Autopilot Pool Pilot Professional PPP-2, Owners & Installation Manual

Page 1: ...MENT IS PURCHASER S PROPERTY AND IS TO REMAIN WITH THE EQUIPMENT OWNER LTP0155 REV 5 Important This manual covers the installation and operation of the Pool Pilot Professional Salt Chlorine Generators Read this manual and product labels before installing or operating this equipment ...

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Page 3: ...dible Alarm 6 3 4 Normal Display Modes 6 Section 4 Specifications and Approvals 4 1 Specifications 7 4 2 Manifold Pressure Drop vs Flow 7 Section 5 Features 5 1 Patented Temperature Compensation 8 5 2 Water Manifold Assemblies Available Options 8 5 2 a Automatic Flow Bypass Manifold Assembly 8 5 2 b Cell 9 Section 6 Maintenance 6 1 Accessing the Power Module 10 6 2 Removing Inspecting Cleaning Tri...

Page 4: ...it 20 7 4 Review of Installer Menu Programming 21 7 4 a Calibrate Temperature 21 7 4 b Calibrate Salt 21 7 4 c Set Pool Volume 21 Section 8 Installation 8 1 Basic System Overview 22 8 2 Planning the Installation 23 8 3 Installation Steps 23 8 4 Mounting the Control Center 23 8 5 Plumbing the System 24 8 5 a Plumbing the Manifold Assembly 24 8 5 b Plumbing for Convection Cell Applications 24 8 5 c ...

Page 5: ... 1 Basic Water Chemistry 37 10 1 a Chlorine 38 10 1 b pH 38 10 1 c Total Alkalinity 38 10 1 d Calcium Hardness 38 10 1 e Cyanuric Acid 39 10 2 Using the Saturation Index 39 10 3 Salt Addition Chart 40 Section 11 Approvals 11 1 Agency Approvals 41 11 2 FCC Compliance 41 iii ...

Page 6: ...sult in equipment damage WARNING Failure to heed the following may result in permanent injury or death l RISK OF ELECTRICAL SHOCK Disconnect all AC power when installing or servicing this system Follow all state local and National Electrical Code s provincial and Canadian Electrical Code s if applicable unless local guidelines supersede Use copper conductors only l RISK OF ELECTRICAL SHOCK To redu...

Page 7: ...ne gas buildup can occur The Pool Pilot should never be energized when the pool pump is OFF and there is no water flow PERSONAL SAFETY HAZARD To reduce the risk of injury do not permit children to operate this device RISK OF CHILD DROWNING OR INJURY Children must be closely supervised at all times around pool or spa equipment CAUTION Failure to heed the following may result in equipment damage l T...

Page 8: ...Never use any sharp or metallic objects to remove scale The warranty will be voided l Reduced polarity reversing cycle times will reduce cell life and should only be used due to uncontrollable scale formation on the cell ALWAYS test and adjust water balance before attempting scale control via shortening reverse period SAVE THESE INSTRUCTIONS ...

Page 9: ...l Serial B3 Cell Serial C3 Cell Serial A4 Cell Serial B4 Cell Serial C4 Cell Serial A5 Cell Serial B5 Cell Serial C5 Cell Serial A6 Cell Serial B6 Cell Serial C6 2 2 Pool Pilot Professional Model Options To reduce the risk of personal injury the Pool Pilot Professional control center must be installed on an automation filter pump relay wired to the load side of the time clock electronically contro...

Page 10: ...l Pilot Professional PPP 6 15 72 lbs 6 16 kg Model w PPC5 Convection Cell Chlorine Output lbs kg Per 24 Hours Pool Pilot Professional PPP 2 CONV 4 53 lbs 2 05 kg Pool Pilot Professional PPP 3 CONV 6 79 lbs 3 08 kg Pool Pilot Professional PPP 4 CONV 9 06 lbs 4 11 kg Pool Pilot Professional PPP 5 CONV 11 32 lbs 5 14 kg Pool Pilot Professional PPP 6 CONV 13 59 lbs 6 16 kg 2 3 Main Components 2 3 a Co...

Page 11: ...through the cells the electrolytic process splits the sodium from the chloride and generates chlorine After the chlorine reacts with the organics and debris in the water the chlorine recombines with the sodium and the process is repeated The manifold assembly model 941 215AC is shown below and consists of two commercial PPC5 cells The Pool Pilot Professional can accomodate up to a six 6 cell manif...

