AquaCal AutoPilot Pool Pilot PROB28 User manual

Titanium Electrode
Replacement Electrode for the Pool Pilot® Professional, Model PROB28
REGISTRATION NO. 33688 PEST CONTROL PRODUCTS ACT
This electrode must only be used on this model of chlorine generating device.
READ THE LABEL AND REFER TO OWNERS MANUAL OF THE
Pool Pilot® Professional, Model PROB28, BEFORE USING
AquaCal AutoPilot, Inc.
2737 24th St. North
St. Petersburg, Florida, U.S.A, 33713
1-727-823-5642
2020-0223
2020-01-31

USER’S GUIDE
MODEL PROB28

2
TABLE OF CONTENTS
INTRODUCTION… ................................................................................... 4
WARRANTY INFORMATION… ................................................................ 5
SAFETY INFORMATION… ................................................................... 6-7
PREPARING YOUR WATER BEFORE INSTALLATION… ................... 8-9
SALT CHART FOR CORRECT MAINTENANCE… ................................ 10
TOOLS AND PARTS REQUIRED FOR INSTALLATION….................... 11
PLUMBING YOUR SYSTEM .............................................................. 12-13
ELECTRICAL SPECIFICATIONS ............................................................. 14
ELECTRICAL SPECIFICATIONS AND FUSE SIZING… ....................... 15
STARTING THE SYSTEM… .................................................................... 15
GENERAL OPERATION… ....................................................................... 16
MAINTENANCE AND CLEANING… ........................................................ 17

3
Pool Pilot® Professional Saline Chlorination System, Model PROB28
CHLORINE GENERATOR
CONTROLS BACTERIA AND ALGAE
in
Swimming Pool (and Spa) Waters
COMMERCIAL
A maximum of 1,420,000 L of water can be treated with
Pool Pilot® Professional Saline Chlorination System,
Model PROB28
Maximum output of hypochlorous acid equivalent to 11.34 kg
of free available chlorine per day
For swimming pools, a range of 1.0 - 3.0 ppm of free available chlorine
must be maintained.
For spas, a range of 3.0 - 5.0 ppm of free available chlorine must be maintained.
KEEP OUT OF REACH OF CHILDREN
READ THE LABEL AND OPERATING MANUAL BEFORE USING
REGISTRATION NO. 33688 PEST CONTROL PRODUCT ACT
WARNING: Operating the Pool Pilot® Professional Saline Chlorination System,
Model PROB28, without water flow through the cell can cause a buildup of flammable
gases
which can result in FIRE OR EXPLOSION.
WARNING: Do not use this device with bromide products.
NOTE TO USER: This pest control product is to be used only in accordance with the
directions on the label. It is an offence under the Pest Control Products Act, to use
this product in a way that is inconsistent with the directions on the label.
AquaCal AutoPilot, Inc.
2737 24th St. North
St Petersburg, FL, USA 33713
1-727-8235642

4
Titanium Electrode Replacement Electrode for the Pool Pilot
®
Professional, Model PROB28
Registration No. 33688 Pest Control Products Act This electrode must only be used on this model of
chlorine generating device.
READ THE LABEL AND REFER TO OWNERS MANUAL OF THE Pool Pilot
®
Professional, Model
PROB28, BEFORE USING THE POOL
AquaCal AutoPilot, Inc.
2737 24th St. North St. Petersburg, Florida, U.S.A, 33713
1-727-823-5642
INTRODUCTION
AquaCal AutoPilot, Inc.
2737 24th St. North
St. Petersburg, Florida, U.S.A, 33713
1-727-823-5642
Patent # US 6821398B2
EPA Est. # 082229-GA-001
NSF-50 / UL-1081 listed
Congratulations on purchasing your new Pool Pilot® Professional Saline
Chlorination System, we trust that this system will offer you the ultimate in
swimming environments, and give you years of trouble free operation.
This user’s manual will explain in detail the operation of your new system, as well
as water chemistry guides, warranty information, and much more.
If at any time you need additional information on your system, please feel free to
contact us.

