Pentair CAL Instructions Manual

CAL™ (

Color AquaLuminator

®

) Light and Return Water Flow

for Above Ground Pools Owners Manual

IMPORTANT SAFETY INSTRUCTIONS

READ AND FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Table of Contents

SECTION I. IMPORTANT SAFETY INSTRUCTIONS .......................................................... 2

SECTION II. LAMP HOUSING INSTALLATION ................................................................... 2

SECTION III. ELECTRICAL CONNECTIONS FOR STORABLE POOLS ............................... 5

SECTION IV. ELECTRICAL CONNECTIONS FOR PERMANENT POOLS ........................... 6

SECTION V. RELAMPING INSTRUCTIONS .......................................................................... 9

SECTION VI. STORAGE AND WINTERIZING INSTRUCTIONS ........................................11

SECTION. VII. TECHNICAL DATA .......................................................................................... 12

A. Replacement Parts ..............................................................................................................12

WARNING

Before installing this product, read and follow all warning notices and instructions
accompanying this light. Failure to follow safety warnings and instructions can result in
severe injury, death, or property damage. Call [phone] for additional free copies
of these instructions.

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/operator of this equipment.

Pentair Water Pool and Spa, Inc.

1620 Hawkins Ave., Sanford, NC 27330 • [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone]

Visit us on the Internet at: www.pentairpool.com

REV. B 1-6-05 1 P/N 619582

Listed

SECTION I. IMPORTANT SAFETY INSTRUCTIONS

When installing and using this electrical equipment, basic safety precautions should always be followed,
including the following.

1. This light can be installed on storable above ground or permanent above ground pools.

2. A storable pool has a maximum water depth of 42 inches and is so constructed that it may be readily
disassembled for storage and re-assembled to its original integrity.

3. A permanent pool has a maximum water depth of over 42 inches. Do not install on therapeutic pools,
hydro-massage bathtubs, spas or hot tubs.

4. To reduce the risk of electric shock, if any cord becomes damaged, return the entire transformer assembly
for repair or replacement.

5. Risk of entrapment, injury or death. Use plumbing passageways only to return water to pool.
Do not use as a suction device.

6. Risk of electrical shock. Connect only to a grounding type circuit protected by a ground fault circuit
interrupter (GFCI). Contact a licensed electrician if you cannot verify that the receptacle or circuit is
protected by a GFCI. Do not use an extension cord.

7. Locate your pool so that the wall is at least 10 feet from all electrical receptacles and at least 20 feet from
all receptacles not protected by a GFCI. It is also very important to locate the pool so that it is not under
any electrical wiring, that is less than 18 feet vertically above the pool wall and within an area located
10 feet outside the pool walls. The pool must also never be located under any lighting fixture or within
five (5) feet measured horizontally from any fixture mounted less than five (5) feet vertically above the
pool water level.

8. Risk of injury. Install the top of the lens with a minimum of 8 inches and a maximum of 10 inches
below top of pool wall or in manufacturers pre-punched return fitting hole.

9. Do not use electrical equipment within 10 feet of pool wall unless specifically U.L. listed for that use.

SECTION II. LAMP HOUSING INSTALLATION

NOTE

Installation of the lamp housing into the pool wall is the same for both the storable and the permanent above ground pools.

Pool Wall

Snap-On
Cord Cap

Control

PCB Assy.

Clip

Washer

(12 o'clock position)

Body

Fitting

Gasket Gasket

Wall

Flange

Figure 1.

P/N 619582 2 REV. B 1-6-05

Flow

Director

Red Cap/Plug

Remove after bulb is in
place in the Fitting Body.

O-ring—

Use silicone
lubricant only. Do not use
any petroleum lubricants.

Bulb Assy.

1. Push the bulb assembly out from the rear of the body fitting so that
it will come out of the front of the fitting. The flow director will come
off along with the bulb assembly; see Figure 2. Push the red cap/
plug in the end of the bulb assembly. It will be removed later.

