Pool Pilot ® Digital Salt Chlorine Generator By 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. IMPORTANT.
IMPORTANT SAFETY INSTRUCTIONS When installing and using this electrical equipment, basic safety precautions should always be followed, including the following: 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.
UNIT NUMBERS AND CONTACT INFORMATION Please record the following information prior to installation: Installer: ....................................................... Date of Installation: ..................................... Control Unit Model Type: ................................................ Control Unit Serial Number: ............................................. SuperCell Model Type: ................................................ SuperCell Serial Number: ...................................
TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS ..................................................................................................... ii UNIT NUMBERS / AUTOPILOT CONTACT INFO .................................................................................... iii TABLE OF CONTENTS ........................................................................................................................... iv - vi SYSTEM OVERVIEW ..................................................................
TABLE OF CONTENTS LOW VOLTAGE WIRING .................................................................................................................................... 15 CONNECTING THE SUPERCELL CABLE ........................................................................................................................................... 15 CONNECTING THE TRI-SENSOR CABLE .....................................................................................................................................
TABLE OF CONTENTS SALT CALIBRATION .......................................................................................................................................... 34 ADJUSTING TEMPERATURE DISPLAY ................................................................................................................. 34 PROGRAMMING POOL VOLUME ....................................................................................................................... 34 PROGRAMMING CELL TYPE ...................
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: Purifier – standard mode, manually adjusted purifier output. See pg. 27 for system operation and programming.
SYSTEM OVERVIEW pH 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.
SYSTEM OVERVIEW Control Unit Features The control unit has the following features: Patented temperature compensation for chlorine output Programmable Microprocessor Control Multi-language digital display – (English, Spanish, French & 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.
SPECIFICATIONS Specifications #75003 Pool Pilot Digital Control unit Input Power 230 Vac 115 Vac Dry Contact 1.5 amps 3 amps 5 mA typical (Normal input configuration shipped from the factory) (Optional input configuration – jumper wire to convert included) Non-factory ORP input circuit (110Vac output require a Relay Kit – PN# 110-ORP) Chlorine Output SuperCell Type SC-36 SC-48 SC-60 CC-15 Maximum Chlorine Output (# 75003 Control unit set on Cell Power 3) 1.28 lbs/day (0.58 kg/day) 1.56 lbs/day (0.
PREPARING THE POOL WATER Calculating Pool Volume (needed to determine proper balance chemical additions) Average Depth Pool Shape Rectangular Round Oval depth of deep end depth of shallow end Gallons (pool size measured in feet) Length x Width x Average Depth x 7.5 Diameter x Diameter x Average Depth x 5.9 Length x Width x Average Depth x 5.
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.
PREPARING THE POOL WATER Basic Water Chemistry Your Pool Pilot Digital is designed to produce chlorine 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 Free Chlorine 1.0 To 3.0 pH 7.2 To 7.
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.
INSTALLATION Before Installing the # 75003 Pool Pilot Digital System Determine that everything needed for installation is 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
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.
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). It is 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.
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 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).
INSTALLATION Electrical Connections The Pool Pilot Digital uses both high and 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.
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. 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.
INSTALLATION Low voltage wiring Connecting the SuperCell Cable 1. 2. 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. The other end of the SuperCell cable may have a red weather plug located in one of the holes.
INSTALLATION Pool Chemistry Controller Installation (Turn off power before making any electrical connections) Time Clock Electronic Controller System #75001 Total Control #75003 Digital Unit AUTOPILOT SYSTEMS AUTOPILOT SYSTEMS Circuit Breaker #75008 Auxiliary Relay Kit (optional) INC INC autopilot.com autopilot.
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 Determine that everything needed for installation is on hand Find a suitable mounting location for the Pool Chemistry Controller Unit within proper cord length to the Digital Control Unit Find a suitable mounting location for the Stenner acid feeder and tank.
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.
INSTALLATION Connecting the #75001 Pool Chemistry Controller ORP and pH Sensors The ORP and pH 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.
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.
INSTALLATION Pool Chemistry Controller Flow Cell Plumbing Optional Tap Points For Digital 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 Tap Point Locations Have these tools on hand prior to starting this step: Drill 1/2” standard drill bit Utility knife Water Out ② ➀ Always Insert tubing into appropriate inlet/outlet.
INSTALLATION pH Control Installation Optional Tap Points For Digital TC Total Control Plumbing Have these tools on hand prior to starting this step: Drill 1/2” standard drill bit (or 1/4” NPT bit and tap if using Stenner components) Utility knife Acid In Tap Point Locations Water Out ② ➀ A hole must be drilled into the manifold assembly for installation of the injector fitting for the Muriatic Acid. 1.
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.
