Autopilot Pool Pilot PROA Series User manual

PROA / PROB Manual 9/24/19
PRO WC
PROA & PROB Water Cooled Series
Swimming Pool Purification System
Owner’s Manual: Installation / Operation and Maintenance
This manual covers the installation and operation of the AutoPilot®PRO WC Chlorine
Generators
Important!
Read this manual and product labels before installing or operating this equipment.
This document is Purchaser’s property and is to remain with the equipment owner.
LTP0155

PROA / PROB Manual 9/24/19

PROA / PROB Manual 9/24/19
TABLE OF CONTENTS
1.0 DESCRIPTION 6
1.1 General Information 6
1.2 Principles of Operation 7
1.3 General Specifications and Sizing Guidelines 4
2.0 INSTALLATION 10
2.1 Unpacking 10
2.2 Storage 10
2.3 Safety Considerations 10
2.4 Plan Ahead 11
2.5 Additional Parts Required for Installation 11
2.6 Installation Diagram 12
2.7 Power Supply Installation 13
2.8 Electrolytic Cell Installation 13
2.9 Install Kit Installation 14
2.10 Plumbing the System 15
2.11 Plumbing the Power Supply Cooling Lines 15
2.12 System Wiring 16
2.13 Instructions for Adding a Salt Feed Relay 17
2.14 Electrolytic Cell Wiring 17
2.15 Bonding the System 17
3.0 OPERATION 18
3.1 Preparing the Water 18
3.2 Starting the System 18
3.3 System Operation 19
3.4 Display Information 19
4.0 MAINTENANCE 23
4.1 Acid Wash Operation 24
5.0 WARRANTY INFORMATION 26

PROA / PROB Manual 9/24/19

PROA / PROB Manual Page 5 of 28 9/24/19
If you should need to contact AquaCal AutoPilot, Inc. for questions, service, 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 website 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] Install Date
Address
AquaCal AutoPilot, Inc.
2737 24th Street North
St. Petersburg, Florida 33713
USA
Installer
Factory Direct Customer Assistance
Email to: [email protected]
Visit Us On The Internet @
www.autopilot.com

PROA / PROB Manual Page 6 of 28 9/24/19
SECTION 1
DESCRIPTION
1.1 GENERAL INFORMATION
The AutoPilot®PRO WC Water Cooled Series Saline Chlorination system is the most
electrically efficient, on-site sodium hypochlorite generator offered by AquaCal AutoPilot, Inc.
The system is designed for commercial swimming pool applications and is capable of
producing up to 28 lbs. of equivalent chlorine per day. The system manufactures bleach
continuously from a salt concentration of 3,500 to 5,000 ppm added to the pool or spa. The
AutoPilot® system is designed for commercial service and can be operated 24 hours a day or
controlled by any pool controller. All models have digital displays that show system status, salt
concentration, and temperature.
1.2 PRINCIPLES OF OPERATION
Electrolytic Cell Assembly
The electrolytic cell assembly consists of a clear PVC cell housing containing an electrolytic
cell made from precious metal coated cell plates. Pool water from the pool circulation system
is directed through the cell in an off-line installation. The pool water maintained between 3,500
and 5,000 ppm salt concentration is converted in the electrolytic cell to sodium hypochlorite.
The sodium hypochlorite is then circulated to the pool and combines with organics and further
combines to form salt to be used again by the electrolytic cell. This is called a closed loop
system because the salt is used repeatedly and is only lost through splash-out, backwashing
and rainfall.
Power Supply and Control Box
The power supply provides current to the electrolytic cells to produce the rated amount of
sodium hypochlorite. The power supply uses switched-mode technology, currently the most
electrically efficient method of producing current for an electrolytic cell. The power supply is
equipped with safety features to prevent system operation in the event of a malfunction.
Salt Control
Salt control can be added to the AutoPilot®PRO WC Series Chlorinator. The AutoPilot®PRO
WC Series Chlorinator monitors the salt concentration of the pool water and will only allow the
system to generate chlorine if the salt concentration is above 3,000 ppm. This will protect the
system from low salt conditions.The system uses a non-contacting toroidal sensor to monitor
salt concentrations. The toroidal probe is connected to the power supply. The LCD displays
the salt concentration. The controller is factory programmed to prevent chlorinator operation in
the event of low salt and can be used to automate salt concentrations in the pool with the
addition of a Saturated Salt Feeder, peristaltic pump, and relay box.

