Aquacal Pool Pilot Digital Nano User manual

INSTALLER: This Document is Purchaser’s Property and is to remain with the Equipment Owner
LTP0086 Rev-1C 07/28/2015
Pool Pilot®
Digital Nano/Nano+
Digital Nano Models: 75040, 75040-xx, 75041 and 75041-xx
Manifold: 94105
Cell: RC35/22
Digital Nano+Models: 75042, 75042-xx, 75043 and 75043-xx
Manifold: 94106
Cells: RC35/22 or RC28
Owner’s Manual
Installation / Operation
This manual covers the installation
and operation of Digital Nano and
Digital Nano+Chlorine Generators
Important!
Read This Manual And Product
Labels Before Installing Or
Operating This Equipment

i
TABLE OF CONTENTS
SECTION 1 - FACTORY CONTACT INFORMATION...........................................................................................1
SECTION 2 - SAFETY INFORMATION ................................................................................................................1
SECTION 3 - OWNER QUICK START & RUN.....................................................................................................3
3.1 How Your Digital Nano/Nano+Works ............................................................................................................3
3.2 Control Overview ............................................................................................................................................4
3.2.1 Up and Down Arrows...................................................................................................................4
3.2.2 The Boost Button ......................................................................................................................... 4
3.2.3 Menu and Select Button...............................................................................................................4
3.2.4 Check System Light and Audio Alarm .........................................................................................4
3.3 Normal Display................................................................................................................................................5
3.4 Water Balance & Chemistry Recommendations ............................................................................................5
SECTION 4 - SPECIFICATION AND APPROVALS.............................................................................................6
4.1 Specifications..................................................................................................................................................6
4.2 Manifold Pressure Drop Versus Flow .............................................................................................................6
4.3 Agency Approvals...........................................................................................................................................6
SECTION 5 - FEATURES......................................................................................................................................7
5.1 Patented Temperature Compensation............................................................................................................7
5.2 Water Manifolds Assemblies - Available Options...........................................................................................7
5.2.1 Automatic-Flow Bypass Manifold Assembly (#94105 and #94106) ............................................8
5.2.2 CoPilot Manifold Assembly.......................................................................................................... 8
SECTION 6 - MAINTENANCE...............................................................................................................................9
6.1 Fuse Location and Ratings.............................................................................................................................9
6.2 Removing / Inspecting / Cleaning Tri-Sensor...............................................................................................10
6.2.1 Tri-Sensor Assembly Overview..................................................................................................10
6.2.2 Inspect Tri-Sensor......................................................................................................................10
6.2.3 Cleaning Tri-Sensor...................................................................................................................11
6.2.4 Test Tri-Sensor Flow Switch......................................................................................................11
6.3 Servicing the Cell..........................................................................................................................................12
6.3.1 Removal.....................................................................................................................................12
6.3.2 Visual Inspection........................................................................................................................12
6.3.3 Manual Cleaning........................................................................................................................13
6.3.4 Installing.....................................................................................................................................13
6.4 Winterizing ....................................................................................................................................................14
6.5 Spring Start-up..............................................................................................................................................14
SECTION 7 -PROGRAMMING...........................................................................................................................15
7.1 Control Panel................................................................................................................................................15
7.1.1 Button Overview.........................................................................................................................15
7.1.2 Menu Button...............................................................................................................................15
7.1.3 Display Overview .......................................................................................................................15
7.2 Menus ...........................................................................................................................................................16
7.3 Basic Operational Programming...................................................................................................................16
7.3.1 Adjusting the Chlorine Output %................................................................................................16
7.3.2 Boost or Super Boost.................................................................................................................17
7.3.3 Chlorine Mode............................................................................................................................17
7.3.4 Chlorine % Adjustment Procedure.............................................................................................17
7.4 Test Pool Pilot (Diagnostic Menu) ................................................................................................................18
7.5 View Setup....................................................................................................................................................18

