot Digital Low voltage connections will be made to the Tri Sensor and SuperCell Additional low voltage connections are provided for optional equipment such as 75008 pH feeder 75001 Pool Chemistry Controller or an ORP or electronic control Ensure that power is disconnected before wiring this unit DANGER Follow all state local NEC CEC if applicable electrical codes Use copper conductors only Grounding and Bonding Connect a ground wire from the primary electrical input to the grounding lug located inside the box Also ground any piece of high voltage equipment that is connected to the Pool Pilot Digital relay The Pool Pilot Digital must also be connected to the pool bonding system with an SAWG 6AWG for Canada wire A lug is provided on exterior of the unit at the bottom High Voltage Wiring Converting from 230 Vac to 115Vac The 75003 Pool Pilot Digital has been configured at the factory for 230Vac service Verify that this is the desired input voltage configuration If 115 Vac input power is required follow the directions below to convert the input voltage If the cover has not been removed review the steps in Mounting the 75003 Pool Pilot Digital on pg 12 for instructions on removing the cover and disconnecting the
23. mating plug The slot on the plug is aligned with the 1 Tri Sensor Directional Flow Indicator Do NOT force e Carefully slide the connector into the mating plug Tri Twist the cable connector locking ring to secure the puc assembly Ground Lug Cell Cord Connector Digital Control Panel Base Plate HUM Tri Sensor a Cable connector to the Tri Sensor Tri Sensor Warnin g The pins in the Tri Sensor plug will be permanently damaged requiring Tri Sensor replacement if the connector is forced on or not aligned properly during insertion DO NOT FORCE 15 INSTALLATION Pool Chemistr y Controller Installation Tum off power before making any electrical connections Time 11 Circuit Clock Breaker 1 75008 75001 75003 Auxiliary Total Control Digital Unit I Relay AUTOPILOT SYSTEMS AUTOPILOT SYSTEMS I optional 7 AutPitcom AutPiotcom L 5977 Acid Pump Power Wire Water Sample feed line Water Sample return line pH Acid Feed System 75004 75005 75006 75007 en 16 INSTALLATION Before Installing the 75001 Pool Pilot Pool Chemistry Controller System or the 75004 75005 75006 or 75007 pH Acid Feed Pump and Tank System e Determine that everything needed for installation is on hand Find a suitable mounting location for the Pool Chemistr
24. or Low speed start time a Press A or V to adjust the hour up or down Press SELECT when hour is correct B Or press V Delete to delete the current pump program C Or press SELECT to leave program unchanged 4 Press Aor V until End menu mode 1s displayed then press SELECT 32 PROGRAMMING AND OPERATION MENUS For the Installer Menu press and hold SELECT button for approximately 13 seconds to access this feature Programming the SuperCell to activate a Force reverse cycle for testing Used to verify if the Digital unit is reversing polarity self cleaning There is a 30 second delay before reversing takes place after you End menu mode 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT Press or V until Force reverse is displayed then press SELECT Cell reversing will display temporarily Press or V until End menu mode is displayed then press SELECT The period on the end of 2 line of the display will either appear or disappear based on its previous state to indicate that the cell has reversed jb a le Programming the SuperCell reverse time self cleaning cycle 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Set reverse time is displayed then press SELECT 4 hours is the factory setting 3 Press A or V until the desired cycle time 2 4 8 or 16 hours is displayed then press SELECT Warni
25. or increase temperature on heater if applicable The salt level is below 2800 ppm 2 8 g l amp temperature below 70 21 The salt display differs from Adjust salt display in the Salt Calibration mode see pg 34 to calibrate salt test The cell is scaled Determine frequency of scaling e ONE week or less Power Supply not reversing polarity contact factory TWO weeks or more Water Chemistry related problem check the Saturation Index see pg 8 Adjust water chemistry or adjust Set Reverse to a shorter cycle Verify that the incoming voltage matches the voltage of the Control Unit see pg 13 1 Check the cell for calcium scale build up Clean as needed 2 Check for visual wear on the edges of the terminal blades 3 Check the cell cord for tight connections on the cell and on the power supply Check the cell cord banana terminals and cell plug for burns Tighten or replace as needed The cell cord is disconnected Verify cell cables are inserted fully into the Digital base cell connector The cell 15 heavily scaled Remove and acid wash as described on pgs 41 42 If this is a new installation Verify that the incoming voltage matches the voltage of the Control Unit see pg 13 Warning Cell is not receiving the Enter Test Pool Pilot mode through the menu Write down the salt level Low Amps expected Amps water temperature and cell volts and amps Cell e Ifthe volts are 28 29 then
26. plastic housing and replace if needed 40 SYSTEM MAINTENANCE Testing the Flow Switch Cleaning the Filter Screen and Cleaning the Bypass Valve The flow switch is an important safety protection device When water flow has stopped it 1s important that the SuperCell be automatically turned off to prevent damage to the cell or system It is important to verify the safe and proper operation of the Tri sensor s Flow Switch protection device The following procedure can be used to verify the proper operation of the flow switch or to flush debris from the Bypass Valve 1 2 3 on 10 11 12 13 14 15 Turn off the pump Slightly loosen the union nut just below the cell on the side of the manifold that does not contain the filter screen Completely loosen the manifold union nut that contains the filter screen and pivot the manifold to gain access to the filter screen Remove the screen Clean the screen if dirty If the screen was dirty then the system may need to be purged to remove excess debris Leave the manifold off and run the pump for a few seconds until clear ime Wrap the strainer screen securely with a small piece of TLL plastic wrap saran wrap food wrap or zip lock bag as indicated in the diagram place it back in the union Tighten the two unions that were loosened Reconnect the tri sensor cord onto the tri sensor Turn on the pump and the Pool Pilot The plastic will stop water flow to the
27. temperature bather load exposure to direct sunlight special water features and pump runtime particularly in commercial applications 1 SYSTEM OVERVIEW Control Mode Manual purifier and pH control Note Requires option 75004 75005 75006 or 75007 pH Acid Feed Pump and Tank System must be installed with the 75003 Digital Controller for this mode to function Option 75008 Auxiliary Relay Kit will be necessary if the Digital is used to control the main circulation pump This mode adds to the Purifier mode by using an Acid feed pump that is user programmed for manual feed of diluted muriatic acid The Acid Feed Pump and Tank System come with AutoPilot and Stenner factory components If the Stenner factory components are used for the installation follow their installation instructions Otherwise follow the instructions 1 this manual Total Control Mode Pool Chemistry Controller Automated purifier and pH control Note Option 75001 Pool Chemistry Controller and the pH Control System must both be installed with the 75003 Digital Controller for this mode to function These options activate the Total Control mode in which the purifier defined below and pH levels are monitored using sensors and controlled automatically to maintain proper levels The system automatically enters the Total Control configuration if it is able to communicate with the Pool Chemistry Controller The system will display Error purify of
28. to 230 Vac it must be installed at least 5 1 5m horizontal distance from the pool or spa wall or more if local codes require If it is connected to 115 Vac it must be installed at least 10 3m horizontal distance from the pool or spa wall The Pool Pilot Digital is designed to mount vertically on a flat surface with the wiring inputs facing downward The enclosure is designed to allow heat to dissipate from inside the box It is important not to block the top or bottom of the box Do NOT mount the unit inside a panel or a tightly enclosed area without proper ventilation The cover of the Pool Pilot Digital is removed from the sides by four thumbscrews so it 15 advisable to leave adequate space on the sides for hand access to the thumbscrews When selecting a location for installing the Pool Pilot Digital please note that the Tri Sensor and SuperCell cables are 12 3 6 m long Warning Verify that the selected Pool Pilot Digital location is close enough to the Manifold Assembly so that the Tri Sensor and SuperCell Cables will have enough slack so that the cables can be easily handled for service or maintenance Read the following section completely before proceeding damage to wires and connectors may occur 1 Level and tape the mounting template to the selected mounting location Mark the wall for the 4 mounting holes 2 Plastic anchors and screws have been provided for concrete or stucco walls Drill and install the plastic anc
29. water to acid 22 RPT ee 70 INSTALLATION Connecting the 75003 Digital Control unit to any other external ORP controller A Dry Contact closure must be provided and the Purifier output must be set to 0 Turn off power before making any electrical connections The ORP connection must be made to the internal ORP IN TERMINAL marked TB2 on the lower Circuit Board where indicated in the diagram above and should send a closed circuit condition when the ORP level is below the set point When the ORP set point is satisfied the ORP controller should send an opened circuit condition automatically deactivating the Pool Pilot For ORP control systems not providing a dry contact closure PN 110 ORP Relay Kit is required To avoid damage to the Pool Pilot Control Unit or voiding the warranty do NOT CAUTION 4 idee energize the ORP inputs The ORP input is for dry contact use only Low Voltage Access Port L TB2 AY fy 838 PCB 75003 Digital Control Panel Base Plate ORPandContollerTemamah and Controller Terminals on Circuit Board Installing the Optional 110 ORP Relay Kit Warning Turn off power to the Pool Pilot Digital and ORP controller before connecting any wires In the event that the controller does not provide dry contact closure a standard 110 Vac output can be used with the 1 10 ORP relay kit to provide
30. 00 ppm 3 0 g l Add salt Lbs xx Kg The amount of salt needed to maintain 3000 ppm 3 0 g I Temperature XX F XX C The temperature of the water flowing through the Tri Sensor XX XX x A The measured voltage and current that was sent to the SuperCell Amp Hrs xxxxxx The amount of current times hours of operation received by the SuperCell xx oz xx ml acid fed The amount of acid dispensed into the pool when set to TCC or Acid Feed mode ORP xxx The user programmed ORP set point when set to TC mode pH X x The user programmed pH set point when set to TC mode The unit will automatically leave the menus and revert to normal operation Running the View setup program Program and parameter menu to view the current programmed settings Press MENU press or V until View Setup is displayed then press SELECT The display will automatically toggle through the following displays or pressing A or V allows manual control forward and back While in this feature pressing MENU will override the remaining displays and exit back to normal operation 1 2 Software V X Xx The version number of the Pool Pilot Digital 75003 software OpEC V X X X If installed the version number of the PCC 75001 software The serial number of the unit may be displayed if entered Cell xC XX The cell type programmed in the Installation Menu SC 48 is the factor
31. 5 dora 13 GROUNDING AND BONDING 32 21 52 6 2 13 13 CONVERTING PRONE VAC AC 13 CONNECTING POWER TO THE dU gate eo ete 14 CONNECTING POOL PILOT TO AN EXTERNAL TIMER OR CONTROLLER 14 CONNECTING POOL PILOT TO ONE SPEED PUMP OR 0 0 6 een esi se 14 CONNECTING POOL PROT TO XLWO SPEED PUMPD 4 core dass 14 1V TABLE OF CONTENTS TOW VOLTAGE WIRING sales desta 15 O er rds roc URN are NR Sen 15 CONNECTING THE R SENSOR CABI E LE 15 INSTALLATION POOL CHEMISTRY CONTROLLER AND PH CONTROL SYSTEM 16 BEFORE INSTALLING THE 75001 POOL PILOT POOL CHEMISTRY CONTROLLER SYSTEM 17
32. Approvals e ETL tested to conform to the following UL specifications o ULIOSI Standard for Safety for Swimming Pool Pumps Filters and Chlorinators o UL 1563 Standard for Safety for Electric Spas Equipment Assemblies and Associated Equipment CAN CSA E335 1 Safety of Household and Similar Electrical Appliances 75001 Pool Pilot Pool Chemistry Control unit pH Acid Feed Pump and Tank AC Input Power 75004 120 Vac 1 7 amps 75005 220 Vac 0 9 amps 75006 230 Vac 0 9 amps 75007 250 Vac 0 9 amps 75008 Auxiliary Relay Kit 115 230 Vac Relay 30 amps max Low Voltage Input Power PCC Communication Factory Low Voltage Interface Cable provided with 75001 75008 pH Auxiliary Relay Kit Optional Dedicated Factory Low Voltage Terminal Flow Cell Flow Sensor Fail Safe status Maximum working pressure 50 psi PREPARING THE POOL WATER Calculating Pool Volume needed to determine proper balance chemical additions depth of deep end depth of shallow end 2 Pool Shape Gallons pool size measured in feet Liters pool size measured in meters Average Depth Length x Width x Average Depth x 7 5 Length x Width x Average Depth x 1000 Diameter x Diameter x Average Depth x 5 9 Diameter x Diameter x Average Depth x 785 Length x Width x Average Depth x 5 9 Length x Width x Average Depth x 785 Your calculated pool volume is Enter this number for reference on the information section pg iii Type of Salt It is im