Page 12: ...alanced has proper levels of pH Total Alkalinity and Calcium Hardness Balanced water can also be defined as water that is not corrosive or scaling Water that is not balanced can damage equipment and pool surfaces See Basic Water Chemistry on page 37 Proper water chemistry levels are essential to maintain safe and consistent swimming pool operation Sanitizers are used to destroy harmful or otherwis...

Page 13: ...chlorine output level is tuned in the unit will automatically make fine output adjustments as water temperature fluctuates This temperature compensation feature will adjust output depending on water temperature See Patented Temperature Compensation on page 8 Note The optimum output setting will vary based upon pool size location exposure to sunlight number of users vegetation around the pool water...

Page 14: ...ient chlorine production l Add Salt lbs Amount needed to maintain 3 000 ppm mg L l Water Temperature F C The temperature of the water flowing through the Tri sensor l Pool Volume gallons litres The pool volume programmed in the Installation Menu l Cell x V Cell number and volts to the cell measured for each cell connected l Amp Hrs and then l SW Ver l RS232 Enabled Disabled Factory use only and se...

Page 15: ...4 kg 13 59 lbs day 6 16 kg Rated Power in AC Amps 230 V 4 4 A 230 V 6 6 A 230 V 8 8 A 230 V 11 0 A 230 V 13 2 A Minimum Water Flow Rate gpm 30 50 gpm 6 8 11 3 m hr Maximum Water Flow Rate gpm 70 gpm 22 6 m hr ORP Input Dry contact 10 mA typical ORP controllers with 110 V output and multiple power supplies will require relay kit part 110 ORP ORP Relay Box 110V US plug Weight Power Supply 83 lbs 91 ...

Page 16: ... Automatic Flow Bypass Manifold Assembly The AutoPilot manifold assembly is available with two 2 three 3 four 4 five 5 or six 6 cells including the Tri sensor Each cell must have a corresponding power module Example If you order a PPP 4 unit there will be four 4 power modules in the control center and a 941 415AC manifold assembly with four 4 cells and one 1 Tri sensor assembly The manifold is con...

Page 17: ...anifold Assembly Options Figure 5 5 2 b Cell The cell is installed with unions on each end of the cell to allow for quick and easy removal To remove and inspect the cell loosen the unions and remove from the plumbing assembly Figure 6 ...

Page 18: ...le flange is held by an L bracket The L bracket has two screws on each end and each power module angle flange has a screw Take out the screws on the end of the L bracket and on each power module angle flange 3 Remove the L bracket from the power center cabinet 4 Each module uses two 2 hold down screws to attach the power board angle flange to the back plate Locations are shown below Using a long s...

Page 19: ...ntenance or cleaning 6 2 b Inspect Tri sensor 1 Disconnect the Tri sensor cable from the power center 2 Remove the two 2 screws retaining the Tri sensor in the Tee joint of the manifold l Note the orientation of the Direction of Flow Tab The Tri sensor must be installed in the same orientation when it is reinstalled or replaced 3 The Tri sensor can now be pulled out of the Tee CAUTION Failure to h...

Page 20: ...or to flush debris from the bypass valve Figure 11 1 Turn off the circulation pump 2 Slightly loosen the union nut just below the cell on the side of the manifold that does not contain the filter screen A strap wrench may be required 3 Completely loosen the manifold union nut that contains the filter screen and pivot the manifold to gain access to the filter screen 4 Remove the screen Clean the sc...

Page 21: ...spection Figure 13 Your Pool Pilot is designed to automatically self clean calcium scale build up that may form on the blades during normal operation However unbalanced water chemistry can cause a heavy scale build up exceeding self cleaning capabilities thus periodic manual cleaning may be necessary The simplest way to avoid this extra work is to maintain the water chemistry at the levels recomme...

Page 22: ...re inspect the cell and repeat acid cleaning if the cell is still scaled 6 3 d Installing CAUTION Failure to heed the following may result in equipment damage l The electrical terminals must be completely dry to avoid corrosion and failure of the cell or cable l Ensure that the cell cable is fully engaged A partially seated cable may result in damage to the cable or cell during operation 1 Clean a...

Page 23: ...ions on page 4 Be sure to check salt and Cyanuric acid stabilizer bringing those readings up to the recommended levels It is also a good idea to inspect the cell manifold screen and test the Tri sensor flow switch clean and or replace those items as necessary See Removing Inspecting Cleaning Tri sensor on page 11 See Servicing the Cell on page 13 SECTION 7 PROGRAMMING 7 1 Control Panel 7 1 a Butto...