ii TABLE OF CONTENTS
7.6 Review of Installer, Owner, & Maintenance Menu Programming.................................................................19
7.6.1 Pool Volume...............................................................................................................................19
7.6.2 Calibrating Salt...........................................................................................................................19
7.6.3 Select Language........................................................................................................................19
7.6.4 Calibrating Temperature ............................................................................................................20
7.6.5 Select Units................................................................................................................................20
7.6.6 Temperature...............................................................................................................................20
7.6.7 Set Reverse Time ......................................................................................................................20
7.6.8 Program Cell’s self-cleaning cycle.............................................................................................20
7.6.9 Force Reverse:...........................................................................................................................21
7.6.10 Audio Alarm:.............................................................................................................................21
SECTION 8 -INSTALLATION.............................................................................................................................22
8.1 Basic System Overview................................................................................................................................22
8.2 Before Installing ............................................................................................................................................23
8.3 Parts..............................................................................................................................................................23
8.4 Installation Steps...........................................................................................................................................24
8.5 Plumbing Requirements................................................................................................................................24
8.5.1 Plumbing the Manifold Assembly...............................................................................................24
8.6 Mounting the Digital Nano/Nano+.................................................................................................................25
8.7 Electrical........................................................................................................................................................26
8.7.1 Electrical Connections................................................................................................................26
8.7.2 AC Input Voltage........................................................................................................................26
8.7.3 Low Voltage Wiring....................................................................................................................26
8.7.4 Low-Voltage Cable Connections at Control Center...................................................................27
8.7.5 Grounding and Bonding.............................................................................................................27
8.7.6 Connecting to an External Timer or Controller ..........................................................................27
8.8 Preparing the Pool Water..............................................................................................................................28
8.8.1 Steps to Prepare Water..............................................................................................................28
8.8.2 Calculating Pool Volume............................................................................................................28
8.8.3 Adding Salt.................................................................................................................................29
8.9 Programming at Installation..........................................................................................................................30
SECTION 9 - TROUBLESHOOTING...................................................................................................................31
SECTION 10 - REFERENCE.................................................................................................................................36
10.1 Basic Water Chemistry ...............................................................................................................................36
10.1.1 Chlorine....................................................................................................................................38
10.1.2 pH.............................................................................................................................................38
10.1.3 Total Alkalinity..........................................................................................................................38
10.1.4 Calcium Hardness....................................................................................................................38
10.1.5 Cyanuric Acid...........................................................................................................................38
10.2 Using the Saturation Index .........................................................................................................................39
10.3 Salt Addition Chart......................................................................................................................................39
10.4 Declaration of Conformity ...........................................................................................................................41
10.5 FCC Compliance.........................................................................................................................................41

Page 1
SECTION 1 - FACTORY CONTACT INFORMATION
If you should need to call AquaCal AutoPilot, Inc. for questions, services, or parts, please have your
model and serial numbers available. Please also have the name of your installer and date of your
equipment’s installation. If you have questions, please refer to our web site for the latest manual
revisions, additional information, and helpful service advice.
Web
www.AutoPilot.com
Power Supply Serial
Phone
[phone]
8-5 pm, Est., M-F
Cell Serial
Fax
[phone]
Tri-Sensor Serial
Address
AquaCal AutoPilot, Inc.
2737 24th Street North
St. Petersburg, Florida 33713
USA
Installer
Install Date
SECTION 2 - SAFETY INFORMATION
For personal safety, and to avoid damage to equipment, follow all safety instructions displayed on the
equipment and within this manual. Repair and service of your Digital Nano/Nano+must be performed
by qualified 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. Warranties will be voided if the Digital Nano/Nano+has been improperly installed. Failures to
properly operate, maintain, or repair the Digital Nano/Nano+will void factory warranty.
Throughout this manual safety signals are placed where particular attention is required. Please note
"WARNING" signals relate to personal safety, while "CAUTION” signals promote avoiding damage to
equipment.
Follow all state, provincial and NEC (National Electrical Codes) and applicable CEC (Canadian
Electrical Codes) unless local guidelines supersede. When installing and using your Digital
Nano/Nano+, basic safety precautions must always be followed, including the following:
WARNING - Failure to heed the following may result in injury or death.
RISK OF ELECTRICAL SHOCK - Disconnect all AC power when installing or servicing
this system. Follow all state, local, and National Electrical Code(s) (provincial and
Canadian Electrical Code(s) if applicable). Use copper conductors only.
RISK OF ELECTRICAL SHOCK - Digital Nano/Nano+contains no Owner-repairable
components. Repairs must not be attempted by untrained and/or unqualified individuals.
If service is deemed necessary, contact installing dealer or AquaCal AutoPilot Customer
Support.
RISK OF ELECTRICAL SHOCK - A bonding lug has been provided on the outside of the
Digital Nano/Nano+. This lug permits the connection of a No. 8 AWG (8.4 mm2) solid
copper-bonding conductor (No. 6 AWG in Canada). Make this connection between the
Digital Nano/Nano+and all other electrical equipment and exposed metal within 5-feet
(1.5 m) of the Digital Nano/Nano+. 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

