Autopilot Pool Pilot Professional PPP-2 Quick start guide

AutoPilot®
Owner's / Installation Manual
Pool Pilot®Professional
INSTALLER: THIS DOCUMENT IS PURCHASER’S PROPERTY AND IS TO REMAIN WITH THE EQUIPMENT OWNER
LTP0155 REV 5
Important!
This manual covers the installation and operation of the Pool Pilot®Professional Salt Chlorine Generators.
Read this manual and product labels before installing or operating this equipment.

Table of Contents
Section 1 - Safety Information
1.1 Important Safety Instructions iv
Section 2 - General Information
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2.1 Contacting AquaCal AutoPilot, Inc.
2.2 Pool Pilot® Professional Model Options
2.3 Main Components 2
2.3.a Control Center 2
2.4 Cells and Manifold Assembly 3
Section 3 - Owner Quick Start & Run
3.1 How Your Chlorinator Works 4
3.2 Water Balance and Chemistry Recommendations 4
3.3 Owner / Operator Control Buttons, Check System Fault and Audible Alarm 5
3.3.a UP and DOWN Arrows 5
3.3.b MENU/ENTER Button 5
3.3.c On / Off Power Circuit Breaker 5
3.3.d TEST Button (Diagnostic Menu) 6
3.3.e WARNING Light and Audible Alarm 6
3.4 Normal Display Modes 6
Section 4 - Specifications and Approvals
4.1 Specifications 7
4.2 Manifold Pressure Drop vs Flow 7
Section 5 - Features
5.1 Patented Temperature Compensation 8
5.2 Water Manifold Assemblies - Available Options 8
5.2.a Automatic - Flow Bypass Manifold Assembly 8
5.2.b Cell 9
Section 6 - Maintenance
6.1 Accessing the Power Module 10
6.2 Removing / Inspecting / Cleaning Tri-sensor 11
6.2.a Tri-sensor Assembly Overview 11
6.2.b Inspect Tri-sensor 11
6.2.c Cleaning Tri-sensor / Salt Sensor 12
6.2.d Test Tri-sensor Flow Switch 12
6.3 Servicing the Cell 13
6.3.a Removal 13
6.3.b Visual Inspection 13
6.3.c Manual Cleaning 14
6.3.d Installing 14
6.4 Winterizing 14
6.5 Spring Start Up 15
Section 7 - Programming
7.1 Control Panel 15
7.1.a Button Overview 15
7.1.b On / Off Power Circuit Breaker 15
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7.1.c Up or Down ( △/▽) Buttons 15
7.1.d MENU/ENTER Button 16
7.1.e TEST Button (Diagnostic Menu) 16
7.1.f WARNING Light and Audible Alarm 16
7.1.g Cell Indicator Lights 17
7.1.h Display Overview 17
7.2 Basic Operational Programming 17
7.2.a Adjusting the Purifier Output % 17
7.2.b Boost 17
7.2.c Purifier Mode 18
7.2.d Purifier % Adjustment Procedure 18
7.3 Review of Main Menu Programming 19
7.3.a Enable / Disable Audible Alarm 19
7.3.b Boost 19
7.3.c Set Reverse Time 20
7.3.d Force Reverse 20
7.3.e Replace a Cell 20
7.3.f Set Cell Power 20
7.3.g English/Metric (units) 20
7.3.h Set Temperature Unit 20
7.4 Review of Installer Menu Programming 21
7.4.a Calibrate Temperature 21
7.4.b Calibrate Salt 21
7.4.c Set Pool Volume 21
Section 8 - Installation
8.1 Basic System Overview 22
8.2 Planning the Installation 23
8.3 Installation Steps 23
8.4 Mounting the Control Center 23
8.5 Plumbing the System 24
8.5.a Plumbing the Manifold Assembly 24
8.5.b Plumbing for Convection Cell Applications 24
8.5.c Flow Rates 20 – 70 gpm (76 – 265 L/min) 25
8.6 Preparing the Pool Water 25
8.6.a Calculating Pool Volume 25
8.6.b Steps to Prepare Water 26
8.6.c Adding Salt 26
8.7 Programming at Installation 27
8.8 Electrical Connections 28
8.8.a AC Input Voltage 28
8.8.b Bonding 28
8.9 High Voltage Wiring 28
8.10 Low Voltage Wiring 29
8.10.a Tri-sensor Cord 29
8.10.b Cell Cord 29
8.11 ORP Connection 30
ii

