Aquacal Pool Pilot 75003 Owner'S Manual Download Page 45

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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.

Main Power Board

Location Fuse

Specification Description

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 1 amp

PCC Fuse

Total Control Interface Board #838
Location Fuse

Specification Description

250 Vac 1 amps

AC Input Power Fuse

250 Vac 1 amps

12V Feeder Power Fuse

AC IN

12V
Feeder

Summary of Contents for Pool Pilot 75003

Page 1: ... 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 Pool Owner Save this manual for reference Installer ...

Page 2: ... 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 discon...

Page 3: ...ion 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 teamho...

Page 4: ... FEED PUMP AND TANK AC INPUT POWER 4 Low Voltage Input Power 4 Flow Cell 4 PREPARING THE POOL WATER 5 CALCULATING POOL VOLUME 5 TYPE OF SALT 5 HOW TO ADD SALT OR REMOVE SALT 5 SALT LEVEL 5 SALT ADDITION CHART 6 BASIC WATER CHEMISTRY 7 SATURATION INDEX SI 8 INSTALLATION 9 BEFORE INSTALLING THE 75003 POOL PILOT DIGITAL SYSTEM 9 WHAT IS INCLUDED 9 WHAT IS NOT INCLUDED 9 PLUMBING REQUIREMENTS 10 ELECT...

Page 5: ...3 DIGITAL TO ANY OTHER ORP CONTROLLER 23 INSTALLING THE OPTIONAL 110 ORP RELAY KIT 23 CONNECTING THE 75003 DIGITAL TO AN ELECTRONIC CONTROLLER 24 MENU OVERVIEW 25 PROGRAMMING AND OPERATION 27 CONTROL PANEL FEATURES AND FUNCTIONS 26 CONTROL OPTIONS AND SYSTEM START UP 27 PURIFIER MODE QUICK PROGRAMMING 27 PH CONTROL MODE QUICK PROGRAMMING 28 TOTAL CONTROL TC MODE QUICK PROGRAMMING 28 OPERATION OF B...

Page 6: ...LOT THROUGH THE ELECTRONIC CONTROLLER CONTROL PANEL 37 PROGRAMMING THE POOL PILOT DIGITAL FOR AN ELECTRONIC CONTROLLER 37 ELECTRONIC CONTROLLER DISPLAYS CHECK POOL PILOT 37 SYSTEM MAINTENANCE 38 WINTERIZING 38 FREEZE PROTECTION PROGRAM 38 SPRING START UP 38 FUSE LOCATIONS AND RATINGS 39 TRI SENSOR ASSEMBLY 40 REMOVING INSPECTING CLEANING THE TRI SENSOR 40 TESTING THE FLOW SWITCH CLEANING THE FILTE...

Page 7: ...gital can also be programmed to control the main circulation pump operating times or be controller by an external timer switch relay 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...

Page 8: ...es not dispense acid until after flow has been detected a minimum of three 3 minutes after activation 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 sys...

Page 9: ...n 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 is installed as a part of the Digital TC Total Control System in conjun...

Page 10: ...m 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 Approvals ETL tested to conform to the following UL specifications o UL1081 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...

Page 11: ...e 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 brushing as staining may occur If the salt level in the pool becomes undesirably high the only way to remove e...

Page 12: ...5 000 40 000 Current salt level ppm g l 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 0 11 23 57 114 170 227 284 341 398 454 23 46 115 230 344 459 574 689 803 918 250 0 25 10 21 52 104 156 208 260 312 364 416 21 42 104 209 313 417 522 626 730 835 500 0 50 9 19 47 95 142 189 237 284 331 379 19 38 94 188 282 376 470 563 657 751 750 0 7...

Page 13: ...e at a time may take a week or more to lower the TA Aerate by pointing return jets toward the surface Salt 2500 To 3500 ppm Monthly 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 Salt Add salt according t...

Page 14: ... Factors TF CF AF Constant from the chart below to determine your Saturation Index Adjust your chemicals to maintain balanced water pH TF CF AF SC SI Temperature TF Calcium Hardness CF Total Alkalinity AF Salt Level SC 60o F 15 6o C 0 4 150 ppm 1 8 75 ppm 1 9 0 1000 ppm 12 1 66o F 18 9o C 0 5 200 ppm 1 9 100 ppm 2 0 1001 2000 ppm 12 2 76o F 24 4o C 0 6 250 ppm 2 0 125 ppm 2 1 2001 3000 ppm 12 3 84...

Page 15: ... 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 DIGITAL CONTROLLER Quantity Item Description 1 75003 Pool Pilot Digital Control Unit AC ...

Page 16: ... Details on each step of the installation process are presented on the following pages 1 Plumbing the Manifold Assembly pg 11 2 Mounting the Pool Pilot Digital pg 12 3 Electrical connections pgs 13 15 a Grounding and bonding b High voltage wiring i 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 Dig...