PROA / PROB Manual Page 7 of 28 9/24/19
1.3 GENERAL SPECIFICATIONS
Sodium Hypochlorite Production:
Model
Designation
Sodium
Hypochlorite
Production
(lbs/day)
Rated
Power in
DC Amps
Rated
Pressure
Minimum
Water Flow
Rate (gpm)
Inlet
Diameter
(Inches)
Outlet
Diameter
(Inches)
PROA8 8 lbs/day
(3.63 kg) 50 50 psi
(345 kpa)
20 gpm
(4.54 m
3
/h)
1 in
(2.5 cm) 1 in (2.5 cm)
PROA11
11 lbs/day
(4.99 kg)
50
50 psi
(345 kpa)
20 gpm
(4.54 m
3
/h)
1 in
(2.5 cm)
1 in
(2.5 cm)
PROA14 14 lbs/day
(6.35 kg) 50 50 psi
(345 kpa)
20 gpm
(4.54 m
3
/h)
1 in
(2.5 cm) 1 in (2.5 cm)
PROB17 17 lbs/day
(7.71 kg) 100 50 psi
(345 kpa)
20 gpm
(4.54 m
3
/h)
1 in
(2.5 cm) 1 in (2.5 cm)
PROB22 22 lbs/day
(9.98 kg) 100 50 psi
(345 kpa)
20 gpm
(
4.54 m
3
/h)
1-1/2 in
(3.8 cm)
1-1/2 in
(3.8 cm)
PROB28 28 lbs/day
(12.7 kg) 100 50 psi
345 kpa)
20 gpm
(4.54 m
3
/h)
1-1/2 in
(3.8 cm)
1-1/2 in
(3.8 cm)
Electrical Requirements:
The AutoPilot®PRO WC systems require a 120 VAC control signal from a chemical feed
controller or from a standard 15-amp wall outlet. The control connection is rated at 1-amp.
Model
Designation
AC Input Voltage
Phases
Frequency
Amps
Fuse
Size
GFCI Breaker
PROA8
110 to 240
1
50/60 Hz
15/7.5
20A
20A
PROA11
110 to 240
1
50/60 Hz
15/7.5
20A
20A
PROA14
110 to 240
1
50/60 Hz
15/7.5
20A
20A
PROB17
208 to 240
1
50/60 Hz
15
20A
30A
PROB22
208 to 240
1
50/60 Hz
15
20A
30A
PROB28
208 to 240
1
50/60 Hz
15
20A
30A

PROA / PROB Manual Page 8 of 28 9/24/19
Space Requirements
PROA8, 11, 14 & PROB17
PROB22 & PROB28
11
27
6"
Cell
Tube
Cooling Water
Lines
DC Power to
Cell
22”
Cooling Water
Lines
DC Power to
Cell
26”
22”
26” (66 cm)
6”
(15.2 cm)
11”
(28 cm)
15”
(38.6 cm)
Sensors
AC Input
Sensors
AC Input
26” (66 cm)
14”
(35.6 cm)
27”
(68.6 cm)
8”
(20.3 cm)

PROA / PROB Manual Page 9 of 28 9/24/19
0.00
0.035
0.126
0.267
0.456
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0gpm 10gpm 20gpm 30gpm 40gpm
0.00 0.005
0.018
0.037
0.063
0.096
0.134
0.00
0.02
0.04
0.06
0.08
0.10
0.12
0.14
0.16
Sizing Guidelines
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.
Head Loss Data – Cell Only Without Accessory Kit
PROA8, 11, 14 & PROB17, 22 PROB22 & PROB28
Head loss data reported in feet of H
2
O

PROA / PROB Manual Page 10 of 28 9/24/19
SECTION 2
INSTALLATION
2.1 UNPACKING
Units are shipped from the factory. In the event of damages during shipping, it is the
responsibility of the customer to notify the carrier immediately and to file a damage claim.
Open the boxes carefully and examine all material inside. Check against the packing list to be
sure that all items are accounted for and intact.
2.2 STORAGE
When storing units, use the original packaging and store under a shelter to protect the
contents from weather.
2.3 SAFETY IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
When installing, operating, and maintaining this equipment, keep safety considerations
foremost. Use proper tools, protective clothing, and eye protection when working on or
installing the equipment. Follow the instructions in this manual and take any additional safety
measures appropriate. Be extremely careful in the presence of hazardous substances.
The personnel responsible for installation, operation, and maintenance of this equipment must
be fully familiar with the contents of this manual.
Any servicing of this equipment must be done with the unit fully off and disconnected from the
power source and all pressure bled from the liquid lines.
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 - AutoPilot®PRO WC systems are intended
to be installed according to all local and national regulations.
•RISK OF ELECTRICAL SHOCK - Connect the equipment assembly to a
circuit protected by a ground-fault circuit-interrupter.
•RISK OF ELECTRICAL SHOCK - Only a certified technician may install and
service the AutoPilot®PRO WC system.