5
WARRANTY INFORMATION
The Pool Pilot® Professional system carries a limited 3 year warranty
1. 3 year warranty on assembly of electrical components and cell
housing.
2. 1 year on all electrical items.
3. 2 years or 15,000 hours, which ever occurs first, pro-rated hourly,
on titanium electrodes. (Year 1 is warranted fully, thereafter pro-
rated warranty applies, applicable over the full 2 year period)
• AquaCal AutoPilot, Inc. advises that titanium electrodes will have to be
replaced every 15,000 hours of operating time. Under no circumstances
shall the replacement titanium electrodes exceed the original 15,000 hour
warranty.
• AquaCal AutoPilot, Inc. warranties will not be honored should it be
shown that the operating and maintenance procedures have not been
followed, particularly with regard to the correct maintenance of salt
concentration and water chemistry.
• AquaCal AutoPilot, Inc. warranties of the titanium electrodes will not
be honored if the system is operated in water temperatures lower than
15 degrees C.
• AquaCal AutoPilot, Inc. warranties of the titanium electrodes will not be
honored if the system is operated in water where the salt concentration is
lower than 3000 ppm.
• During the warranty period, the customer shall return the defective
component, freight prepaid, accompanied by the original invoice or proof
of purchase, and AquaCal AutoPilot, Inc. shall at it’s sole discretion
elect to repair or replace the defective component and return it to the
customer, freight pre- paid.
AquaCal AutoPilot, Inc. accepts no responsibility other than to repair or
replace a defective component, and this warranty specifically excludes product
failure due to accidental damage, abuse, misuse, negligence, damage due to
non-compliance of the operating manual or unauthorized alterations or
modifications to the system. AquaCal AutoPilot, Inc. accepts no responsibility
and is not liable for any extended warranties or variations to this warranty
offered by re-sellers of Pool Pilot® Professional systems.

6
SAFETY INFORMATION
PLEASE READ THE FOLLOWING SAFETY INFORMATION CAREFULLY!
WARNING!
• Only a certified technician may install and service your Pool Pilot®
Professional
system.
• Modifying your Pool Pilot® Professional system in anyway may
cause bodily injury and will void your warranty.
• Warning: To reduce the risk of injury, do not allow children to operate this
device.
• Only replace components with those specified by manufacturer.
• When installing your system, ensure that power is linked to the main pump
power source for the pool to ensure that your Pool Pilot® Professional
system never operates when the pumps are off.
• All boxes on your Pool Pilot® Professional system contain high voltage
components.
Never open any box while power is “on”.
• WARNING: Heavy pool (and/or spa) usage, and higher temperatures may
require higher chlorine output to maintain proper free available chlorine
residuals.
• If additional chlorine is required due to heavy bather loads, use granular or
liquid chlorine to maintain appropriate chlorine residual in the water.
• Maintaining high salt and chlorine levels above recommended range can
contribute to corrosion of pool (and/or spa) equipment.
• DO NOT add pool (and/or spa) chemicals directly to the skimmer. This
may damage the cell.
• Check the expiry date of the test kit as results may be inaccurate if used
after that date.

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• When replacing the cell, only use replacement cells having a label that
clearly states that it is a replacement cell for the chlorine generating
device Pool Pilot® Professional Chlorination System, Model PROB28,
REGISTRATION NUMBER XXXXX, PEST CONTROL PRODUCTS
ACT.
• Follow all aspects of the local and National Electrical Code(s) when
installing Pool Pilot® Professional model PROB28.
• NOTE: For outdoor pools, chlorine residuals can be protected from
destruction by sunlight by addition of stabilizer (cyanuric acid).
• NOTE FOR USE ON SPAS: For proper sanitation, spas must be
completely drained periodically. The number of days between COMPLETE
DRAINAGE is equal to the volume of spa water in litres, divided by 10
times the maximum number of daily spa users. Refill spa with water and
repeat DIRECTIONS FOR USE of the device.
• HEALTH AND HYPERTHERMIA WARNINGS FOR SPA DEVICES:
 People with a medical condition should consult a physician before
entering pool or spa water.
 Maximum spa water usage temperature is 40 degrees C. Bathing in
spa water at 40 degrees C should not exceed 15 minutes.

