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!

2
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

3
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

4
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)

5
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:

6
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 !

7
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

8
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)

9
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

10
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

11
Mounting the Control Unit:
The AG power center is suitable for indoor or outdoor mounting.
When connected to 230-VAC, the power center must be installed at least 5’(1.5 m) horizontal distance
from the pool or spa wall.
When connected to 115-VAC with a standard plug (Model 75090) power supply must be mounted at least
10’from the pool or spa wall. Model 75090-TLhas a twist-lock plug, and must be mounted at least 5’ from
the pool or spa. Both options must include a GFCI (Ground Fault Circuit Interrupter).
When using the Inline-Cell (75094) the control unit should be wired load-side to ensure the control unit
is powered on and off with the circulation pump.
1. Hold the power center chassis in the selected mounting location. Through the top, narrow portion
of mounting slots, mark the wall for the four (4) mounting holes.
2. Plastic anchors and screws have been provided for concrete or stucco walls; anchors are not required
when mounting to wood or composite materials. Drill and install the plastic anchors (as applicable).
Using a screwdriver, run the screws into the anchors, leaving a ¼” gap between the wall and the underside
of the screw heads.
3. Holding the power center slotted openings to the screw heads, allow the screw
heads to pass through the larger portion of the mount holes; hang the power
center on the four (4) mounting screws; using a long shaft screwdriver, tighten
the screws.
To avoid damage to wiring and connectors, thoroughly read the following section before proceeding:
STEP-2: The manifold will accept an RC-11 or RC35/22 residential cell; use of any other cell may
damage the power supply and the equipment warranty will be voided.
CAUTION! Use RC-11 or RC-35/22 cell ONLY. Install the cell into the manifold. Tighten the unions
by hand for a watertight seal.
All electrical connections should be made by a licensed electrician or certified electrical contractor.
INSTALLATION
Note: Insure flow rates for two-speed pump can provide sufficient flow at low
speed.
Flow Rates:
•The manifold can be directly plumbed into the system (as shown in the diagrams
on the prior page).
•If the flow rate for the system is less than 20-gpm (76 L/m), a larger pump must
be installed (or steps taken to improve flow rate).

12
The control center uses both high (line) and low voltage connections. Line-voltage connections are intended
as electrical input to the power center. Low-voltage cables connect to the Flow-Switch and SuperCell.
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 !
Grounding and Bonding:
TheAG must also be connected to the pool/spa bonding system with an 8-AWG (6-AWG for Canada)
wire. A bonding lug is provided at the bottom, exterior of the control center.
TheAG 75090 and 75090-TL have been configured for 115-VAC operation. TheAG 75091 has been factory
configured for 230-VAC operation. The configuration can be changed in the field.
The reconfiguration from 110 to 230-VAC requires removal of the power cord, and changing jumpers inside
the unit. Also, the fuse has to be changed: 1-amp slow blow for 230-VAC (110-VAC units use a 2-amp
slow blow fuse).
INSTALLATION
Electrical Connections:
High Voltage Wiring:
All electrical connections should be made by a licensed electrician or certified electrical contractor.
Determine what type of connector is to be used when installed theAG power supply. (Three-Prong connector,
Twist-Lock connector, or hard wired to the electrical panel) then connect as show on diagram below.
Three-Prong Connector:
Twist-Lock Connector:

13
Low Voltage Wiring:
1. The SuperCell cable connector (75093 & 75094 only) is keyed and must be aligned to connect
properly. Line up the cell cord and plug into the cell cord connector located on the bottom right
of the AG base plate.
2. The other end of the SuperCell cable will have a red weather plug located in one of the three (3)
contact holes. The SuperCell will have two (2) electrical terminals:
As the SuperCell has two (2) electrical contact terminals, the red weather plug will seal the
unused contact in the cable.
Position the SuperCell plug to align the two open holes with the two mating cell terminals:
push gently, but firmly, to connect.
BASE OF AG
3. The Flow Switch cable is used with the 75094 “Inline-cell manifold system”. This cable connector
is also keyed and must be aligned to connect properly.
DO NOT use a flow switch jumper to circumvent the inline manifold systems flow switch. Dam-
age to the cell and power supply can occur if the unit is run without water flowing through the
75094 manifold system.
Failure to heed the following may result in equipment
damage.
CAUTION !
Flow
Switch
Cable A Flow Switch Jumper has been provided with
yourAG system to disable the water flow switch
when used with the 75093 and 75092 manifold
systems. These manifold systems do
not use a flow switch to monitor water
flow. Do not use this jumper with the
75094 “Inline-cell manifold system”.
SuperCell
Cable
INSTALLATION
Hard Wired:

14
PREPARING THE POOL WATER
Steps to Prepare Water:
1. Calculate Pool Volume: See next section, below.
2. Adjust Water Chemistry: (Via saturation index... consider pH, total alkalinity, hardness, and
water temperature; also adjust stabilizer level). See Reference sections on pages 17-22.
3. Add Initial Chlorine Dosage: Use liquid chlorine (sodium hypochlorite), as obtained from pool
supply center, to achieve 1-3 ppm free chlorine.
4. Add salt to water (test the water for salt level, first). Adjust to 3000 - 3500 ppm. See salt chart
on page-17.
Calculating Pool Volume:
Liters (pool size measured in meters)
= Length x Width x Average Depth x 1000
= Diameter x Diameter xAverage Depth x 785
= Length x Width x Average Depth x 785
Rectangular
Round
Oval
Rectangular
Round
Oval
Gallons (pool size measured in feet)
= Length x Width x Average Depth x 7.5
= Diameter x Diameter xAverage Depth x 5.9
= Length x Width x Average Depth x 5.9
When properly sized to the site, theAG will meet the sanitizer “maintenance” requirements of the pool/
spa. The AG is not designed to chlorine shock treat, or build up a chlorine residual, when starting with
a zero or very low chlorine level.
Before starting the AG, the water must be properly balanced, and the chlorine level must be adjusted
to between 1-to-3 ppm free chlorine. More on adjusting water balance, and start-up chlorine levels, follows
below.
Installer Please Note:
depth of deep end + depth of shallow end
2
Average Depth =
Calculated pool volume is:
Enter Pool Volume figure in the information section, page-4.

15
PREPARING THE POOL WATER
How to add the salt (or remove it if too much)...
DetermineAmount of Salt Required (and salt level to maintain)...
The ideal salt range is 3000 - 3500 ppm (2500 minimum) (2.5 - 3.5 g/l). However, if so desired, the AG
can operate with salt levels in excess of 35,000 PPM (35.0 g/l). Salt levels above 6000 PPM are not normally
recommended, as corrosion issues may result. Salt levels below 2500 ppm will reduce the efficiency
of theAG, and will result in low chlorine production and shorten the life of SuperCell. Please see the reference
table, on page-17 for information on amount of salt to be added relative to the gallons of water to be treated
vs. existing salt level.
Type of Salt to Add...
It is important to use Sodium Chloride (NaCl) salt that is greater than 99% pure.Acceptable types of salt
include granular food grade, water softener pellets, or solar salt flakes; these are usually available in
25-lb to 80-lb bags at local pool or building supply outlets. Water softener and solar salt will have a slower
dissolve rate than food grade salt. Rock salt and Granular Salt with Iodine or Rust Preventatives should
not be used, as these mixtures contain high levels of impurities and may cause staining.
Note:
While not recommended, granular salt containing anti-caking additives such as YPS (Yellow Prussiate
of Soda) or Sodium Ferrocyanide can be used. However, these mixtures—if not mixed and dissolved
immediately— may cause a localized tint to the water or yellow staining of the pool/spa finish.
Adding Salt:
The object is to have the salt fully dissolve into the water.
Start the water circulation pump and set to operate in continuous mode (24/7).Add salt directly to pool
(or spa, if a spa-only installation), and over the main drain (If main drain is present). If there is no main
drain, a vacuum head may be used to encourage salt circulation. Distributing the salt through brushing
is also helpful; brush the salt toward the main drain (if one is present). Set pump operation to normal
run time after salt has fully dissolved into water.
If the salt level becomes undesirably high, the only way to remove excess salt is to partially drain the
pool/spa and refill with fresh water.
FIRST... Test the water for current salt content !!!
Add Salt to Pool Water...
Do not allow granular salt to pile up in one location, without brushing, as staining may occur.
Failure to heed the following may result in equipment
damage.
CAUTION !
Using Standard Pool Salt