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•RISK OF ELECTRICAL SHOCK - Modifying the AutoPilot®PRO WC system in
any way may cause bodily injury and will void the warranty.
•RISK OF ELECTRICAL SHOCK - Only replace components with those specified
by the manufacturer.
•RISK OF ELECTRICAL SHOCK - When installing the system, ensure that power
is linked to the main pump power source for the pool to ensure that the
AutoPilot®PRO WC system never operates when the pumps are off.
•RISK OF ELECTRICAL SHOCK - All boxes on the AutoPilot®PRO WC system
contain high voltage components. Never open any box while the power is on.
•RISK OF ELECTRICAL SHOCK – DANGER
oReplace damaged cord immediately
oDo not bury cord
•PERSONAL SAFETY HAZARD – The system has the potential to release high
doses of chorine. Use caution when handling, servicing, or operating the
equipment. Do not energize or operate the system if the cell housing is damaged
or improperly assembled.
•PERSONAL SAFETY HAZARD – Do not allow children to operate the AutoPilot®
PRO WC system.
•CHEMICAL HAZARD - Always follow the instructions on the manufacturer's label
whenever handling or using chemicals.
•Cord Connected at time of manufacture.
2.4 PLAN AHEAD
Almost every pump room encountered is different. It is imperative to have prior knowledge of
the facility in which the unit is to be installed and to evaluate what type of tools, wall anchors,
etc. will be needed to make the installation as problem free as possible.
2.5 ADDITIONAL PARTS REQUIRED FOR INSTALLATION
•Polypropylene tubing, both 1/2 and 3/8 inch
•1 or 1-1/2 inch PVC tubing or pipe
•PVC fittings as needed
•Anchors and mounting hardware

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2.6 INSTALLATION DIAGRAM
Rated
(See Table)

PROA / PROB Manual Page 13 of 28 9/24/19
2.7 POWER SUPPLY INSTALLATION
WARNING: Failure to heed the following may result in injury or death.
•RISK OF ELECTRICAL SHOCK - All electrical connections should be made by a
licensed electrician or certified electrical contractor.
•RISK OF ELECTRICAL SHOCK - Ensure electrical power is disconnected before
wiring the unit. Follow all state / local NEC (CEC if applicable) electrical codes. Use
copper conductors, only.
•RISK OF ELECTRICAL SHOCK - The AutoPilot®PRO WC system must be mounted
a minimum of 5 ft. (1.5 m) from the pool.
CAUTION: Failure to heed the following may result in personal injury or equipment
damage.
•Due to the weight of the Control Center, it is recommended to have another person
assist you when mounting to the wall.
•Never try to support the weight of the power supply or electrolytic cell using only
drywall anchors.
Locate a suitable space on the wall, in the equipment room, that will accommodate the
dimensions of the system. The power supply brackets should be mounted to a solid wall
surface or wall stud. Failure to mount the power supply properly may result in the dislodging of
the unit, which can cause serious injury. Make certain there is a clear area in front of the power
supply so that the front access door can swing open completely. The cell assembly must be
mounted no more than 8’ (2.4 m) away from the power supply to ensure that the cables will
reach the cell.
2.8 ELECTROLYTIC CELL INSTALLATION
WARNING: Failure to heed the following may result in injury or death.
•The mounting location of the electrolytic cell must be at least 5 ft.
(1.5 m) from the pool.
Install the cell mounting bracket to the wall using appropriate hardware. Ensure that the wall
mount is level. Mount the electrolytic cell and tube to the mounting backboard. The cell and
tube should be mounted within 8 ft. (2.4 m) of the power supply. In order to allow for easy
service and maintenance, do not install any other equipment less than 30 in (77 cm) above the
cell tube. The cell anode assembly may need to be removed for service.