Section 9 - Troubleshooting
9.1 Troubleshooting 31
Section 10 - Reference
10.1 Basic Water Chemistry 37
10.1.a Chlorine 38
10.1.b pH 38
10.1.c Total Alkalinity 38
10.1.d Calcium Hardness 38
10.1.e Cyanuric Acid 39
10.2 Using the Saturation Index 39
10.3 Salt Addition Chart 40
Section 11 - Approvals
11.1 Agency Approvals 41
11.2 FCC Compliance 41
iii

SECTION 1 - SAFETY INFORMATION
1.1 Important Safety Instructions
When installing and using this electrical equipment, basic safety precautions should always be
followed, including the following:
READ AND FOLLOW ALL INSTRUCTIONS.
lA green colored terminal or terminal marked G, GR, Ground, Grounding, or the symbol is located inside
the power center terminal box or compartment. To reduce the risk of electric shock, this terminal must be
connected to the grounding means provided in the electric service panel with a continuous copper wire
equivalent in size to the circuit conductors supplying this equipment.
lFollow all state, local, and National Electrical Code(s) (provincial and Canadian Electrical Code(s) if
applicable) unless local guidelines supersede.
lFor 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 AutoPilot®chlorinator must be performed by
qualified service personnel.
lShould you suspect your chlorine generator is not performing properly, refer to the Troubleshooting section in
this manual to determine if service is required. See "Troubleshooting" on page 31.
lWarranties will be voided if the chlorinator has been improperly installed. Failure to properly operate, maintain
or repair the AutoPilot®chlorinator will void the factory warranty.
SAFETY SIGNALS
Throughout this manual safety signals are placed where particular attention is
required.
WARNING - Failure to heed the following may result in permanent injury or
death.
CAUTION - Failure to heed the following may result in equipment damage.
WARNING - Failure to heed the following may result in permanent injury or death.
lRISK 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)
unless local guidelines supersede. Use copper conductors only.
lRISK OF ELECTRICAL SHOCK - To reduce the risk of electrical shock, replace damaged cord
immediately.
lRISK OF ELECTRICAL SHOCK - The AutoPilot®chlorinator 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.
lRISK OF ELECTRICAL SHOCK - A bonding lug has been provided on the outside of the power supply. 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 Pool Pilot® power supply and all other electrical equipment and
exposed metal within 5 ft (1.5 m) of the unit. All field-installed metal components (such as rails, ladders,
drains, etc.) within 10 ft of the pool, spa, or hot tub, must be bonded to the equipment grounding bus using
copper conductors not smaller than No. 8 AWG (8.4 mm2) (No. 6 AWG in Canada). Install control center at
least 10' (3 m) from the inside wall of the pool or spa using non-metallic plumbing.
lRISK 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).
lRISK 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.

