Instruction/ maintenance manual of the product 75003 Aquacal
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Pool Pilot ® Digital Salt Chlorine Generator By Swimming Pool and Spa Purification System Model # 75003 Owners Manual (For Indoor or Outdoor Use) IMPORTANT .
IMPORTANT SAFETY INSTRUCTIONS ii 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.
UNIT NUMBERS AND CONTACT INFORMATION iii Please record the following inform ation prior to installation: Installer: ..................................................... . Date of Installation: ................................... . Control Unit Model Type: .
TABLE OF CONTENTS iv IMPORTANT SAFETY INSTRUCTIONS .................................................................................................. ... ii UNIT NUMBERS / AUTOPILOT CONTACT INFO ........................................................
TABLE OF CONTENTS v L OW VOLTAGE WIRING .................................................................................................................................... 15 C ONNECTING THE S UPER C ELL C ABLE .......................................
TABLE OF CONTENTS vi S ALT CALIBRATION .......................................................................................................................................... 34 ADJUSTING TEMPERATURE DISPLAY ........................................
SYSTEM OVERVIEW 1 System Overview Although the Pool Pilot is easy to use, it is important to read through the manual before attempting to operate the unit.
SYSTEM OVERVIEW 2 pH Control Mode (Manual purifier and pH control) Note: Requires option # 750 04, 75005, 75006, or 75007 pH Acid Feed Pump and Tan k System must be installed with the #75003 Digital Controller for this mode to fun ction.
SYSTEM OVERVIEW 3 Control Unit Features The control unit has the fo llowing features: • Patented tem perature com pensation fo r chlorine output • Programmable Microprocessor Control • Multi-lan.
SPECIFICATIONS 4 Specifications #75003 Pool Pilot Digital Control unit Input Power 230 Vac 1.5 amps (Normal i nput configurat ion ship ped from the fact ory) 115 Vac 3 amps (Optional i nput confi gura.
PREPARING THE POOL WATER 5 Calculating Pool Volume (needed to determine proper balance chemical additions) ( ) 2 end shallow of depth end deep of depth Depth Average + = Pool Shape Gallons (pool size measure d in f eet) Liters (pool size measured in meters) Rectangular Length x Width x Ave rage Depth x 7.
PREPARING THE POOL WATER 6 Salt Addition Chart The following salt chart is included for refe rence onl y. Once y our Pool Pil ot Digital i s properly program med to the p ool water volume, it will automatically indicate how much salt is needed. To use this chart: 1.
PREPARING THE POOL WATER 7 Basic Water Chemistry Your Pool Pilot Digit al is designe d to pr oduce chlorine on a daily basis. To m onitor your system’s effici ency, the wat er chemistry ranges and schedule of periodic checks outlined below should be followed.
PREPARING THE POOL WATER 8 Saturation Index (SI) The Saturation Index is a formula used to predict th e calcium carbonate saturation of water, th at is, wheth er your water will precipitate, dissolve, or be in equilibrium with calcium carbonate. Your water is properly balanced if the SI is 0 ± 0.
INSTALLATION 9 Before Installing the # 75003 Pool Pilot Digital System • Determine that everything needed for installatio n is on hand • Determine where the Manifold Assembly will be plumbed • F.
INSTALLATION 10 Plumbing Requirements The Manifold Assembly is 2” Schedule 40 and is typically p lumbe d int o the pool return line an d, if applicable, after the heater and spa return diverter valve. Electrical Requirements Power must be shut off at t he circuit brea ker before pe rforming a ny wiring.
INSTALLATION 11 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 th e control unit.
INSTALLATION 12 Mounting the #75003 Pool P ilot Digital Control Unit Caution: All electrical connecti ons should be ma de by a licensed electri cian or certified electrical co ntractor. Your Pool Pilot Digital is suitable for indoor or outdoor moun tin g.
INSTALLATION 13 Optional 115 Volt configuration 230 Volt factory configuration Electrical Connections The Pool Pilot Digital uses both high and low voltage connection s . High vo ltag e connections will be made for providing the direct input power to it.
INSTALLATION 14 High Voltage Wiring Connecting Power to the Pool Pilot Digital The Pool Pilot Digital is typically provid ed input power in one of two ways.
INSTALLATION 15 Digital Control Panel Base Plate Ground Lug Cell Cord Con nector Tri-sensor assembly connector Low voltage wiring Connecting the SuperCell Cable 1.