Page 2
equipment grounding bus using copper conductors not smaller than No. 8 AWG
(8.4mm2) (No. 6 AWG in Canada).Maintain water chemistry in accordance with
manufacturer’s instructions.
RISK OF ELECTRICAL SHOCK - Digital Nano/Nano+configured to 115 Vac must be
installed at least 10 feet (3 m) from the pool or spa wall. Digital Nano/Nano+configured
to 230 Vac must be installed at least 5 feet (1.5m) from the pool or spa wall.
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).
RISK OF ELECTRICAL SHOCK - Connect only to a branch circuit protected by a
ground-fault circuit-interrupter (GFCI). Contact a qualified electrician if you cannot verify
that the circuit is protected by a GFCI.
RISK OF ELECTRICAL SHOCK - Digital Nano/Nano+must be connected only to a
supply circuit that is protected by a ground-fault circuit-interrupter (GFCI). The GFCI
must be tested on a routine basis. To test, push the GFCI test button. Power should be
interrupted. Push the reset button. Power should be restored. If the GFCI fails to operate
in this manner, it is defective.
RISK OF ELECTRICAL SHOCK - If the ground-fault circuit-interrupter (GFCI) interrupts
power to the equipment without the test button being pushed, a ground current is flowing
with a possibility of an electrical shock. Do not use equipment. Disconnect the
equipment and have the problem corrected by a qualified service representative before
using.
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.
CHEMICAL HAZARD - Always follow the instructions on the manufacturer's label
whenever handling or using chemicals.
CHEMICAL HAZARD –Heavy pool (or spa) usage and higher temperatures may require
a higher chlorine output in order to maintain proper free available chlorine residuals.
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 certain pool maintenance chemicals can reduce the effectiveness of chlorine.
Maintain Pool / Spa water per standards detailed later in this manual.
COMBUSTIBLE HAZARD –The AquaCal AutoPilot Digital Nano/Nano+is equipped with
an electronic flow switch that automatically turns the unit off in the event of a “low water
flow” situation. Do not tamper in any way with this safety feature.
PERSONAL SAFETY HAZARD –To reduce the risk of injury, do not permit children to
operate this device.
RISK OF CHILD DROWNING OR INJURY - Children must be closely supervised at all
times around pool or spa equipment.
CAUTION - Failure to heed the following may result in equipment damage.
The AquaCal AutoPilot Digital Nano/Nano+must be installed and operated as specified.
Failure to do so will void the equipment warranty.
To permit proper air circulation, the Digital Nano/Nano+must be mounted at least 1-foot
(30 cm) above ground level or any other cooling obstruction.
Special measures are required in the event of freezing conditions. Your Digital
Nano/Nano+may be damaged if measures are not taken in advance of freezing