8
PREPARING YOUR WATER BEFORE INSTALLATION
Pool Pilot® Professional saline chlorination systems operate by utilizing the
sodium chloride that has been added to the pool water, to produce sodium
hypochlorite (liquid chlorine), through the process of electrolysis.
In order for your Pool Pilot® Professional system to operate correctly, sodium
chloride (salt) must be added directly to the pool at least 24 hours before the
installation of the equipment.
5 kg of sodium chloride must be added for every 1,000 litres of pool water (ie: a
200,000-litre pool will require 1,000 kg of salt for start-up).
It is best to add the salt around the pool, and not load all salt in one section.
Once the salt has been added, brush the surface of the pool continuously until
the salt has all dissolved. You must never leave large amounts of salt on the
surface of the pool, as this may cause damage to the pool surface.
When you add the initial load of salt, you will need to add additional chlorine, as
the salt will cause a chlorine demand.
Your pool water should be balanced in the following range before turning your
Pool Pilot® Professional system on;
Water balance parameters
Swimming pool
Spa
Free available chlorine
1.0 – 3.0 ppm
3.0 – 5.0 ppm
pH
7.2 – 7.8
7.2 – 7.8
Total alkalinity
100 – 120 ppm
100 – 120 ppm
Calcium hardness
200 – 300 ppm
150 – 200 ppm
Cyanuric Acid (stabilizer)
30 – 100 ppm
30 – 100 ppm
Salt ranges
Swimming pool
Spa
Salt level
4,000 – 5,000 ppm
4,000 – 5,000 ppm
NOTE: Low salt levels will cause a reduction in chlorine production and will
damage the device. High salt levels will increase the possibility of corrosion on
pool equipment.
NOTE: If too much salt has been added, dilute with fresh water.

9
Use standard test kits to check water chemistry, and use either a conductivity
tester or salt test strip to check saline levels.
(Note that most conductivity testers require frequent calibration to ensure
accurate readings, failure to calibrate the equipment will result in
inaccurate readings.)
How to Calculate volume of a pool
For a rectangular shaped pool
Length (m) x Width (m) x Average Depth (m) x 1000 = Litres of water
For an oval shaped pool
Length (m) x Width (m) x Average Depth (m) x 0.785 x 1000 = Litres of water
For an oval shaped pool
Diameter (m) x Diameter (m) x Average Depth (m) x 0.785 x 1000 = Litres of
water

The following is a chart to determine the amount of salt required to raise a pool or spa to 5000 ppm
SALT CHART FOR CORRECT MAINTENANCE
ppm Salt Levels
Number of KG of Salt to Be Added
ppm Salt
Pool and or sp Volume (litres)
1,000 100,000 200,000 300,000 400,000 500,000 600,000 700,000 800,000 900,000 1,000,000
5000 CORRECT
CORRECT CORRECT CORRECT CORRECT CORRECT CORRECT CORRECT CORRECT CORRECT CORRECT
4800 2 20 40 60 80 100 120 140 160 180 200
4400 6 60 120 180 240 300 360 420 480 540 600
4000 10 100 200 300 400 500 600 700 800 900 1000
3800 12 120 240 360 480 600 720 840 960 1080 1200
3500 15 150 300 450 600 750 900 1050 1200 1350 1500
3200 18 180 360 540 720 900 1080 1260 1440 1620 1800
3000 20 200 400 600 800 1000 1200 1400 1600 1800 2000
2700 23 230 460 690 920 1150 1380 1610 1840 2070 2300
2500 25 250 500 750 1000 1250 1500 1750 2000 2250 2500
0-(Initial Salt Addition) 50 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Note:
There may already be some salt present in the pool or spa water.
Be sure to test the salt levels prior to adding more salt to the water.

TOOLS AND PARTS REQUIRED FOR INSTALLATION
Your Pool Pilot® Professional system will include an installation kit
comprising of the following items:
Description Qty
Strainer clear bowl with 20 mesh
1
PVC ball valve Sch. 40
2
PVC male adaptor Sch. 40
4
PVC nipple SCH 80
2
PVC bushing Threaded
1
PVC union S EPDM w/o
O-ring Sch. 80 threaded
2
Akenstrut clamps
2
Polypropylene valve, speed fit
2
Elbow street 90, SCH 80
2
Salt test strips
1
Additionally you will need the following items, not included, to complete
the installation:
• Polypropylene tubing
• Flex PVC tubing
• Wall anchors
•
Disconnect box, fuse box, conduit, wiring and related material to supply 220v to systems
(220v systems only)
The following tools will be required to complete the installation:
Power Tools Drill Bits
Drill Hole saw
Hammer Drill Paddle bit
Steel bit drill set
Mason bit
Hand Tools Taps
Set of sockets 2.5cm
Hammer 0.9cm
Screw Drivers – Flat & Phillips
Wire Strippers
PVC Cutters Hand Tools cont..
24” (60 cm) Level Tape Measure
Slip joint pliers Teflon Tape
Crescent wrench Allen Wrenches
True RMS Clamp Meter
Wire Cutters