2. Unscrew the threaded wall flange from the body fitting by rotating
it counter-clockwise.

NOTE

Retain the gaskets supplied and keep them accessible.

3. Use the Teflon™ tape provided. Snugly wrap the threaded wall
flange in a clockwise direction (as viewed from the back) starting at
the edge of the threads; see Figure 3. Work towards the wall flange
lip (overlapping 1/2 of the tape width with each wrap) then back
towards the starting point.

• If you have a new pool, move on to Step 10.

• If the water level is below the return fitting on an existing pool, remove

the old fitting and move on to Step 10.

• If the pool is full of water, follow Steps 5 through 9.

Figure 2.

Always wrap
Teflon™ tape
clockwise

Start at
the edge

NOTE

Figure 3.

Steps 4 through 8 require two (2) No. 9 winterizing plugs (not supplied).

4. Remove the existing eyeball fitting from the return fitting on your
pool wall, see Figure 4.

5. Place a winterizing plug in the front side of the existing return fitting
and disconnect the return hose and clamp from the existing fitting.

6. Place a winterizing plug in the front side of the CAL threaded wall
flange.

7. While holding the existing return fitting from the inside of the pool,
remove the large nut or the existing body fitting on the outside of the
pool wall.

8. Using a folded rag in the palm of your hand, push the old return
fitting out of the wall from the outside of the pool; see Figure 5. Hold
the rag firmly against the wall to prevent water spillage.

9. Insert the wall flange and gasket from the inside of the pool through
the hole cut out for the inlet fitting. Ensure that the threaded wall
flange is centered on the hole.

10. Take the remaining gasket and put it on the threaded wall flange from
the outside of the pool; see Figure 1. Standard sheet metal walls will
have one gasket and one spacer left over. Do not use these two items, as they are for use on narrow
interlocking wall panels only.

Pool Wall

Hose

Return
Fitting Nut

Use a folded rag in the palm of your
hand to hold the water in the pool
while changing fittings.

Figure 5.

Figure 4.

Liner

Existing
Eyeball

REV. B 1-6-05 3 P/N 619582

NOTE

• For narrow, interlocking, extruded aluminum wall panels, center wall flange between
the ridges while viewed from the inside of the pool. Add the spacer and additional
gasket to the wall flange before inserting the wall flange through the wall panel.

• The spacer and additional gasket is necessary to accommodate a

fountain attachment.

Inlet Port
3 O’clock
position

WARNING

The light fixture must be mounted so that the word "top" is at the top of
the fixture when installed. Incorrect orientation and a low water condition
can damage the light fixture.

11. With the inlet port of the body fitting in the 3 O’clock position,

place the body fitting against the threads of the wall flange
and keeping the inlet port in the 3 O’clock position; see Figure

6. Hand tighten the wall flange as tight as possible. Rotate the
wall flange, not the body.

CAUTION

Do not over tighten the wall flange.

12. To complete the tightening process, hold the wall flange in

place and rotate the body fitting until the inlet port is in the
6 o’clock position; see Figure 6.

13. Take a hose clamp and place it over the return hose cuff.

14. Slip the return hose from the equipment, over the inlet port,

and tighten the hose clamp securely; see Figure 7.

15. If applicable, remove winterizing plug that was applied in Step 6.

16. Take the bulb assembly and insert it through the flow director.

Note the aligning keyway on the bulb assembly as shown in
Figure 8. The keyway must point in the same direction as the
top key on the body fitting.

17. Now, from inside the pool, push the bulb assembly and flow

director with the red cap/plug in place into the body fitting until
the bulb assembly/flow director are nearly flush against the
inside pool wall.

18. Slide clip washer into position with the plastic stopper at the

12 o'clock position as shown in Figure 1.

19. Feed wire from the bulb body through the center hole of the

controller as you align the controller with the bulb body.

6 O’clock

Figure 7.

Key

Figure 8.

Figure 6.

Keyway

O-Ring—use silicone
lubricant only. Do not use
any petroleum products.

P/N 619582 4 REV. B 1-6-05