Page 3
conditions. Equipment damage due to freezing conditions is NOT covered under the
equipment warranty.
Do not use a pool cleaner or vacuum head with wheels, as wheels can leave track
marks on newly-plastered pools. Do not allow Granular salt to pile up in one location,
without brushing, as staining may occur.
Excessively high chlorine levels can cause premature cell failure and corrosion damage
to pool fixtures and equipment.
For maximum cell life, maintain water in a balanced condition. Water maintained in a
scaling condition will shorten cell life and may render the Digital Nano/Nano+
inoperative. Damage and/or service calls, caused by improper water balance, will NOT
be covered under the equipment warranty.
Scraping or scratching the titanium blade’s edge or surface will damage the blade
catalyst coating and cause premature failure of the cell... warranty will be voided. Never
use any sharp or metallic objects to remove scale.
Reduced polarity reversing cycle times will reduce cell life, and should only be used due
to uncontrollable scale formation on the cell. ALWAYS test and adjust water balance,
before attempting scale control via shortening reverse period.
The Tri-Sensor should not be pulled out at an angle, or the flow paddle or flow post may
be damaged. SAVE THESE INSTRUCTIONS
SECTION 3 - OWNER QUICK START & RUN
1) Balance the water chemistry according to the water chemistry parameters on page 5 and salt
recommendations on page 29. The Digital Nano/Nano+may be started immediately. The salt
reading, however, may initially be inaccurate until the circulation pump has been run for 24
hours to fully dissolve newly added salt.
2) Use the “UP” and “DOWN” arrow buttons to set the chlorine percentage to 50%.
3) During the first two weeks, test the water chemistry parameters every 3-4 days. Adjust chlorine
percentage as needed.
4) Once ideal chlorine percentage has been determined, follow normal maintenance procedures.
3.1 HOW YOUR DIGITAL NANO/NANO+WORKS
The Digital Nano/Nano+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.
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 Digital Nano/Nano+
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.
The water circulation pump must be operating for your Digital Nano/Nano+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.

Page 4
3.2 CONTROL OVERVIEW
The following is a brief explanation of owner or operator control options. For full features of the Owner
Options Menu, please see page 19. The MENU button is pressed to obtain access to the Owner
Options Menu.
Please Note: This 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 (mg/L) chlorine.
Attention Owner: Should Centigrade vs. Fahrenheit, choice of language, or other owner options
require modification, please refer to the programming information located on page 19.
See: Menu Button and Owner Options.
3.2.1 Up and Down Arrows
Use the UP and DOWN arrows to control the chlorine output level, then press the SELECT
button to save the value chosen. With a properly prepared pool, the recommended starting
output level is 50%.
Upon initial start-up, check sanitizer every 3-4 days and make small output level adjustments as
necessary to maintain 1-3 ppm (mg/L) free chlorine levels. Keep in mind, your Digital
Nano/Nano+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.
After the chlorine output level is “tuned in,” the unit will automatically make fine output
adjustments as the water temperature fluctuates. This temperature compensation feature will
adjust output depending on water temperature. See page 7 for more information concerning the
patented temperature compensation feature.
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.
3.2.2 The Boost Button
The BOOST button increases output to 100%. Use this feature when a heavier than 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
3.2.3 Menu and Select Button
This allows access to the “Test,” “Setup,” “Owner Option,” “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.
3.2.4 Check System Light and Audio Alarm
The CHECK SYSTEM light will flash to warn the unit may need attention. A warning message will
also be displayed. If enabled, an audio alarm* may also be heard when the system light is flashing.
Unless deemed a normal condition, per below, see troubleshooting section.
Flashes red when pump is off / water flow is insufficient. (It is normal for the light to flash if
the circulation pump is off)
Flashes when salt is low

Page 5
Flashes when water temperature exceeds 125°F, or drops below 10°F
Note: When enabled, an audio alarm will sound due to any of the above three (3) conditions. If
water flow ceases (or falls below minimum acceptable levels) the alarm will automatically silence
after 10 minutes. To enable or disable audio alarm, see “Audio Alarm” in programming instructions.
3.3 NORMAL DISPLAY
Chlorine Output level..............in 1% increments, from 0% to 100%
Water Temperature................in Fahrenheit or Celsius
Cell Status..............................ON or OFF
Check System Light ...............OFF when operating normally
Check System Light ...............Normally blinking when circulation pump is off and supply power to
the controller remains on.
3.4 WATER BALANCE & CHEMISTRY RECOMMENDATIONS
Proper water balance is critical to the operation of your Digital Nano/Nano+.
Conditions such as high pH levels, low Cyanuric acid (stabilizer) levels, or other factors causing
unbalanced water, will mask the sanitizer production of your Digital Nano/Nano+.
Please note the following recommended water chemistry parameters are for residential pool/spa
applications only. Follow local regulatory guidelines for any commercial pool applications.
POOL
SPA
PARAMETER
UNITS
MIN
IDEAL
MAX
MIN
IDEAL
MAX
Free Chlorine
ppm (mg/L)
1.0
2.0 - 4.0
5
2.0
3.0 - 4.0
10
Combined Chlorine
ppm (mg/L)
0.0
0.0
0.2
0.0
0.0
0.5
pH
7.2
7.2 -7.8
7.8
7.2
7.2 -7.8
7.8
Total Alkalinity
ppm (mg/L)
60
80 - 100
180
60
80 - 100
180
Calcium Hardness
ppm (mg/L)
150
200 - 400
1000
100
150 - 250
1000
Salt
ppm (mg/L)
2000
2500 - 3500
**
2000
2500 - 3500
**
Cyanuric Acid (stabilizer)
ppm (mg/L)
0
30 - 50
***
0
30 - 50
***
Table 1
** Typically 6000 ppm (mg/L) or less is recommended; unit can operate with levels as high as
35,000+ ppm (mg/L).
*** This is dictated by state or local codes but is typically 100 ppm (mg/L).
See “Basic Water Chemistry” on page 36 and “Using the Saturation Index” on page 39 for further
information concerning pool/spa water chemistry maintenance requirements. Or refer to the
Troubleshooting section in the back of this manual.