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RISK OF ELECTRICAL SHOCK - The Pool Pilot® unit 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 AutoPilot® chlorinator 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.
CHEMICAL HAZARD – CHLORINE GAS BUILDUP CAN OCCUR WITH IMPROPER WIRING: To reduce
the risk of personal injury the Pool Pilot® power center must be installed on and wired to the load side of the
time clock, electronically controlled switch, or relay load side, so that it will receive power only when the pool
pump is on. Dangerous chlorine gas buildup can occur. The Pool Pilot® should never be energized when the
pool pump is OFF and there is no water flow.
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.
lThe Pool Pilot®must be installed and operated as specified. Failure to do so will void the equipment
warranty.
lTo permit proper air circulation, the Pool Pilot®power supply must be mounted at least 1ft (30 cm) above
ground level or any other air flow obstruction.
lSpecial measures are required in the event of freezing conditions. Your chlorinator may be damaged if
measures are not taken in advance of freezing conditions. Equipment damage due to freezing conditions is
NOT covered under the equipment warranty.
lDo 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.
lFor all newly constructed or resurfaced plaster pools: Do not operate the Pool Pilot®with newly poured or
resurfaced pool plaster. Before adding salt and operating the chlorinator, wait 30 days after construction is
completed to allow proper curing of the surface material. Follow the pool surface manufacturer’s guidelines
for your specific pool. FOR NEW VINYL LINER POOLS, contact the manufacturer for recommended
instructions before adding salt and operating the Pool Pilot®.
lSalt is an inherently corrosive material. While the recommended level of salt for your AutoPilot®product
should not damage your equipment, excessively high chlorine levels can cause corrosion damage to pool
fixtures and equipment. Consult your pool professional for equipment selection, proper use and
maintenance of these products.
lFor maximum cell life, maintain water in a balanced condition according to the Saturation Index. Water
maintained in a scaling condition will shorten cell life and may render the Pool Pilot®inoperative. Damage,
and / or service calls, caused by improper water balance will NOT be covered under the equipment
warranty.

lScraping or scratching the titanium blade’s edge or surface will damage the blade catalyst coating and
cause premature failure of the cell. Never use any sharp or metallic objects to remove scale. The warranty
will be voided.
lReduced 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.
SAVE THESE INSTRUCTIONS

Page - 1
SECTION 2 - GENERAL INFORMATION
2.1 Contacting AquaCal AutoPilot, Inc.
If you need to call AquaCal AutoPilot, Inc. for questions, service, or parts, please have your
model and serial numbers available. Also have the name of your installer and date of your
equipment’s installation. Please refer to our website for the latest manual revisions, additional
information and helpful service advice.
Website www.autopilot.com
Phone [phone]
Fax [phone]
Address
AquaCal AutoPilot, Inc.
2737 24th Street North
St. Petersburg, FL 33713, USA
Installation Co.: Installation Date: Model #:
Power Supply (A) Serial # Power Supply (B) Serial # Power Supply (C) Serial #
Cell Serial #: A1 Cell Serial #: B1 Cell Serial #: C1
Cell Serial #: A2 Cell Serial #: B2 Cell Serial #: C2
Cell Serial #: A3 Cell Serial #: B3 Cell Serial #: C3
Cell Serial #: A4 Cell Serial #: B4 Cell Serial #: C4
Cell Serial #: A5 Cell Serial #: B5 Cell Serial #: C5
Cell Serial #: A6 Cell Serial #: B6 Cell Serial #: C6
2.2 Pool Pilot®Professional Model Options
To reduce the risk of personal injury, the Pool Pilot®Professional control center must be installed
on an automation filter pump relay wired to the load side of the time clock, electronically
controlled switch, or relay load side so that it will receive power only when the pool pump is on.
Otherwise, dangerous chlorine gas buildup can occur. The chlorinator should never be
energized when the pool pump is off and water is not flowing through the unit.
Chlorinator sizing must comply with all state and local codes. Please contact your local health
department for specific requirements or contact your local AquaCal AutoPilot, Inc. representative
for assistance. For more information on sizing, see our Commercial Sizing Calculator at
www.autopilot.com.

Page - 2
The chlorine output for each of the Pool Pilot®Professional chlorinator models, which is based
on a 24 hour chlorinator / pump run time and a salt concentration of 3,500 ppm (mg/L), is listed
here.
Model (w / Mfld Assy & PPC5 Cell) Chlorine Output lbs. (kg) Per 24 Hours
Pool Pilot®Professional PPP-2 5.24 lbs. (2.05 kg)
Pool Pilot®Professional PPP-3 7.86 lbs. (3.08 kg)
Pool Pilot®Professional PPP-4 10.48 lbs. (4.11 kg)
Pool Pilot®Professional PPP-5 13.10 lbs. (5.14 kg)
Pool Pilot®Professional PPP-6 15.72 lbs. (6.16 kg)
Model (w / PPC5 Convection Cell) Chlorine Output lbs. (kg) Per 24 Hours
Pool Pilot®Professional PPP-2-CONV 4.53 lbs. (2.05 kg)
Pool Pilot®Professional PPP-3-CONV 6.79 lbs. (3.08 kg)
Pool Pilot®Professional PPP-4-CONV 9.06 lbs. (4.11 kg)
Pool Pilot®Professional PPP-5-CONV 11.32 lbs. (5.14 kg)
Pool Pilot®Professional PPP-6-CONV 13.59 lbs. (6.16 kg)
2.3 Main Components
2.3.a Control Center
The Pool Pilot®Professional Control Center converts incoming AC power to low voltage DC
power, which energizes the cells. The power modules that energize the cells are mounted
vertically inside the control center.
Pool Pilot®Professional
Figure 1