16
OPERATION
Getting Unit Information:
1 Press INFO button.
3 The displays will time out and return to the Purified Output display.
2 Presses of INFO cycles through the information displays.
 A = xx (Measuredcurrent sentto theSuperCell,where xxis assumed
to have a decimal point. i.e. “A=49” = 4.9 Amps.
 U = xx (Measured voltage sent to the SuperCell, i.e. “U=17” = 17
Volts.
 Lr = xxx ( Percentage of Cell Life remaining based on 28800 Amp
Hours)
 x.xx (The current software version)
1 Start with prepared pool water as described in prior section.
2 Test pool water for free chlorine.
3 If free chlorine level is not at least 1 ppm, add liquid chlorine to insure a 1 -3 ppm free chlorine
residual.
4 Add the proper amount of salt as described on next page, and run the circulation pump continuously
for 24-hours allowing the salt to be fully mixed and dissolved into the pool.
5 Use the UP and DOWN arrow buttons to set the purifier percentage to 50%, and then allow the
pool to operate normally. Display will show P=50 (scrolling) once output is adjusted.
6For the first two weeks, test the water chemistry parameters every 3-4 days. Adjust output
percentage as needed to maintain free chlorine reading.After the optimal output percentage (%)
has been determined, this setting will not normally require further adjustment.
Adjusting Chlorine Output:
TheAG will revert to the normal display if there is no activity on the keypad for ten (10) or more
seconds.
The “Check System” light will show solid green when generating chlorine and flash red if an error
condition exists. See “Troubleshooting” section if an error condition exists.
The solid green light cycles on and off as it periodically stops generating to achieve the correct
percentage output.
Normal Operation:
Note: If water temperature falls below 55 degrees F, theAG should be unplugged to avoid over-
chlorination and/or damage to the cell.

17
Example:
An 11,000 gallon pool with a salt level of 500-ppm
• The column value for 1000 gallons is 21 pounds
• The column value for 10,000 gallons is 209 pounds.
• The total of 230 pounds of salt is needed to reach pool salt level of 3000-ppm.
Salt Addition Chart:
To use this chart:
1 Find current salt level (ppm or g/l) in the left column.
2. Find pool/spa volume in the second row (Gallons or Liters).
3. Find the amount of salt needed to bring pool to the ideal level by finding the intersection of the
row and column.
REFERENCE SECTION
The salt is constantly recycled during normal operation. Loss of salt during a swimming season should
be minimal. Filter backwashing, draining due to rain water overflow, splashing and bathing suit drag out,
and leaks (excessive salt loss in a short span of time) are typical ways salt is lost. Salt does not leave
the pool when water evaporates.
1,000 2,500 5,000 7,500 10,000 12,500 15,000 17,500 20,000
(3,786) (9,465) (18,930) (28,395) (37,860) (47,325) (56,790) (66,255) (75,720)
025 63 125 188 250 313 376 438 501
(11) (28) (57) (85) (114) (142) (170) (199) (227)
250 23 57 115 172 230 287 344 402 459
(0.25) (10) (26) (52) (78) (104) (130) (156) (182) (208)
500 21 52 104 157 209 261 313 365 417
(0.50) (9) (24) (47) (71) (95) (118) (142) (166) (189)
750 19 47 94 141 188 235 282 329 376
(0.75) (9) (21) (43) (64) (85) (106) (128) (149) (170)
1,000 17 42 83 125 167 209 250 292 334
(1.0) (8) (19) (38) (57) (76) (95) (114) (133) (151)
1,250 15 37 73 110 146 183 219 256 292
(1.25) (7) (17) (33) (50) (66) (83) (99) (116) (133)
1,500 13 31 63 94 125 157 188 219 250
(1.5) (6) (14) (28) (43) (57) (71) (85) (99) (114)
1,750 10 26 52 78 104 130 157 183 209
(1.75) (5) (12) (24) (35) (47) (59) (71) (83) (95)
2,000 8 21 42 63 83 104 125 146 167
(2.0) (4) (9) (19) (28) (38) (47) (57) (66) (76)
2,250 6 16 31 47 63 78 94 110 125
(2.25) (3) (7) (14) (21) (28) (35) (43) (50) (57)
2,500 4 1021314252637383
(2.5) (2) (5) (9) (14) (19) (24) (28) (33) (38)
3,000
(3.0)
3,500
(3.5)
35,000 OK for Pool Pilot Operation - (salt water would need to be diluted to lower salt level)
Pounds(kilograms) of Salt needed to attain 3000 ppm (mg/l)
Pool/Spa Volume in Gallons (Liters)
Current
level of
salt ppm
(mg/l)
Ideal
OK
For volumes other than what is shown, use combinations of various columns.
Standard Pool Salt

