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Aquacal 75003 - page 1
Pool Pilot ® Digital Salt Chlorine Generator By Swimming Pool and Spa Purification System Model # 75003 Owners Manual (For Indoor or Outdoor Use) IMPORTANT . Read This Manual Before Installing & Operating This manual covers the installation of the Digital Chlorine Generator with any of the following Cell/Manif old assemblies (sold separately); ...
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Aquacal 75003 - page 2
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. A bonding lug has been pr ovided on the outside of ...
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UNIT NUMBERS AND CONTACT INFORMATION iii Please record the following inform ation prior to installation: Installer: ..................................................... . Date of Installation: ................................... . Control Unit Model Type: .............................................. . Control Unit Serial Number: ................ ...
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TABLE OF CONTENTS iv IMPORTANT SAFETY INSTRUCTIONS .................................................................................................. ... ii UNIT NUMBERS / AUTOPILOT CONTACT INFO .................................................................................... iii TABLE OF CONTENTS ................................................ ...
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TABLE OF CONTENTS v L OW VOLTAGE WIRING .................................................................................................................................... 15 C ONNECTING THE S UPER C ELL C ABLE ............................................................................................................................... .......... ...
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TABLE OF CONTENTS vi S ALT CALIBRATION .......................................................................................................................................... 34 ADJUSTING TEMPERATURE DISPLAY ................................................................................................................. 34 P ROGRAMMI NG P OOL V ...
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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. The Pool Pilot Digital, #75003, is a salt chlorination system for pool or spa purification, which is designed to operate in the followin g configurations: • Purifier – standar d mode, m anua ...
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Aquacal 75003 - page 8
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. Option # 75008 Auxiliary Relay Kit will be necessary if the Digital is used to control the main circul ation pum ...
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Aquacal 75003 - page 9
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-language digital display – (English, Sp an ish, French & German) • Digitally controlled power to the Sup erCell • Tri-sensor Circuitry to monit ...
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Aquacal 75003 - page 10
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 guration – jumper wire t o convert incl uded) Dry Contact 5 mA typical Non-factory ORP input ci rcuit (11 0Vac output re quire a Rel ay Kit – PN # 110 ...
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Aquacal 75003 - page 11
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. 5 Length x Widt h x Average De pt h x 1 00 ...
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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. Find your current salt level (ppm or g/l) in the left column. (This can be obtained ...
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Aquacal 75003 - page 13
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. CHEMICAL IDEAL RANGE IDEAL TEST SCHEDULE EFFECT OF LOW/HIGH LEVELS CORRECTIVE ACTIONS Fr ...
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Aquacal 75003 - page 14
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 ± 0.3. If your SI is greater than 0.3, scaling and stain ...
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Aquacal 75003 - page 15
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 • Find a suitable mounting location for the Control Unit within proper cord len gth to the manifold • Plan cord ru ns for Su perCell Cabl e and Tri-Sen ...
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Aquacal 75003 - page 16
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. Al l local and NEC electrical codes s hould ...
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Aquacal 75003 - page 17
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. The Control Unit will need to be installed close enough to the Manifold As ...
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Aquacal 75003 - page 18
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. If it is connected to 230 Vac, it must be installed at lea st 5’ (1.5m) horizontal distance ...
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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. Additional h igh voltage connections ma y be made to the filter pump from the Pool Pilot Digita ...
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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. Determine which is best for your application. • AC input directly from a cir cuit breaker, time clock, or pump relay in an electronic controller: T his met hod is used when the AC power to th ...
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Aquacal 75003 - page 21
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. The SuperCel l cable connecto r is keyed an d must be ali gned to connect properly. Line up the cell cord and plug into the ce ll cord connector, located on the bottom right of the Pool ...
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Aquacal 75003 - page 22
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.com #75001 Total Control Water Sample return line Water Sample feed line Acid Pump Power Wire # ...