Page - 3
2.4 Cells and Manifold Assembly
The cell assembly consists of a clear PVC housing containing titanium metal coated cell blades.
The electrolytic cell receives the low voltage DC power from the control center and initiates the
electrolytic process. This process converts ordinary table salt (Sodium Chloride) to 100% pure
Sodium Hypochlorite which in turn purifies your pool. Water from the pool circulation system is
directed through the cell. As the dissolved salt cycles through the cells, the electrolytic process
splits the sodium from the chloride and generates chlorine. After the chlorine reacts with the
organics and debris in the water, the chlorine recombines with the sodium and the process is
repeated.
The manifold assembly model #941-215AC is shown below and consists of two commercial
PPC5 cells. The Pool Pilot®Professional can accomodate up to a six (6) cell manifold assembly.
Please note that one power module per cell is required. See "Water Manifold Assemblies -
Available Options" on page 8.
The cell is installed with unions on each end to allow quick and easy removal.
Pool Pilot®Professional Cell
Figure 2
941-215AC Manifold Assy.
Figure 3

Page - 4
SECTION 3 - OWNER QUICK START & RUN
3.1 How Your Chlorinator Works
The Pool Pilot®Professional is designed to handle the purification needs of commercial
swimming pools and spas. The amount of chlorine required for proper sanitization will vary
based on the pool size and 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 that is
normally maintained between 3,000 and 4,500 ppm (mg/L). The AutoPilot®unit uses the salt to
generate chlorine, which your pool / spa requires to remain sanitized. The chlorine reverts back
to salt after treating the water. Since the chlorine generation process does not reduce pool water
salinity, there is minimal loss during a swimming season. Salt can be lost due to filter back
washing, rain water overflow, leaks, or bather splashing / carry out, but not through evaporation.
The water circulation pump must be operating for your Pool Pilot®to produce chlorine, so run
time is one of several key factors to maintaining proper sanitizer levels. Refer to your local health
codes and / or your pool service professional for required pool filtration turnover rates and
suggested pump run times.
3.2 Water Balance and Chemistry Recommendations
Water balance is the relationship between different chemical measurements in your pool water.
A pool that is balanced has proper levels of pH, Total Alkalinity and Calcium Hardness.
Balanced water can also be defined as water that is not corrosive or scaling. Water that is not
balanced can damage equipment and pool surfaces. See "Basic Water Chemistry" on page 37.
Proper water chemistry levels are essential to maintain safe and consistent swimming pool
operation. Sanitizers are used to destroy harmful or otherwise objectionable organisms.
Stabilizer or Cyanuric Acid (CYA) is used to prevent unnecessary loss of chlorine to sunlight.
Salt is used by the Pool Pilot®to generate chlorine sanitizer.
The following recommended water chemistry parameters are for residential pool / spa
applications only. Follow local regulatory guidelines for any commercial pool / spa applications.
POOL SPA
Parameter Units Min Ideal Max Min Ideal Max
Free Chlorine ppm (mg/L) 1.0 2.0 - 4.0 5.0 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 7.4 -7.6 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) 2,000 3,500 - 4,500 ** 2,000 3,500 - 4,500 **
Cyanuric Acid (stabilizer) ppm (mg/L) 0 30 - 50 *** 0 30 - 50 ***
** Typically 6,000 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 80 ppm (mg/L).
See "Basic Water Chemistry" and "Using the Saturation Index" sections later in this manual for further
information concerning pool / spa water chemistry maintenance requirements. Refer to the
"Troubleshooting" section for assistance with resolving low or high chlorine issues.