PROA / PROB Manual Page 14 of 28 9/24/19
2.9 INSTALL KIT INSTALLATION
Confirm all parts listed in the installation kit are available. Follow the diagram below when
positioning the parts provided in the installation kit.
NOTE: The flow switch must be installed with the arrow facing the bottom of the cell
tube. PROA8, PROA11, PROA14, PROB17 Assembly Diagram
PROB22 & PROB28 Assembly Diagram

PROA / PROB Manual Page 15 of 28 9/24/19
2.10 PLUMBING THE SYSTEM
AutoPilot®PRO WC systems require a minimum of 20 gpm of flow through the electrolytic cell
to achieve the rated production of chlorine. The cell housing is plumbed using a bypass to
achieve the 20 gpm of flow required. The cell return line must be installed after all other
components. The cell housing return line must be installed as the last component in the return
line of the pool, after all other equipment. See the plumbing diagram below.
2.11 PLUMBING THE POWER SUPPLY COOLING LINES
The power supply cooling lines are plumbed from the return line to pump suction. The cooling
lines on the power supply will accommodate 3/8 inch tubing.
NOTE: If a chemical feed controller is being used, the same 3/8 inch tubing can be used for
both the sample cell and power supply cooling lines. Plumb the tubing from the return line into
the controller sample cell, then from the sample cell into one power supply cooling line, and
from the other cooling line to the pump suction.

PROA / PROB Manual Page 16 of 28 9/24/19
2.12 SYSTEM WIRING
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 - The earth terminals and the equipment bonding
wire must be connected. The electrical supply must match the system rated voltage
and current. Ensure that power is linked to the main pump power source for the pool
to ensure that the AutoPilot®PRO WC system never operates when the pool pumps
are off.
•RISK OF ELECTRICAL SHOCK - For ease of service it is recommended that a
manual disconnect box be installed between the electrical service and the system.
Follow the steps below:
1. Connect the electrical supply from the pool equipment room to the terminal block on
the lower left side of the power supply enclosure. Ensure that the electrical service
is protected by a ground fault circuit interrupter and is rated for the model that is
installed. ProA8-14 models can use 110-240Vac. ProB17-28 models use
208/240Vac. See Electrical Requirements in section 1.3 for details.
All PROA and PROB Models
2. Connect the blue control cord to a chemical feed controller or for manual operation,
to a 120 volt AC outlet. When connecting to a chemical feed controller, be sure the
Ground
(Green)
Line 2
(Red)
Line 1
(Black)

PROA / PROB Manual Page 17 of 28 9/24/19
controller is set to continuous feed and not set on proportional control. Proportional
control will reduce the life of power supply components.
3. Connect the four-pin salt sensor connector to the four-pin connector labeled SALT
SENSOR.
4. Connect the two-pin flow switch connector to the two pin terminal labeled FLOW
SWITCH.
5. The terminal labeled FEED SALT is used with the optional Saturated Salt Feeder.
When using the optional Salt Feeder, plug the cable from the Saturated Salt Feeder
Relay Box to the terminal marked FEED SALT.
6. Connect the red connector from the power supply to the red connector on the cell.
CAUTION: Failure to heed the following may result in equipment damage
•Never remove the cables from the top of the cell. Always disconnect the cell
with the red connector.
2.13 INSTRUCTIONS FOR ADDING A SALT FEED RELAY
Mount the salt feed relay box to the wall close enough to the power supply so that the patch
cord will connect to the FEED SALT connector on the power supply. Plug the relay box into a
120 VAC outlet. Plug the peristaltic pump used for feeding salt into the output plug on the
relay box.
2.14 ELECTROLYTIC CELL WIRING
Connect the red connector from the power supply to the red connector at the cell.
NOTE: Never remove the cables from the top of the cell. Always disconnect the cell
with the red connector.
2.15 BONDING THE SYSTEM
All AutoPilot®PRO WC systems include cell-bonding assemblies. These assemblies are
included in the install kit. The bonding assemblies must be connected with a minimum #8 AWG
bonding wire. Connect the bonding wire from the top cell grounding assembly to the bottom
cell grounding assembly and then from the bottom cell grounding assembly to the bonding lug
located on the outside of the power supply. The bonding lugs on the power supply are clearly
marked with a decal that reads “Bonding Lugs”. Connect the second bonding lug on the power
supply to the bonding grid at the facility.