33. Control Unit will use this data to determine if Strainer Screen the conditions are safe for the SuperCell to operate u Bypass Flow Valve The SuperCell receives power from the Control Unit and converts the salt water to chlorine The Bypass Flow Valve allows water flow rate to be optimized through the SuperCell The slower water flow through the SuperCell results in a more efficient Super Chlorination effect in the cell that results in better overall sanitization results mz SPECIFICATIONS Specifications 75003 Pool Pilot Digital Control unit Input Power 230 Vac 1 5 amps Normal input configuration shipped from the factory 115 Vac 3 amps Optional input configuration jumper wire to convert included Dry Contact 5mAtypical Non factory input circuit 110Vac output require a Relay Kit PN 110 ORP Chlorine Output SuperCell Type Maximum Chlorine Output 75003 Control unit set on Cell Power 3 SC 36 1 28 Ibs day 0 58 kg day SC 48 1 56 Ibs day 0 71 kg day SC 60 1 92 Ibs day 0 88 kg day CC 15 2 50 Ibs day 1 14 kg day Commercial Cell Manifold Flow Requirements Minimum Flow Rate 20 gallons per minute gpm 76 liters minute L m Maximum Flow Rate 100 gallons per minute gpm 379 liters minute L m Maximum Pressure 85 psi as tested by NSF Pump Auxiliary Relay Output Voltage Input Amps HP max 115 Vac 30 amps 1 HP 230 Vac 30 amps 2 5 HP Agency
34. F AF Constant from the chart below to determine your Saturation Index Adjust your chemicals to maintain balanced water pH TF 5 SI 7 244 C 0 6 94F 344C 0 8 __103 394 C 0 9 d Jd metals etches staining and plaster HR cloudy water finishes and conditions irritates skin Examples Water test results 1 Total Alkalinity 125 ppm gt AF 2 1 Calcium Hardness 400 ppm gt CF 2 2 pH 7 4 gt 7 4 Water Temperature 84 F gt 0 7 Salt Level 3000 ppm gt SC 12 4 7 4 0 7 2 2 2 1 12 4 0 Water is perfectly balanced Water test results 2 Total Alkalinity 2 200 ppm gt 2 3 Calcium Hardness 600 ppm gt CF 2 4 7 8 gt 7 8 Water Temperature 84 F gt 0 7 Salt Level 3000 ppm gt SC 12 4 7 84 0 74 2 4 2 3 12 4 0 8 Water is scale forming INSTALLATION Before Installing the 75003 Pool Pilot Digital System Determine that everything needed for installation 1s on hand Determine where the Manifold Assembly will be plumbed Find a suitable mounting location for the Control Unit within proper cord length to the manifold Plan cord runs for SuperCell Cable and Tri Sensor Cable For optional TC or pH control systems plan for flow cell water feed tubes and acid feed tube and electrical connections Plan wire runs and wiring connections for source power and optional con
35. M Cc Re Ns eH Pr Se 17 WEA TAS INO TENG EU DED 17 MOUNTING THE POOL CHEMISTRY CONTROLLER UNIT cttm 18 POOL CHEMISTRY CONTROLLER SENSORS AND INTERFACE CABLE 19 CONNECTING THE ORE AND PITCONNECTORS esie EE eeu E DR ME VAL 19 CONNECTING THE INTER EAGE C AB EB 25 EROR rece acne ances Jean 19 PH BB NL UP 20 CONNECTING THE Plt PRED PUMP 3 52 32 3 55 2 99 3995 3230 0322599391 958940 8 6 0 400058 0 2550 45 aes id ane roo reu Seco de Ro eoe eed 20 INTO THE DIGITAL 01483968 9002 I lae ped LAM AES eb 20 ENTO THE 372008 AUXILIARY RELAY IET sos eon rie Seeds e EE Ere erm astu o ted br wea sents oo do P aate 20 POOL CHEMISTRY CONTROLLER FLOW CELL PLUMBING cmm 21 DH CONTROL PRU MER UNG btt a isin 22 CONNECTING THE 75003 DIGITAL TO ANY OTHER CONTROLLER 23 INS FALLING THE OPTIONAEAELTO ORP RSEDAY ee Bi
36. Ns O 77007000000 iv vi SYSTEM 1 CHLORINE TION Mem NT 1 PG ONT ROM VU ae tae M 2 TOTAL CON WU MODE 2 TOLAD CONTROL PROTECTION rentia sodes brote pesas 2 DEFINING ACTIVE CHLORINE 0 00 0 00 00 0 66 hene ne e rese ses esse es sese tese 2 DEFINING PH OPERATION bow gon 2 CONTROL UNIT PEA TURES 3 PATENTED LEMPERAXTURE CONIPENS ATION 3 PATENTED AUTOMATIC FLOW BYPASS MANIFOLD 55 2 0 6 ee sese ee see sten sees ee sese sees 3 SPECIFICATION 4 FOR 75003 POOL PILOT DIGITAL CONTROL UNIT Ca a
37. Pool Pilot Digital Salt Chlorine Generator AUTOPILOT Swimming Pool and Spa Purification System Model 75003 Owners Manual For Indoor or Outdoor Use Pool Owner Save this manual for reference Installer Leave this manual with pool owner MPORTANT Read This Manual Before Installing amp Operating This manual covers the installation of the Digital Chlorine Generator with any of the following Cell Manifold assemblies sold separately 94105 94107 94113 941 15C This manual also covers the installation connection and programming of the optional 75001 Pool Chemistry Controller for the Pool Pilot Digital Total Control and the 75004 75005 75006 or 75007 pH Acid Feed Pump and Tank Kit LOR Y 300 OL 99841 IMPORTANT SAFETY INSTRUCTIONS When installing and using this electrical equipment basic safety precautions should always be followed including the following READ AND FOLLOW ALL INSTRUCTIONS DANGER RISK OF ELECTRICAL SHOCK Disconnect all AC power when installing or servicing this system A bonding lug has been provided on the outside of the Control Unit This lug permits the connection of a No 8 AWG 8 4mm solid copper bonding conductor Make this connection between the Control Unit and all other electrical equipment and exposed metal within 5 feet 1 5m of the Control Unit field installed metal components such as rails ladders drains etc within 10 feet o
38. RATION Operating the Pool Pilot with an Electronic Control System Note Refer to the instructions in the manual for the Electronic Controller to adjust and boost the Pool Pilot Digital output setting When configured for operation with an electronic control system the Electronic Control System takes control of the pump operation purifier output and Boost mode and will display Remote Operation To test the Pool Pilot enter the Maintenance menu and select Disable Remote see pg 33 for instructions This will disable the electronic controller and restore the Pool Pilot to the normal operating mode for diagnostics Once completed reactivate Enable Remote to restore Electronic Control operation Note Remote Operation disables the Temperature Compensation feature and will require periodic testing and adjusting of your chlorine level due to seasonal temperature changes Remote Operation also overrides the Pool Pilot Purifier setting and operates as per the Electronic Control System setting When the pump stops or the electronic controller is in the Service mode the purifier output will be turned off The purifier output and Boost operation are both functions within the electronic controller menus and are accessible only when the pump is running Programming the Pool Pilot Digital for an Electronic Control System Programming must be done in two menu modes 1 Press MENU then press A or V until Installer menu is displayed then press and
39. SIDE or to the same location as the circulation pump wires pump connected to circuit breaker time clock or electronic controller and run through the conduit to the Pool Pilot Digital 3 Connect the ac wires into the Pool Pilot Digital to terminals 1 and 2 on the Terminal Strip 4 Connect the ground wire to the ground lug to the left of the Terminal Strip LOAD OUT to Digital Terminal Strip LINE IN from Circuit Breaker or Electrical Panel Ground Wire 43 4 5 6 2 Time Clock or Electronic Controller Relay To Pump Connecting Pool Pilot Digital to One Speed Pump or pH Acid Feed Pump LINE IN Terminal Strip 1 Follow the LINE IN instructions above 2 Select wire gauge and type that meets local and national electrical codes for powering the pump LINE OUT 1 Connect the LINE OUT pump wires to terminals 4 6 and the ground lug as labeled LINE OUT to One Speed Pump Connecting Pool Pilot Digital to Two Speed Pump pH Acid Feed Pump LINE IN 1 Follow the LINE IN instructions above 2 Select wire gauge and type that meets local and national electrical codes for powering the pump Note The pump is always powered A safety shut off wall switch Terminal Strip if the circuit breaker cannot be accessed quickly LINE OUT Connect the LINE OUT pump wires to terminals LINE OUT 3 4 5 and the ground lug as labeled to Two Speed Pump 14
40. a Pool Spa combination the manifold must be located as the last component in the POOL RETURN LINE to avoid over sanitization of the SPA For flow rates within the normal range e The manifold can be directly plumbed into the system as shown in the diagram to the right If the flow rate for the system is less than 20 gpm 76 L m a larger pump must be installed Note Ensure that flow rates for a two speed pump can provide sufficient flow at low speed For flow rates greater than 100 gpm 379 L m 516 spring bypass check valve must plumbed in parallel with the manifold as shown in the diagram to the right Flow gt gt C gt To Pool Return 5 Ib bypass valve Step 2 Install the cell into the manifold with the cell cable terminals at the bottom of the manifold as illustrated in the picture Tighten the unions by hand for a watertight seal The manifold will accept the SC 36 SC 48 SC 60 residential cells or the CC 15 commercial cell If the cell is improperly installed upside down water from rain or other sources may enter WARNING d the cable contacts and result in failure of the SuperCell and void your warranty 11 INSTALLATION Mounting the 75003 Pool Pilot Digital Control Unit Caution All electrical connections should be made by a licensed electrician or certified electrical contractor Your Pool Pilot Digital is suitable for indoor or outdoor mounting If it is connected
41. acent to where indicated on the label marked Water Out Do not drill through the label Use a drill stop attachment if available or wrap a piece of masking tape exposing 1 of the tip of the drill bit as a stop indicator This will prevent drilling through the far side of the PVC damaging the manifold Note Use care to drill the hole perpendicular and deburr for a leak free connection of the injector fitting Do not over drill or ream the hole as oversized holes will leak and are not oS F 9 E covered under warranty 3 Insert the Uniseal fitting into the hole Note Do not use any lubrication or sealing compounds 4 Insert the Black Water sample tube approx 1 into the Uniseal fitting 5 Roll out the tubing and connect into the Flow Cell Inlet valve left side ensuring a squared edge 6 Leave enough slack in the tubing to secure the tubing with ty wraps Avoid any sharp bends and over tightening the ty wrap to the tubin y D g g ty g Caution which can hinder proper flow of the chemicals Water Sample Return Tube The Flow cell sample return tube must be connected to the suction side of the circulation pump This can be done by drilling a 42 hole in the pipe and using the Uniseal fitting or by Drill and Tapping then threading the Stenner 4 NPT fitting in the pipe Using the Uniseal fitting Turn Pump Off prior to drilling into the pipe 1 Mark spot on a straight section of suction pipe into th
42. adjusting as chlorine and pH demand changes DUAL Programming Start up Follow the instructions from the Purifier mode for programming start up In addition enter the Installer Menu and program the following Press MENU press A or V until Installer menu is displayed then press and hold SELECT for approximately 13 seconds to enter Installer menu Press A or V until Select system 15 displayed then press SELECT Purifier is the factory setting Press A or V to program Select system to pH control then press SELECT Press A or V until Set Relay 1 is displayed then press SELECT Relay not used is the factory setting Press A or V to program Set Relay 1 to Acid pump controlling the Acid pump through the Digital Relay or One speed pump controlling the Acid pump through the 75008 Auxiliary Relay Kit depending on the configuration Total Control Mode Pool Chemistry Control PCC Mode Note Optional Pool Chemistry Controller 75001 pH Control Acid Tank amp Pump s 75004 75005 75006 or 75007 must be installed for this mode to function The Digital Unit can be programmed to the Total Control option in which the purifier and pH levels are monitored and controlled automatically In this mode ORP purifier and pH sensors are used to constantly test the pool water and determine whether chlorine or muriatic acid is needed to maintain proper levels The system automatically enters the Total Con
43. ale buildup mix one 1 part Muriatic Acid into four 4 parts water Mix the solution in a container high enough to cover the cell blades e Immerse the cell so that the blades are completely covered in the solution for up to 15 minutes An effervescing action indicates the calcium is being dissolved off the blades Drain the cell Rinse with fresh water Re inspect Repeat the immersion if necessary Rinse and dry the electrical terminal contacts on the SuperCell thoroughly to eliminate all traces of acid or residue before installing the cell Installation of the Cell e Clean and dry the electrical terminals on the SuperCell The contacts must be completely dry to avoid corrosion and failure of the SuperCell or cable e Ensure that the union O rings are firmly in place then slide SuperCell into the manifold with cell terminals located at the bottom of the manifold as illustrated in the picture of the manifold in Low voltage wiring on pg 15 If the cell is improperlv installed upside down water from rain or other sources mav enter WARNING the cable contacts and result in failure of the SuperCell and void your warranty e Tighten the unions by hand for a watertight seal e The SuperCell will have either 2 or 3 electrical terminals The SuperCell cable may have a red weather plug located in one of the holes e If the SuperCell has three 3 electrical contact terminals then the red weather plug should be removed