Page - 5
3.3 Owner / Operator Control Buttons, Check System Fault and Audible Alarm
This section assumes the installer has already programmed the system for specific site
parameters, established proper water balance and pretreated water to 1-3 ppm (mg/L) chlorine.
Should Celsius vs. Fahrenheit, language preference, or other owner options require
modification, refer to the "Programming" section of this manual. See "Review of Main Menu
Programming" on page 19.
The following is a brief explanation of owner or operator control buttons.
3.3.a UP and DOWN Arrows
Use the UP and DOWN ( △or▽) arrows to control the purifier output level. This is also used in
conjunction with the MENU/ENTER button to step through the menu selections.
After output level is adjusted, press the MENU/ENTER 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 Pool Pilot®
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 water temperature fluctuates. This temperature compensation feature will adjust
output depending on water temperature. See "Patented Temperature Compensation" on page 8.
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.
3.3.b MENU/ENTER Button
The MENU/ENTER 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 the
"Programming" section for additional information related to the menu options. See "Review of
Main Menu Programming" on page 19.
Press to enter the Service Menu. Use the UP and DOWN ( △or▽) buttons to scroll through the
menu and the MENU/ENTER button to select the function. The list of functions are as follows:
lAlarm On / Off
lBoost
lSet Reverse Time
lReplace a Cell
lSet Cell Power
lEnglish / Metric
lTemperature Unit
lInstaller Menu
lExit Menu Mode
3.3.c On / Off Power Circuit Breaker
This main switch activates and deactivates the power going to the control center. The circuit
breaker may trip when power surges occur. To reset, turn completely off and then back on.

Page - 6
3.3.d TEST Button (Diagnostic Menu)
Follow the instructions listed below to get accurate results.
1. If the unit is in the Boost mode, take the unit out of Boost mode.
2. Power the system off at the power breaker switch. Wait three (3) minutes for unit to completely
discharge any remaining electricity to the cells.
3. Power on the unit and put back into the Boost mode or increase the Purifier to 100% output. Let the
unit run for three (3) minutes.
4. Press TEST to initiate the test sequence. Record diagnostics information, including cell Amps and
Volts, for each cell.
5. Deactivate Boost mode and return purifier output % to the original setting.
The unit will automatically sequence through various displays and then return to normal
operation. You can also press the △or▽arrow to scroll forwards and backwards. Press the
MENU/ENTER button again to skip the remaining displays and exit back to normal operation.
lSoftware Ver. X.x – Current version of the control board display software
lPower Setting – High/Low (Factory default is Low)
lAlarm – Enabled/Disabled (Factory default is Enabled)
lReverse – # hrs. –The reverse rate programmed in the Installation Menu (Factory default is 4 hrs)
lSalt – ### ppm (#.# g/L)” – The Tri-sensor salt reading. The optimum salt level is 3,500 ppm (mg/L),
4,500 ppm (mg/L) for efficient chlorine production
lAdd ## Salt (lbs.) – (Amount needed to maintain 3,000 ppm (mg/L)
lWater Temperature ##° F (##° C) – The temperature of the water flowing through the Tri-sensor
lPool Volume - gallons (litres) –The pool volume programmed in the Installation Menu
lCell x - ##V – Cell number and volts to the cell measured for each cell connected
l##### Amp-Hrs, and then
lSW Ver: - #.##
lRS232 Enabled/Disabled - Factory use only and set to Enabled
lATC Enabled/Disabled - Automatic Temperature Compensation feature. See "Patented Temperature
Compensation" on page 8. Enabled is the factory default and cannot be changed
3.3.e WARNING Light and Audible Alarm
The WARNING light will flash to warn the unit may need attention. A warning message will also
be displayed. If enabled, an audible alarm may also be heard when the system light is flashing.
Unless deemed a normal condition per below, refer to the "Troubleshooting" section.
lFlashes red when pump is off / water flow is insufficient
lFlashes when salt is low (check salt and add as needed)
lFlashes when water temperature exceeds 125 °F (51 °C), or drops below 10 °F (-12 °C)
3.4 Normal Display Modes
Purifier Mode
Purifier (Chlorine Output %) level..................... Shown in 1% increments
Water Temperature
Displayed in Fahrenheit or Celsius
Salt Level
Pool / spa water salt concentration level..................... Shown in ppm (mg/L)
WARNING! Light
Off when operating normally. The Warning light will blink red when an error has occurred, such
as for insufficient flow and low salt levels. See "Troubleshooting" on page 31.