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Aquacal 75003 - page 23
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 needed for installatio n is on hand • Find a suitable mounting location for the Pool Chemistry Co ntroller Unit within prop er cord length to the Digital ...
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Aquacal 75003 - page 24
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. Th e cover of th e Pool Chemistry Controller is removed from the sides by four thum bscrews so it ...
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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. 1. Before inserting the se nsors, ensure that all hoses are ...
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Aquacal 75003 - page 26
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. 34. • One Speed or Two Spee d Pu mp – Digital is control ...
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Aquacal 75003 - page 27
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. See Di gital TC manual for dr ...
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Aquacal 75003 - page 28
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. See Digi tal TC manu al for drilling inst ructions. Stenner Acid Pump and Tank Kit pH Control Installation Plumbing Have these tools on hand prior to starting this step: • Drill • ...
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Aquacal 75003 - page 29
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%. Turn off power befo re maki ng any electrical connections ) The ORP conn ection must be made to the int ernal ORP IN TERMINAL (marked TB2 on the low er Circuit Board ...
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Aquacal 75003 - page 30
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 (version I, K or L), Polaris® EOS, or Pentair IntelliTouch ®) may be connected to the external RS-485 or the internal connector (marked TB1 on the lo ...
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Aquacal 75003 - page 31
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. Mai n Men u Notes Tes t p o o l pilo t 1 Co ntro l ...
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Aquacal 75003 - page 32
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. The second line displays the c urrent time of day in 12- or 24-hr m ode, the temperature in Fahrenheit or Celsius, a ...
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Aquacal 75003 - page 33
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. In this mode the Pool Pilot will autom at ically displa y informative messages about the condition of ...
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Aquacal 75003 - page 34
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. 35), to the pH Control ...
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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. Typically, once the ...
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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.) P ...
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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. 3. The display will automatically toggle through th e follo ...
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Aquacal 75003 - page 38
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. 2. Press ...
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Aquacal 75003 - page 39
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)). There is a 30 second delay before reversing takes ...
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Aquacal 75003 - page 40
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. I n the event t hat the salt display d oes not match on-site test results, follo ...
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Aquacal 75003 - page 41
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. Press MENU, pr ess ∆ or ∇ until “ Installer menu ” is displayed, then press and hold SELECT ...
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Aquacal 75003 - page 42
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 the #75003 and #75001 systems) Set pH overfee d (Range: No pH overfeed - 120 mi nutes in 5 minute incre ments) (Used t o stop the chlorine a nd acid fe ...
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Aquacal 75003 - page 43
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. When confi gured for ope ration with an electronic control sy stem , the Electro nic Control System takes control of the pump o ...
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Aquacal 75003 - page 44
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. In areas that experience severe cold weat her or ex te nde d pe riods of freezing tem p eratures, the syste m should be winterized by draining ...
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Aquacal 75003 - page 45
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. Main Power Bo ard Location Fuse Specification Description F1 250 Vac 6 am ps Main AC Power F use ...
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Aquacal 75003 - page 46
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. When the wa ...
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Aquacal 75003 - page 47
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 . It is important to verify the safe and proper op ...
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Aquacal 75003 - page 48
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. A white f laky or crusty calcium build-up on the edge ...
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Aquacal 75003 - page 49
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. ...
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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 954.772.2255, by email at AutoPilotTechSuppo rt@teamhorner.com , or by FA X at 954.772. 4070. Run the ...
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Aquacal 75003 - page 51
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. 2. For water tem peratures below 65 ° F (18.3 ° C), increase salt to 350 0 ppm (3.5 g/l). 3 ...
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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. Press the Bo ost button to ...
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Aquacal 75003 - page 53
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. 44, Check Flow, steps 1 - 10. T ...
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Aquacal 75003 - page 54
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Aquacal 75003 - page 55
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. Ensure sufficie nt flow to the flow cell, pg. 44. Open the inlet and outlet valv es to ...
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