IntelliChlor™ Electronic Chlorine Generator (Model IC20, IC40) User’s Guide ETL Listed Conforms to UL Standard 1081 3077230 US Patents Pending IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS
© 2005 Pentair Water Pool and Spa, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400 Trademarks and disclaimers IntelliChlor and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa, Inc. Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products.
i Contents System Description ..................................................................................................................................... 1 Features ...................................................................................................................................................... 1 IntelliChlor models .......................................................................................................................................
ii IMPORTANT SAFETY PRECAUTIONS Important Notice: Attention Installer: This manual contains important information about the installation, operation and safe use of this product. This information should be given to the owner and/or operator of this equipment. WARNING: IMPORTANT SAFETY INSTRUCTIONS PERTAINING TO A RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS READ. AND FOLLOW ALL INSTRUCTIONS. Before installing this product, read and follow all warning notices and instructions which are included.
iii IMPORTANT SAFETY PRECAUTIONS SAVE THESE INSTRUCTIONS FCC Regulatory Safety Notice - This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
iv Installation Steps Summary The recommended IntelliChlor installation steps are: 1 Review Chemistry You Need to Know (page 12): Review this important information. 2 Review Optimum Pool Water Conditions (page 13): Review NSPI standards information. 3 Review Pool Water Preparation (page 17): Review this important information. 4 Installing the cell into the plumbing system - Connecting the cell to the Power Center (page 19 - 26): Installing the cell into the pool plumbing system.
1 Introduction System Description The IntelliChlor™ salt chlorinator uses a process known as electrolysis to produce Sodium Hypochlorite (liquid chlorine) from a low concentration of salt added to the pool water. Hypochlorite kills bacteria, oxidizes organic material, and kills algae, then reverts back to salt. IntelliChlor then reuses the salt and the process starts over again. The IntelliChlor system is comprised of the Power Center and Electrolytic Cell.
2 Electrolytic Cell Controller The electrolytic cell controller includes a control panel with buttons and LED indicators to fully control and produce chlorine. The cell controller measures the water temperature and salt level to optimally produce chlorine. If the salt level is too low (red on salt display), the cell is turned off until salt is added to the pool. The controller has a self-cleaning cycle which reverses the cell polarity, reducing calcium buildup.
3 Power Center The Power Center converts AC electrical current to a low voltage DC current which is required by the cell to perform the electrolysis. The power supply is connected with the pool circulation pump electrical source so that the electrolytic cell only operates when the pool pump is on. The enclosure can be mounted vertically on the wall up to 15 feet away from the cell controller.
4 Loop Plumbing Diagram The IntelliChlor will operate in water flow rates from 15 gallons per minute up to 110 gallons per minute (the limit of 2” plumbing). For flow rates over 80 gallons per minute, it is recommend that you use a bypass loop (shown below) for best chlorine production. Installations with flow rates over 80 gallons per minute are those that have in-floor cleaning systems or boost pumps. These systems should use a bypass loop with the IntelliChlor.
5 Section 1 IntelliChlor Control Panel This section describes the IntelliChlor control panel status LEDs and the More, Less and Boost/On/Off control buttons. Salt Level Status LEDs The salt level is checked daily and is displayed on this section of the unit. • • • Green: Good salt. The water salt level is above 2900 ppm, the cell will produce chlorine. Flash green: Salt is above 4000 ppm. Chlorine is being produced but the pool water may be corrosive to other pool equipment.
6 Operator Control Panel (continued) Sanitizer Output LED Indicators The five LED indicators display as a bar graph to show in 20% increments, the amount of time the chlorine is produced per hour. In BOOST mode, these LEDs scroll in a pattern.
7 Section 2 Operating IntelliChlor This section describes the start up procedure and operating instructions for IntelliChlor. Initial Start up Period For the first 30 days of cell operation, the self-cleaning cycle will be set to 2 hours. After 30 days has elapsed, the unit will automatically set itself to four hour self-cleaning cycle. This feature will clean the cell more often on a new pool installation, then go to a more standard self-cleaning cycle for longer cell life.
8 Startup Procedure (Super Chlorination) Shocking (Super Chlorination) is recommended before pool startup. Start out with clean pool water from the beginning. IntelliChlor will build up a sufficient level of chlorine for sanitation in several hours. However, if pool water has a high demand from the start-up IntelliChlor will not be able to produce enough chlorine to reach break-point chlorination. So, it is best to super chlorinate from an outside source at the time of pool startup.
