Pentair IC20 User Manual

IntelliChlor®

Electronic Chlorine Generator

(Model IC20, IC40)

Installation and User’s Guide

Patents pending

Certified to NSF/ANSI 50

IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS

WARNING - Salt is an inherently corrosive material. While the levels of salt required for proper operation of the IntelliChlor Electronic Chlorine Generator are relatively low when compared to sea water and other salt solutions, placing any amount of salt in your pool increases the likelihood of corrosion or other deterioration of pool equipment and any surfaces used in and around your pool. Metal parts and certain natural and man-made surfaces are particularly susceptible to corrosion and deterioration when used in and around salt water pools. Pentair Water Pool and Spa does not represent or otherwise guarantee that the proper use of the IntelliChlor Electronic Chlorine Generator will prevent corrosion or other deterioration of pool equipment and any surfaces used in and around your pool. Consult your experienced pool professional, who should be able to advise you on the proper material selection, installation techniques for those materials, and the proper use, care and maintenance of those materials for your specific pool type and location in order to minimize the corrosion and deterioration that is inherent in and around salt water pools.

© 2007 Pentair Water Pool and Spa, Inc. All rights reserved

This document is subject to change without notice

1620 Hawkins Ave., Sanford, NC 27330 • [phone]

10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone]

IntelliChlor, IntelliTouch, EasyTouch and the Pentair Water Pool and Spa logo are trademarks and registered 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. Pentair Water Pool and Spa Inc. disclaims proprietary interest in marks and names of others.

P/N 520589 Rev E - 06/27/07

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Contents
Important Safety Precautions ...........................................................................................................	iii - iv
IntelliChlor and Controller System Part Numbers .........................................................................................	v
Technical Support ........................................................................................................................................	v
IntelliChlor® Electronic Chlorine Generator Overview ....................................................................................	1
Features ..................................................................................................................................................	1
IntelliChlor System Components ..................................................................................................................	2
IntelliChlor Electronic Chlorine Generator Control Panel and Cell Description ...............................................	2
IntelliChlor Power Center ..............................................................................................................................	3
System Schematic Diagram ........................................................................................................................	4
Loop Plumbing Diagram ...............................................................................................................................	4
IntelliChlor Plumbing Diagram ......................................................................................................................	5
Section 1: IntelliChlor Control Panel .........................................................................................	7
Salt Level Status LEDs ...............................................................................................................................	7
Status LEDs ................................................................................................................................................	7
Sanitizer Output LED Indicators ..................................................................................................................	8
More and Less Output Buttons ....................................................................................................................	8
Self-Cleaning ...............................................................................................................................................	8
Section 2: Pool Water and Chemistry, Conditions and Precautions .......................................	9
Pool Water Chemistry, Conditions and Precautions ......................................................................................	9
Optimum Pool Water Conditions for Salt Water Pools (using the IntelliChlor Electronic Chlorine Generator) 10
Covered Pools and Vinyl Liner Pool and Lowering Chlorine Output Levels ..................................................	10
Chlorine Testing .........................................................................................................................................	11
What Type of Salt to Use ...........................................................................................................................	11
How Much Salt to Use? .............................................................................................................................	11
Calculating the Saturation Index ................................................................................................................	12
Saturation Index Factors .......................................................................................................................	12
How to Add Salt to the Pool .......................................................................................................................	13
Table 1. Approximate Pounds (Kg) of salt needed to obtain 3,400 ppm in pool ......................................	13
Table 2. Approximate Pounds (Kg) of salt needed to maintain 3,000 ppm in pool ..................................	14
Table 3. Approximate amount of cyanuric acid to obtain 75 ppm in pool ................................................	14
Pool Water Preparation ...............................................................................................................................	15
Determining Pool Size (Gallons of Water in Your Pool) ...........................................................................	15
Determining Pool Size (liters of water in your pool) ................................................................................	15
Section 3: Operating IntelliChlor .............................................................................................	17
Initial Start up Period .................................................................................................................................	17
Operation ..............................................................................................................................................	17
Use of an external Pool Pump Timer is not required ..............................................................................	17
If you use a Pool Pump Timer ...............................................................................................................	17
Startup Procedure (Super Chlorination) ......................................................................................................	18
Sanitizer Output Settings and Adjustments ...............................................................................................	18
Operating in Winter ....................................................................................................................................	18
General Recommendations ...................................................................................................................	19
General Cautions ....................................................................................................................................	19
Section 4: User Maintenance....................................................................................................	21
Daily service ..............................................................................................................................................	21
Weekly service ..........................................................................................................................................	21
Monthly Service.........................................................................................................................................	21
IECG Usage Hours Meter ..........................................................................................................................	22
Cleaning the IECG Cell Blades ..................................................................................................................	22
Winterizing.................................................................................................................................................	23