44. ayed then release the Boost button The display will show Boost for approximately 8 seconds after that Boost 72 hour ON will display then when Boost is released Superboost Mode is displayed until completed When Boost is activated with an external time clock the time remaining for the boost cycle is held in memory and Boost will continue when the pump restarts until the 24 or 72 hrs are expired With the One Speed Pump setting programmed the pump time clock will be overridden and run continuously producing purifier until the end of the boost cycle Two Speed Pump setting will activate 100 boost for 24 or 72 hrs To exit Boost or Superboost mode and revert to normal operation e Allow the Boost or Superboost cycle to expire e Press BOOST at anytime to manually deactivate Boost Superboost The Boost button is not active when the Pool Pilot Digital is programmed to be controlled by an Electronic Controller Menu Button The MENU button is used to leave the normal operation mode and enter the program and diagnostic modes Use the Up Down arrow and Select buttons to navigate through the menus and sub menus MAIN MENUS e Test Pool Pilot displays various operating parameters and diagnostic results e View setup displays the programmed setup parameters e Owner options programs the primary operating parameters that an owner would need to change e Maintenance menu tests and programs the primary features that a servi
45. cable from the Digital Control unit and dilute the remaining acid water solution in the tank Once diluted it can be discard safely Rinse out the acid tank with fresh water The acid tank pump and tubing should be removed and stored indoor The Pool Chemistry Control Unit is not affected by the cold and does not need to be removed Remove both sensors and fill the sensor caps with pool water prior to sealing the caps onto the sensors Tighten the caps and store sensors indoor Freeze protection program and its limits When configured to control the circulation pump the Pool Pilot can reduce the possibility of freeze damage to the filter and pipes in milder climates where freezing weather is not normally expected Caution AutoPilot System s warranty does not cover damage caused by freezing conditions Precautions must be taken to protect your equipment Winterizing procedures should be done prior to periods of freezing temperatures The Pool Pilot will turn on the pump and circulate pool water while the water temperature is below 40 F 4 4 C Circulating the pool water will reduce the possibility of damage to the filter and pipes due to freezing The Pool Pilot freeze protect feature will NOT work properly unless all of the following conditions are met The Pool Pilot must be powered continuously An external switch or timer should not be used to turn off the Pool Pilot power during the freezing weather e The Pool Pilot must control the p
46. cable plugs at the display board e Remove the single jumper wire and re attach as shown in the diagram e Locate the jumper wire provided in the installation kit and attach as shown in the diagram 230 VAC Co 230 Volt factory configuration ESE co C Optional 115 Volt configuration 13 INSTALLATION High Voltage Wiring Connecting Power to the Pool Pilot Digital The Pool Pilot Digital is typically provided input power in one of two ways Determine which is best for your application e AC input directly from a circuit breaker time clock or pump relay in an electronic controller This method is used when the AC power to the pump and Pool Pilot will be turned on and off by an external device such as a circuit breaker time clock or electronic controller e AC input directly from an external breaker This method is used only when the Pool Pilot Digital will be used to time and control the filter pump on off cycles Note Turn Power OFF and remove the short factory test wire stubs connected to the top terminals and ground lug before wiring You must provide the appropriate gauge LINE IN wires for pump or non pump applications Check with your local codes or NEC guidelines Connecting Pool Pilot Digital to an External Timer or Controller LINE IN 1 Measure and cut the appropriate gauge wires and 12 non metallic flexible conduit from the Power source to the Pool Pilot Digital 2 Connect ac wires to the LOAD
47. ce technician would need to access when servicing the system e Installer menu program the initial system setup Note Some features are accessed or programmed in several menus to allow quick access to the features needed Select Button The SELECT button chooses the displayed menu option For the Installer Menu press and hold the SELECT button for approximately 13 seconds to access this feature 29 PROGRAMMING AND OPERATION Operation of Buttons Continued Pump Button This button is not active if the Set Relay 1 is programmed for Acid Pump or Relay not used If the Pump button is pressed when programmed for one of these modes Acid Pump or Relay I not used will display then revert back to the normal display Pump Button One speed pump control The Pool Pilot must be wired to control the main circulation pump and programmed for a One speed pump for this feature to be active see pg 34 With PUMP ON to turn PUMP OFF 1 Press PUMP 2 V Stop Pump will be displayed Press V 3 pump off will be displayed With PUMP OFF to turn PUMP OFF FOR SERVICE This mode disables Pump operation indefinitely until manually enabled Boost and Pump program modes will not enable pump 1 Display indicates pump off Press PUMP 2 3 Press Maintenance 4 PUMP OFF FOR SERVICE and a Red CHECK SYSTEM light will now be displayed With PUMP OFF FOR SERVICE to term
48. cient flow loss of prime when set to One speed pump mode No prime protect 15 the factory setting pg 33 Pump Program 1 User programmed Time On Off when set to One speed pump mode No program is the factory setting pg 32 Pump Program 2 User programmed Time On Off when set to One speed pump mode No program is the factory setting pg 32 Remote X User programmed in the Maintenance menu to identify the electronic controller system connected to pg 35 Freeze protect Will display only when set to One speed pump mode pg 34 The unit will automatically leave the menus and revert to normal operation 3 PROGRAMMING AND OPERATION MENUS For the Installer Menu press and hold SELECT button for approximately 13 seconds to access this feature Programming the language for the display Allows for personal preference language display 1 Press MENU press A or V until Owner or Installer Menu is displayed then press SELECT 2 Press Aor V until Select language is displayed then press SELECT English is the factory setting 3 Press A V until desired language English Spanish French or German is displayed then press SELECT 4 Press Aor V until End menu mode 1s displayed then press SELECT Programming the liquid and weight measurement units for the display Allows for personal preference units display 1 Press MENU press A or V until Owner or Installer Menu
49. d Press the Pump button to manually override a stored program for e Turning the pump on off or off for maintenance Changing the speed of a 2 speed pump Not applicable if the Set Relay 1 is programmed for Acid Pump or Relay not used Press the Select button to choose the item on the display PROGRAMMING AND OPERATION Control Options There are three different modes of operation e Purifier factory setting Control e Total Control Purifier Mode The Control Unit normally runs in the manually controlled purifier mode In this mode the Pool Pilot will automatically display informative messages about the condition of the chlorinator Purifier Output time of day water temperature warning messages etc and requires manual adjustment of purifier setting as described on pg 27 The Pool Pilot will revert to this normal display if there 1s no activity on the keypad for 13 or more seconds Purifier Start Up the normal startup procedure is as follows 1 Balance your water chemistry according to the water chemistry parameters See Basic Water Chemistry on pgs 7 8 2 Add the proper amount of salt as indicated by the Pool Pilot or as described in Salt Level on pg 6 and run the circulation pump continuously for 24 hours for the salt to be fully mixed and dissolved into the pool If the salt level is too low the Pool Pilot amp Digital will warn you and will not generate purifier until the minimum salt le
50. d 4 H control End menu mode otal control ensor flow Set relay 1 25 PROGRAMMING AND OPERATION Basic Programming Control Panel Features and Functions The first line of the display typically indicates the Purifier Output Level in percent or whether the system is in Boost or Super Boost mode The second line displays the current time of day in 12 or 24 hr mode the temperature in Fahrenheit or Celsius and purifier on off mode A small dot in the bottom right corner indicates the self cleaning forward reverse cycle In pH mode display will toggle between Purifier display to the pH Feed display then the Acid Meter but only when the acid pump is actually feeding In TC mode display will toggle between normal display ORP measurement set point and pH measurement set point Pool Pilot Dic tek Press the Up or Down Arrow to e Set Chlorine Level and ORP pH levels when optional Digital TC components are installed e Scroll through Menus and sub Menus e Increase or Decrease programming values for menus A 421P 8F ON Press Boost to start 24 Press Menu to leave normal operation hour boost mode or to access the menus for programming press and hold Boost for and diagnostics 8 seconds to start 72 hour boost mode Press Boost again to cancel boost 26 Check system Red LED flashes to warn that attention is needed A warning message will also be displaye
51. djust the purifier output percentage to the desired output from 0 off to 100 maximum output then Press SELECT or allow it to default back to the normal display Typically once the initial setting 1s established very little adjustment is needed The purifier setting refers to the amount of time that the cell is energized within a 15 minute cycle The system cycles on and off as indicated on the display s lower right display as On when generating chlorine Higher settings will generate more chlorine Follow the instructions on pg 29 to determine proper purifier settings Ex 50 setting 50 of 15 minutes or 7 5 minutes ON and 7 5 minutes OFF 25 setting 3 75 min ON 11 25 min OFF Note When operating in Total Control mode Purifier Output is adjusted by changing the ORP set point The Purifier Output must be set on O when used with an external ORP controller Boost or Superboost The Boost feature is used to increase the purifier from its normal setting to 100 for a 24 hour or 72 hour cycle When the Boost cycle expires or is manually terminated the Purifier returns to its previous setting and normal operation Boost purifier output to 100 for 24 hours From the normal operation press and release the BOOST button The display will flash Boost 24 hour ON then Boost Mode e Boost purifier output to 100 for 72 hours From the normal operation press and hold the Boost button until Boost 72 hour ON is displ
52. e Appropriate gauge electrical wire W liquidtite non metallic flex conduit 12 conduit connector for service to the Pool Pilot Digital Control unit 17 INSTALLATION Mounting the Pool Chemistry Controller Unit Caution All electrical connections should be made by a licensed electrician or certified electrical contractor Your Pool Chemistry Controller is suitable for indoor or outdoor mounting The cover of the Pool Chemistry Controller is removed from the sides by four thumbscrews so it is advisable to leave adequate space on the sides for hand access to the thumbscrews Read the following section completely before proceeding 1 Level and tape the mounting template to the selected mounting location Mark the wall for the 4 mounting holes 2 Plastic anchors and screws have been provided for concrete or stucco walls Drill and install the plastic anchors and or screws Leave a 4 gap from the wall when tightening the screws Loosen but do not remove the 4 thumbscrews on the sides of the Control Unit n 2 thumbscrews on each side E Carefully slide off the outer housing cover Safely set the cover aside Hang the Pool Chemistry Controller unit on the four mounting screws Using a long shaft slotted screwdriver tighten the screws through the black plastic access holes indicated by gt 18 INSTALLATION Connecting the 75001 Pool Chemistry Controller ORP and pH Sensors The ORP and pH
53. e pump Make sure it is after all suction valves and directly into the pump suction 2 hole Use a drill stop attachment if available or wrap a piece of masking tape exposing 1 of the tip of the drill bit as a stop indicator This will prevent drilling through the far side of the PVC damaging the pipe Note Use care to drill the hole perpendicular and deburr for a leak free connection of the injector fitting Do not over drill or ream the hole as oversized holes will leak and are not covered under warranty 3 Insert the Uniseal Fitting into the hole Insert the black water sample tubing into the suction side fitting Roll out the tubing and connect into the Flow Cell Outlet valve right side ensuring a squared edge Leave enough slack in the tubing to secure the tubing with ty wraps Install the ORP and pH sensors as shown on pg 19 8 Turn the pump on and check for leaks A 6 section of tubing can be inserted into the water sample valve middle valve to allow better access to take a water sample from the flow cell ee 21 INSTALLATION pH Con trol Installation Optional Tap Points Digital Total Control Plumbing Have these tools on hand prior to starting this step Drill Acid In e 1 2 standard drill bit or 1 4 NPT bit and tap if using Stenner components Utility knife A hole must be drilled into the manifold assembly for installation of the Always Insert tubing into appropriate injector fit