9 Section 3 User Maintenance This section describes how to maintain the IntelliChlor chlorination system. Daily service. None is needed. Weekly service. 1. Chlorine Test: Test pool water chlorine level with a reliable test kit. Maintain ideal range by adjusting IntelliChlor chlorine production rate. See “Buttons,” on page 6. • Chlorine is 1-3 PPM. Note: Above 3.0 PPM of chlorine may cause corrosion of pool metals and possibly cause damage to associated pool equipment.
10 Monthly Service To ensure that the correct chemical balance is maintained in your pool, it is important to perform the following recommended salt and pool water tests every month. 1. Salt Level Test: Check salt display lights on the unit and check that the green “GOOD” light is on. • If the yellow ADD Salt light is on (see page 5), add salt by following the procedures and charts described on page 14 and 15. • If salt level does not rise after 24 hours, see “Troubleshooting,” page 25.
11 Electrolytic Cell Cleaning 1. Automatic Cleaning. This unit has an automatic cell-cleaning feature (Cell Reversing) that removes scale deposits from the electrolytic cell. Note Automatic Cleaning does not interrupt Chlorine Production. “Scale” is a white crusty deposit that forms in excessively hard water or from pool water that is out of balance and in a scaling condition. If the cell shows excessive scaling, you need to perform an acid wash cleaning. Proceed to “Acid Wash Cleaning,” Step 2. 2.
12 Chemistry You Need to Know 1. Chlorine Stabilizer (cyanuric acid) is needed in outdoor pools to maintain proper levels of chlorine. Most unstable chlorine is destroyed by the UV radiation from the sun within 2 hours. Chlorine stabilizer should be maintained between 50 - 75 PPM. See Table 3, page 16. 2. Nitrates can cause extremely high chlorine demands and will deplete chlorine from your swimming pool. In some cases Nitrates may even lower your chlorine levels to zero.
13 Optimum Pool Water Conditions In accordance with the Association of Pool and Spa Professionals (APSP) standards, it is recommended that the following water balance conditions be maintained on an on going basis to protect the pool finish and equipment and ensure the pleasing appearance of the water. IntelliChlor is warranted to operate properly only if these conditions are met. Free Chlorine: 2.0 - 3.0 PPM. Above 3.
14 Chlorine Testing It is recommended that chlorine test samples be taken from two places. Compare the samples. A higher level should be found at the pool return line. The higher level at the pool return line indicates IntelliChlor is producing chlorine. 1. At the pool return line. 2. 18 inches (457 mm) below the surface and well away from the pool return line. What Type of Salt to Use The purer the salt the better the life and performance of the electrolytic cell. Use a salt that is at least 99.
15 How to Add Salt to the Pool CAUTION: Do not operate IntelliChlor with newly poured pool plaster; salt damage can occur. Wait at least 1 MONTH to allow new pool plaster to cure before operating IntelliChlor. 1. Switch on the pump to circulate the pool water. 2. Determine the amount of salt from the following charts. 3. Slowly pour in the salt around the outer perimeter of the pool for quick and even distribution.
16 Table 2. Approximate Pounds (kg) of Salt Needed to Maintain 3.0 gpl (3,000 PPM) Salt Concentration BeforeAddition Salt Addition Requiredper 1000 gallon pool capacity Salt Concentration BeforeAddition 0 ppm 25.6 lbs (11.6 kg) 1500 ppm 300 ppm 23.5 lbs (10.7 kg) 1800 ppm 500 ppm 21.4 lbs (9.7 kg) 2000 ppm 800 ppm 19.2 lbs (8.7 kg) 2300 ppm 1000 ppm 17.1 lbs (7.8 kg) 2500 ppm 1300 ppm 15 lbs (6.8 kg) 2800 ppm Salt Addition Required per 1000 gallon pool capacity 12.8 lbs (5.8 kg) 10.
17 Pool Water Preparation Determining Pool Size (m3 of Water in Your Pool) • Rectangular Pools: Length x width (meters) x average depth x 1000 • Circular Pools: Diameter x diameter x average depth x 785 • Oval Pools: Length x width (meters) x average depth x 893 • Sloping Sides: Multiply total m3 by 0.85 = m3 capacity. Determining Pool Size (Gallons of Water in Your Pool) • Rectangular Pools: Length x width x average depth x 7.5 • Circular Pools: Diameter x diameter x average depth x 5.
18 Selecting Model Size IntelliChlor Model IC20 IntelliChlor Model IC40 Chlorine Production Chlorine Production 0.70 lb (317 gm) per 24-hour period. 1.40 lb (635 gm) per 24-hour period. Residential Pools Residential Pools One unit per 57 m3 (up to 20,000 gallons) pool (year round use) One unit per 114 m3 (up to 40,000 gallons) pool (year round use) One unit per 66 m3 (up to 17,500 gallons) pool (winterized). One unit per 132 m3 (up to 35,000 gallons) pool (winterized).
