Aquacal DIG-220 User manual

1
Model: DIG-220
INSTALLER: THIS DOCUMENT IS PURCHASER’SPROPERTY AND IS TO REMAIN WITH THE EQUIPMENT OWNER
18500-DIG R13
Owner’s
Manual
Salt Chlorine Generator
IMPORTANT !
Swimming Pool & Spa Purification System
Read This Manual Before
Installing or Operating
Installation and Operation
This manual covers the installation and operation of
the DIG-220 Chlorine Generator with associated
manifold assembly.
3/9/17
PoolPilot®
PN: #

2
TABLE OF CONTENTS
CONTACTING THE FACTORY..................................................................................................... 4-5
SAFETY INFORMATION ............................................................................................................... 5-6
OWNER QUICK START & RUN ................................................................................................. 7-10
SPECIFICATIONS............................................................................................................................11
Input Power ......................................................................................................................................... 11
Output Power ...................................................................................................................................... 11
Optional Internal Pump Relay Ratings ................................................................................................. 11
Chlorine Output ................................................................................................................................... 11
Manifold Flow Requirements................................................................................................................ 11
Agency Approvals ................................................................................................................................11
INSTALLATION ...........................................................................................................................11-16
Before Installing: .................................................................................................................................. 11
What is included: ................................................................................................................................ 11
What is not included: .......................................................................................................................... 11
Required Components for a complete system:.................................................................................... 12
Installation Steps: ................................................................................................................................ 12
Plumbing the Manifold Assembly ............................................................................................ 12
Flow Rates Within Normal Range: ................................................................................... 13
Flow Rates Exceeding 100-gpm (379 L/m):...................................................................... 13
Mounting the Control Unit:.............................................................................................................. 13-14
Electrical Connections ................................................................................................................... 14-16
Grounding and Bonding .......................................................................................................... 14
Determine Incoming Voltage Requirements ............................................................................. 14
For incoming voltage of 230 Vac: ................................................................................ 14
For incoming voltage of 115 Vac: ................................................................................ 15
Connecting DIG-220 to External Equipment ........................................................................... 15
Connecting DIG-220 to External Time Clock: ................................................................... 15
Connecting DIG-220 to Control a One-Speed Pump......................................................... 16
Connecting DIG-220 to Control a Two-Speed Pump ......................................................... 16
Cell and Tri-Sensor Cord Connections.............................................................................. 16
PREPARING THE POOL WATER ...................................................................................................17
Steps to Prepare Water: ...................................................................................................................... 17
Calculating Pool Volume: .................................................................................................................... 17
Adding Salt: ........................................................................................................................................ 17
Type of Salt to Add... .............................................................................................................. 17
Determine Amount of Salt Required (and salt level to maintain)... .......................................... 17
How to add the salt (or remove it if too much)... ..................................................................... 17
MENU OVERVIEW ...........................................................................................................................18
ACCESS TO PROGRAMMING................................................................................................. 18-23
Control Panel: ..................................................................................................................................... 18
Operation of Buttons: ..................................................................................................................... 18-19
Menu Button ........................................................................................................................... 18
Select Button ......................................................................................................................... 18
Pump Button ..................................................................................................................... 18-19
Basic Operational Programming: ......................................................................................................... 19
Adjusting the Purifier Output % ... .......................................................................................... 19
Boost or SuperBoost... ........................................................................................................... 19
Purifier Mode .......................................................................................................................... 19
Purifier % Adjustment Procedure: ..................................................................................... 19