Page 24: ...press or to scroll forwards and backwards Press the MENU ENTER button again to skip the remaining displays and exit back to normal operation l Software Ver X x Current version of the control board display software l Power Setting High Low Factory default is Low l Alarm Enabled Disabled Factory default is Enabled l Reverse hrs The reverse rate programmed in the Installation Menu Factory default is ...

Page 25: ...e display s lower right display and On when generating chlorine Higher settings will generate more chlorine 1 Use the or buttons to adjust the purifier chlorine output percentage to the desired output from 0 off to 100 then press MENU ENTER to save the new output value and default back to the normal display At start up of a new system the standard output setting starting point is 50 50 setting 50 ...

Page 26: ...vide a warning and will not generate chlorine until the minimum salt level has been reached 3 Use the or buttons to set the purifier to 50 and then allow the pool to operate normally For the first two weeks test the water chemistry parameters every 3 4 days Adjust chemicals as needed to maintain correct water balance For the Free Chlorine adjustment use the following table for fine tuning the cont...

Page 27: ...arm Disable is displayed then press MENU ENTER to select desired option When complete the unit will automatically advance to the next menu option 7 3 b Boost The Boost feature is used to increase the purifier from its normal setting to 100 for a cumulative amount of time between one 1 and seventy two 72 hour period of pool pump run time When the Boost period expires or is manually terminated the p...

Page 28: ...play will show Cell x Press or until the desired cell to be replaced is shown and press MENU ENTER 3 Press the MENU ENTER button to reset the ampere hour counter The unit will automatically advance to the next menu option 7 3 f Set Cell Power The Pool Pilot Professional is equipped with two power level options Your pool service professional will determine which power level best suits the sanitizin...

Page 29: ...e steps it is necessary to wait 2 minutes after water flow has started before calibrating salt 1 Press MENU ENTER press until Installer Menu is displayed and press MENU ENTER 2 Press until Calibrate salt is displayed and press MENU ENTER 3 Press or until the number on the display matches the accurately measured pool sample press MENU ENTER The maximum adjustment is 1 000 ppm mg L 4 Press or until ...

Page 30: ...c System Overview The Pool Pilot salt chlorination system is designed to operate in the following configurations Shown with automatic flow bypass manifold assembly 941 615AC Figure 17 Shown with the convection cell option surge tank required ...

Page 31: ...the Pool Pilot See Mounting the Control Center on page 23 2 Electrical Connections See Electrical Connections on page 28 l Electrical Connections Overview l AC Input Voltage l High Voltage Wiring l Low Voltage Wiring o Connecting the Cell Cord o Connecting the Tri sensor o Bonding 3 Plumbing the System See Plumbing the System on page 24 4 Preparing the Water See Preparing the Pool Water on page 25...

Page 32: ...to the pool return line after the heater if applicable For convection cell applications a surge water collection tank is required in place of the manifold assembly 8 5 a Plumbing the Manifold Assembly Select the location for installing the manifold l It is recommended to select a secure location for the Pool Pilot control center prior to plumbing the manifold The unit must be installed close enoug...

Page 33: ...When properly sized to the site the Pool Pilot will meet the sanitizer maintenance requirements of the pool spa The unit is not designed to chlorine shock treat or build up a chlorine residual when starting with a zero or very low chlorine level Before starting the chlorinator the water must be properly balanced and the chlorine level adjusted to between 1 3 ppm mg L free chlorine More on adjustin...

Page 34: ...to the chlorinator See Set Pool Volume on page 21 8 6 c Adding Salt Type of Salt to Add It is important to use Sodium Chloride NaCl salt that is greater than 99 pure Acceptable types of salt include granular food grade pool salt water softener pellets or solar salt flakes these are usually available in 25 to 60 lb bags 11 to 27 kg at local pool or building supply outlets Pool salt or food grade gr...

Page 35: ... toward the main drain if one is present Set pump operation to normal run time after salt has fully dissolved into water If the salt level becomes undesirably high the only way to remove excess salt is to partially drain the pool spa and refill with fresh water 8 7 Programming at Installation The Pool Pilot requires the pool volume be programmed into the installer menu The Pool Pilot will then ind...

Page 36: ...ectly from a GFCI breaker or from a timer or controller Determine which is best for your application Although not required ideally the circulation pump and Pool Pilot are controlled by the same power 8 8 b Bonding The Pool Pilot chlorinator must be connected to the pool spa bonding system with an 8 AWG 6 AWG for Canada wire A bonding lug is provided at the bottom exterior of the control center 8 9...