IntelliChlor Electronic Chlorine Generator Installation and User’s Guide

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Section 5: Installation ...............................................................................................................	25
Kit Contents ..............................................................................................................................................	25
Required Tools ...........................................................................................................................................	25
IntelliChlor “Dummy” Cell ...........................................................................................................................	26
Selecting Model Size - IntelliChlor Model IC20 / IntelliChlor Model IC40 ....................................................	26
Installing the IntelliChlor Cell Assembly .....................................................................................................	26
Connecting the Cell Power Cable to the Power Center ...........................................................................	27
Connecting the Power Center to an IntelliTouch, EasyTouch or SunTouch System ................................	28
Connecting IntelliChlor to an IntelliTouch System ..................................................................................	29
Connecting IntelliChlor to an EasyTouch System ..................................................................................	30
Connecting IntelliChlor to an SunTouch System ....................................................................................	31
Section 6: Troubleshooting ......................................................................................................	33
Table 1: Troubleshooting ............................................................................................................................	33
System Specifications - 110 VAC and 220 VAC Wiring ..............................................................................	35
220 VAC Basic System Wiring...............................................................................................................	35
110 VAC Basic System Wiring...............................................................................................................	36
Warranty ......................................................................................................................................	37

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IMPORTANT SAFETY PRECAUTIONS

SAVE 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 and/or operator of this equipment. When installing and using this electrical equipment, basic safety precautions should always be followed, including the following:

WARNING: IMPORTANT SAFETY INSTRUCTIONS PERTAININGTO A RISK OF FIRE,

ELECTRIC SHOCK, OR INJURYTO PERSONS. READ AND FOLLOW ALL INSTRUCTIONS.

Before installing this product, read and follow all warning notices and instructions which are included. 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, or obtain a copy of these instructions at: http://www.pentairpool.com/misc/owners_manuals/sanitizers/IntelliChlor_Owners.pdf

WARNING: To reduce the risk of injury, do not permit children to use this product.

WARNING: CHLORINE GAS BUILDUP CAN OCCUR WITH IMPROPER WIRING: To reduce the risk of personal injury the IntelliChlor® Electronic Chlorine Generator (IECG) Power Center must be installed on and wirded to the load side of the time clock, electronically controlled switch, or relay load side, so that it will receive power only when the pool pump is on. Otherwise, dangerous chlorine gas buildup can occur.The IECG should never be energized when the pool pump is OFF and water is not flowing through the unit.

WARNING: To reduce the risk of injury, service should only be personnel by a qualified pool service professional.

WARNING: Never operate the IntelliChlor Electronic Chlorine Generator (IECG) without proper flow or water circulation. A build-up of flammable gases will result in hazardous conditions.

CAUTION - IntelliChlor Electronic Chlorine Generator (IECG) is for use with permanently-installed pools and may also be used with hot tubs and spas if so marked. Do not use with storable pools. A permanentlyinstalled pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is constructed so that it is capable of being readily disassembled for storage and reassembled to its original integrity.