3
Menus ............................................................................................................................................ 20-23
Test Pool Pilot ........................................................................................................................ 20
View Setup ............................................................................................................................. 20
Owner Options: ................................................................................................................. 20-21
Select Language: ............................................................................................................. 20
Select Units: .................................................................................................................... 21
Temperature Units ............................................................................................................ 21
12/24 Hour Clock: ............................................................................................................ 21
Set Time of Day: .............................................................................................................. 21
Maintenance Menu: ........................................................................................................... 21-22
Test Pool Pilot: ................................................................................................................21
Set Time of Day: .............................................................................................................. 21
Force Reverse .................................................................................................................. 21
Set Reverse Time: ............................................................................................................ 21
Replace Cell .................................................................................................................... 22
Calibrating Temperature: .................................................................................................. 22
Calibrating Salt: ...............................................................................................................22
Installer Menu: ................................................................................................................... 22-23
Select Language: ............................................................................................................. 22
Select Units: .................................................................................................................... 22
Temperature Units ............................................................................................................ 22
12/24 Hour Clock: ............................................................................................................ 22
Pool Volume .................................................................................................................... 22
Cell Type .......................................................................................................................... 23
Cell Power ....................................................................................................................... 23
Pump Control ................................................................................................................... 23
Set Time of Day ............................................................................................................... 23
Select Remote: ................................................................................................................ 23
Select Minerals: ............................................................................................................... 23
Pump Program 1 and 2: ................................................................................................... 23
Enable Demo: .................................................................................................................. 23
REFERENCE SECTION............................................................................................................ 24-26
Salt Addition Chart: ............................................................................................................................. 24
Basic Water Chemistry: ................................................................................................................. 24-25
Using the Saturation Index (SI):...................................................................................................... 25-26
Part Numbers: ..................................................................................................................................... 26
MAINTENANCE ......................................................................................................................... 27-30
Fuse Location and Ratings:................................................................................................................. 27
Removing \ Inspecting \ Cleaning the Tri-Sensor............................................................................. 27-28
Testing the Flow Switch, Cleaning the Filter Screen,Cleaning the Bypass Valve ............................... 28
Servicing the Pool Pilot Cell .......................................................................................................... 28-29
Visual Inspection of the Pool Pilot Cell.................................................................................. 29
Manual Cleaning of the Pool Pilot Cell... ................................................................................ 29
Installing a Pool Pilot Cell....................................................................................................... 29
Winterizing .......................................................................................................................................... 30
Freeze protection program and its limits ................................................................................. 30
Spring Start-Up .................................................................................................................................... 30
TROUBLESHOOTING.............................................................................................................. 31-32
APPENDIX........................................................................................................................................33
Delaration of Conformity ...................................................................................................................... 33
FCC Compliance ................................................................................................................................. 33
TABLE OF CONTENTS

4
CONTACT INFORMATION
What We Need to Know If You need To Contact Us...
If you should need to call AquaCal AutoPilot, Inc. for questions, service, or parts, please have the following
information ready:
Dear Owner:
Congratulations on your wise decision to make an AquaCal AutoPilot chlorinator a part of your home. Just
add salt, and let your DIG-220 produce the chlorine to sanitize your pool or spa.
A wonderful thing happens to the salt after it is turned into chlorine and
does the work of purifying the water—it turns back into salt and the process
begins all over again.
s,Plus, the salt, being at a much lower level than even contact lens solution
means no “salty” taste to the water for the average bather. And, no
more odors from harsh chlorine products.
No longer experience the discomfort and inconvenience of harsh chemical
reactions like red eyes, green hair, itchy skin, or faded swim wear. Our
product makes it easy to retain a constant level of chlorine, purifying the water while making it soft and silky
to the touch.
“You can rest assured knowing
your new chlorinator is of the
highest quality and effciency, and
is designed and built to provide
years of trouble-free operation.”
INSTALLER - Please record the following information prior to installation:
Control Unit
Date of Installation:
Control Unit
Installer:
Pool Pilot Cell
Serial Number:
Serial Number:Model Type:
Pool Pilot Cell
Model Type:
Pool Volume in Gallons:
DIG-220
1
Use the view set up menu, and test pool pilot menu and write down the results
(see programming on page-20)
3“VIEW SETUP” and “TEST POOL PILOT” information
CHEMISTRY: (from a current water sample)
Salt Level:
Stabilizer (CYA):
pH:
Total Alkalinity:
Calcium Hardness:
Approximate Water Temperature
of pool:
Total Chlorine (TC):
Combined Chlorine (CC):
Free Chlorine (FC):
2NOTE RECOMMENDED LEVELS ON PAGE-24 & 25.