INSTALLATION 16 Pool Chemistry Controller Installation (Turn off powe r bef ore making any ele ctrical connections ) Electronic Controller System #75008 Auxiliar y Relay Kit (optional) AUTOPILOT SYSTEMS INC AutoPi lot.com AUTOPILOT SYSTEMS INC AutoPi lot.
INSTALLATION 17 Before Installing the #75001 Pool Pilot Po ol Chemistry Controller System or the #75004, #75005, #75006, or #75007 pH Acid Feed Pump and Tank System • Determine that everything neede.
INSTALLATION 18 Mounting the Pool Chemistry Controller Unit Caution: All electrical connecti ons should be ma de by a licensed electri cian or certified electrical co ntractor. Your Pool Chemistry Controller is suitable for indoor or outd oor mounting.
INSTALLATION 19 Connecting the #75001 Pool Chemistry Controller ORP and pH Sensors The ORP and pH sensors are packaged with liquid filled protective caps. To avoid prem ature failure or damage, it is necessary to ensure that the sensor ti ps are always ke pt wet, usi ng normal pool water.
INSTALLATION 20 #75003 Digita l Cont rol Panel Base Plate pH Installation Connecting the pH Acid Feed Pump (Turn off power before m aking any e lectrical conne ctions) The electrical instructions will depend on the Set Relay 1 con f iguration of the Pool Pilot Digital (#75003) – see pg.
INSTALLATION 21 ➀ ② Optional Tap Points For Digital TC Total Control A cid In Water Out Tap Poin t Locations A lways Insert tubing into appropriate inlet/outlet. See Digi tal TC manu al for drilling inst ructions. Optional Tap Points For Digital TC Total Control Always In se rt tubing into appropriate inlet/outlet.
INSTALLATION 22 ➀ ② Optional Tap Points For Digital TC Total Control A cid In Water Out Tap Poin t Locations A lways Insert tubing into appropriate inlet/outlet.
INSTALLATION 23 Connecting the #75003 Digital Control unit to any other external ORP controller (A Dry C ontact closure must b e provided an d the Purifier % output m ust be set to 0%.
INSTALLATION 24 Electronic Controller Installation (Turn off power before makin g any electrical connections) Connecting to an Electronic Controller An Electronic Control System (Jandy® AquaLink RS (.
MENU OVERVIEW 25 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 cont acting AutoPilot systems when acce ss t o the “Protected Access” menus is desir ed.
PROGRAMMING AND OPERATION 26 Basic Programming Control Panel Features and Functions The first line of the display typically indicates the Purifier Output Level in percent (%), or whether t he system is in B oost or Super -Boost mode.
PROGRAMMING AND OPERATION 27 Control Options There are thre e d ifferent modes of opera tion. • Purifier (factory setting) • pH Control • Total Control Purifier Mode The Control Unit norm ally runs in the manua lly controlled purifier m ode.
PROGRAMMING AND OPERATION 28 pH Control Mode (Manually adjusted pH control and Purifier) Note: Optional pH Con trol Acid Tank & Pump #’s 75004 , 75005, 75006, or 75007 must be insta lled fo r this mode to function. The Digital Unit must be initially programmed through the Installer Menu (Select System m ode – see pg.
PROGRAMMING AND OPERATION 29 Operation of Buttons Adjusting the Purifier Output % Press the up/down arrow buttons to enter th e Purifier Adjustm ent mode. Adjust the purifi er output percentage to the desired output, from 0% (off) to 100 % (maxim um output), t hen Press S ELECT or allow it to default back to t he normal display.
PROGRAMMING AND OPERATION 30 Operation of Buttons (Continued) Pump Button (This button is not active if the Set Relay 1 is programmed f or “Acid Pump” or “Relay not used”. If the Pump button is pre ssed when programmed for one of these modes, ” Acid Pump” or ”Relay 1 not used” will display, then revert back to the normal display.
PROGRAMMING AND OPERATION 31 MENUS (For the Instal ler Menu, pre ss and hold SELECT butt on for approximately 13 seconds to access this feature) Running the Test Pool Pilot progra m ( Diagnostic menu) 1. Press MENU. 2. “ Test Pool Pilot ” is autom atically displayed, then press SELECT.
PROGRAMMING AND OPERATION 32 MENUS (For the Installer Menu, press and hold SELEC T button for approximat ely 13 seconds to access this feature) Programming the language for the display (Allows f or personal prefe rence language dis play) 1. Press MENU, pr ess ∆ or ∇ until “ Owner or Installer Menu ” is displayed, then press SELECT.