CAUTION - When using the IntelliChlor Electronic Chlorine Generator (IECG) with an IntelliTouch®, EasyTouch® or SunTouch® system, always wire the IECG Power Center to the pump side of the relay located in the IntelliTouch, EasyTouch or SunTouch load center.This wiring method does not require a ground fault circuitinterrupter (GFCI) to protect the circuit. A green colored terminal (or a wire connector marked “G”, “GR”, “Ground” or “Grounding”) is provided within the terminal compartment in the Power Center transformer enclosure. To reduce risk of electric shock, connect this terminal or connector to the grounding terminal of your electric service or supply panel with a conductor equivalent in size to the circuit conductors supplying this equipment. The power supply must be interconnected with pool pump motor power source. This insures the IECG and pool pump will switch on and off together.

IntelliChlor Electronic Chlorine Generator Installation and User’s Guide

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IMPORTANT SAFETY PRECAUTIONS

SAVE THESE INSTRUCTIONS

WARNING: When mixing acid with water, ALWAYS ADD ACID TO WATER. NEVER ADD

WATER TO ACID.

CAUTION - Use of chemicals other than those recommended may be hazardous. Even proper use of the recommended chemicals can be hazardous. Follow the Chemical Manufacturer’s Instructions.

CAUTION - To reduce the risk of electric shock, install IntelliChlor Electronic Chlorine Generator (IECG) a minimum of five (5) feet away from the inside wall of the pool.

CAUTION - Install the IECG a minimum of three (3) feet away from the heater outlet.

CAUTION - It is recommended to install a Pentair two (2) inch CHECK VALVE (P/N 263042) between the input side of the IECG and the main heater output pipe.

CAUTION - A solid copper, bonding conductor not smaller than No. 8 AWG (8.4 mm) should be connected from the accessible wire connector on the unit to all metal parts of the swimming pool, spa, or hot tub structure and to all electrical equipment, metal conduit, and metal piping within five (5) feet (1.5 m) of the inside walls of a swimming pool, spa, or hot tub, when the unit is installed within five (5) feet of the inside walls of the swimming pool, spa, or hot tub.

Canada - Industry Canada (IC) - This device complies with RSS210 of Industry Canada. (1999)

FCC Standard - 47 CFR Part 15, Subpart C (Section 15.247). This version is limited to chapter 1 to chapter 11 by specified firmware controlled in the U.S.A.

Federal Communications Commission (FCC) - This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

Interference Statement - 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. 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 be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

•Reorient or relocate the receiving antenna.

•Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

•Consult the dealer or an experienced radio/TV technician for help.

Note: Modifications not expressly approved by the party responsible for FCC compliance could void the user’s authority to operate the device.

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IntelliChlor® and Controller System Part Numbers

Refer to the following part numbers when configuring the IntelliChlor Electronic Chlorine Generator and the IntelliChlor Power Center with an IntelliTouch, EasyTouch or SunTouch system.

	IntelliTouch	EasyTouch	EasyTouch	SunTouch
	(P/N 520505 - 520510	Salt P/N's (*)	Non-Salt P/N's (**)
	Power Center	N/A	P/N 520556	P/N 520556
	(P/N 520556)
	IntelliChlor IC20	Included in kit	P/N 520554	P/N 520554
	(P/N 520554)
	or
		Included in kit	P/N 520555	P/N 520555
	IntelliChlor IC40
	(P/N 520555)

(*) EasyTouch (Salt Systems) - P/N 520592, 520593, 520704, 520705, 520542, 520543, 520544, 520545

(**) EasyTouch (Non-Salt Systems) - P/N 520591, 520703, 520538, 520540

Note: IntelliTouch Personality Kits - P/N 520505 - 520510

Technical Support

Sanford, North Carolina (8 A.M. to 5 P.M. Eastern Time)

Moorpark, California (8 A.M. to 5 P.M. Pacific Time)

Phone: [phone]

Fax: [phone]

Web sites

visit www.pentairpool.com and www.staritepool.com

Download the IntelliChlor User’s Guide (PDF)

http://www.pentairpool.com/misc/owners_manuals/sanitizers/IntelliChlor_Owners.pdf

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IntelliChlor Electronic Chlorine Generator Installation and User’s Guide

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IntelliChlor® Electronic Chlorine Generator Overview

The IntelliChlor Electronic Chlorine Generator (IECG) salt chlorinator uses a process known as electrolysis to produce chlorine gas which immediately dissolves into a solution to create Hypochlorite (a pool and spa water sanitizer) 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. The IECG then reuses the salt and the process starts over again. The IntelliChlor system is comprised of the IECG and Power Center.