Page 37: ... the cord to the connector on the side electrical panel 6 When the Tri sensor is attached replace the small rectangular plate on the underside of the cabinet 8 10 b Cell Cord Depending on the model there will be two 2 six 6 cell cords provided with the complete system The cell cords are prewired to the unit at the factory 1 The cell cord should be seated firmly onto the cell terminals 2 The other ...

Page 38: ...o produce chlorine until the set point is satisfied Check your local commercial guidelines for minimum and maximum ORP levels CAUTION Failure to heed the following may result in equipment damage l The remote connections are compatible with either dry contact closure or solid state relay Do not energize these inputs Damage to the control panel will occur and the warranty will be voided LBP0218 Figu...

Page 39: ...The unit has detected that a power module is connected to that cell position but a signal is not being sent past the power module connection Typical Solution Confirm all connections are secure Problem The cell cord may need to be replaced Typical Solution Switch cell cord with another cell to verify Problem The cell may need to be replaced Typical Solution Switch with another cell to verify Proble...

Page 40: ...id wash See Servicing the Cell on page 13 If all steps above have been performed and the error message is still shown do the following 1 Turn off power to the unit by the power switch on the control panel and wait three 3 minutes If the unit was in Boost mode deactivate the Boost cycle prior to powering off the unit 2 Power the unit on and put in Boost mode or increase the purifier output to 100 a...

Page 41: ...o make note of the cell amps and volts for each cell 5 Deactivate Boost mode or return purifier output to the original setting If high volts and low amps check the cell and cell cord connections If test shows low volts and low amps there may be a problem with the power module Call your local AutoPilot service center or AquaCal AutoPilot Customer Support for assistance CELL X light is not green Pro...

Page 42: ...heck for a leak at the pump basket o ring a leaking valve or fitting 10 If the pump is a variable speed pump ensure there is sufficient flow to the manifold or Tri sensor if a convection cell system to activate the flow switch The low speed may not create enough flow for the manifold Warning Low Salt Add xxx lb Problem The salt level is below 2 500 ppm mg L which is low Typical Solution This messa...

Page 43: ...d the Purifier output down to 1 to avoid over chlorination Bacteria and algae activity is greatly reduced at these temperatures so this should not be a problem Hand dose additional chlorine if necessary or a short Boost cycle will override the temperature compensation feature 6 Obtain an independent salt reading to check the Pool Pilot reading Add salt if needed and re calibrate the Pool Pilot sal...

Page 44: ...sure the cell cord is pressed completely onto the cell terminal Check the terminals and clean with a dry cloth to remove possible dirt and corrosion If the cell terminals leak contact the AquaCal AutoPilot Customer Support department Premature cell failure Typical Solution Abnormally high cell usage due to an insufficient stabilizer Cyanuric acid level Check the stabilizer levels as recommended an...

Page 45: ... more frequently until the TA is within an acceptable range Calcium Hardness Monthly Low CH Etching the plaster equipment corrosion Low CH Add calcium chloride flakes High CH Scale formation cloudy water Rapid cell scale buildup may exceed the system s self cleaning capability and require manual cleaning High CH Partially drain and refill pool with fresh water to dilute Diluting will reduce salt a...

Page 46: ...e regions with sustained low temperatures contact your local pool professional for proper pool winterizing instructions 10 1 b pH pH is a term used to refer to the degree of activity of an acid or base in the water A low pH acidic or corrosive water contributes to eye and skin irritation as well as damage to pool equipment A high pH will result in scaling cloudy water and ineffective sanitation Im...

Page 47: ... Total Dissolved Solids factor in this case the bulk of the dissolved solids are salt This is expressed in the formula SI pH TF CF AF TDSF and uses the following charts TEMPERATURE TF 60 F 15 6 F 0 4 66 F 18 9 F 0 5 76 F 24 4 F 0 6 84 F 28 9 F 0 7 94 F 34 4 F 0 8 103 F 39 4 F 0 9 CALCIUM HARDNESS CF 150 ppm mg L 1 8 200 ppm mg L 1 9 250 ppm mg L 2 0 300 ppm mg L 2 1 400 ppm mg L 2 2 600 ppm mg L 2...

Page 48: ... pools will already have a significant salt residual so always test water before adding salt This can be obtained from the control display or by testing water 3 Using the Salt Addition Chart below find the current salt level in the left column 4 Determine and locate the pool spa volume in the top column 5 Locate the intersection of the row and column to find the amount of salt needed to bring the ...

Page 49: ...residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can ...

Page 50: ...www aquacal com www autopilot com AquaCal AutoPilot Inc 2737 24th Street North St Petersburg Florida 33713 727 823 5642 ...