18
Basic Water Chemistry - Salt:
TheAG unit is designed to produce chlorine on a daily basis. To monitor the system’s efficiency, the water
chemistry ranges, and schedule of periodic checks—per below—should be followed.
Excessively high chlorine levels can cause premature cell failure and corrosion damage to pool
fixtures and equipment.
Failure to heed the following may result in equipment
damage.
CAUTION !
REFERENCE SECTION
Always follow the instructions on the manufacturer's label whenever handling or using chemicals.
Failure to heed the following may result in equipment
damage.
CAUTION !
Standard Pool Salt
CHEMICAL
or FACTOR
IDEAL
RANGE IDEAL TEST SCHEDULE EFFECT OF LOW/HIGH LEVELS CORRECTIVE ACTIONS
Low free chlorine: Not enough residual
chlorine to safely sanitize pool water. Low free chlorine: Check for combined chlorine level and shock as necessary.
Increase purifier output to maintain a 1-3
ppm residual reading.
Free
Chlorine 1 to 3 ppm Weekly
High free chlorine: Corrosive to metallic
fixtures in pool water. Can bleach
swimwear and hair.
High free chlorine:
Decrease purifier output.
Let chlorine dissipate normally until 1-3 ppm
is achieved. In extreme cases, pool water
can be diluted with fresh water or a chlorine
neutralizer added. (Diluting will reduce salt
and CYA. Check and adjust as needed.)
Low pH: (acidic) Equipment corrosion,
eye/skin irritation, plaster etching, rapid
chlorine consumption
Low pH: Add sodium carbonate or soda ash
pH 7.2 to 7.8
ppm Weekly
High pH: (basic) Scale formation, cloudy
water, eye/skin irritation, poor chlorine
effectiveness
High pH: Add muriatic acid or sodium
bisulfate.
Low TA: Eye irritation, pH "bounce",
stained/etched plaster and metal corrosion.
Low TA: Add sodium bicarbonate.
Total
Alkalinity 80 to 100
ppm Monthly
High TA: Constant acid demand, difficulty
in maintaining pH, and contributes to scale
formation or cloudy water conditions.
High TA: Add muriatic acid often, a little at a
time (may take a week or more to lower the
TA).
Low Salt: Below 2,500 ppm causes
premature cell failure and reduces chlorine
production
Low Salt: Add salt according to digital
display on Pool Pilot unit or salt chart.
Salt 3000 to 3500
ppm
Monthly
High Salt: Above 6,000 ppm can cause
corrosion of metallic fixtures and will taste
salty. Note: Cubby can safely operate
with salt levels up to 35,000.
High Salt: If undesirably high, partially drain
and refill the pool with fresh water. (Diluting
will reduce CYA. Check and adjust as
needed.)
Low CH: Etching of plaster, equipment
corrosion Low CH: Add calcium chloride flakes.
Calcium
Hardness 200 to 400
ppm Monthly
High CH: Scale formation, cloudy water.
Rapid buildup of scale may exceed the
system's self-cleaning capability and
require manual cleaning of the SuperCell.
High CH: Partially drain and refill pool with
fresh water to dilute. (Diluting will reduce
salt and CYA. Check and adjust as
needed.)
Cyanuric
Acid (CYA)
- Stabilizer
-
60 to 80 ppm
Outdoors
Low CYA: destruction of chlorine by the UV
rays from the sun. Low CYA: Add cyanuric acid(1 lb/5000 gallons increases CYA 25 ppm)
30 to 50 ppm
Indoors or
Colder
Climates
Monthly
High CYA: Requires more chlorine to
maintain proper sanitizer levels. Note:
CYA not needed for indoor or bromine
pools.CYA can be reduced to 30 - 50 ppm
for AG in colder climate regions.
High CYA: Partially drain and refill pool with
fresh water to dilute. (Diluting will reduce
salt. Check and adjust as needed.)