54. ectors These are designed to install and lock into position as shown on pg 19 e Slide the BNC connector onto terminal and twist the lock knob clockwise to lock in place e Twist the lock knob counterclockwise and slide down to remove Similarly unthread the sensors counterclockwise to remove from the flow cell and clockwise to install into the flow cell Take care to keep to keep the sensor tips wet unless cleaning Cleaning The sensor tips should be cleaned periodically using a degreasing dish detergent such as Dawn and a soft cloth or soft bristle brush Follow these steps for cleaning 1 Turn the Main circulation pump off 2 Remove the sensor from the Flow Cell 3 Clean the sensor tips with a soft cloth or brush and detergent 4 Rinse with fresh water re tape with Teflon tape and reinstall 5 Allow 24 hours or operation to re stabilize the sensor display Testing the Flow Cell The flow switch contained in the Flow Cell is an important safety protection device When water flow has stopped it is important that the SuperCell be automatically turned off to prevent damage to the cell or system It is important to verify the safe and proper operation of the Flow Cell s Flow Switch protection device The following procedure can be used to verify the proper operation of the flow switch Turn the Flow Cell inlet left side valve to the off position 2 The Digital Control Unit should detect a low water flow at the Flow Cell and act
55. erature so this should not be a problem Purifier fluctuates from adjusted The AutoPilot unit has a patented process for automatically increasing value and reducing the chlorine output as the temperature of the water fluctuates It 15 normal for output to increase as the water temperature increases and decrease as the water temperature decreases Blank The Pool Pilot Display is blank If the display is in bright sunlight then shade the display to read display Verify the external time clock has not turned off the power to the Control Unit Temporarily override the time clock if it is desired to check out the Pool Pilot Verify that local shut off switch and or the main circuit breaker for the Control Unit 1s turned on If power is provided to the unit by an external control device verify that power is provided to and from the device Other Conditions These conditions may exist in addition to the previous Troubleshooting section Display messages but recommended range 60 80 ppm gallons to increase 25 ppm Chlorine detected range 2500 3500 ppm gallons to increase 600 ppm in the pool Purifier Output not set high enough to generate chlorine Super boost 72 hrs the system and remove the time clock trippers for 3 days Increased chlorine will show system is Pump run time not set long enough functioning properly Check daily to avoid over chlorinating to generate chlorine above maximum levels normal range
56. f Error acid off Check OpEC if it is not able to communicate with the Pool Chemistry Controller OpEC is the acronym for pH Electronic Controller and is the electronic control logic of the Pool Chemistry Controller Under normal operating mode the Total Control display cycles between the screen the screen and the Salt level screen Total Control Protection The Total Control system does not generate chlorine or dispense acid if one speed or two speed pump is not running Flow at the Manifold Tri sensor or Flow Cell flow switch is not detected Salt is below 2000 ppm Communications with the 75001 Pool Chemistry Controller is lost A sensor error is detected An overfeed condition is detected if set to detect pH or ORP overfeed An extended period of high pH condition is detected Also The Total Control system does not dispense acid until after flow has been detected a minimum of three 3 minutes after activation e The Total Control system does not generate chlorine or dispense acid one 1 minute prior to the Pump Program Off time when programmed for a One speed pump ORP Oxidation Reduction Potential measured in millivolts mV ORP is a measurement of the amount of active oxidizer chlorine in the water This system controls ORP by generating chlorine when the ORP measurement falls below a user programmable set point which should correspond with the desired free chlorine le
57. f the pool spa or hot tub must be bonded to the equipment grounding bus with copper conductors not smaller than No 8 AWG 8 4mm WARNING RISK OF ELECTRICAL SHOCK Control units configured to 115 Vac must be installed at least 10 feet 3m from the pool or spa wall Control units configured to 230 Vac must be installed at least 5 feet 1 5m from the pool or spa wall WARNING RISK OF CHILD DROWNING OR INJURY Children should never use this equipment or a pool spa or hot tub unless they are closely supervised at all times The AutoPilot chlorinator is equipped with an electronic flow switch that automatically turns the unit off in the event of a low water flow situation Do not tamper in any way with this safety feature A disconnect device incorporated in the fixed wiring must be included in the supply circuit such as a time clock relay or circuit breaker The proper residual chlorine level and water chemistry must be maintained The addition of certain pool maintenance chemicals can reduce the effectiveness of chlorine WARNING The Control Unit must be mounted at least 1 foot 300mm off the ground to allow for air circulation around it and permanently installed over concrete The AutoPilot chlorinator must be installed and operated as specified Failure to do so will void the AutoPilot warranty The SC 36 SC 48 and SC 60 SuperCells are designed for residential use only Use in any other applica
58. fitting provided with the pH Acid Feed Pump Installation Kit 2 Cut back the cord jacket approximately 3 7 3 cm and strip the wires approximately 1 2 1 3 cm and insert into terminal strip 4 and 6 3 Connect the Green Ground wire to the ground lug 75003 Digital Control Unit Terminal Strip LINE OUT to Acid Feeder 4 Complete the plumbing of the acid tank see pg 22 5 Set the Select System mode to pH Control see pg 35 20 INSTALLATION Optional Tap Points For Pool Chemistry Controller Flow Cell Plumbing TC Total Control It is necessary to have a constant flow to the flow cell to ensure accurate water sampling This is done by locating the water sample tubes as indicated in the diagram on pg 16 Acid In Have these tools on hand prior to starting this step e Drill e 1 2 standard drill bit e Utility knife into appropriate inlet outlet Water Sample Feed Tube See Digital manua A hole must be drilled into the manifold assembly for installation of the injector fitting for the Water Sample Feed Line 1 Turn the pump off disconnect the cell and tri sensor cords and remove the manifold piping without the cell to a clean working area See diagram above for which unions to remove marked in diagram 2 Locate the label on the manifold assembly marked Optional Tap Points marked in diagram and drill the appropriate mounting hole adj
59. flow switch which is part of the Tri Sensor that is located in the upper portion of the manifold of the water will be forced through the Bypass Valve This will normally flush out any small bits of debris that are trapped in the Bypass Valve The Control Unit should detect a low water flow at the Tri Sensor and activate the red Check System LED The Control Unit will also display the message Purifier Off Check Flow If the Control Unit did not display this warning then check the Tri Sensor cable connections and inspect and clean the Tri Sensor as outlined in the previous section If the warning message still does not appear then turn the Pool Pilot off and contact the factory or your local dealer for assistance Turn the pump off Loosen the unions Remove the plastic wrap and replace the strainer screen Resume operation SuperCell The SuperCell may require removal for periodic visual inspections or for servicing when debris or calcium mineral deposits develop the Control Unit displays the Check System light and the message Low Flow Purifier OFF or Check Cell Clean Removal of the SuperCell The SuperCell is installed with Unions on each end to allow quick and easy installation and removal Turn off all power Detach the SuperCell cable from the SuperCell Unscrew the unions at both ends of the SuperCell Slide the SuperCell out of the Manifold Assembly SuperCell and Unio
60. for Proper balance see pgs 7 8 Pool is being treated or was just Turn the Pool Pilot to 0 or disconnect the cell cord from the treated for algae using an algaecide cell Add and repeat manual additions of pool bleach to maintain treatment containing Sodium 3 5 ppm until able to maintain this residual for 3 4 days Bromide which will cause chlorine continually then plug the cell cord back on or readjust the to generation and testing problems normal operation Cell inspect due This is a reminder message to Remove cell as instructed on pg 41 inspect and clean if needed SELECT to clear inspect the cell for scale formation reinstall cell and start the system then press SELECT to reset The reminder is programmed to If scale 1s present check and adjust the water chemistry display every 2500 amp hours for according to the Saturation Index pg 8 or adjust the Set SC 36 and SC 48 Every 5000 hours reverse time pg 33 If scaled the cell may need to be for SC 60 and CC 15 inspected more frequently Pool Pilot SCG Due to the CR2025 battery missing Replace the CR2025 battery on the 75003 Digital Control units Check the clock or dead Message only displays at display board start up 47 Message on Display Error Purifier off Error Acid off Check flow at sensors Error Purifier off Error Acid off Check ORP sensor Error Purifier off Error Acid off ORP overfeed Error Purifier off Error Acid off Chec
61. g season should be minimal Filter backwashing draining due to rain water overflow splashing and bathing suit drag out and leaks excessive salt loss in a short span of time are typical ways the salt is lost Salt does not evaporate from the pool when the water evaporates PREPARING THE POOL WATER Salt Addition Chart The following salt chart is included for reference only Once your Pool Pilot Digital is properly programmed to the pool water volume it will automatically indicate how much salt is needed To use this chart 1 Find your current salt level ppm or g l in the left column This can be obtained from your Pool Pilot display or by testing your water 2 Find your pool spa volume in the second row Gallons or Liters 3 Find the amount of salt needed to bring your pool to the ideal level by finding the intersection of the row and column For volumes other than what is shown use combinations of various columns For example for an 11 000 gallon 41 646 liter pool with a salt level of 500 ppm 5 mg l the column value for 1000 gallons 4 000 liters 21 pounds 9 kg is added to the column value for 10 000 gallons 38 000 liters 209 pounds 95 kg which gives total of 230 pounds 104 kg of salt needed to bring your pool salt level up to the ideal level of 3000 ppm 3 0 g l Pounds kilograms of Salt needed to attain 3000 ppm 3 0 Pool Spa Volume in Gallons Liters 1 000 2 000 5 000 10 000 15 000 20
62. hold the SELECT button for 13 seconds The display will update when the INSTALLER mode has activated 2 Press or V until Set Relay 1 is displayed then press SELECT Relay not used is the factory setting 3 Press Aor V until Relay not used is displayed if previously adjusted from the factory setting then press SELECT 4 Press Aor V until Select Remote is displayed then press SELECT Select Remote 1 for the more common electronic control system interface then press SELECT Select Remote 2 for the modified Jandy Rev L software then press SELECT 5 Press Aor V until End menu mode 15 displayed then press SELECT Adjusting the Pool Pilot through the Electronic Controller Control Panel The operating instructions for the electronic control system will describe how to adjust the output and boost settings When necessary the display will alert the user to Check Pool Pilot Note The Electronic Controller will recognize the Pool Pilot only when the circulation pump is operating The Pool Pilot will display REMOTE OPERATION once the Electronic Controller is connected and communicates The Electronic Controller will periodically display the Pool Pilot chlorine output setting and salt level The Electronic Controller Displays CHECK POOL PILOT The Electronic Control System will display this message when the Pool Pilot reports a problem such as low salt loss of flow or a cell problem The problem shou
63. hors and or screws Leave a 4 gap from the wall when tightening the screws 3 Loosen but do not remove the 4 thumbscrews on the sides of the Control Unit 2 thumbscrews on each side Carefully slide off the outer housing cover Disconnect the 3 plugs that connect to the display board indicated by that is mounted inside the cover The display circuit board does not need to be removed from the cover Safely set the cover aside 6 Hang the Pool Pilot Digital on the four mounting screws Using a long shaft slotted screwdriver tighten the screws through the black plastic access holes indicated by gt For access to the electrical terminal strip remove the four screws and lift off the inner metal protective cover Route the 2 ribbon connectors from the display circuit board side through the slotted access hole then remove the 1 power plug on the power circuit board side and route through the slotted access hole 9 Safely set the metal protective cover aside 10 See Electrical Connections on pgs 13 15 for terminal connections 11 Reverse steps 3 8 to re install the metal and outer covers Make sure to route and connect the ribbon connectors and power plug through the metal protective cover properly then replace the outer housing cover after first connecting the 3 plugs that were disconnected in Step 4 12 INSTALLATION Electrical Connections The Pool Pilot Digital uses both high and
64. inate maintenance mode and return to PUMP OFP 1 Press PUMP 2 Press A End Maint 3 Pump will be in the pump off status With PUMP OFF to turn PUMP 1 Press PUMP 2 Press A Start Pump 3 The pump will run until the pump program reaches the next scheduled turn off time Pump Button Two speed pump control The Pool Pilot must be wired to control a two speed main circulation pump and programmed for Two speed pump for this feature to be active The Pool Pilot cannot turn off the pump and can only change pump speeds between high and low See pg 34 With pump on HIGH SPEED to switch to LOW SPEED 1 Press PUMP 2 Press V Low Speed 3 Pump will switch to low speed With pump on LOW SPEED to switch to HIGH SPEED 1 Press PUMP 2 Press A High Speed 3 Pump will switch to high speed 30 PROGRAMMING AND OPERATION MENUS For the Installer Menu press and hold SELECT button for approximately 13 seconds to access this feature Running the Test Pool Pilot program Diagnostic menu Press MENU Test Pool Pilot is automatically displayed then press SELECT The display will automatically toggle through the following displays A or V allows manual control forward and back While in this feature pressing MENU will override the remaining displays and exit back to normal operation 1 2 4 Salt XXXX ppm g l The optimum salt level is 30
