Aquacal AutoPilot Pool Pilot AG Safety guide

1
AG
INSTALLER: THIS DOCUMENT IS PURCHASER’SPROPERTY AND IS TO REMAIN WITH THE EQUIPMENT OWNER
PN: LTP0059 REV-1
03/10/2010
Owner’s
Manual
Salt Chlorine Generator
IMPORTANT !
Swimming Pool & Spa Purification System
Models: 75090, 75090-TL, and 75091
Read This Manual Before
Installing or Operating
InstallationandOperation
Pool Pilot®
For use with RC-11 & RC-35/22 Cells, ONLY!

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TABLE OF CONTENTS
CONTACT INFORMATION .................................................................................................. 4
What We Need to Know If You need To Contact Us............................................................. 4
SAFETY INFORMATION ..................................................................................................... 5
SPECIFICATIONS................................................................................................................ 7
Chlorine Output...................................................................................................................... 7
Manifold Flow Requirements ................................................................................................. 7
Agency Approvals .................................................................................................................. 7
How Your Chlorine Generator Works .................................................................................... 7
What is included .................................................................................................................... 8
Three Available Water Manifold Assemblies ......................................................................... 8
INSTALLATION....................................................................................................................9
Basic System Overview ......................................................................................................... 9
Plumbing the Floating-Cell Manifold Assembly (75092)...................................................... 10
Plumbing the Above Ground Manifold Assembly (75093)................................................... 10
Plumbing the Inline-Cell Manifold Assembly (75094) .......................................................... 10
Mounting the Control Unit .....................................................................................................11
Flow Rates.....................................................................................................11
Electrical Connections ......................................................................................................... 12
Grounding and Bonding........................................................................................... 12
High Voltage Wiring ................................................................................................. 12
Twist-Lock Connector................................................................................... 12
Three-Prong Connector ............................................................................... 12
Hard Wired ................................................................................................... 13
Low Voltage Wiring .................................................................................................. 13
PREPARING THE POOL WATER ..................................................................................... 14
Installer Please Note:........................................................................................................... 14
Steps to Prepare Water: ...................................................................................................... 14
Calculating Pool Volume:..................................................................................................... 14
PREPARING THE POOL WATER ..................................................................................... 15
Using Standard Pool Salt..................................................................................................... 15
Adding Salt........................................................................................................................... 15
Type of Salt to Add................................................................................................... 15
Determine Amount of Salt Required (and salt level to maintain)............................. 15
Add Salt to Pool Water............................................................................................. 15
How to add the salt (or remove it if too much)......................................................... 15
OPERATION ...................................................................................................................... 16
Adjusting Chlorine Output ........................................................................................ 16
Getting Unit Information ........................................................................................... 16
Normal Operation..................................................................................................... 16

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TABLE OF CONTENTS
REFERENCE SECTION .................................................................................................... 17
Standard Pool Salt................................................................................................... 17
Salt Addition Chart ................................................................................................... 17
Basic Water Chemistry - Salt ................................................................................... 18
Saturation Index (SI) - Salt....................................................................................... 19
E4aqua .................................................................................................................... 20
E4aqua Addition Chart ............................................................................................. 20
Basic Water Chemistry - E4aqua............................................................................. 21
Saturation Index (SI) - E4aqua ................................................................................ 22
MAINTENANCE ................................................................................................................. 23
Fuse Location and Ratings.................................................................................................. 23
Testing the Flow Switch ....................................................................................................... 23
Servicing the SuperCell ....................................................................................................... 24
Removal of the SuperCell........................................................................................ 24
Visual Inspection of the SuperCell........................................................................... 25
Manual Cleaning of the SuperCell........................................................................... 25
Installing a SuperCell... ............................................................................................ 25
Winterizing ........................................................................................................................... 26
Spring Start-Up..................................................................................................................... 26
TROUBLESHOOTING....................................................................................................... 27
APPENDIX ......................................................................................................................... 29
Declaration of Conformity .................................................................................................... 29
FCC Compliance:.................................................................................................................29