INSTALLATION Electronic Controller Installation (Turn off power before making any electrical connections) Connecting to an Electronic Controller An Electronic Control System (Jandy® AquaLink RS (version I, K or L), Polaris® EOS, or Pentair IntelliTouch®) may be 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.
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.
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.
PROGRAMMING AND OPERATION Control Options There are three different modes of operation. • Purifier (factory setting) • pH Control • 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.
PROGRAMMING AND OPERATION pH Control Mode (Manually adjusted pH control and Purifier) Note: Optional pH Control Acid Tank & Pump #’s 75004, 75005, 75006, or 75007 must be installed 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.
PROGRAMMING AND OPERATION Operation of Buttons Adjusting the Purifier Output % Press the up/down arrow buttons to enter the Purifier Adjustment mode. Adjust 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 is 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.
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 1 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).
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) 1. Press MENU. 2. “Test Pool Pilot” is automatically displayed, then press SELECT. 3. The display will automatically toggle through the following displays ( or allows manual control forward and back.
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. 2. 3. 4. Press MENU, press or until “Owner or Installer Menu” is displayed, then press SELECT. Press or until “Select language” is displayed, then press SELECT (English is the factory setting).
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. 2. 3. 4. 5. Press MENU, press or until “Maintenance menu” is displayed, then press SELECT.
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. 2. 3. 4. Press MENU, press or until “Maintenance menu” is displayed, then press SELECT.
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. 2. 3. 4. Press MENU, press or until “Installer menu” is displayed, then press and hold SELECT for 13 seconds. Press or until “Select remote” is displayed, then press SELECT.
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 chlorine and acid feed if the pH set point is not reached in the user programmed time.) 1. 2. 3. 4. Press MENU, press or until “Maintenance menu” is displayed, then press SELECT.
PROGRAMMING AND OPERATION 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.
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.
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. ! DANGER Turn off the power from the circuit breaker Before servicing this unit.
SYSTEM MAINTENANCE Tri-Sensor Assembly Tri-Sensor Assembly The Tri-Sensor Assembly is used to measure water flow, salt level, and water temperature. (#909-GO1.5) (Cable Ordered Separately) When the water flow reaches a minimum flow rate of 20 gpm (76 L/m), the flow paddle magnet closes a micro-switch that is monitored by the Control Unit.
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 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 Trisensor’s Flow Switch protection device.
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 life of the cell. Clean the cell immediately and determine the cause of scaling. See Troubleshooting Section, pgs. 44-49.
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. The sensor tips must always be kept wet when in use or storage. The sensors are threaded into the Flow Cell using Teflon tape.
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 727.823.5642 or by FAX at 727.821.7471. Run the “View Setup” (pg. 31) and record the information displayed and have the information available prior to contacting Autopilot.
TROUBLESHOOTING GUIDE Message on Display Warning! Check /Clean Cell Problem Typical Solution Conductivity of the water is reduced and is usually caused by Low salt, cold water, or a scaled cell. 1. Check the salt level and adjust to 3000 ppm (3.0 g/l) or verify salt calibration. 2. For water temperatures below 65F (18.3C), increase salt to 3500 ppm (3.5 g/l). 3. Remove and inspect the cell for white calcium scale. Follow the instructions on pgs. 41 – 42 to clean the cell.
TROUBLESHOOTING GUIDE Message on Display Normal display Problem Typical Solution There are no warning messages on the display but the chlorine level is too low. Water quality looks dirty or cloudy. 1. 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. 2.
TROUBLESHOOTING GUIDE Message on Display Error! Pump did not prime Purifier display Problem Typical Solution Chlorine production, acid feed for pHC and PCC modes, and pump operation (when programmed for one speed pump) has stopped due to inadequate flow. Purifier locked at 1% Follow the instructions for clearing the system as recommended on pg. 44, Check Flow, steps 1 - 10. Then follow these additional steps: 11. Some systems may take longer to prime the pump, such as a solar system.
TROUBLESHOOTING GUIDE Total Control and pH Control Displays Message on Display Warning! Replace sensors Warning! pH low 6.50 Warning! pH high 8.50 ORP disabled Acid disabled Problem Typical Solution The pH sensor could not be calibrated to match the results of a reliable pH test kit. The pH sensor reading is off by more than its calibration limit of ±2.0 pH units. pH is below a user programmable minimum pH between 6.5 and 8.0. Low pH may result in a low chlorine level.
TROUBLESHOOTING GUIDE Total Control Error Displays Message on Display Problem Typical Solution Error! Purifier off Error! Acid off Check flow at sensors Flow at sensors is not detected. Chlorine and acid are not fed under these conditions, until corrected. Error! Purifier off Error! Acid off Check ORP sensor 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.