12
PLUMBING YOUR SYSTEM
Your Pool Pilot® Professional system can be plumbed using two different
methods. Both will work fine, however, the following must be taken into account
before making the decision of what method to use.
1. Your Pool Pilot® Professional system requires a minimum of 75 Lpm of
flow through the cell to produce the rated amount of chlorine. Be sure that if
you use the pressure drop plumbing method [1] you have sufficient pressure
drop across your filter to adequately flow 75 Lpm through the cell.
2. When using the pressure drop plumbing method [1], you are sending
un-filtered water through the cell, so you need to ensure that you clean the
included strainer at least 1 time per week to remove any debris. Failure to
clean the strainer will result in a lack of flow, reducing chlorine production, and
ultimately reducing flow to the point that the flow switch de-activates the
system.
3. If you elect to use the bypass plumbing method [2], you will need to purchase
a butterfly valve based on the size of the pipe you are using. This can
sometimes be cost prohibitive, but the upside of this plumbing method is that
you are sending filtered water through the cell, which reduces the frequency of
needing to clean the strainer. Bypass plumbing method [2] also generally
allows for more flow through the cell, which is recommended.
4. Remember, always ensure that the return line from the Pool Pilot®
Professional cell is plumbed after the heater. Never plumb the return line
before the heater, as you will be sending a high ppm of chlorine through
heater, which maycause damage.
5. No matter which plumbing method you use, you will always have to plumb the
cooling line into box 3 (rectifier) using filtered water. This cooling line allows
the heat sink in box 3 to cool the critical components.

13
PRESSURE-DROP PLUMBING METHOD [1]
Pool Pilot® Professional power supply Pool Pilot® Professional cell
NOTES:
THE RECTIFIER COOLING LINES MUST BE CONNECTED FROM
THE SUCTION SIDE OF THE PUMP AND AFTER THE FILTER.
ALWAYS USE FILTERED WATER.
IF THERE IS A CONTROLLER PRESENT, THE OUTLET LINE THAT
FEEDS THE CONTROLLER PROBES COULD BE CONNECTED TO
THE RECTIFIER.
BYPASS MANIFOLD PLUMBING METHOD [2]
NOTES:
THE RECTIFIER COOLING LINES MUST BE CONNECTED FROM
THE SUCTION SIDE OF THE PUMP AND AFTER THE FILTER.
ALWAYS USE FILTERED WATER.
ALTERNATIVELY, IF THERE IS A CONTROLLER PRESENT, THE
OUTLET LINE THAT FEEDS THE CONTROLLER PROBES COULD
BE CONNECTED TO THE RECTIFIER.
Pool Pilot® Professional power supply Pool Pilot® Professional cell

14
ELECTRICAL SPECIFICATIONS
Each Pool Pilot® Professional model has very specific wiring requirements
based on its line voltage and amperage draw.
• Model CHLOR-25 operates at 208 – 240v requiring advanced wiring,
which should only be done by a qualified electrician. 208 – 240v power
needs to be run from your main breaker panel to a safety switch, then into
the Pool Pilot® Professional main power box 1. As above, the cord
labeled ORP must be plugged into a controller, or a 120v outlet.
• Your Pool Pilot® Professional system must be wired to the main pump
power supply, so that if the pump is shut down, the power to your Pool
Pilot® Professional system is lost.
ELECTRICAL SPECIFICATIONS AND FUSE SIZING
MODEL:
MAX PRIMARY AC
AMPS
SYSTEM INPUT
VOLTAGE
BREAKER
REQUIRED
PROB28
20.9
208 – 240v
30amp
Fuse sizing:
Model Fuse size and type
PROB28
30amp dual element, slow blow, RK5 fuse