Page 17: ... the last component in the POOL RETURN LINE to avoid over sanitization of the SPA For flow rates within the normal range 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...

Page 18: ...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 anchors and or screws Leave a gap from the wall when tightening the screws 3 Loosen but do not remove the 4 thumbscrews on...

Page 19: ... 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 8AWG 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 P...

Page 20: ...me 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 Connecting Pool Pilot Digital to One Speed Pump or pH Acid Feed Pump LINE IN 1 Follow the LINE IN instructions above 2 Select wire gauge and...

Page 21: ...gether 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 Connect the white 6 pin connector to the mating plug located on the base of the Pool Pilot Digital Remove the black dust cap that covers the electrical connector on the Tri Sensor Assembly located...

Page 22: ...r System 75008 Auxiliary Relay Kit optional AUTOPILOT SYSTEMS INC AutoPilot com AUTOPILOT SYSTEMS INC AutoPilot com 75001 Total Control Water Sample return line Water Sample feed line Acid Pump Power Wire 75001 Interface wire Acid Feed Tubing pH Acid Feed System 75004 75005 75006 75007 Time Clock Circuit Breaker 75003 Digital Unit ...

Page 23: ...ng Wall Anchors 4 Mounting Screws 16 5 3 m 3 8 Water Sample tubing 2 Injection Fitting with gasket and S S saddle clamp 1 In line check valve adapter fitting Before attempting the pH Acid Feed Pump and Tank Kit installation check that the following items have been included with the pH Control System For 75008 Auxiliary Relay Kit Quantity Item Description 1 Auxiliary Relay box with internal relay a...

Page 24: ...ore 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 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...

Page 25: ...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 Electrical Connections Connecting the 75001 Pool Chemistry Controller Turn off power before making any electrical connections The 75001 Pool Chemistry Controller is pr...

Page 26: ...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 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 Acid Pump Digital is controlling the Stenner Acid Pump Note The Pool Pilot Digital voltag...

Page 27: ...nsert 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 Caution Avoid any sharp bends and over tightening the ty wrap to th...

Page 28: ...r fitting Uniseal into the hole Note Do not use any lubrication or sealing compounds 5 Insert the one direction check valve assembly into the Uniseal and then insert the AutoPilot supplied black plastic tubing marked 1 8 ID x 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 det...

Page 29: ...arning Turn off power to the Pool Pilot Digital and ORP controller before connecting any wires In the event that the ORP controller does not provide a dry contact closure a standard 110 Vac output can be used with the 110 ORP relay kit to provide 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 ...

Page 30: ...d 2 2 DATA Black Pin 1 Yellow 3 3 DATA Yellow Pin 2 Green 4 4 GND Green Pin 3 Black Jandy Controller Connect to the red 4 pin connector on the rear of the Jandy circuit board matching the color code in the chart below Connect in parallel to the existing wires Polaris Controller Connect to the 4 pin removable connector on the command center board matching the color code in the chart below Pentair C...

Page 31: ...vel Replace cell 5 oz ml Acid Fed 3 Set pool volume Pool size Set prime protect 2 ORP ORP setpoint 4 Set cell type Reverse time Set pump program 1 1 pH pH setpoint 4 Set cell power Temp adjust Set pump program 2 1 Set relay 1 Salt adjust Calibrate salt Owner Options Set prime protect 2 Select system mode Calibrate temperature Select language Set pump program 1 1 ORP overfeed 4 Prime acid pump 3 Se...

Page 32: ...nt Check system Red LED flashes to warn that attention is needed A warning message will also be displayed Press the Up or Down Arrow to Set Chlorine Level and ORP pH levels when optional Digital TC components are installed Scroll through Menus and sub Menus Increase or Decrease programming values for menus Press the Pump button to manually override a stored program for Turning the pump on off or o...

Page 33: ...ximum 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 Cell Power is probably set correctly 1 Use the up arrow button to increase the Purifier Output The Purifier output needs to be decreased T...

Page 34: ...s the factory setting Press or to program Select system to pH control then press SELECT Press or until Set Relay 1 is displayed then press SELECT Relay not used is the factory setting Press or 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 ...

Page 35: ...oost 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 set...

Page 36: ...l not enable pump 1 Display indicates pump off 2 Press PUMP 3 Press Maintenance 4 PUMP OFF FOR SERVICE and a Red CHECK SYSTEM light will now be displayed With PUMP OFF FOR SERVICE to terminate maintenance mode and return to PUMP OFF 1 Press PUMP 2 Press End Maint 3 Pump will be in the pump off status With PUMP OFF to turn PUMP ON 1 Press PUMP 2 Press Start Pump 3 The pump will run until the pump p...