19
Saturation Index (SI) - Salt:
The Saturation Index is a formula used to predict the calcium carbonate saturation of water, that is, whether
your water will precipitate, dissolve, or be in equilibrium with calcium carbonate.
Water is properly balanced if the SI is 0 ± 0.3. If SI is greater than 0.3, scaling and staining will occur.
If SI is less than -0.3, then the water is corrosive to metallic fixtures and aggressive to plaster surfaces
and vinyl liners.
A high or low SI can cause premature damage to the cell, equipment or pool finish. As a general rule,
higher concentrations of calcium, total dissolved solids, pH, and alkalinity all promote a greater tendency
for scale. Scaling potential also increases with increasing temperature.
pH + TF + CF + AF - SC = SI
-0.3 -0.2 -0.1 0 0.1 0.2 0.3
Corrosive to
metals, etches
plaster finishes,
and irritates
skin
Scaling, staining
,
and cloudy wate
r
conditions
Ok
Examples:
pH = 7.4 .....................................:
Water Temperature = 84 F .............:
Calcium Hardness = 400 ppm ........:
Total Alkalinity = 125 ppm ..............:
Salt Level = 3000 ppm ...................:
REFERENCE SECTION
Use the chart below to determine your overall water balance. Test water for pH, water temperature, Calcium
Hardness, Total Alkalinity, Salt Level, and use the equivalent Factors (TF, CF, AF, Constant) from the
chart below to determine your Saturation Index. Adjust chemicals to maintain balanced water.
pH = 7.8 .....................................:
Water Temperature = 84 F..............:
Calcium Hardness = 600 ppm ..........:
Total Alkalinity = 200 ppm ..............:
Salt Level = 3000 ppm ...................:
TF Calcium
Hardness CF Total Alkalinity AF Salt Level SC
60 F 15.6C 0.4 150 ppm 1.8 75 ppm 1.9 0 - 1000 ppm 12.1
66 F 18.9C 0.5 200 ppm 1.9 100 ppm 2.0 1001 - 2000 ppm 12.2
76 F 24.4C 0.6 250 ppm 2.0 125 ppm 2.1 2001 - 3000 ppm 12.3
84 F 28.9C 0.7 300 ppm 2.1 150 ppm 2.2 3001 - 4000 ppm 12.4
94 F 34.4C 0.8 400 ppm 2.2 200 ppm 2.3 4001 - 5000 ppm 12.5
103 F 39.4C 0.9 600 ppm 2.4 250 ppm 2.4 5001 - 6000 ppm 12.6
Temperature
pH = 7.4
TF = 0.7
CF = 2.2
AF = 2.1
SC = 12.4
7.4 + 0.7 + 2.2 + 2.1 – 12.4 = 0
(Water is perfectly balanced)
Water Test Results #1
7.8 + 0.7 + 2.4 + 2.3 - 12.4 = 0.8
(Water is scale forming)
Water Test Results #2
pH = 7.8
TF = 0.7
CF = 2.4
AF = 2.3
SC = 12.4
Standard Pool Salt

20
TheAG unit is designed to produce chlorine on a daily basis. To monitor the system’s efficiency, the water
chemistry ranges, and schedule of periodic checks—per below—should be followed. Note that in this
section “salt” refers to standard pool salt; E4aqua will be referred to as “E4aqua” or “additive”.
REFERENCE SECTION
The following instructions and chart should be used for seasonal start up of an above ground pool using
theAG in conjunction with E4aqua®additive package. E4aqua®additive is used in applications where
a lower salt concentration is desired. Note that lower salt will result in lower chlorine output.
1 Fill pool to desired water level.
2 Start circulation pump.
For Fresh Water / New Pool Start up:
For Winterized / Existing Pool Water Start up:
1 Measure current salt level (ppm or mg/l) by testing the water.
• If current salt level is 0 to 250ppm, proceed to step 2.
• If current salt level is 250 to 500ppm, drain half of pool water, refill to desired level, then
proceed to step 2.
• If current salt level is 750ppm or higher, drain entire pool, and refill with fresh water and
proceed to step 2.
2 With desired water level, begin circulation pump.
Example:
An 11,000 gallon pool
• The column value for 1000 gallons is 1 bag (19lbs).
• The column value for 10,000 gallons is 10 bags (190lbs).
• The total of 11 bags or 209 pounds of E4aqua®is needed to reach pool salt level of
3000-ppm.
For volumes other than what is shown, use combinations of various columns.
Adding E4aqua:
E4aqua Addition Chart:
3 Follow E4aqua®addition chart below for the correct amount of additive package addition.
Allow to dissolve completely before step 4
4 Begin operating Pool Pilot AG chlorine generator as directed.
3 Follow E4aqua®addition chart below for the correct amount of additive package addition.
One bag equals 19 pounds. Allow to dissolve completely.
4 Begin operating Pool Pilot AG chlorine generator as directed.
1 bag of E4aqua = 19 pounds
Gallons 1,000 2,000 2,500 5,000 7,500 10,000 13,500 15,00
0
Liters 4,000 8,000 9,500 19,000 28,000 38,000 51,000 57,00
0
Amount of
E4aqua needed
(in bags) 12358101415
Pool / Spa Volume in Gallons or Liters
®