15
STARTING THE SYSTEM
Once your Pool Pilot® Professional system has been successfully wired and
plumbed, it is ready for use.
• Make sure that the valves to and from the cell are in the open position.
• Make sure that you have water flowing through the water-cooled heat sink
in box 3.
• Ensure that the cord labeled ORP is either plugged into a controller or
directly into a 110v outlet
1. Move the safety switch to the “on” position.
2. Wait 10 seconds for the system to respond.
3. Turn the black knob on the side of box 1 clockwise, and watch the
amp or voltmeter on box 3 slowly increase.
(
If your system is linked to an automatic ORP controller, we suggest you
turn the system to maximum, which will allow for full production every time
the controller calls for it. If you are running your system manually, you will
need to find the point at which you keep a satisfactory level of chlorine in
the water. It may take several days to find this point.)
• If your Pool Pilot® Professional system is linked to an automatic
controller, remember that it will only work when the controller is in feed
mode. It is also a good idea to make sure that your controller is not set in
proportional band mode, instead try using double set point control (if your
controller supports this function). An example of this is if you want to
maintain a 700 ORP, have the controller set to turn on at 695 ORP and
turn off at 705 ORP, that way your Pool Pilot® Professional system is
not switching on and off all the time.
(Call the manufacturer of your controller if you are having difficulties in
comprehending the saline chlorination system set up instructions. Most
controllers also require a “gold tip” ORP probe when working with a saline
chlorination system.)

16
GENERAL OPERATION
Your Pool Pilot® Professional system operates when power is activated by the
main pumps, and from your ORP controller, and will continue to operate for as
long as power is applied from those two sources.
• The system has an output range of 5-100% of the rated chlorine
production, and can be adjusted by turning the black knob of the side of
box 1 in a clockwise or anti-clockwise motion. When adjusting thecontrol
knob on the side of box 1, you will notice the amperage needle of the
gauge on box 3 increases or decreases.
Higher amperage = higher chlorine production.
Normal operating amps and volts for this model device are:
 PROB28 - 125amps @ 15v
• Water flow through the Pool Pilot® Professional cell is critical. Whether
you plumbed your system in using the pressure drop or bypass method,
pleaseensure that you have at least 75 Lpm through the cell to achieve
the rated chlorine production.
** Remember, your Pool Pilot® Professional system is a chlorine
generator, and will only operate as well as you maintain it. Careful
attention must always be paid to proper chemical balancing, and
regular service.

17
MAINTENANCE AND CLEANING
Your Pool Pilot® Professional systems is designed to operate 24/7 at max
power, and will give you years of trouble free use if you follow these basic
maintenance and cleaning instructions.
• Remember, this system produces sodium hypochlorite “liquid chlorine”
from the salt that you have added to the water. It will only continue to
operate correctly if salt is maintained at the correct 5000ppm level. Low
salt will lower the amount of chlorine produced, and cause damage to the
electrolytic cell.
(Warranty’s will not be honored if it is determined that salt has
been run low.)
• There is a strainer mounted at the bottom of your Pool Pilot®
Professional cell, which will trap debris and stop it from entering the
cell, this strainer needs to be cleaned regularly.
• The plates that are inside the PVC cell housing are the most critical part of
the system. You will notice that over time a white substance (calcium
minerals) will build up on the plates, especially at the top of the cell. This
buildup needs to be cleaned by removing the cell from the housing and
soaking it in a dilute muriatic solution (1:5) for about 10 – 15 minutes.
Reverse polarity systems will need to be cleaned every 3 – 6 months.
(Warranty’s will not be honored if it is determined that the cell has not been
cleaned regularly.)
• Remember, the titanium plates that make up the cell are the most
expensive part of the Pool Pilot® Professional system and are going
to need to be replaced roughly every 15,000 hours of operating time.
By ensuring that salt is always at the correct level, and plates are
cleaned regularly, you will increase their “life”, thus saving you
money…
AquaCal AutoPilot, Inc. offers a wide range of other products that can help you
maintain salt levels in your pool, including conductivity controllers and saturated
salt feeders for those pools that lose large amounts of water.