Page 37: ...ll xC XX The cell type programmed in the Installation Menu SC 48 is the factory setting pg 34 Power level X The power level being sent to the cell 2 is 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 adjus...

Page 38: ...s or until 12 24 hour clock is displayed then press SELECT 12 hour is the factory setting 3 Press or until desired time format 12 hour or 24 hour is displayed then press SELECT 4 Press or until End menu mode is displayed then press SELECT Programming the time of day Allows for changes to the time of day displays for time zones or day light savings 1 Press MENU press or until Owner Maintenance Menu...

Page 39: ...Press MENU press or until Maintenance menu is displayed then press SELECT 2 Press or until Enable remote or Disable remote is displayed if Enable remote then the electronic controller is disabled press SELECT to enable the electronic controller if Disable remote then the electronic controller is enabled press SELECT to disable the electronic controller 3 Press or until End menu mode is displayed t...

Page 40: ...lons 1 000 to 226 000 liters 3 Press or until correct pool size is displayed then press SELECT 4 Press or until End menu mode is displayed then press SELECT Program the cell type Must match the installed cell 1 Press MENU press or until Installer menu is displayed then press and hold SELECT for 13 seconds 2 Press or until Set cell type is displayed then press SELECT Factory setting is SC 48 3 Pres...

Page 41: ...ivate 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 or until Owner Options is displayed then press SELECT 2 Press or until Boost acid is displayed then press SELECT 3 Press or to assign the amount of acid solution needed 1 oz to 250 oz 29 ml to 7 4 L then press SELECT 4 Press or until En...

Page 42: ...isplayed then press SELECT 8 0 is the factory setting 3 Press or to the desired pH max setting then press SELECT 4 Press or until End menu mode is displayed then press SELECT Calibrate pH Used to match the pH display of the Digital to the results of a reliable pH test kit 1 Press MENU press or until Maintenance menu is displayed then press SELECT 2 Press or until Calibrate pH is displayed then pre...

Page 43: ...T button for 13 seconds The display will update when the INSTALLER mode has activated 2 Press or until Set Relay 1 is displayed then press SELECT Relay not used is the factory setting 3 Press or until Relay not used is displayed if previously adjusted from the factory setting then press SELECT 4 Press or until Select Remote is displayed then press SELECT Select Remote 1 for the more common electro...

Page 44: ...rior 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 conti...

Page 45: ...r Before servicing this unit Main Power Board Location Fuse Specification Description F1 250 Vac 6 amps Main AC Power Fuse F2 250 Vac 3 amps Control Panel Circuit Board Fuse F3 250 Vac 20 amps Cell Fuse F4 250 Vac 1 amp PCC Fuse Total Control Interface Board 838 Location Fuse Specification Description F1 250 Vac 1 amps AC Input Power Fuse F2 250 Vac 1 amps 12V Feeder Power Fuse F1 F2 F1 F2 F3 AC I...

Page 46: ...ensor 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 replaced 5 The Tri Sensor can now be pulled ou...

Page 47: ...p and the Pool Pilot The plastic will stop water flow to the flow switch which is part of the Tri Sensor that is located in the upper portion of the manifold All 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 10 The Control Unit should detect a low water flow at the Tri Sensor and activate the red Chec...

Page 48: ...cing 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 Clean and dry the electrical terminals on the SuperCell The contacts must be co...

Page 49: ...ess 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 ...

Page 50: ...nstructions and see illustrations in Connecting the Tri Sensor Cable on pg 15 9 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 10 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 t...

Page 51: ...als 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 is heavily scaled Remove and acid wash as described on pgs 41 42 Warming Low Amps Cell If this is a new installation Verify that the incoming voltage matches the voltage of the Control Unit see pg 13 Warning Low Amps Cell Warning...

Page 52: ...reading Add salt if needed and re calibrate the Pool Pilot salt display Normal display There are no warning messages on the display The chlorine level is too low but the pool water looks fine 1 The test kit reagents or strips may be old or have been exposed to sunlight Replace the kit and retest 2 There is too much chlorine in the pool The chlorine is bleaching the test kit reagents Dilute the wat...

Page 53: ...recommended range 60 80 ppm Test and add to recommended range Dosage is 1lb per 5000 gallons to increase 25 ppm Salt Level not within recommended range 2500 3500 ppm Test and add to recommended range Dosage is 5lb per 1000 gallons to increase 600 ppm Purifier Output not set high enough to generate chlorine Pump run time not set long enough to generate chlorine Super boost 72 hrs the system and rem...

Page 54: ......

Page 55: ...cid are not fed under these conditions until corrected Check and secure ORP connections Replace ORP sensor Error Purifier off Error Acid off ORP overfeed 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 Clear the ORP overfe...

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