65. ing as staining may occur If the salt level in the pool becomes undesirably high the only way to remove excess salt is to partially drain the pool and refill with fresh water Sall Level Your Pool Pilot requires that the size of your pool be entered into the microprocessor so that it can automatically measure the amount of salt in your pool and indicate how many pounds kgs to add when the salt level falls low To program your pool size see Set Pool Volume on pg 34 To calculate the number of gallons liters of water in your pool see Calculating Pool Volume above The salt chart on the following page can also be used to calculate how much salt in pounds kgs should be added to reach the recommended level of 3000 ppm 3 0 g l The ideal salt range is 2500 3500 PPM parts per million 2 5 3 5 g l However the Pool Pilot can operate with salt levels in excess of 35 000 PPM 35 0 g l if so desired High salt levels above 6000 PPM not normally recommended as this may cause corrosion to metallic objects such as light fixtures ladders handrails heaters and pumps Low salt levels below 2400ppm will reduce the efficiency of the Pool Pilot and result in low chlorine production Extremely low salt levels below 1900 ppm will activate the low salt safety cut off and halt chlorine production until salt is replenished to proper salt levels The salt is constantly recycled during normal operation The loss of salt during a swimmin
66. is probably set correctly maximum output 1 Use the down arrow button to decrease the Purifier 2 Use the down arrow button to set the Purifier Output Output to 50 The Free Chlorine will need to be tested frequently and the Purifier Output will need to be adjusted as needed to attain the desired level Additional increases can be made by extending the pump circulation time so that the Pool Pilot can operate longer 4 After the optimal Purifier setting has been determined this setting normally will not need to be adjusted you will only need to adjust your level or select a Boost Cycle to compensate for increased bather usage or heavy rainfalls that can quickly consume chlorine Purifier Programming Start up Enter the Installer Menu and program Set time of day to your time zone Set pool volume to your specific pool and Set cell type to match the model cell installed If the Digital 1s used to control the main circulation pump also program Relay 1 Prime protect Pump program 1 and Pump program 2 see pgs 32 34 In addition there are user programmable menu display preferences including Select language Select units Temperature unit and 12 24 clock but are not needed for proper operation see pg 32 21 PROGRAMMING AND OPERATION Control Mode Manually adjusted pH control and Purifier Note Optional pH Control Acid Tank amp Pump s 75004 75005 75006 or 75007 must be i
67. ivate the red Check System LED The Digital Control Unit will also display the message Purifier Off Check Flow at sensors 3 Control Unit did not display this warning then check the flow switch or cable connections for damage or loose connections 4 Remove the flow switch and using a continuity tester check for continuity while manually activating the flow switch If the flow switch operates properly service is needed on the Pool Chemistry Controller electronic circuit 6 Contact AutoPilot for service m 43 TROUBLESHOOTING GUIDE Troubleshooting Guide Visit www AutoPilot com for the latest manual revisions additional information and helpful troubleshooting tips You can also reach our factory direct customer assistance by calling 800 922 6246 or 954 772 2255 by email at AutoPilotTechSupport teamhorner com or by FAX at 954 772 4070 Run the View Setup pg 31 and record the information displayed and have the information available prior to contacting AutoPilot e Current measured salt level e Software version The following will also be needed but may have been recorded by the installer in the front of your manual on pg 111 e Date of installation e Control Unit model type should be 75003 e Control Unit serial number SuperCell model type e SuperCell serial number e Tri Sensor serial number Message on Display Typical Solution Error Purifier off Chlorine generation has Turn the circulation pump on
68. k pH sensor TROUBLESHOOTING GUIDE Total Control Error Displays Problem Flow at sensors is not detected Chlorine and acid are not fed under these conditions until corrected The measured ORP is out of range and may be caused when the sensor is not properly connected or if the sensor is past its useful life Out of range ORP measurement is below 100 mv or above 900 mv Chlorine and acid are not fed under these conditions until corrected The measured ORP has not reached its set point within a user programmable time between No ORP Overfeed to 120 minutes The factory setting is No ORP overfeed Chlorine and acid are not fed under these conditions until corrected The measured pH is out of range and may be caused when the sensor is not properly connected or if the sensor is past its useful life Out of range pH measurement is below 4 0 or above 9 9 Chlorine and acid are not fed under these conditions until corrected 49 Typical Solution Ensure sufficient flow to the flow cell pg 44 Open the inlet and outlet valves to the flow cell Valve handles should be vertical Verify that the sample water valve is closed valve handle horizontal Check and secure ORP connections Replace ORP sensor Clear the ORP overfeed warning by programming ORP overfeed OFF and back ON pg 36 Check the operation of the purifier mode by ensuring proper salt pH and stabilizer levels Check and clean ORP sensor Check Othe
69. l 4 Press V until End menu mode is displayed then press SELECT Calibrating the temperature display to match another thermometer Used only when it is desired to match the display of the Digital to another thermometer display 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Calibrate temp is displayed then press SELECT 3 Press A or V to adjust temperature up or down to the desired temperature then press SELECT The maximum adjustment is 6 3 C To maximize protection only negative adjustments will be used to calculate freeze protection temperature 4 Press Aor V until End menu mode 15 displayed then press SELECT Program the pool volume Must be programmed for the salt amount needed display to be accurate 1 Press MENU press or V until nstaller menu 1s displayed then press and hold SELECT for 13 seconds 2 Press Aor V until Set pool volume is displayed then press SELECT Factory setting is 15 000 gallons The range is 500 to 127 500 gallons 1 000 to 226 000 liters 3 Press Aor V until correct pool size is displayed then press SELECT 4 Press Aor V until End menu mode is displayed then press SELECT Program the cell type Must match the installed cell 1 Press MENU press or V until nstaller menu 1s displayed then press and hold SELECT for 13 seconds 2 Press Aor V until Set cell type
70. l Solution Display There are no warning messages on the display but the chlorine level is too low Water quality looks dirty or cloudy There are no warning messages on the display The chlorine level is too low but the pool water looks fine Pump does not turn on or is off when it should be on Pump does not turn off or 1s on when it should be off Pump does not turn Off or 1s off when it should be on The chlorine setting has been fine but a temporary boost of chlorine is needed to adjust for rain or a temporary bather increase Press the Boost button to temporarily elevate the chlorine production level to 100 for 24 hrs The chlorine output will revert to the original setting after 24 hrs The chlorine setting has been fine but a temporary or longer SuperBoost of chlorine is needed to adjust for heavier rain or bather increase Press and hold the Boost button for 8 seconds to temporarily elevate the chlorine production level to 100 for 72 hrs The chlorine output will revert to the original setting after 72 hrs Check your pool chemistry parameters See Basic Water Chemistry on pg 7 The cyanuric acid level may be low and the chlorine is being consumed quickly by the UV from the sun The chlorine output needs to be increased Use the up arrow key to increase the chlorine output setting e Increase the pump run time so that the chlorinator is generating chlorine for a longer period of time Test
71. lastic tubing marked 1 8 ID x 4 OD onto the check valve Ensure the tubing is square edged before inserting use the utility knife to cut if needed Note If it seems too tight use some water or dishwashing detergent Do not use any other lubricants 6 IFUSING THE STENNER FACTORY COMPONENTS FOLLOW THE INSTRUCTIONS IN THE STENNER INSTALLATION MANUAL AND USE ALL STENNER SUPPLIED TUBING AND FITTINGS as AutoPilot and Stenner factory tubing and fittings are not interchangeable 7 Ifthe acid collection tube has not already been installed do so at this time AM a St This will connect to the closer fitting on the Stenner head assembly 25 8 Roll out the tubing to connect into the Acid Feed Pump again ensuring a squared edge and TI Leave enough slack in the tubing to secure the tubing with ty wraps i Kit 9 Remove the tank access lid and adjust the Stenner acid tank tubing weight so that it is about 1 2 1 5 cm from the bottom of the tank 10 Add 1 2 gallons of water into the acid tank STOP At this point turn on the circulation pump and perform the Prime Acid Pump see pg 35 and check for any leaks in the acid tubing and fittings 11 Once secured and adjusted continue adding water and muriatic acid into the tank for a recommended acid mixture of 4 parts water to 1 part muriatic acid dilution 5 avoid damaging splashes ALWAYS ADD WE i ACID WATER never
72. ld be checked on the Pool Pilot Follow the instructions on pg 33 to Disable Remote and then check the Digital display message for fault Once the Check System has been corrected Enable Remote to resume Electronic Controller operation See pgs 44 49 Troubleshooter Section for other Pool Pilot Error Messages 37 SYSTEM MAINTENANCE System Maintenance Winterizing Pool Pilot Digital The Pool Pilot Manifold including the SuperCell and Tri Sensor will be damaged by freezing water just as your pool plumbing would In areas that experience severe cold weather or extended periods of freezing temperatures the system should be winterized by draining all water from the Manifold Assembly SuperCell and Tri Sensor pump filter supply and return lines prior to freezing weather The Control Unit is not affected by the cold and does not need to be removed Pool Pilot Total Control The Flow Cell and Acid tank can be damaged by freezing water conditions In areas that experience severe cold weather or extended periods of freezing temperatures the system should be winterized Allow the acid tank level to drop so that it 1s easier to drain For the Flow Cell empty it by opening the water sample center valve to drain all water from the Flow Cell Leave this valve opened during the winter months Continue with your normal pool winterizing procedures For the acid tank and tubing remove the acid tube from the manifold disconnect the interface
73. loudy water Rapid buildup of scale may exceed the system s self cleaning capability and require manual cleaning of the SuperCell Low CYA destruction of chlorine by the UV rays from the sun High CYA Requires more chlorine to maintain proper sanitizer levels Note CYA not needed for indoor or bromine pools CYA can be reduced to 30 50 ppm for Pool Pilot Digital TC ORP or colder climate regions CORRECTIVE ACTIONS Low free chlorine Check for combined chlorine level and shock as necessary Increase purifier output to maintain a 1 3 ppm residual reading High free chlorine Decrease purifier output Let chlorine dissipate normally until 1 3 ppm is achieved In extreme cases pool water can be diluted with fresh water or a chlorine neutralizer added Diluting will reduce salt and CYA Check and adjust as needed Low pH Add sodium carbonate or soda ash High pH Add muriatic acid or sodium bisulfate Low TA Add sodium bicarbonate High TA Add muriatic acid often a little at a time may take a week or more to lower the TA Aerate by pointing return jets toward the surface Low Salt Add salt according to digital display on Pool Pilot unit or salt chart High Salt If undesirably high partially drain and refill the pool with fresh water Diluting will reduce CYA Check and adjust as needed Low CH Add calcium chloride flakes High CH Partially drain and refill pool with fresh water to dilute
74. low relative to the set point If the measured pH is equal to the set point a block with no text is displayed If the measurement falls below the set point the W and Low displayed and no acid is fed If the measurement exceeds the set point the A and High are displayed and acid 15 fed until set point is reached pH 4 00 7 50 pH 7 50 7 50 pH 9 90 7 50 On Low Hish 2 SYSTEM OVERVIEW Control Unit Features The control unit has the following features e Patented temperature compensation for chlorine output Programmable Microprocessor Control Multi language digital display English Spanish French amp German Digitally controlled power to the SuperCell Tri sensor Circuitry to monitor water flow water temperature and salt level and salt addition amounts to maintain 3000 ppm 3 0 g I Internal Relay for controlling an external pump or acid feeder On board Diagnostic and Test programs Lithium battery CR 2025 back up for clock and program settings ORP dry contact interface for connection to an external ORP controller Electronic controller interface for Jandy Versions I K and newer Polaris EOS or Pentair IntelliTouch controllers Patented Temperature Compensation The Tri Sensor Assembly s temperature sensor works in conjunction with the purifier output to automatically adjust the chlorine output based upon changes in the water temperature between the range of 55 F