Page 6
SECTION 4 - SPECIFICATION AND APPROVALS
4.1 SPECIFICATIONS
SPECIFICATION
75040, 75040-XX
75041, 75041-XX
75042, 75042-XX
75043, 75043-XX
Input Power
110-120 Vac
2.0 A
220-240 Vac
1.0 A
110-120 Vac
2.0 A
220-240 Vac
1.0 A
Maximum Chlorine Output
RC35/22
0.8 lb. /day (15.11 g/hr.)
0.8 lb. /day (15.1 g/hr.))
Maximum Chlorine Output
RC28
not applicable
1.06 lb. /day (20.0 g/hr.)
Minimum Flow Rate
for 941xx
15 gpm (76 L/min)
Minimum Flow Rate for
Co-Pilot Ozone
25 gpm (95 L/min)
Maximum Flow Rate
100 gpm (379 L/min)
Maximum Operating
Pressure
85 psi
Table 2
4.2 MANIFOLD PRESSURE DROP VERSUS FLOW
The following chart shows pressure drops versus flow for all Digital Nano/Nano+ manifolds. The
optional CoPilot Ozone manifold is also listed.
Table 3
4.3 AGENCY APPROVALS
Tested to conform to the following specifications:
APPROVAL
DESCRIPTION
UL1081
Standard for Safety for Swimming Pool Pumps, Filters, and Chlorinators.
CAN / CSA-E60335-1
Safety of Household and Similar Electrical Appliances.

Page 7
SECTION 5 - FEATURES
Patented temperature compensation for chlorine output control.
Programmable microprocessor control.
Multi-language digital display (English, Spanish, French and either Italian or Czech).
Digitally controlled power to the 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
(mg/L) salt concentration level.
5.1 PATENTED TEMPERATURE COMPENSATION
WARNING - Failure to heed the following may result in permanent injury or death.
Pool or Spa water temperature should not exceed 104°F (40°C).
The Tri-Sensor temperature sensor works in conjunction with the chlorine % feature to automatically
adjust chlorine output based upon changes in water temperature. The automatic compensation feature
operates between 55°F and 125°F (13°C - 52°C).
As water temperature falls below 65°F (18°C), the controller will activate a high chlorine percent
lockout, and may not allow chlorine adjustments up to 100%. This feature prevents the controller from
over-driving 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, thus
preventing over-chlorination and premature cell failure.
As the water temperature rises above set point, the controller will adjust at 5% per °F up to 100%, thus
preventing under-chlorination during warmer water temperatures.
5.2 WATER MANIFOLDS ASSEMBLIES - AVAILABLE OPTIONS
CAUTION - Failure to heed the following may result in equipment damage.
The Digital Nano manifold may only use the RC35/22 cell. The Digital Nano+
may use either the RC35/22 or RC28 cell.
The Digital Nano uses the patented automatic-flow bypass manifold assembly (models 94105,
94105M). The Digital Nano should ONLY use the RC35/22 cell.
The Digital Nano+ uses the patented automatic-flow bypass manifold assembly (models 94106,
94106M) with an RC28 cell. The Digital Nano+ may also use an RC35/22 cell but the maximum
chlorine output will be lower. See the Specifications table in section 4.1 on 6.
The CoPilot manifold assembly comes with an automatic-flow bypass, check valve assembly and
ozone injector venturi assembly.