CAUTION - The IntelliChlor Electronic Chlorine Generator (IECG) is designed only to produce chlorine. The IECG does not monitor or control chlorine levels in the pool or spa water. It is the pool owner’s responsibility for monitoring and maintaining free chlorine levels at the APSP recommended range of 2.0 to 4.0 parts per million (ppm). It is the pool owner’s responsibility to check, on a regular basis, the free chlorine level while the pool pump is running, and adjust the IntelliChlor Electronic Chlorine Generator accordingly.

WARNING - Salt is an inherently corrosive material. While the levels of salt required for proper operation of the IntelliChlor Electronic Chlorine Generator are relatively low when compared to sea water and other salt solutions, placing any amount of salt in your pool increases the likelihood of corrosion or other deterioration of pool equipment and any surfaces used in and around your pool. Metal parts and certain natural and man-made surfaces are particularly susceptible to corrosion and deterioration when used in and around salt water pools. Pentair Water Pool and Spa does not represent or otherwise guarantee that the proper use of the IntelliChlor Electronic Chlorine Generator will prevent corrosion or other deterioration of pool equipment and any surfaces used in and around your pool. Consult your experienced pool professional, who should be able to advise you on the proper material selection, installation techniques for those materials, and the proper use, care and maintenance of those materials for your specific pool type and location in order to minimize the corrosion and deterioration that is inherent in and around salt water pools.

CAUTION - Do not operate the IECG with newly poured pool plaster or newly constructed pool, regardless of pool lining material. Severe salt damage can occur. FOR ALL NEW POOLS wait at least ONE (1) MONTH after construction and filling of pool water before operating IECG.

Features

•Superior design combines cell and control panel as one assembly.

•Cell blades are made from a titanium metal base and coated with precious metal Ruthenium oxide.

•Cell blades are capable of producing chlorine for at least 10,000 hours, when the IECG is used properly.

•The IECG can be installed horizontally or vertically.

•Separate Power Center mounts to wall at equipment pad, for easy AC wiring.

•Electronics run cool for long, reliable life.

•Cell hour meter reports current usage to determine how many hours remain in the life of the unit.

•IC40 model produces up to 1.40 lbs. of chlorine per day and the IC20 model produces up to 0.70 lbs per day.

•Salt level LED indicators show four ranges for the amount of salt in pool.

•Red and green LED indicators show system status for power, water flow, and cell status.

•MORE and LESS output buttons control how much chlorine is produced.

•BOOST cycle sets the unit to maximum chlorine output for 24 hours of pump run time.

•Cell lifetime is tracked with at-a-glance green LED indicators.

•UL listed to UL1081 standards for swimming pool chlorinators.

•Approved NSF regulatory standards, and CE certified.

IntelliChlor Electronic Chlorine Generator Installation and User’s Guide

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IntelliChlor System Components

An IntelliChlor Electronic Chlorine Generator IntelliChlor system consists of one or more of the following:

•PC 100 (P/N 520556): Power Center Kit. Provides power and control communication to and from the IntelliChlor cell.

•IC 20 Cell (P/N 520554): Designed for pools up to 20,000 U.S. gallons (75,000 liters). The cell will produce the equivalent of 0.70 pounds of pure chlorine per 24 hours of continuous pool pump run time. The IC20 cell uses two terminal blades and five bi-polar blades.

•IC 40 Cell (P/N 520555): Designed for pools up to 40,000 U.S. gallons (150,000 liters). The cell will produce the equivalent of 1.40 pounds of pure chlorine per 24 hours of continuous pool pump run time. The cell uses three terminal blades and ten bi-polar blades, five on each side of the center terminal blade.