75. n your home if so equipped or through an external ORP controller The Pool Pilot Digital can also be programmed to control the main circulation pump operating times or be controller by an external timer switch relay Dotted lines are optional connections Circuit rr 75001 equipment schematics Breaker Digital Pool 1 75008 and components Chemistry Auxiliary Control Relay Kit AUTOPILOT pH Acid Feed System 75005 75004 75006 lt Chlorine Generation Manual purifier control The system requires a low concentration of dissolved salt sodium chloride in the pool water This level is normally below the taste threshold The Pool Pilot automatically converts the salt into free chlorine which keeps your pool sanitized and algae free The chlorine reverts back to a salt after treating the water Since the salt is constantly recycled there is minimal loss during a swimming season However salt can be lost due to filter backwash rain water overflow leaks or bather splashing carryout but not through evaporation The Pool Pilot Control Unit is designed to handle the purification needs of residential and commercial swimming pools The cell must be properly sized according to the chlorine requirements The amount of chlorine required for proper sanitization will vary based on the pool size and various factors such as water
76. nections if any o Determine where input power for the Pool Pilot will originate directly from a circuit breaker Digital Time clock is used to control the main pump or pump is also running off the breaker an external Timer or Pool Pilot is to be wired to the same location as the main filter pump an electronic controller so that it only activated when the pump is energized Determine whether the input voltage for the Pool Pilot is 230Vac factory configured or 115 Vac Determine whether the Pool Pilot will be used to control a single speed pump or a dual speed pump Determine whether the Pool Pilot will be controlled by an ORP controller or TCC Option Determine whether the Pool Pilot will be controlled by an Electronic Controller system O O What is included Although the manifold assembly may be sold separately both a manifold and a Pool Pilot Digital Control unit are required for a complete installation and start up The standard cell manifold assembly is available with the following cells SC 36 SC 48 SC 60 residential cells or the CC 15 commercial cell Before attempting the installation check that the following items have been included with the Pool Pilot Pool Pilot Digital Control unit Quantity Item Description 1 1 1 1 4 4 2 68mm x 2 metric adapters 19059 European Systems only m cations What is not included Some of the additional equipment that may be
77. needed to complete the installation 1l SuperCell Cable DIGITAL CONTROLLER 75003 Pool Pilot Digital Control Unit AC jumper for 115 Vac configuration Tri Sensor Cable Mounting Template Plastic Anchors Mounting Screws MOUNTING TEMPLATE 4 gt For any installation Appropriate gauge electrical wire V7 liquidtite non metallic flex conduit 10 conduit connector for service to the Pool Pilot Drill masonry drill bit For installations using optional equipment Appropriate gauge electrical wire 10 liquidtite non metallic flex conduit V7 conduit connector for filter pump Cable for connection for ORP interface PN 315 AC 4 Conductor cable for connection to Electronic Controller option INSTALLATION Plumbing Requirements The Manifold Assembly is 2 Schedule 40 and is typically plumbed into the pool return line and if applicable after the heater and spa return diverter valve Electrical Requirements Power must be shut off at the circuit breaker before performing any wiring All local and NEC electrical codes should be followed The Pool Pilot Digital has been factory configured for 230Vac operation If it needs to be reconfigured for 115 Vac operation then see Converting from 230 Vac to 115Vac on pg 13 Installation Steps Details on each step of the installation process are presented on the following pages 1 Plumbing the Manifold Assembly pg 11 2 Mounting the Po
78. ng Shorter cycle times can reduce the SuperCell life and should only be changed due to uncontrollable scale formation on the SuperCell 4 Press Aor V until End menu mode 1s displayed then press SELECT Programming the unit to enable or disable a remote electronic control system by the Jandy Polaris or Pentair electronic control systems Used only when wired to operate through the electronic control system Press MENU press A or V until Maintenance menu 1s displayed then press SELECT 2 Press Aor V until Enable remote or Disable remote is displayed if Enable remote then the electronic controller is disabled press SELECT to enable the electronic controller e if Disable remote then the electronic controller is enabled press SELECT to disable the electronic controller 3 Press A or V until End menu mode is displayed then press SELECT Replace Cell Used to reset the ampere hour counter after a cell is replaced Press MENU press A or V until Maintenance menu 1s displayed then press SELECT 2 Press A or V until Replace Cell is displayed then press and hold SELECT for 13 seconds Amp hours zero will be momentarily displayed 3 Press V until End menu mode is displayed then press SELECT Programming the unit to Set prime protect Range No prime protect 1 2 4 8 minutes used to provide protection against potential damage of a one speed pump by loss of prime and will shut down pump
79. nit uses dedicated salt sensor blades to Le 4 Pirectional Flow Indicator measure the level of salt in the water The Control Unit uses the temperature sensor to determine the temperature of the water This is needed for the Patented Automatic Temperature Compensation feature that automatically adjusts the chlorine output for temperature variations Less chlorine is needed in cold water so the chlorine output is automatically reduced as the temperature drops to avoid excess chlorine production Similarly more chlorine is needed in warmer water and is automatically adjusted higher The temperature sensor 15 also used for the Freeze Protection Feature as described on pg 38 View of locking Quick Connect head Removing iInspecting Cleaning the Tri Sensor Pump must be off Turn off the pump power at the circuit breaker before servicing this unit Personal injury or DANGER LM 2 equipment damage could occur if the pump activates 1 Disconnect the Tri Sensor cable from the Tri Sensor Place the end of the cable out of the way where it will stay dry when the Tri Sensor is removed 2 Cover the contact pins on the Tri Sensor with the dust cap to prevent damage and to keep them dry and clean 3 Remove the two 2 screws that retain the Tri Sensor in the Tee joint on the Manifold 4 Note the orientation of the Directional Flow Indicator The Tri Sensor must be installed in the same orientation when it is re installed or re
80. ns side view 41 SYSTEM MAINTENANCE Visual Inspection of the SuperCell Remove the SuperCell from the Manifold Assembly following the directions in the previous section The SuperCell titanium blades seen inside the cell body should be straight and clear of any debris on the ends or between the blades A white flaky or crusty calcium build up on the edge or between the blades will shorten the P life of the cell Clean the cell immediately and determine the cause of scaling See Troubleshooting Section pgs 44 49 Your Pool Pilot Digital is designed to automatically self clean calcium scale and build up that may form on the blade However unbalanced water chemistry can cause heavier scale build up that exceeds self cleaning capability 1 thus requiring periodic manual cleaning The simplest way to avoid this problem is to bring the pool chemistry to the levels recommended Basic Water Chemistry on pg 7 is o mm oU End View of the Supercell looking at the blades Manual Cleaning of the SuperCell e Follow the directions to remove cell on pg 41 Scraping or scratching the titanium blade s edge or surface will damage the blade catalyst coating and cause premature failure of the cell and will void your warranty Never use any sharp or metallic objects to remove scale Use a high pressure hose nozzle to spray off as much loose scale and debris as possible To remove calcium sc
81. nstalled for this mode to function The Digital Unit must be initially programmed through the Installer Menu Select System mode see pg 35 to the pH Control mode In this mode the Purifier and pH control are adjusted manually The display toggles from the Purifier display to the pH Feed Display then the Acid Meter but only when the acid pump 15 actually feeding The total volume of acid dispensed is available in the Test Pool Pilot mode which is reset through the Maintenance Menu and can indicate when more acid needs to be added to the tank pH Feed Rate Start up Adjust the Purifier levels as described on pg 29 The pH Control is adjusted by assigning the amount of acid that 15 to be delivered by a feed rate pump with a user programmable fixed rate between Acid Feed Off to 330 oz day 10 000 ml day If the acid feed rate 1s not known follow these instructions Testand record your starting pH level See Basic Water Chemistry on pg 7 2 Press the Up or Down Arrow while the display is in the pH Feed Display The display will then show the current Feed Rate setting Adjust the Acid Feed rate to 5 oz per day per 10 000 gallons 148 mL per day per 38 000 liters of pool volume After adjusting the acid feed rate to the desired value press Select Test the pH the following day and adjust the Acid Feed rate higher or lower as needed Repeat until your desired pH level is maintained This will require periodic testing and
82. ol Pilot Digital pg 12 3 Electrical connections pgs 13 15 a Grounding and bonding b High voltage wiring 1 Pool Pilot Digital to an external timer or controller ii Pool Pilot Digital relay for a One speed pump or pH acid feed pump optional iii Pool Pilot Digital relay for a Two speed pump output optional iv Pool Pilot Digital relay for acid feeder optional c Low voltage wiring i SuperCell cable Tri Sensor cable 75001 Pool Chemistry Controller Configuration optional pgs 16 23 Electronic Control Configuration optional pg 24 Menu Overview pg 25 System Startup and programming pgs 26 37 AE 10 INSTALLATION Plumbing the Manifold Assembly Step 1 Select the location for installing the manifold The manifold is designed for a flow rate of 20 to 100 gpm 76 to 379 L m tis recommended that the manifold be installed prior to installation of the control unit The Control Unit will need to be installed close enough to the Manifold Assembly so that the Tri Sensor and SuperCell Cables 12 long will have enough slack so that the cables can be serviced easily e The manifold cell should be installed in a vertical orientation as illustrated in the picture below This orientation prevents hazardous gas buildup in the system if the flow switch should fail to detect insufficient flow e The direction of the water flow through the manifold must be as indicated for the D to work properly e For
83. ones or day light savings 1 Press MENU press A or V until Owner Maintenance Menu or Installer Menu is displayed then press SELECT Press or V until Set time of day is displayed then press SELECT Eastern standard time is the factory setting Press or V until the desired hour is displayed then press SELECT Press or V until the desired minutes are displayed then press SELECT Press or V until End menu mode 15 displayed then press SELECT Ha ae Programming the operating times for a pump controlled the Pool Pilot Relay two pump program modes available This feature is only available when Set Relay 1 is programmed for a one speed or two speed pump Caution Do not overlap Pump Program 1 and Pump Program 2 times as the unit will perform the earliest ON and OFF times which may cause decreased pump run times 1 Press MENU press A or V until Owner Maintenance Menu or Installer Menu is displayed then press SELECT 2 Press Aor V until Pump Program I or Pump Program 2 1s displayed then press SELECT Any programmed time will display briefly and then toggle to the options menu 3 A Press A Prog to program the pump times 1 Program the Pump on time or High speed start time a Press A or V to adjust the hour up or down Press SELECT when hour is correct b Press A or V to adjust the minutes up or down Press SELECT when minutes are correct Program the Pump off time
84. ower to the circulation pump e The Pool Pilot Set Relay 1 must be programmed for One speed pump see 34 When the Tri Sensor indicates that water temperature is below 38 F 4 4 C the Control Unit will override the normal timed program cycle and run the pump 30 minutes minimum or continuously while the water temperature is below 38 F 4 4 Pool Pilot uses a temperature sensor located in the Tri Sensor to determine water temperature If the Tri Sensor 15 located so that it cannot accurately detect the cold water then the freeze protection becomes ineffective For example if the Tri Sensor is located inside a protected or warm location and the other pool components are located in an unprotected area the other pool components could freeze before the Tri Sensor detects the cold water Spring Start Up Pool Pilot Digital It is recommended that you manually shock the pool when you first start up the pool in the springtime Test your water and add the appropriate chemicals to balance the pool water per the levels recommended in Basic Water Chemistry on pg 7 Make sure to check your salt and cyanuric acid stabilizer levels and bring them up to the recommended levels as required It is a good idea to inspect the cell filter screen test the Tri Sensor flow switch and clean as necessary See the next sections Pool Pilot pH Control or Total Control System No special instructions are necessary for spring start ups However it