Page - 7
SECTION 4 - SPECIFICATIONS AND APPROVALS
4.1 Specifications
For more information on sizing, see our Commercial Sizing Calculator on our website at
https://apservicecenter.com/sizing
Model Designation PPP-2 PPP-3 PPP-4 PPP-5 PPP-6
Max. Chlorine Output w / PPC5 Cell
(lbs/day)
5.24 lbs/day
(2.38 kg)
7.86 lbs/day
(3.57 kg)
10.48 lbs/day
(4.75 kg)
13.1 lbs/day
(5.94 kg)
15.72 lbs/day
(7.13 kg)
Max. Chlorine Output w / Convection
Cell (no manifold) (lbs/day)
4.53 lbs/day
(2.05 kg)
6.79 lbs/day
(3.08 kg)
9.06 lbs/day
(4.11 kg)
11.32 lbs/day
(5.14 kg)
13.59 lbs/day
(6.16 kg)
Rated Power in AC Amps 230 V/4.4 A 230 V/6.6 A 230 V/8.8 A 230 V/11.0 A 230 V/13.2 A
Minimum Water Flow Rate (gpm) 30 – 50 gpm (6.8 – 11.3 m³/hr)
Maximum Water Flow Rate (gpm) 70 gpm (22.6 m³/hr)
ORP Input (Dry contact) 10 mA typical (ORP controllers with 110 V output and multiple power supplies will
require relay kit part #110-ORP: ORP Relay Box (110V US plug)
Weight (Power Supply) 83 lbs. 91 lbs. 99 lbs. 107 lbs. 115 lbs.
Weight (Manifold) 10 lbs. 20 lbs. 20 lbs. 30 lbs. 30 lbs.
Convection Cells 10 lbs. 15 lbs. 20 lbs. 25 lbs. 30 lbs.
4.2 Manifold Pressure Drop vs Flow
The following chart shows pressure drop versus flow for Pool Pilot®Professional manifolds.
Pool Pilot®Professional Manifold Pressure Drop vs. Flow
Figure 4

Page - 8
SECTION 5 - FEATURES
lPatented temperature compensation for chlorine output control
lProgrammable microprocessor control
lDigitally controlled power to the cell
lTri-sensor circuitry to monitor water flow, water temperature, and salt level
lCalculates and displays amount of salt needed to reach the recommended 3,000 ppm (mg/L) salt
concentration level
lOn board diagnostic and test programs
lInterface for connection to an external ORP controller
5.1 Patented Temperature Compensation
WARNING - Failure to heed the following may result in permanent injury or death.
l Pool or Spa water temperature should not exceed 104 °F (40 °C).
The water temperature sensor works in conjunction with the purifier % feature to automatically
adjust chlorine output based upon changes in water temperature. This feature operates between
55 °F and 125 °F (13 °C - 52 °C).
As water temperature falls below 65 °F (18 °C), the controller will reduce the maximum output %
that can be selected. This feature prevents the controller from generating excessive chlorine in
cold water where it is not needed and prevents premature cell failure.
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.
This feature is disabled when connected to an ORP controller and purifier output is set to 0%.
5.2 Water Manifold Assemblies - Available Options
5.2.a Automatic - Flow Bypass Manifold Assembly
The AutoPilot®manifold assembly is available with two (2), three (3), four (4), five (5), or six (6)
cells, including the Tri-sensor. Each cell must have a corresponding power module.
Example: If you order a PPP- 4 unit, there will be four (4) power modules in the control center and
a 941- 415AC manifold assembly with four (4) cells and one (1) Tri-sensor assembly.
The manifold is connected into the plumbing after all other equipment. Water from the pool / spa
is moved though the manifold by the circulation pump. Ensure there is enough flow to the
manifold base (min. 30 – 50 gpm / max. 70 gpm (min. 6.8 – 11.3 m³/hr / max. 22.6 m³/hr)).
The manifold uses four key components:
lThe Tri-sensor provides data (from electronic sensors) to the Pool Pilot®for monitoring water flow, water
temperature, and salt concentration level. The Pool Pilot®uses this data to determine if conditions are
suitable for the cell to operate; the signal read from the temperature sensor allows the automatic
temperature compensation feature to function.
lThe Cell (PPCx) receives power from the Pool Pilot®and converts the salt contained in the water to
chlorine.
lThe Strainer Screen prevents debris in the water from entering the Tri-sensor or cell and requires
periodic inspection and cleaning.
lThe Bypass Check Valve allows the water flow rate to be slowed and optimized through the cell while
permitting the pump to continue to circulate water to-and-from the pool / spa at full flow rates. The
reduced water flow through the cell results in a more efficient "Super-Chlorination” effect, resulting in
improved overall sanitization.