PROA / PROB Manual Page 18 of 28 9/24/19
SECTION 3
OPERATION
3.1 POOL WATER PREPARATION
AutoPilot®PRO WC saline chlorination systems operate by electrolyzing sodium chloride (salt)
that has been added to the pool into sodium hypochlorite (liquid chlorine). In order for the
AutoPilot®PRO WC system to operate, salt must be added directly to the pool at least 24
hours before the system is started. On existing pools, check salt levels before adding
additional salt.
Forty (40) pounds of salt must be added for every 1,000 gallons (3,785 liters) of pool water to
reach 5,000 ppm (mg/L) (i.e.: a 50,000 gal (189,271 liters) pool will require 2,000 lbs. (907 kg)
of salt or fifty x 40 lb. bags to reach 5,000 ppm (mg/L)). Once the salt has been added, brush
the surface of the pool continuously until the salt has dissolved. Never leave large amounts of
salt on the surface of the pool.
Use only pure NaCl. Do not use salt with additives. Contact your dealer or AquaCal AutoPilot,
Inc. for a list of approved salt.
Your pool water should be balanced in the following range before turning your AutoPilot®PRO
WC system on.
Chlorine: 2 – 5 ppm
Total Chlorine: No more than 0.5 ppm above free chlorine
Ph: 7.2 – 7.6
Alkalinity: 80 – 120
Hardness: 180 – 280 ppm
Salt: 3,500 – 5,000 ppm
Cyanuric acid: 20 – 50 ppm (Outdoor Pools only)
Phosphates: Less than 100 ppm
Note: Sulfuric acid and dry acid (sodium bisulfate) are not recommended for pH
adjustment. Under some conditions the electrolytic cell can be damaged.
Use standard test kits to check water chemistry, and use either a conductivity tester or salt test
strip to check saline levels. Note: most conductivity testers require frequent calibration to
ensure accurate readings, failure to calibrate the equipment will result in inaccurate readings.
3.2 STARTING THE SYSTEM
Follow the steps below:
1. Confirm that the salt concentration is between 3,500 – 5,000 PPM.
2. Confirm that the valves to and from the cell are in the open position and water is flowing
through the cell tube.
3. Make sure that water is flowing through the cooling water lines to the water-cooled heat
sink.

PROA / PROB Manual Page 19 of 28 9/24/19
4. Ensure that the blue cord labeled ORP or Controller is plugged either into controller or
directly into a wall outlet.
5. Be sure the disconnect box is in the on position.
6. Confirm that the output control knob located on the front of the power supply is turned
fully clockwise.
7. Depending on the model, the system will begin producing chlorine in 10 to 60 seconds.
If the AutoPilot® PRO WC system is linked to a chemical feed controller, adjust the output to
the system maximum, which will allow for full production every time the controller calls for it. If
the system is being operated manually, adjust the system to find the point at which chlorine
levels are maintained to the desired level. This may take several days of monitoring.
AutoPilot® PRO WC systems connected to a chemical feed controller will only operate when
the controller is in feed mode. Make sure that the chemical feed controller is not set in
proportional mode or system damage may occur.
3.3 SYSTEM OPERATION
AutoPilot®PRO WC systems operate when both the main power supply and blue control cord
have power applied to them. The AutoPilot® PRO WC system will continue to operate for as
long as power is applied from those two sources.
The system has an output range of 5-100% of the rated chlorine production for the model
installed and can be adjusted by turning the black knob on the side of power supply box in a
clockwise or anti-clockwise direction.
3.4 DISPLAY INFORMATION
During normal operation the display will have the following information available:
This screen is displayed when the system is waiting for a signal on the blue cord from an
external source such as a chemical feed controller. The system will not generate chlorine until
this signal is received.

PROA / PROB Manual Page 20 of 28 9/24/19
The screen below is displayed when the system detects no flow through the electrolytic cell
housing. This condition will stop the system from generating chorine. Once flow is restored,
the system will start automatically, and this screen will no longer be active.
This screen is displayed if a low salt condition is present. Salt concentration below 3,000 ppm
will stop the system output and display this screen. When the salt concentration is raised
above 3,000 ppm, normal system operation will resume.
This screen will be displayed if water temperature drops below 59º F. The system will continue
to generate chlorine. Prolonged operation at high system outputs and temperatures below
59º F is not recommended. Adjusting the system output to 50% or less will eliminate this
screen.