85. placed 5 The Tri Sensor can now be pulled out of the Tee Firmly grip the Tri Sensor assembly This is typically done with a large pair of channel lock pliers Twist the Tri Sensor back and forth while simultaneously pulling the Tri Sensor straight out of the Tee joint Warning The Tri Sensor should not be pulled out at an angle or the flow paddle or flow post will be damaged 6 Inspect the following on the flow switch Verify that the thin metalic paddle is straight and free from erosion Verify the the long plastic post is straight and free of cracks Do not twist or bend the paddle or the long plastic post 7 Inspect the two salt sensor blades The two blades should not have any mineral deposits scale or other debris on them If the blades need to be cleaned use the following method Do not use any metallic objects to scrape the blade surfaces or you will remove or damage the blade sensor coating To remove calcium scale buildup mix one 1 part Muriatic Acid into four 4 parts water Mix the solution in a small container high enough to cover the cell blades 17 41 avoid damaging splashes always add acid to water never water to acid e Immerse the salt blades in the solution for up to 15 minutes An effervescing action indicates the calcium is being dissolved off of the blades e Rinse with fresh water and re inspect Repeat the acid treatment if necessary 8 Check the tri sensor assembly for any damage to the
86. portant to use Sodium Chloride NaCl salt that is greater than 99 pure Common types of salt include granular food grade water softener pellets or solar salt flakes These are usually available in 25 Ib to 80 Ib bags at a local pool or building supply store Water softener and solar salt will have a slower dissolve rate than food grade salt Rock salt and Granular Salt with Iodine or Rust Preventatives should not be used as they contain high levels of impurities that will cause staining Note Granular salt with anti caking additives such as YPS Yellow Prussiate of Soda or Sodium Ferrocyanide can be used but may cause localized tint to the water or yellow staining on the pool finish if not mixed and dissolved immediately How to Add or Remove Salt The filter pump should be turned on and run continuously for 24 hours after salt is added to the pool to allow for proper dissolving and circulation throughout the pool The filter pump should be run continually for up to 24 hours The salt should be added directly to the pool and over the bottom main drain if so equipped If there is no main drain a vacuum head can be used to circulate the salt Vacuum the salt brush it around to agitate or brush into the main drain if applicable to speed up the dissolving process Caution Do not use a pool cleaner or vacuum head with wheels as they can leave track marks on newly plastered pools Do not allow Granular salt to pile up in one location without brush
87. r am ULL board matching code in the chart the color code in below the chart below code in the chart below Connect in parallel to the existing wires On the Pool Pilot Digital Pool Pilot Jandy Polaris Pentair External Internal fe 2 DATA Black Pin 1 Yellow 4 3 2 1 Command Genter Board Connection RS 485 wire harness External RS 485 Terminal on Digital Base Plate 24 MENU OVERVIEW Menu Overview Use this menu overview for quick reference to the menu program sequence Some menu features will only display with specific System Configurations as noted below We recommend contacting AutoPilot systems when access to the Protected Access menus is desired Notes 1 Control Main Pump 2 Control One speed pump 3 Control Acid pump 4 Sensors Installed 5 Protected Access Maintenance Menu Set time of day Force reverse Set reverse time Enable Disable remote Replace cell 5 Set prime protect 2 Set pump program 1 pH pH setpoint Set pump program 2 1 Calibrate salt Owner Options 2 Calibrate temperature elect language 4 Prime acid pump 3 elect units 4 Reset acid meter 3 Temperature unit 4 Enable Disable acid 3 et 12 24 Hour Clock 4 Set pH overfeed 4 et time of day Set pH min 4 et pump program 1 2 Set pH max 4 et pump program 2 Calibrate pH 4 elect System Enable Disable 4 End menu mode urifier Set ORP overfee
88. r conditions on pg 47
89. rammed properly for controlling the pump See pg 34 2 The pump operating times were not properly programmed in Pump Program 1 and Pump Program 2 or may be overlapping See pg 32 3 The Pump Program has been temporarily manually overridden by the Pump button Boost SuperBoost mode will activate the pump continuously until the time has expired 2 If the unit is programmed properly the freeze protection circuit will activate the pump continuously when water temperature falls below 40 F 4 4 C After the pump turns on it will run for 30 minutes or continuously if the temperature remains below 45 F 7 2 46 TROUBLESHOOTING GUIDE Message Problem Typical Solution Display Error Pump Chlorine production acid feed for Follow the instructions for clearing the system as recommended on pg did not prime pHC and PCC modes and pump 44 Check Flow steps 1 10 Then follow these additional steps operation when programmed for 11 Some systems may take longer to prime the pump such as a solar one speed pump has stopped due to system Increase the Prime Protect to the next higher time setting inadequate flow 12 Disable Prime Protect by setting to Prime Protect Purifier Purifier locked at 1 If the water temperature is 55 10 or colder the Pool Pilot has display automatically turned the Chlorine output down to 1 to avoid over chlorination Bacteria and algae stop growing at this temp
90. re detected press any panel key button to immediately stop the pump Warning Do not operate the acid pump until the leak is repaired See enable disable acid below 5 Otherwise the acid pump will continue to prime until the countdown timer ends or is manually stopped Reset acid meter used to reset the acid meter display to 0 1 Press MENU press A or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Reset acid meter is displayed then press SELECT 3 display will flash to verify Acid meter reset 4 Press Aor V until End menu mode 15 displayed then press SELECT Enable Disable acid used to enable or disable the acid feed pump 1 Press MENU press or V until Maintenance menu is displayed then press SELECT 2 Press Aor V until Enable acid or Disable acid is displayed then press SELECT if Enable acid then acid pump is disabled press SELECT to enable the acid pump if Disable acid then the acid pump is enabled press SELECT to disable acid pump 3 Press A or V until menu mode 15 displayed then press SELECT 35 PROGRAMMING AND OPERATION Total Control Menus System configuration must indicate Total Control configuration and is automatically detected when the electrical connections are made between the 75003 and 75001 systems Set pH overfeed Range No pH overfeed 120 minutes in 5 minute increments Used to stop the
91. rine on a daily basis To monitor your system s efficiency the water chemistry ranges and schedule of periodic checks outlined below should be followed CHEMICAL IDEAL RANGE IDEAL TEST SCHEDULE Free Chlorine 1 0 To 30 ppm Weekly au 7 2 To 7 8 Weekly Total Alkalinity Calcium Hardness Cyanuric Acid 60 To 80 CYA or Stabilizer 30 To 50 WARNING WARNING 80 To 120 ppm 2500 To 3500 ppm 200 To 400 ppm ppm ppm Monthly Monthly Monthly Monthly EFFECT OF LOW HIGH LEVELS Low free chlorine Not enough residual chlorine to safely sanitize pool water High free chlorine Corrosive to metallic fixtures in pool water Can bleach swimwear and hair Low pH acidic Equipment corrosion eye skin irritation plaster etching rapid chlorine consumption High pH basic Scale formation cloudy water eye skin irritation poor chlorine effectiveness Low TA Eye irritation pH bounce stained etched plaster and metal corrosion High TA Constant acid demand difficulty in maintaining pH and contributes to scale formation or cloudy water conditions Low Salt Below 2 400 ppm causes premature cell failure and reduces chlorine production High Salt Above 6 000 ppm can cause corrosion of metallic fixtures and will taste salty Note AutoPilot can safely operate with salt levels up to 35 000 Low CH Etching of plaster equipment corrosion High CH Scale formation c
92. s V until the desired configuration is reached then press SELECT 5 Press A or V until End menu mode 15 displayed then press SELECT 34 PROGRAMMING AND OPERATION MENUS For the Installer Menu press and hold SELECT button for approximately 13 seconds to access this feature Programming the system remote Used when interfaced to communicate with electronic control systems 1 Press MENU press A or V until nstaller menu 1s displayed then press and hold SELECT for 13 seconds 2 Press Aor V until Select remote is displayed then press SELECT 3 Select Remote 1 or Remote 2 depending on the electronic control system being connected to then press SELECT Remote 1 is used for most electronic control systems with a universal communication program Remote 2 is used for controllers with a modified communication program such as Jandy Aqualink Rev L 4 Press V until End menu mode 1s displayed then press SELECT Programming the system mode Used when controlling the pH or Pool Chemistry Controller optional components 1 Press MENU press or V until Installer menu 1s displayed then press and hold SELECT for 13 seconds 2 Press Aor V until Select system 15 displayed then press SELECT Purifier 15 the factory setting 3 The display will show the current configuration Purifier sanitizer production only pH Control pH acid feeder option s 75004 75005 75006 or 75007 is installed
93. sensors are packaged with liquid filled protective caps To avoid premature failure or damage it is necessary to ensure that the sensor tips are always kept wet using normal pool water 1 Before inserting the sensors ensure that all hoses are properly connected to the flow cell manifold and pump inlet plumbing 2 Start the pump to fill the flow cell with pool water and check for leaks Turn the pump off when water starts to flow out of the pH and ORP sensor mounting holes but leave the valves opened so the water can drain down some 3 Remove the sensors from the caps remove the old Teflon tape and rewrap with new Teflon tape 2 3 turns 4 Thread the sensors into the mounting holes and connect the BNC connectors to the appropriate locations as described below place the storage caps in the cap holders When shipping or storing the sensors fill the protective caps with normal pool water prior to securing the caps onto the sensors Tighten the caps and store in a safe location The ORP and pH sensors are connected to the 75001 Pool Chemistry Controller electronic processor using BNC connectors These are designed to install and lock into position The sensors and connectors are marked for ORP and pH 75001 Pool Chemistry Controller Electronic Processor Box pH white ring ORP black ring Move the plastic cover to reveal the metal BNC connector Slide the BNC connector onto terminal and twist the lock knob clockwise to lock in place
94. tes ONE 23 CONNECTING THE 75003 DIGITAL AN ELECTRONIC CONTROLLER 24 pa NE OVERVIEW 25 PROGRAMMING AND OPERA LION tete n ee 27 CONTROL PANELFEATURES AND FUNCTION S 55 26 CONTROL OPTIONS AND SYSTEM START UP eel iy haat eae cea DNE 27 PURIFIER MODE S QUICK PROGRAMMING S 525 das es 27 PITCONTROE MODE QUICK PROGRAMMING 2 6 Loo detus edi ca beso oa du soos pRabeL asso UR eU NO Nd 28 TOPALCONIBOLCDC MODESEQUICK PROGRAMMIING S s LU con beo qo a ana On Coa vo ae AP EOS 28 OPERA TON OL BUTTON eit i ES ene A M E 29 ADIUSTING THE PURIFIER OUTPUT CN seve DER so ben Oca eo fct e 29 BOOST OR SUPERBOOST e pU e I 29 MENU BUTEION i eitis bebe NL LI EE 29 amp Te Pe NE PT TE SOY AE 29 PUMP BUTTON
95. the dry contact closure 1 Plug the ORP 110 Vac cord into the relay box s 110 Vac cord 2 Remove the two position plug from the end of the interface cable 3 Insert the Relay Kit s interface cable through the Low Voltage Access Port as shown above 4 Connect the cable to the ORP IN Terminals as shown in the diagram above From ORP Controller To Pool Pilot 110 Digital Relay Kit Controller 23 INSTALLATION Electronic Controller Installation Tun ott power before making any electrical connections Connecting to an Electronic Controller An Electronic Control System Jandy AquaLink RS version I or L Polaris EOS or Pentair IntelliTouch may connected to the external RS 485 or the internal connector marked TB1 on the lower Circuit Board using a 4 wire cable Jandy JDY 4278 or equivalent Program Select Remote to match the Electronic Control System see pg 35 ECCO ont 0 age uii Access Port Electronic Controller Terminal 75003 Digital Control Panel Base Plate Electronic Controller Terminals on Circuit Board Jandy Controller Polaris Controller Pentair Controller cE 7 D e Connect to the red 2 iy e Connect to the e Connect to any of E 4 pin connector on D mE 4 pin removable the IntelliTouch Mud ACTUATOR the rear of the Jandy connector on the COMM ports and Ey circuit board command center match to the color matching the colo
96. the problem is usually caused by low salt improperly connected disconnected or loose cell cord water less than 65 F 18 3 C a scaled cell or cell near end of life Correct as appropriate If the volts are less than 25 then contact AutoPilot Systems for assistance Installer If the unit is configured for 230 Vac operation then verify that that the input AC voltage is not 115 Vac Fix wiring or reconfigure the unit as appropriate Temperature is out of range 1 Check the Tri sensor cable at both ends to make sure it is not disconnected or loose 2 Remove the cable at the Tri sensor and verify that the pins are not bent Plug it in using care to orient it correctly before inserting it Warning Read warning instructions and see illustrations in Connecting the Tri Sensor Cable on pg 15 3 Otherwise contact AutoPilot Systems for assistance If this 1s a new installation Cell is completely clogged from calcium scale has failed or the cell cord is loose or damaged Warming Low Amps Cell Warning Check Clean e Cell Warning Bad Temp Sensor Warning Remote Comm Error The Electronic Control unit is not sending communication messages to the Pool Pilot Turn the Electronic Control unit on Check for disconnected cable 45 Normal display Normal display or PUMP OFF Normal display or PUMP ON Normal display or PUMP ON TROUBLESHOOTING GUIDE Message on Problem Typica