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PoolPilot
What We Need to Know If You need To Contact Us...
If you should need to callAquaCal AutoPilot for questions, service, or parts, please have the following
information ready:
CONTACT INFORMATION
If you have questions, please refer to our web site at www.autopilot.com for the latest manual
revisions, additional information, and helpful service advice.
You can also call us at: [phone]. We are here to serve you from 8:00A.M. to 5:00 P.M.
Eastern time, Monday through Friday. If calling after hours, our voice mail system will handle your
call. Please be sure to leave your name, a complete address, and your telephone number.
You may also reach us by email at: [e-mail].
Or, if you prefer, you may FAX us at: [phone]. Be certain to provide your full address and a daytime
telephone number.
AG
®
Manufactured by
AquaCal AutoPilot, Inc.
2737 24th Street North
St. Petersburg, Florida 33713
U.S.A.
INSTALLER - Please record the following information prior to installation:
Control Unit
Date of Installation:
Control Unit
SuperCellSuperCell Model
(Pool Volume in Liters:)
Pool Volume in Gallons:
Installer:
Serial Number:
Serial Number:Model Type:
Type: RC-11 & RC-35/22
(only permitted type)

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Used and maintained properly, your chlorine generator will provide year-upon-year of safe and economical
service. However, as with any mechanical or electrical device, to get the most from your equipment—
while insuring personal safety for you and others—certain operational and maintenance factors must
be observed.
Likewise, excepting a few minor owner-capable maintenance items (explained later in this manual), repair
and service of your chlorinator must be performed only by experienced service personnel. Should you,
the owner, suspect your chlorine generator is not performing properly, please refer to the section in this
manual entitled: "Troubleshooting." You can also access the most current troubleshooting advice at
www.autopilot.com. If you determine that a service call is necessary, your installer can be one source
of service, or AquaCal AutoPilot Customer Support can recommend a service company.
Please note that warranties may be voided if the chlorinator has been installed, operated, maintained,
or repaired improperly. In addition to voiding the manufacturer’s warranty, unapproved installation methods,
modifications, poor or incorrect maintenance, service by unqualified personnel, or improper use of the
chlorinator may result in personal injury and/or property damage. For personal safety, and to avoid damage
to equipment, follow all safety instructions displayed on the equipment and within this manual.
SAFETY INFORMATION
Throughout this manual the following two safety signals are placed where particular attention is required.
Please note "WARNING" relates to personal safety, while "CAUTION" signals promote avoiding damage
to equipment.
Safety Signals
Safety Information Main Table
A “warning” signal appears in this manual where special attention is required for personal safe-
ty. (Specific instructions will appear in this box.)
Failure to heed the following may result in permanent
injury or death.
WARNING !
A “caution” signal appears in this manual where special care is required to avoid equipment dam-
age. (Specific instructions will appear in this box.)
Failure to heed the following may result in equipment
damage.
CAUTION !
Failure to heed the following may result in permanent
injury or death.
WARNING !
RISK OF ELECTRICAL SHOCK -A bonding lug has been provided on the outside of the Control
Unit. This lug permits the connection of a No. 8 AWG (8.4mm2) solid copper-bonding conductor
(No. 6 AWG in Canada). Make this connection between the Control Unit and all other electrical
equipment and exposed metal within 5-feet (1.5m) of the Control Unit.All field-installed metal
components (such as rails, ladders, drains, etc.) within 10-feet of the pool, spa, or hot tub, must
be bonded to the equipment grounding bus using copper conductors not smaller than No. 8-AWG
(8.4mm2) (No. 6 AWG in Canada).
CHLORINATOR CONTAINS NO OWNER-REPAIRABLE COMPONENTS - Repairs must not be
attempted by untrained and/or unqualified individuals. If service is deemed necessary, contact in-
stalling dealer orAquaCal AutoPilot Customer Support at: [phone].
Failure to heed the following may result in permanent
injury or death.
WARNING !
Follow all National Electric Codes (NEC) unless State or Local guidelines supersede. When installing
and using your AG, basic safety precautions must always be followed, including the following:

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SAFETY INFORMATION
RISK OF ELECTRICAL SHOCK - Control units configured to 115-VAC must be installed at
least 10-feet (3 m) from the pool or spa wall. Control units configured to 230-VAC or 115-VAC
with twist-lock connects must be installed at least 5-feet (1.5m) from the pool or spa wall.
Failure to heed the following may result in permanent
injury or death.
WARNING !
RISK OF ELECTRICAL SHOCK - A disconnect device, incorporated into the fixed wiring, must
be included in the supply circuit (such as a time clock, relay, or circuit breaker).
Failure to heed the following may result in permanent
injury or death.
WARNING !
RISK OF CHILD DROWNING OR INJURY - Children must be closely supervised at all times
around pool or spa equipment.
Failure to heed the following may result in permanent
injury or death.
WARNING !
WATER CHEMISTRY SAFETY - Improper water chemistry can present a serious health hazard.
The proper residual chlorine level and water chemistry must be maintained. The addition of cer-
tain pool maintenance chemicals can reduce the effectiveness of chlorine. Maintain Pool / Spa
water per standards detailed later in this manual.
Failure to heed the following may result in permanent
injury or death.
WARNING !
To permit proper air circulation, the Control Unit must be mounted at least 1-foot (300 mm) off
ground level.
Failure to heed the following may result in equipment
damage.
CAUTION !
TheAquaCal AutoPilot Chlorinator must be installed and operated as specified. Failure to do so
will void the equipment warranty.
Failure to heed the following may result in equipment
damage.
CAUTION !
DO NOT let water level fall below level ofAbove Ground Manifold cell. Damage to cell and power
supply can occur if unit is run without water flow.
Failure to heed the following may result in equipment
damage.
CAUTION !
RISK OF ELECTRICAL SHOCK - Disconnect allAC power when installing or servicing this sys-
tem.
Failure to heed the following may result in permanent
injury or death.
WARNING !
RISK OF ELECTRICAL SHOCK... Insure electrical power is disconnected before wiring the unit.
Follow all state / local / NEC (CEC if applicable) electrical codes. Use copper conductors, only.
Failure to heed the following may result in permanent injury
or death.
WARNING !
CHEMICAL HAZARD... To avoid damaging splashes, always add acid to water, never water to
acid. Wear safety glasses and use other appropriate personal protection equipment.
Failure to heed the following may result in permanent
injury or death.
WARNING !

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How Your Chlorine Generator Works
The system requires a low concentration of dissolved salt (sodium chloride) in the water. The salt concentration
level is normally maintained below the taste threshold.TheAG automatically converts the salt into chlorine,
which your pool/spa requires to remain sanitized and algae free. The chlorine reverts back to salt after
treating the water. Since the salt is constantly recycled, there is minimal loss during a swimming season.
However, salt can be lost due to filter backwashing, rain water overflow, leaks, or bather splashing/carry
out... but not through evaporation.
TheAG is designed to handle the purification needs of residential swimming
pools and spas.The amount of chlorine required for proper sanitization will
vary based on the pool size and various factors such as water temperature,
bather load, exposure to direct sunlight, and special water features.
Thefloating convectioncells andreturn jet manifolds do not require the circulation
pump running to operate. For all other cells the water circulation pump must
be operating for yourAG to produce chlorine, so run time is one of several
key components to maintaining the proper sanitizer levels.
Most installations require a minimum of eight (8) hours-per-day pump
run time to properly filter and sanitize the water.
SPECIFICATIONS
Chlorine Output:
Manifold Flow Requirements for 75094 Manifold:
Minimum Flow Rate.........:
Maximum Flow Rate........:
Maximum Op. Pressure....:
20-gallons per minute (gpm) (76 liters/minute (L/m))
100-gallons per minute (gpm) (379 liters/minute (L/m))
85-psi
Agency Approvals:
Tested to conform to the following specifications:
UL1081......................: Standard for Safety for Swimming Pool Pumps, Filters, and
Chlorinators
Safety of Household and Similar Electrical Appliances
CAN/CSA-E60335-1....:
Input Power:
Model 75090....................:
Model 75090-TL ..............:
Model 75091....................:
110-120 VAC, 2.0 Amp Maximum, with standard 115 VAC plug
220-240 VAC, 1.0 Amp Maximum
110-120 VAC, 2.0 Amp Maximum, with twist-lock plug
SuperCell Type Water Chemistry Max lbs/day Max kg/day
RC-11 Standard Pool Salt 0.40 0.18
RC-35/22 Standard Pool Salt 0.80 0.36
RC-11 E4Aqua - low salt 0.21 0.10
RC-35/22 E4Aqua - low salt 0.42 0.19