Page - 9
Pool Pilot®Professional Manifold Assembly Options
Figure 5
5.2.b Cell
The cell is installed with unions on each end of the cell to allow for quick and easy removal.
To remove and inspect the cell, loosen the unions and remove from the plumbing assembly.
Figure 6

Page - 10
SECTION 6 - MAINTENANCE
6.1 Accessing the Power Module
WARNING - Failure to heed the following may result in permanent injury or death.
lELECTRICAL SHOCK HAZARD – Turn off the electrical power at the main circuit breaker to the unit
before servicing.
Power Module
Figure 7
The power modules, which send power to the cell, are located
inside the control center and mounted vertically as seen in the
diagram below. The control center is capable of housing up to six
(6) power modules. Follow the steps below to replace the fuse or
power module as needed.
1. The front cover plate is secured by four (4) screws. Loosen all four
(4) of the screws and remove the cover plate.
2. The power module angle flange is held by an “L” bracket. The “L”
bracket has two screws on each end and each power module angle
flange has a screw. Take out the screws on the end of the “L” bracket
and on each power module angle flange.
3. Remove the “L” bracket from the power center cabinet.
4. Each module uses two (2) hold down screws to attach the power board angle flange to the back plate.
Locations are shown below. Using a long shaft Phillips head screwdriver, loosen both screws but do
not remove.
5. Remove the top wire assembly that connects to the main control panel and then the front cell cord wire
connections.
6. Slide the power module up until the flange keyholes match the down screws and pull out until you can
reach and disconnect the rear power connectors, then remove the power module.
Professional Power Supply
Figure 8
Power Module Location
Figure 9
For a complete list of parts, visit www.autopilot.com.

Page - 11
6.2 Removing / Inspecting / Cleaning Tri-sensor
6.2.a Tri-sensor Assembly Overview
The Tri-sensor Assembly is used to measure water flow, salt level, and water temperature.
Note: The use of high strength magnet devices in the close proximity of the Tri-sensor can cause
the flow switch to function incorrectly.
Figure 10
lWhen the water flow reaches a minimum flow rate of 20
gpm (76 L/min), the flow paddle magnet closes a micro-
switch monitored by the Pool Pilot®.
lThe Pool Pilot®uses dedicated salt sensor blades to
measure the level of salt in the water.
lThe Pool Pilot®uses the temperature sensor to determine
water temperature. This measurement is required for the
Patented Automatic Temperature Compensation feature
to automatically adjust chlorine output as water
temperature varies. Less chlorine is needed in cold water,
so chlorine output is automatically reduced as water
temperature drops (avoiding excess chlorine production).
Conversely, more chlorine is needed in warmer water, and
production is automatically adjusted higher as water temperature increases.
lPlease note - The Tri-sensor normally does not require maintenance or cleaning.
6.2.b Inspect Tri-sensor
1. Disconnect the Tri-sensor cable from the power center.
2. Remove the two (2) screws retaining the Tri-sensor in the Tee joint of the manifold.
lNote the orientation of the Direction of Flow Tab. The Tri-sensor must be installed in the same
orientation when it is reinstalled or replaced.
3. The Tri-sensor can now be pulled out of the Tee.
CAUTION - Failure to heed the following may result in equipment damage.
lThe Tri-sensor should not be removed from manifold at an angle or the flow paddle and / or flow post
may be damaged.
lFirmly grip the Tri-sensor assembly (this is typically done with a large pair of channel lock pliers).
lTwist the Tri-sensor back-and-forth while simultaneously pulling the Tri-sensor straight out of the Tee
joint.
4. Check the Tri-sensor assembly for any damage to the plastic housing and replace if needed.
5. Inspect the following on the flow switch:
lVerify the thin metallic paddle is straight and free from erosion.
lVerify the plastic post is straight and free of cracks. (Do not twist or bend the paddle or the
plastic post.)
6. Inspect the two salt sensor blades. The blades should not have any mineral deposits (scale) or other
debris on them.
l Do not use any metallic objects to scrape the blade surfaces or you will remove or damage the
blade sensor coating.