5
Your installer can be one source of service, or AquaCal AutoPilot Customer Support personnel stand
ready to assist you at: [phone]. For questions concerning installation, operation, service and upkeep,
please contact your installer or AquaCal AutoPilot Customer Support. 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 "NOTICE" signals promote avoiding damage to
equipment.
Safety Signals
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: (7) -. We are here to serve you from 8:00 a.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
Or, if you prefer, you may FAX us at: [phone]. Be certain to provide your full address and
a daytime telephone number.
To Contact the Factory...
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 suspect
your chlorine generator is not performing properly, refer to the section in this manual entitled:
"Troubleshooting," to determine if a call for service is required.
Failure to heed the following may result in equipment damage.
NOTICE idA “Notice” signal appears in this manual where special care is required to avo
equipment damage. ( Specific instructions will appear in this box.)
A “Warning” signal appears in this manual where special attention is required for
personal safety. (Specific instructions will appear in this box.)
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 DIG-220, basic safety precautions must always be followed, including the following:
CONTACT INFORMATION
(CONTINUED)

6
SAFETY INFORMATION
(CONTINUED)
READ AND FOLLOW ALL INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
All DIG-220 models:
Installation of fixed wiring DIG-220 (115/230Vac, 50/60 Hz):
A disconnect device such as a time clock relay or circuit breaker from the power
source, with a contact separation of at least 0.12” (3mm) in all poles, must be
incorporated in the fixed wiring for permanently wired units.
To avoid personal injury
WARNING
Risk of Electrical Shock.
WARNING Ensure that the electrical panel or filter pump circuit is turned OFF prior to
installation or servicing inside any AutoPilot unit.
Mount the Control Box to ensure the least amount of direct exposure to rain,
garden sprinkler water, direct sunlight, or any corrosive environment.
Risk of Electrical Shock.
WARNING
Install the Control Box at least 10’ (3 m) for 115 Vac Units, from the inside
wall of the pool or spa. Use 5’ (1.5 m) minimum distance for 230 Vac Units.
Risk of Electrical Shock.
WARNING
Do not permit children to use this product unless they are closely supervised
at all times. Children should not use spas, hot tubs, or pools without
permanent adult supervision.
Failure to heed the following may result in permanent injury or death.
WARNING
All field-installed metal components such as rails, ladders, drains, or similar
hardware within 10’(3 m) of the spa or hot tub shall be bonded to the equipment
grounding bus with copper conductors not smaller than No.8 AWG (8.4 mm²).
To avoid personal injury
WARNING
Use the bonding lug provided on the outside of your DIG-220, to connect a min-
imum No. 8 AWG (8.4 mm²) solid copper bonding conductor between the DIG-
220 and any metal equipment, metal enclosures of electrical equipment, metal
water pipe or conduit within 5’ (1.5 m) of the DIG-220.
To avoid personal injury
WARNING
A ground terminal is located on the inside of your DIG-220. To reduce the risk
of electrical shock, this terminal must be connected to the grounding means
provided in the electrical supply panel. A continuous copper wire is to be
used equivalently sized to the circuit conductors supplying your DIG-220.
To avoid personal injury
WARNING
The input voltage to the DIG-220 must match the 115/230Vac jumper
terminals on the Circuit board, marked “TRANSFORMER PRIMARY” (shown
on Page-14 & 15).
To avoid personal injury
WARNING
The proper residual chlorine level and water chemistry must be maintained.
To avoid personal injury
WARNING
The Control Box is provided with (3) knock out holes for electrical conduit con-
nections and has (1) 1/2” Liquidtite fitting already attached. 1/2” nonmetallic flex
conduit is recommended.
To avoid personal injury
WARNING