•IntelliChlor “dummy” bypass cell (P/N 520588): For new pool start-up.

Note: For IntelliChlor and IntelliTouch, EasyTouch and SunTouch controller parts numbers, refer to “IntelliChlor and Controller System Part Numbers” on page v.

IntelliChlor Electronic Chlorine Generator Control Panel and Cell Description

The IntelliChlor Electronic Chlorine Generator (IECG) includes a control panel with buttons and LED indicators to control the IECG and produce chlorine. The IECG measures the water temperature and salt level to produce chlorine at the defined output. If the salt level in the pool water 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. This feature turns the cell on and off at regular intervals to prevent calcium and scale buildup and further maximizes cell life.

The IECG contains the control electronics and bipolar electrodes that electrically produces chlorine when energized with DC current. Chlorine is generated as pool water containing salt passes through the cell. The chlorine production can be varied by either adjusting the sanitizer output level on the control panel and/or by varying the number of hours the IECG is on each day. The IECG automatically reverses the cell electrode blades every few hours to help clean the cell. This process does not interrupt the production of Chlorine.

The IECG also contains a mechanical flow sensor to ensure the proper amount of water is passing through the cell to allow chlorination to occur. The IECG automatically measures the water salinity and temperature and displays four (4) salinity ranges on the control panel using LED indicators. The IECG includes a 15 ft. UL approved four conductor 16-gauge cable for connection to the Power Center.

•Flow Sensor: A flow sensor assures that there will always be adequate water flow through the IECG. If the IECG is not properly plumbed and/or does not receive adequate water flow, no chlorine will be produced.

•Temperature Sensor: To protect the IECG from operation and potential damage when the temperature of the pool water falls below 52° F, ±3° F (11° C, ±1.67° C), the temperature sensor switches the IECG off, and no chlorine is being produced.

•Salt Sensor: Two (2) salt sensor probes in the IECG are activated each time the IECG is switched on and again during every 12 hours of continuous running. At each of those times, the salt level LED indicator lights flash in a scrolling sequence for two (2) minutes to indicate that the IECG is in analysis mode. After two (2) minutes, the LED indicators lights will signal one (1) of four (4) salinity ranges. For more information, see “Salt Level Status LEDs” on page 7.

IntelliChlor Electronic Chlorine Generator Installation and User’s Guide

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Control Panel status LEDs

Clear sliding cover

MORE and LESS output buttons

IntelliChlor Electronic Chlorine Generator

IntelliChlor Power Center

The IntelliChlor Power Center converts AC electrical current to a low-voltage DC electrical current which is required to produce chlorine. The power supply is connected with the pool circulation pump electrical source so that the IECG only operates when the pool pump is on. The Power Center should be mounted vertically on the wall up to fifteen (15) feet away from the IECG. The Power Center contains the transformer, fuse, connector to the cell and the AC electrical current wiring configuration with the DC electrical current output cable to the IECG. A fuse holder is mounted on the bottom of the Power Center for additional protection. There are no other controls or lights on the Power Center. For information about installing and proper use of the Power Center, see the “IntelliChlor Power Center Installation Guide,” (P/N 520590).

CAUTION - The IntelliChlor Power Center does NOT control the pump.The IntelliChlor Electronic Chlorine Generator only produces chlorine when the pool pump is on.

CAUTION - Before plugging or unplugging the IntelliChlor Electronic Chlorine Generator to the Power Center, first switch off the AC power to the Power Center.

IntelliChlor Power Center (Model PC 100)

IntelliChlor Electronic Chlorine Generator Installation and User’s Guide

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System Schematic Diagram

The following schematic diagram shows a typical IntelliChlor system installation. It is recommended that a 2 inch check valve be installed between the input side of the IntelliChlor Electronic Chlorine Generator and the main heater output pipe, as shown below. Note: This schematic diagram is not drawn to scale. Refer to the relevant portions of this Installation and User’s Guide for information regarding proper placement and spacing of all equipment depicted in this diagram.