Page - 12
6.2.c Cleaning Tri-sensor / Salt Sensor
If required, you can remove a calcium scale buildup by creating a solution of water and muriatic
acid as follows. Do not use any metallic objects to scrape the blade surfaces or you will remove
or damage the blade sensor coating.
WARNING - Failure to heed the following may result in permanent injury or death.
lCHEMICAL HAZARD - To avoid damaging splashes always add acid to water, never water to acid.
lWear appropriate personal safety protection, including safety glasses , when using pool chemicals.
1. Mix the solution in a small container tall enough to cover the sensor blades. DO NOT add water to acid;
always add acid to water in container.
2. Mix one (1) part muriatic acid into four (4) parts water.
3. Immerse the salt sensor blades in the solution for up to fifteen (15) minutes. An effervescing action
indicates the calcium is being dissolved from the blades.
4. Rinse with fresh water and re-inspect. Repeat the acid treatment as necessary until all scale has been
eliminated.
6.2.d Test Tri-sensor Flow Switch
WARNING - Failure to heed the following may result in permanent injury or death.
lDo NOT operate system with a faulty water flow switch.
The Flow Switch is a critical equipment protection device to prevent damage to the cell or
system. When water flow has stopped, power to the cell is automatically turned OFF. It is
important to verify the proper operation of the Tri-sensor’s water flow switch protection device.
The following procedure can be used to verify the proper operation of the flow switch or to flush
debris from the bypass valve.
Figure 11
1. Turn off the circulation pump.
2. Slightly loosen the union nut just below the cell on the side of the
manifold that does not contain the filter screen. (A strap wrench
may be required.)
3. Completely loosen the manifold union nut that contains the filter
screen and pivot the manifold to gain access to the filter screen.
4. Remove the screen. Clean the screen if dirty.
5. If the screen was dirty, then the system may need to be purged to
remove excess debris. Leave the manifold off and run the pump for
a few seconds until clear.
6. Wrap the strainer screen securely with a small piece of plastic wrap (saran wrap, food wrap or zip lock
bag) as indicated in the diagram and place it back in the union.
7. Tighten the two unions that were loosened. Do not over tighten.
8. Turn on the pump and the Pool Pilot®. The plastic will stop water flow to the flow switch, which is part of
the Tri-sensor that is located right above the strainer screen. All water will be forced through the
bypass valve. (This action will normally flush out any small bits of debris trapped in the bypass valve.)
9. The Pool Pilot®should detect a low water flow at the Tri-sensor and activate the red WARNING light.
The unit will also display the message “!!! Warning !!! No flow”.
10. If the unit did not display this warning, check the Tri-sensor cable connections and inspect and clean
the Tri-sensor as outlined in the “Inspect Tri-sensor” and “Cleaning Tri-sensor” sections. If the warning
message still does not appear, then turn the Pool Pilot®off and contact the factory or your local dealer
for assistance.
11. Turn the pump off.
12. Loosen the unions.
13. Remove the plastic wrap and replace the strainer screen. Tighten the unions.
14. Resume normal operation.