PROGRAMMING AND OPERATION 33 MENUS (For the Installer Menu, press and hold SELEC T button for approximat ely 13 seconds to access this feature) Programming the SuperC el l t o act iv ate a Force reverse cycle for testing (Used to ve rify if the Dig ital unit is reversi ng polarity (self cleaning)).
PROGRAMMING AND OPERATION 34 MENUS (For the Installer Menu, press and hold SELEC T button for approximat ely 13 seconds to access this feature) Calibrating the sa lt sensor. Note: The uni t has been calib rated at t he factory and s hould not need further a djustments.
PROGRAMMING AND OPERATION 35 MENUS (For the Installer Menu, press and hold SELEC T button for approximat ely 13 seconds to access this feature) Programming the system remote (Used when interfaced t o comm unicat e with electronic control systems) 1.
PROGRAMMING AND OPERATION 36 Total Control Menus (System configuration must indicate Total Con trol config uration and i s automatically detected when the electric al con nections are made b etwee n t.
PROGRAMMING AND OPERATION 37 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.
SYSTEM MAINTENANCE 38 System Maintenance Winterizing Pool Pilot Digital : The Pool Pilot Manifold including the Supe rCell and Tri-Sensor will be dam aged by freezing water just as your pool plumbing would.
SYSTEM MAINTENANCE 39 Fuse Location and Ratings Follow the instructions on pg. 12 for “Mounting t he Contro l 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 40 Tri-Sensor Assembly (#909-GO1 . 5) (Cable Ordered Separately) Temperature Sensor Post Salt Sensor Blades Directional Flow Indicator Tri-Sensor O-Ring (#19028) Flow Paddle View of locking Quick-Connect head Tri-Sensor Assembly The Tri-Sensor Assembly is used t o measure water flow, salt level, and water temperature.
SYSTEM MAINTENANCE 41 Testing the Flow Switch, Cleaning the Filt er Screen, and Cleaning the Bypass Valve The flow switch is an im portant safety protection device. When water flow has stop ped, it is im portant that the SuperCell be automatically turned off to prevent dam age to the cell or system .
SYSTEM MAINTENANCE 42 Visual Inspection of the SuperCell Remove the SuperCell from the Manifold Assem bly following the directions in the previous s ection. T he SuperCell titanium blades, seen inside the cell b ody, should be s traight and clear of any debris on the end s or between the blades.
SYSTEM MAINTENANCE 43 Pool Chemistry Controller Sensor Maintenance Warning: The sensors are very delicate de vices. They must be han dled with care and prote cted at all times. T ake care not to scratch or break the glass t ip. Helpful Hints: • Do not allow the sensor tip to dr y out for more than one hour or damage to life or accuracy may occur.
TROUBLESHOOTING GUIDE 44 Troubleshooting Guide Visit www.AutoPilot.com for the latest m anual revisions, additional inform a tion and helpful troubleshooting tips. You can also reach our factory direct customer assistance by calling 800.922.6246 or 954.
TROUBLESHOOTING GUIDE 45 Message on Display Problem Typical Solution Conductivity of the water is reduced an d 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.
TROUBLESHOOTING GUIDE 46 Message on Display Problem Typical Solution There are no warni ng messages on the display but the chlorine level is too low. Water quality looks dirty or cloudy. 1. The chlorine s etting has been fine , but a temporary boost of chlorine is needed to adjust for rain or a temporary bather increase.
TROUBLESHOOTING GUIDE 47 Message on Display Problem Typical Solution Error! Pump did not prime Chlorine produc tion, acid feed for pHC and PCC m odes, and pum p operation (whe n programmed for one speed pum p) has stopped due to inadequate flow. Follow the instructions for cle aring the system as recomm e nded on pg.
TROUBLESHOOTING GUIDE 49 Total Control Error Displays Message on Display Problem Typical Solution Error! Purifier off Error! Acid of f Check flow at sensors Flow at sensors is not detected. Chl orine and acid are not fed under these cond itions, until corrected.
An important point after buying a device Aquacal 75003 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Aquacal 75003 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Aquacal 75003 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Aquacal 75003 you will learn all the available features of the product, as well as information on its operation. The information that you get Aquacal 75003 will certainly help you make a decision on the purchase.
If you already are a holder of Aquacal 75003, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Aquacal 75003.
However, one of the most important roles played by the user manual is to help in solving problems with Aquacal 75003. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Aquacal 75003 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center