NOT TO SCALE

Loop Plumbing Diagram

The IntelliChlor Electronic Chlorine Generator is designed to operate with water flow rates from 20 gallons per minute (gpm) up to 105 gpm. Do not exceed 105 gpm or pipe manufacturers recommended flow rate, whichever is less. For flow rates over 80 gpm, it is recommend that you use a bypass loop (as shown below) for best chlorine production. Installations with flow rates over 80 gallons per minute are those that have in-floor cleaning systems or booster pumps. These systems should use a bypass loop with the IECG with a flow control valve that assures that the flow through the IECG is maintained within its designed operating water flow rates.

Bypass loop

NOT TO SCALE

Flow control valve

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IntelliChlor Plumbing Diagram

Plumbing the IntelliChlor Electronic Chlorine Generator (IECG):

•Always install the IntelliChlor Electronic Chlorine Generator AFTER the filter and heater (see “System Diagram” on page 4). The ICEG should be no closer than three (3) feet away from the heater outlet.

•If the IECG is installed on a pool/spa combination system, install (see diagram below) the IECG BEFORE the pool/spa return valve to allow proper chlorination of both the pool and spa and also to avoid creating gas traps in the pipes.

NOT TO SCALE

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Section 1

IntelliChlor Control Panel

Salt Level Status LEDs

The IECG salt level checks the pool water daily and displays the levels as follows:

•Green LED: Good salt. The pool water salt level is between 3000 ppm and 4200, and the IECG is producing chlorine.

Flashing green LED: Salt level is above 4200 ppm. Chlorine is being produced but the salt level is too high which increases the risk of corrosion and deterioration of pool equipment and surfaces in and around the pool. Pool water needs to be drained and refilled one (1) foot at a time until the salt level is lowered to 3000-4200 ppm.

•Yellow LED: Check salt. The pool water salt level is between 2500 ppm and 2950 ppm. The salt level should be independently checked and salt added to the pool water if necessary to obtain a salt level of 3000 - 3500 ppm. The cell will continue to produce chlorine but will be at a reduced level. If this Check Salt LED is flashing with the Cell LED, it indicates both that the pool water salt level needs to be checked, adding salt if necessary, and if necessary the IECG needs to be inspected and cleaned.

•Red: Very low salt. The water salt level has fallen below 2500 ppm. The IECG will not produce chlorine until additional salt is added. The IECG is OFF.

Status LEDs

Pwr: Shows the IntelliChlor Electronic Chlorine Generator power status:

•Red: The IECG is OFF and an error is occurring in the IECG. Service is needed.

•Green: The IECG is operational and ready.

Cell: Shows the status of the IECG.

•Red: Water temperature is below 52° F, ±3° F (11° C, ±1.67° C), the IECG is shut off to extend blade life. Chlorine is not being produced.

•Green (flashing): The IECG needs to be inspected. The blades may have calcium buildup. The IECG is not producing chlorine. If the Cell green LED is flashing with the Check Salt LED, it indicates the salt level in the pool needs to be checked, adding if necessary, and the IECG needs to be inspected and cleaned if necessary.

•Green: IECG is good and producing chlorine

•No Light: IECG is off and not producing chlorine. It may be in an off-period of the sanitizing cycle and will return on shortly.

Note: If the Cell green LED is flashing with the Check Salt LED, it indicates

the salt level in the pool needs to be checked, adding if necessary, and the cell needs to be inspected and cleaned if necessary.

Life: The IECG is designed to produce chlorine for approximately 10,000 hours of proper use (approximately five

(5) years of average use) before replacement is needed.

•Green (flash): The IECG has over 8,000 hours of use, replace soon.

•Green: The IECG is under 8,000 hours of use. The IECG is good.

Flow: This light indicates the status of water flowing through the IECG.

•Red: Insufficient water flow through the IECG, no chlorine is being produced.

•Green: Sufficient water flow to produce chlorine.

IntelliChlor Electronic Chlorine Generator Installation and User’s Guide