19 Section 4 Installation This section describes how to install the IntelliChlor electrolytic cell assembly into the pool plumbing system. Also, included are connection instructions for an IntelliTouch system. Before installing, review the IntelliChlor kit contents and required tools. Note: For Power Center installation instructions, see the “IntelliChlor Power Center Installation Guide” P/N 520590. Note: Salt is not provided.
20 Installing the Cell Assembly Install the IntelliChlor cell assembly no closer than three (3) feet from the heater outlet, if used. Note: After new pool construction has been completed, in order to prevent debris from entering the IntelliChlor cell assembly, it is recommended that the IntelliChlor pass-through cell (P/N 520588) be installed before installing the IntelliChlor cell. After the pool system has flushed the debris from the pipes, remove the pass-through cell and install the IntelliChlor cell.
21 Connecting the Cell Assembly to the IntelliTouch System To operate IntelliChlor via the IntelliTouch Indoor Control Panel, connect a 4-wire cable from the IntelliChlor Power Center to the Personality board located in the IntelliTouch Load Center. An alternate connection can be made by splicing the Indoor Control Panel connection wire connected to the Personality board. Note: For IntelliChlor operating instructions using the IntelliTouch system, see the “IntelliTouch User’s Guide” (P/N 520102).
22 Connecting to the IntelliTouch Load Center To connect the 4-wire cable from the IntelliChlor Power Center to the Personality board located in the IntelliTouch Load Center: WARNING Switch OFF main system power to the Load Center before making any connections. 1. Unlatch the Load Center enclosure door spring latches, and open the door. 2. Loosen the two retaining screws from the Outdoor Control Panel. 3.
23 4. Route the four conductor cable up through the low voltage raceway in the Load Center to the Personality board. 5. Strip back the cable conductors ¼ in. Insert the wires into the screw terminals (provided in the kit). Secure the wires with the screws. Make sure to match the color coding of the wires; Red = +15, Yellow = +DT, Green = -DT, and GND = Black. 6. Insert the cable plug onto either of the COM PORTS (J7 or J8) connectors located on the left side of the Personality board. 7.
24 Blank Page IntelliChlor User’s Guide
25 Section 5 Troubleshooting Use the following troubleshooting information to resolve possible problems with the IntelliChlor system. Note: Switch power off to unit before to attempting service or repair. Table 1: Troubleshooting Problem Possible Cause Corrective Action Low or no chlorine Low stabilizer (cyanuric acid) level in pool water Add stabilizer to maintain 50 - 75 PPM per pool professional's recommendations. See Stabilizer Char t, Table 3, page 16.
26 Table 1: Troubleshooting (Continued) Problem Possible Cause Corrective Action Red ADD salt light is on. Pool water needs salt. No chlorine is being produced. Add salt as described on pages 14, 15, and 16. Yellow LOW salt light is on. Not enough salt in pool. Heavy Rainfall. Leak in pool. Add salt to pool, 3.0 gpl to 3.5 gpl. See page 14, 15, and 16. Green GOOD salt light is flashing Too much salt in pool. May cause corrosion on other pool equipment.
27 Table 2: Troubleshooting the Power Center Problem Possible Cause Corrective Action IntelliChlor unit does not have green power light. Fuse in Power Center is open. Replace AC fuse, located at bottom of Power Center. No AC power to Power Center. Verify time clock is providing 110 VAC or 220 VAC to Power Center when active. Tansformer leads not wired correcly in Power Center. Verify transformer leads wired to AC source by referring to wiring diagram decal on inside of Power Center cover.
28 Electrical Specifications and 110 VAC and 220 VAC Wiring Circuit Protection: Two-pole 20 AMP device at the electrical panel. IntelliChlor Model IC20 Input: 90-130 VAC, 50/60 Hz, 220 Watts (2 AMP) or 220-240 VAC, 50/60 Hz, 220 Watts (1 AMP). Output: 22-39 VDC @ 6 AMPS maximum from the Power Center. Chlorine: 0.70 lb. / 24 hour. (317 gm / 24 Hour). IntelliChlor Model IC40 Input: 90-130 VAC, 50/60 Hz, 220 Watts (2 AMP) or 220-240 VAC, 50/60 Hz, 220 Watts (1 AMP).
LIMITED WARRANTY Pentair Water Pool and Spa, Inc. ("Pentair Water") manufactures its products with the highest standards of workmanship, using the best materials available through state of the art process. Pentair Water warrants its products as follows: Limited Warranty: Pentair Water warrants its products to be free from defects in material and/or workmanship for a period of three (3) years or 8,000 hours (parts only) from the original date of installation.
P/N 520589 - Rev C