7
The Pool Pilot DIG-220 is a salt chlorination system designed for pool or spa water purification. Although
the DIG-220 is easy to use, it is important to read through the entire manual before attempting to
operate the system.
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. The DIG-220 automatically converts the salt into chlorin
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 over flow, leaks, or bather
splashing/carry out... but not through evaporation.
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.
The water circulation pump must be operating for your DIG-220 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.
Control Overview
Following is a brief explanation of owner / operator control options. For full features of the Owner Options
Menu, please see page-20 & 21. The MENU button is pressed to obtain access to the Owner Options Menu.
Please Note: This quick start section assumes the installer has already programmed the system for
specific site parameters, has established proper water balance, and has pretreated water to 1 - 3 ppm
chlorine.
Attention Owner: Should Celsius vs. Fahrenheit, choice of language, or other owner options require
modification, please refer to Operation of Buttons located on page-18 and Owner Options on page-20
& 21.
Use the UP and DOWN arrows to control the purifier output
level, then press the SELECT button to save the value chosen.
With a properly prepared pool, the recommended starting output
level is 50%.
Up and Down Arrows:
Please Note: The optimum output setting will vary based upon pool size, location, exposure to sunlight,
number of users, vegetation around the pool, water balance practices, and pump run time. Your
installer should have already taken these factors into consideration when performing installation
programming. Therefore, your adjustments, at this point, should be relatively minor.
n
After the purifier output level is “tuned in,” the unit will automatically make fine output adjustments as the
water temperature fluctuates. This patented temperature compensation feature will adjust output depending
on water temperature. See page-10 & 30 for more information concerning the temperature compensatio
feature.
OWNER QUICK START & RUN
e,
Upon initial start-up, check sanitizer level every few days
and make small output level adjustments as necessary to
maintain 1-3 ppm free chlorine levels.
Your DIG-220 does not directly measure or regulate the sanitizer
levels in your pool. Rather, the owner / operator will need to
periodically test the water to determine the current chlorine
level, and adjust the output setting as needed. FIG-1
Purifier
12:00 pm 80F
100%

8
OWNER QUICK START & RUN
The Boost Button:
The BOOST button increases output to 100%. Use this feature
when a heavier then normal bather load is anticipated.
Press BOOST once........................= 24-Hour Boost
Press and hold BOOST for 8 seconds= 72-Hour Boost
Press BOOST a second time............= Deactivate Boost
Menu and Select Button:
Allows access to the “Test,” “View Setup,” “Owner Options,”
“Maintenance,” and “Installer” menus. The SELECT button
allows the operator to choose program menu options. The
owner / operator should not normally need to access these
features on a regular basis. Consult “Programming” section
or contact factory customer support for additional information.
The CHECK SYSTEM light will flash to warn the DIG-220
may need attention. A warning message will also be.
displayed. Unless deemed a normal condition, per
below, see troubleshooting section on page 21.
Check System Light:
Flashes if the water flow is insufficient under the
following circumstances:
- When DIG-220 is not set up to control the water
pump (uses an External Timer or Remote Runs
Pump), and DIG-220 is wired to the line side
(hot all the time).
- If the DIG-220 controls the pump (One-speed Pump),
the light will not flash when the pump is off.
Flashes when salt is low
Flashes when water temperature exceeds 125° F, or
drops below 10° F
Flashes when “PUMP OFF FOR SERVICE”
Purifier Output level ................................................. :
Water Temperature .................................................. :
Cell Status ............................................................... :
Check System Light ................................................ :
Normal Display:
In 1% increments, from 0% to 100%
In Fahrenheit or Celsius
ON
OFF
FIG-2
FIG-3
FIG-4
Purifier
12:00 pm 80F
100%
Purifier
12:00 pm 80F
100%
Purifier
12:00 pm 80F
100%
After 30-minutes of inactivity, the display will go to a “walking dot” screen saver model. All functions
such as chlorine generation, reverse, boost, etc., will continue in the background. Pressing any key
will call up the normal informational display.