97. ting for the Muriatic Acid inlet outlet 1 Locate the Acid Feed Pump and tank within proper cord See Digital TC manual for drilling instructions distances to the Pool Chemistry Controller System and Power source 2 Turn the pump off disconnect the cell and tri sensor cords and remove the manifold piping without the cell to a clean working area See diagram for which unions to remove marked Din diagram above 3 Locate the label on the manifold assembly marked Optional Tap Points marked in diagram above and drill the appropriate mounting hole adjacent to where indicated on the label marked Acid In Do not drill through the label Use a drill stop attachment if available or wrap a piece of masking tape exposing 1 of the tip of the drill bit as a stop indicator This will prevent drilling through the far side of the PVC damaging the manifold Note Use care to drill the hole perpendicular and deburr for a leak free connection of the injector fitting Do not over drill or ream the hole as oversized holes will leak and are not covered under warranty Follow steps 4 and 5 if using AutoPilot factory components or skip to 6 if using Stenner factory components 4 Insert the black injector fitting Uniseal into the gt hole p 4L Note not use any lubrication sealing compounds 5 Insert the one direction check valve assembly into the Uniseal and then insert the AutoPilot supplied black p
98. tion will void the warranty The CC 15 cell may be used in commercial or residential applications SAVE THESE INSTRUCTIONS UNIT NUMBERS AND CONTACT INFORMATION Please record the following information prior to installation Installer Date of Installation Control Unit Control Unit gt N SuperCell SuperCell T VDO Pool Volume in Gallons Tri Sensor Pool Volume in Liters E Thank you for purchasing an AutoPilot Salt Chlorination System You will enjoy the benefits of ownership for years to come Please take a moment to read this manual before proceeding with the installation Questions Refer to www AutoPilot com for the latest manual revisions additional information and helpful service You can also reach our factory direct customer assistance by calling 800 786 7751 or 727 832 5642 by email at AutoPilotTechSupport teamhorner com or by FAX at 727 824 0847 Pool Pilot Digital Manufactured by AquaCal AutoPilot Inc 2737 24 Street North St Petersburg Florida 33713 U S A 111 TABLE OF CONTENTS IMPORTANTI SABRE TY INSTRUCTIONS S codeine docile 11 UNIT NUMBERS AUTOPILOT CONTAC FP NEGO eive tive etie ea ili TAPE OF CONDE
99. trol Unit and acid feed pump and tank 2 Plug the flat 4 position connector into the Digital unit base plate shown below as 75008 Auxiliary Relay Terminal 3 Route the Input ac power wires through Liquidtite conduit from the AC Power Source to the Auxiliary Relay These wires should be connected to the Auxiliary Relay terminals marked Line 1 and Line 2 4 Cut off the existing ac plug on the acid feed pump and route this cord into the Auxiliary Relay through the strain relief fitting provided on the Relay box shown below as To Acid Pump 5 Cut back the cord jacket approximately 3 7 2 cm and strip the wires approximately 1 2 1 5 cm 6 Insert these wires into the Auxiliary Relay terminals marked Load 1 and Load 2 7 Connect the Green Ground wires together with the provided wire nut and then go to Step 4 below AC Power Conduit or Strain relief fitting for Acid Pump control C 0009 TT Ground Lug 75008 Auxiliary Relay Terminal B Prewired Plug to 75008 Terminal m m m 75008 Auxiliary Relay Kit 75003 Digital Control Panel Base Plate To Acid Pump gt e Acid Pump Digital is controlling the Stenner Acid Pump Note The Pool Pilot Digital voltage and the Stenner Acid Feed Pump voltage must match one another 1 Cut off the existing ac plug on the acid feed pump and route this cord into the Pool Pilot Digital Control unit Control Unit through a strain relief
100. trol configuration if the Digital unit is able to communicate with the Pool Chemistry Controller The system will display Error Purifier Off if the Digital unit is not able to communicate with the Pool Chemistry Controller Ensure the wire interface 1s properly connected between the Digital unit and the Pool Chemistry Controller The Total Control display cycles between the ORP display pH display and the Salt Time of Day Temperature display The pH and adjustment points are accessible when or pH measurement set point is on the display To access through the ORP or pH display press the arrow up or down while the respective mode is displayed This will then change to the specific menu to allow reprogramming the set points To retain the new setting press Select when finished Total Control Programming Start up Follow the Programming Start up instructions from the Purifier and pH Control modes Once the 75001 interface cable is connected and communicating with 75003 Digital Control unit it will automatically program to the Total Control mode In addition enter the Maintenance Menu to access and program any preferences for the following fields Set pH overfeed Set pH min Set pH max Calibrate pH Enable Disable ORP and Set ORP overfeed 28 PROGRAMMING AND OPERATION Operation of Buttons Adjusting the Purifier Output Press the up down arrow buttons to enter the Purifier Adjustment mode A
101. vel A one minute timer prevents the chlorine generation circuit from cycling on off unless an error condition exists The first line of the ORP screen displays the measured ORP followed by the ORP set point in parenthesis as shown below The ORP screen contains the text On only if chlorine is being generated The ORP display range is 200 to 900mV The second line of the ORP screen indicates if the ORP is high or low relative to the set point If the measured ORP 15 equal to the set point a block with no text is displayed If the measurement falls below the set point the W and Low are displayed and chlorine is generated If the measurement exceeds the set point the and High are displayed and no chlorine is generated 200 650 On ORP 650 650 ORP 900 650 T Low High p The system controls pH by dispensing diluted mixture of water and muriatic acid 4 1 ratio recommended when the pH rises above a user programmable set point which should correspond with the desired pH level To avoid overdosing the system dispenses acid in low increments based on the difference between the set point and the measured pH The first line of the pH screen displays the measured pH followed by the pH set point in parenthesis as shown below The pH screen contains the text only if acid 15 being dispensed The pH display range 15 4 00 to 9 90 The second line of the pH screen indicates if the pH 1s high or
102. vel is reached 3 Usethe up and down arrow buttons to set the purifier to 50 and allow the pool to operate normally For the first two weeks test the water chemistry parameters every 3 4 days Adjust chemicals as needed For the Free Chlorine adjustment use the following table for the adjustment procedure Purifier If Free Chlorine is ower than ideal range If Free Chlorine is higher than ideal range eed To avoid accidental adjustments the Cell Power can only be changed in the Installer Menu see page 26 0 25 The Purifier output needs to be increased The The CELL POWER setting is too high Cell Power is probably set correctly 1 Decrease the Cell Power one level to lower the 1 Use the up arrow button to increase the Purifier maximum output Output 2 Use the up arrow button to set the Purifier Output to 50 The Free Chlorine will need to be tested frequently and the Purifier Output will need to be adjusted as needed to attain desired level 25 to 75 The Purifier output needs to be increased The The Purifier output needs to be decreased The Cell Cell Power is probably set correctly Power is probably set correctly 1 Use the up arrow button to increase the Purifier 1 Use the down arrow button to decrease the Purifier Output Output 75 100 The CELL POWER setting may be too low The Purifier output needs to be decreased The Cell 1 Increase the Cell Power one level to raise the Power
103. with 75003 Pool Pilot Digital Total Control 75001 Pool Chemistry Controller and acid feeder options are installed with the 75003 Pool Pilot Digital 4 Press V until the desired configuration is reached then press SELECT 5 Press A or V until End menu mode is displayed then press SELECT pH and Total Control Menus Only applicable with optional acid feeder installed Activating the Boost acid mode Used to override the pH maximum pg 36 shut off protection feature and activate the pH feed pump to a specified amount of acid solution in oz ml or liters to lower the pH when there is acid solution in the storage tank 1 Press MENU press A or V until Owner Options 1s displayed then press SELECT 2 Press V until Boost acid is displayed then press SELECT 3 Press Aor V to assign the amount of acid solution needed 1 oz to 250 oz 29 ml to 7 4 L then press SELECT 4 Press V until End menu mode 1s displayed then press SELECT Prime acid pump used to test for leaks or to fill acid feed tubing during maintenance or installation 1 Press MENU press or V until Maintenance menu is displayed then press SELECT 2 Press V until Prime acid pump is displayed then press SELECT 3 The display will show A Start Pump Press arrow up A a 180 second count down timer will display 4 Once activated the display will show Press any key to stop pump If any leaks a
104. y Controller Unit within proper cord length to the Digital Control Unit e Find a suitable mounting location for the Stenner acid feeder and tank e Plan tubing runs for Flow Cell water sample tubing and Acid Feed lines For optional 75008 pH Auxiliary Relay Kit plan for electrical connections What is included Before attempting the Total Control installation check that the following items have been included with the Pool Chemistry Controller Quantity Item Description 1 75001 Pool Chemistry Control unit with Flow cell flow switch and interface cable 4 16 5 3 m 2 l Before attempting the pH Acid Feed Pump and Tank Kit installation check that the following items have been included with the pH Control System 1 Stenner pH acid feed pump with 15 gallon acid tank 1 Injection Fitting with gasket and S S saddle clamp 1 1 1 In line check valve adapter fitting 1 8 2 7 m 1 8 ID x OD tubing Cable Clamp and Nut assembly 1 pkg Stenner Factory Parts Kit fittings and components For 75008 Auxiliary Relay Kit 1 Auxiliary Relay box with internal relay and interface cable 1 4 Plastic Mounting Wall Anchors What is not included Some of the additional equipment that 15 needed to complete the installation e Drill with 3 8 bit e Utility Knife For installations using Stenner Factory Tube and Fittings NPT drill and tap kit e Teflon Tape For 75008 auxiliary relay kit
105. y setting pg 34 Power level X power level being sent to the cell 2 1s the factory setting pg 34 XX XXX gallons liters The pool volume programmed in the Installation Menu 15 000 is the factory setting pg 34 Reverse X hrs The reverse rate programmed in the Installation Menu 4 hrs is the factory setting pg 33 Temp adjust X The temperature adjustment variation of the actual tri sensor reading pg 34 Salt adjust X The salt calibration adjustment variation of the actual tri sensor reading pg 33 Purifier control or Total control The System mode selected Purifier is the factory setting pg 35 overfeed User programmed in the Maintenance menu No ORP overfeed 15 the factory setting Adjustable up to 120 minutes in 5 minute increments pg 36 pH overfeed User programmed in the Maintenance menu No pH overfeed is the factory setting Adjustable up to 120 minutes in 5 minute increments pg 36 pH minimum User programmed in the Maintenance menu 6 5 is the factory setting pg 36 pH maximum User programmed in the Maintenance menu 8 0 is the factory setting pg 36 Relay not used One speed pump Two speed pump or Acid pump The Set Relay 1 mode selected Relay not used is the factory setting pg 34 Prime Protect No prime protect 1 2 4 8 minutes User programmed setting selected to protect against pump damage due to insuffi
106. your water for high phosphate levels Use a product such as LoChlor Starver to reduce phosphates if the phosphate level is higher than 22 ppm 22 mg l If the water temperature is 55 F 10 or colder the Pool Pilot has automatically turned the Chlorine output down to 146 to avoid over chlorination Bacteria and algae activity 1s greatly reduced at these temperatures so this should not be a problem Hand dose additional chlorine if necessary Obtain an independent salt reading to check the Pool Pilot reading Add salt if needed and re calibrate the Pool Pilot salt display The test kit reagents or strips may be old or have been exposed to sunlight Replace the kit and retest There is too much chlorine in the pool The chlorine is bleaching the test kit reagents Dilute the water sample with distilled water and retest Lower the chlorine output setting with the down arrow button if the chlorine level 15 too high Sodium bromide may have been introduced into the pool by using a bromine based algaecide The DPD red color chlorine test reagent will give false readings if bromine is in the water The OTO yellow color test kit must be used which can test for bromine and chlorine The pump must be wired to the Pool Pilot Relay for any of the following comments to be valid The Pool Pilot will have no effect on the pump if the pump 1s controlled directly by an external timer or Electronic controller The Control Unit was not prog

Aquacal Pool Pilot 75003 User's Manual

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