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What is included:
Although the manifold assembly may be sold separately, both a manifold and anAG Control Center are
required for a complete installation. The standard cell & manifold assembly is available with the RC-
11 or RC-35/22 residential cell. Before attempting the installation, verify the following items have been
included with the Control Center:
Three Available Water Manifold Assemblies:
Floating-Cell Manifold Assembly (#75092)
The 75092 floats in the pool. It does not need the circulation pump and produces its
own flow by convection.
Replacement Parts:
Above Ground Cell Manifold Assembly (#75093)
The 75093 manifold is inserted in the circulation return to the pool or spa.
Replacement Parts:
Inline-Cell Manifold Assembly (#75094)
The manifold is connected into the plumbing after all other equip-
ment. Water from the pool/spa is moved though the manifold
by the circulation pump.
Replacement Parts:
•RC11 (Cell) or RC-35/22 (Cell)
•APK0018 (Manifold Assembly)
•(2) - 312-G - 1 1/4” or 1 1/2” flex hose OR
(2) - 312-D - Standard 2” PVC
•RC11-ML - CC25 (Cell with grate)
•19088 (Swan and Canister)
Control
Center
+or
or
Above
Ground
Cell
Inline
Cell
+
+
+
Floating
Cell
SPECIFICATIONS
•RC11 (Cell) or RC-35/22 (Cell)
•APK0019 (Manifold Assembly)
•(2) - 312-G - 1 1/4” or 1 1/2” flex hose OR
(2) - 312-D - Standard 2” PVC
Quantity Item Description
1 Flow Switch Plug
4 Plastic Anchors
4 Mounting Screws
Quantity Item Description
1 Cell Cord
1 Flow Switch Plug
1 Cell Cord Cap
4 Plastic Anchors
4 Mounting Screws
Quantity Item Description
1 Flow Switch Cord
1 Cell Cord Cap
4 Plastic Anchors
4 Mounting Screws
1 Cell Cord
75092 (FLOATING CELL PARTS)
75093 (ABOVE GROUND CELL PARTS)
75094 (INLINE CELL PARTS)

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Basic System Overview:
The AG unit is a salt chlorination system for pool or spa purification, and is designed to operate in the
following configurations:
INSTALLATION
RISK OF ELECTRICAL SHOCK - Remove floating cell from pool before swimming in pool.
Failure to heed the following may result in permanent
injury or death.
WARNING !
DO NOT let water level fall below level ofAbove Ground Manifold cell. Damage to cell and power
supply can occur if unit is run without water flow.
Failure to heed the following may result in equipment
CAUTION !
Pool
Filter Water Pump
Water
Flow
Shown with Inline-Cell Manifold Assembly
Water
Flow
Filter
Water Pump
Shown with Above Ground Cell Manifold Assembly
APK0018
RC-11
312-G OR 312-D
RC-11
312-G
OR 312-D
312-G
OR
312-D
APK0019
Shown with Floating-Cell Manifold Assembly
Good news, no plumbing required for this type of manifold assembly

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Plumbing the Inline-Cell Manifold Assembly (75094):
STEP-1: Select the location for installing the manifold:
It is recommended the manifold be installed prior to installation of the Control Unit. The Control
Unit must be installed close enough to the Manifold Assembly to allow the SuperCell and
flow switch cables sufficient slack to enable component service and maintenance.The cables
are 12’ long.
The direction of the water flow through the manifold must be as indicated for the system to
operate properly.
For a Pool/Spa combination, the manifold must be located as the last component in the POOL
RETURN LINE (to avoid over-sanitization of the spa).
The ManifoldAssembly is typically plumbed into the pool return line; and, if applicable, after the heater
and spa return diverter valve. Adaptors are supplied for 2” PVC (312-D) or 1 1/2” flex hose (312-G).
INSTALLATION
Plumbing the Above Ground Manifold Assembly (75093):
STEP-1: Select the location for installing the manifold:
It is recommended the manifold be installed prior to installation of the Control Unit. The Control
Unit must be installed close enough to the Manifold Assembly to allow the SuperCell suf-
ficient slack to enable component service and maintenance. The cables are 12’ long.
The direction of the water flow through the manifold must be as indicated for the system to
operate properly.
STEP-3: Install the 75093 into the return line hole and tighten the nut inside the pool wall.
STEP-2: Lower the water level below the return line.
STEP-4: Connect the return pipe to the bottom of the cell. Adaptors are supplied for:
• 2” PVC (312-D) or
• 1 1/2” flexible hose or 1 1/4” flexible hose (312-G)
STEP-5: Add water to bring the level above the return line.
Plumbing the Floating-Cell Manifold Assembly (75092):
STEP-1: Select the area where you would like the swan to float:
Confirm floating cell’s cable will still reach power center as swan floats in pool.The cell cable
is 25’ long.
Make sure that cord will not become a tripping hazard when in pool.
STEP-2: Assemble swan as shown:
1 Unscrew the GRATE from the bottom of the RC-11 Cell
(The grate is included with the cell as Part # RC-11-ML-CC25)
2 Unscrew the CANISTER from the SWAN
(The Cannister is included with the Swan as Part #19088)
3 Insert the RC-11 CELL into the CANISTER, lining up the cable with
the notch on the side of the CANISTER and the hole in the bottom
4 Line the GRATE up on the outside of the CANISTER and screw it
into the RC-11 cell
5 Screw the SWAN assembly into the top of the CANISTER
6 Place SWAN assembly into pool
7 Attach cable to AG Control Unit
8 Plug in AG and enjoy!
Swan
Grate
Cannister