9
Winterizing
Freeze Protection & Extended Shut Down:
Information Critical to the Survival of Your
DIG- 220 Follows...
In areas where freezing conditions are a rare occurrence, allow the filtration system to run continuously
throughout the freeze period. Typically, during light freeze conditions, circulating (moving) water will not
freeze.
In areas where freezing conditions are prevalent and sustained, the DIG-220 MUST be winterized;
please refer to winterizing instructions on page-30.
OWNER QUICK START & RUN
(CONTINUED)
Proper water balance is critical to the operation of your DIG-220.
Conditions such as high pH levels, low cyanuric acid (stabilizer ) levels, or other factors causing unbalanced
water, will mask the sanitizer production of your DIG-220. Please note the following recommended water
chemistry parameters:
See “Basic Water Chemistry,” on page-24 & 25, and “Using the Saturation Index,” on page-25 & 26 for
further information concerning pool/spa water chemistry maintenance requirements.
PH........................................:
Calcium Hardness....................:
Total Alkalinity.........................:
Salt.......................................:
Cyanuric Acid (stabilizer )..........:
Chlorine.................................:
Should you have additional water balance or chemistry questions, please refer to the Troubleshooting
section in the back of this manual.
Water Balance & Chemistry Recommendations
)
7.2 – 7.8
200 – 400 ppm
80 – 100 ppm
2500 – 4500 ppm (ideal 3000 ppm
60 – 80 ppm
1 – 3 ppm
Failure to heed the following may result in equipment damage.
NOTICE Special measures are required in the event of freezing conditions.
Your DIG-220 may be damaged if measures are not taken in advance of freez-
ing conditions. Equipment damage due to freezing conditions is NOT covered
under the equipment warranty.
Important !!!

10
OWNER QUICK START & RUN
(CONTINUED)
s
The Tri-sensor temperature sensor works in conjunction with the purifier % feature to automatically adjust
chlorine output based upon changes in water temperature. The automatic compensation feature operate
between 55°F and 95°F (13°C - 35°C).
As water temperature falls below 65°F (18°C), the controller will activate a high purifier percent lockout, and
may not allow purifier adjustments up to 100%. This feature prevents the controller from overworking the
cell under colder temperatures, thus preventing premature cell wear.
At 55°F (13°C) or colder water temperatures, the controller will adjust to a fixed 1% output (and will not allow
the percentage to be raised manually), thus preventing over-chlorination and premature cell failure.
As the water temperature rises above set point, the controller will increase output up to 100%, thus preventing
under-chlorination during warmer water temperatures.
Patented Temperature Compensation
Water Manifold Assembly
The DIG-220 may be operated with the Patented (Automatic-Flow Bypass) Manifold using the following
Pool Pilot Cells: PPC1, PPC3, PPC4, or PPC5. Please see Installer section: “Basic System Overview,”
for details and diagrams.
Important Features
Patented temperature compensation for chlorine output control...
Programmable microprocessor control...
Multi-language digital display (English, Spanish, Italian, & French)...
Digitally controlled power to the Pool Pilot Cell..
Tri-sensor circuitry to monitor water flow, water temperature, and salt level. Calculates and provides
recommended salt addition amounts required to maintain the recommended 3000 ppm (3.0 g/l) or
4500 ppm for maximum chlorine production) salt concentration level.

di-
Freeze Protection: allows the water pump, if wired and programmed for One-speed pump, to
override the program cycle and run continually (30-minute minimum) when the water temperature
falls below 40° F (4.4° C). This helps to prevent damage to the plumbing during light freeze con
tions.
Optional Internal relay for controlling an external single-speed or two-speed water pump.
On-board diagnostic and test programs.
Lithium battery back up for saving program settings.
ORP dry contact interface for connection to an external ORP controller.
Opitional Electronic controller interface for Jandy (Versions I,K, and newer), Polaris EOS, or
Pentair IntelliTouch controllers.
®
®
Get the Most from Your Purchase!
To become fully-familiar with all the features, the safe operation, and the care of
your new chlorinator, please read through the entire remainder of this manual.
®