BIO-LAB CANADA Pool Pilot Digital 60 User manual

Pool Pilot™
Digital 60
by Bio-Lab Canada Inc.
DOMESTIC Chlorine Generating Device
Installation and Operation Manual
MODEL DIG60 REGISTRATION NUMBER 28065 PEST CONTROL PRODUCTS ACT
Maximum Output Equivalent To 0.88 Kg. Of Free Available Chlorine Per Day
One DIG60 Unit Can Treat a Maximum Of 190,000 Litres Of Swimming Pool Water
Controls Bacteria And Algae In Swimming Pool Waters
(For Indoor or Outdoor Use)
RETAIN MANUAL FOR FUTURE REFERENCE
IMPORTANT
NSF50
C
READ THE LABEL AND THIS MANUAL BEFORE INSTALLING & OPERATING
Notice to User: This control product is to be used only in accordance with the directions on this label. It is
an offense under the Pest Control Products Act to use a control product under unsafe conditions.
Bio-Lab Canada Inc., 1005 Copperstone Drive, Pickering, ON. L1W 4A5
(MINERAL SPRINGS PP DIG60 Residential English Final Nov 2004 TEMP2)
10-JUN-2005

Section 1a – GENERAL PRODUCT INFORMATION
Pool Pilot™
Digital
by Bio-Lab Canada Inc.
Record The Following Information
Installer: _____________________________Date of Installation: __________________________
Control Unit Control Unit
Model Number:
DIG60______________ Serial Number: # ____________________________
Cell Cell
Model: # RC13 Serial Number: # ____________________________
Customer Assistance…
HOTLINE: [phone] or 905-686-8836
FAX: [phone]
Manufactured for
Bio-Lab Canada Inc.
1005 Copperstone Drive, Pickering, ON. L1W 4A5
Pool Pilot™
Digital
by Bio-Lab Canada Inc.
1

Section 1b – GENERAL PRODUCT INFORMATION
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
INSTALLATION AND EQUIPMENT RELATED
Installation of all MINERAL SPRINGS
Pool Pilot Digital models:
When installing and using your Pool Pilot Digital Control Box, basic safety precautions must always be
followed, including the following:
1. Follow all aspects of the local and National Electrical Code(s) when installing your Control Box.
2. During installation, mount your Control Box to ensure the least amount of direct exposure to rain, garden sprinkler water,
direct sunlight or any corrosive environment.
3. DANGER – Risk of electrical shock. Install Control Box at least 3 m (10 ft.) for 115VAC Units, from the inside wall
of the pool or spa using non-metallic plumbing. 1.5 m (5 ft.) minimum distance for 230VAC Units.
4. All field-installed metal components such as rails, ladders, drains or similar hardware within 3 m (10 ft.) of the spa or hot
tub shall be bonded to the equipment grounding bus with copper conductors not smaller than 8.4 mm² (No. 8 AWG) in the
U.S.A. and 6.3mm² (No. 6 AWG) in Canada.
5. WARNING – Maintain water chemistry in accordance with manufacturer’s instructions.
6. DANGER – To reduce the risk of injury, 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.
Equipment Related
115/230VAC, 50/60 Hz Models (fixed wiring)
1 A wire connector is provided on your Pool Pilot Digital to connect a minimum 8.4 mm² (No. 8 AWG) in the U.S.A. and
6.3mm² (No.6 AWG) in Canada solid copper bonding conductor between this unit and any metal equipment, metal
enclosures of electrical equipment, metal water pipe or conduit within 1.5 m (5 ft.) of the unit.
2 A bonding terminal is located inside your Pool Pilot Digital. To reduce the risk of electrical shock, this terminal must be
connected to the grounding means provided in the electrical supply panel with a continuous copper wire equivalent size to
the circuit conductors supplying your Pool Pilot Digital.
3 A disconnection device from the power source, with a contact separation of at least 3mm (0.12 in.) in all poles, must be
incorporated in the fixed wiring for permanently wired units.
4 The input voltage to the Pool Pilot Digital must match the 115/230VAC jumper terminals on the Circuit board, marked
“TRANSFORMER PRIMARY”, shown on Page 4.
SAVE THESE INSTRUCTIONS
2

Section 1c – GENERAL PRODUCT INFORMATION
Table of Contents
Pool Pilot
Digital
by Bio-Lab Canada Inc.
Section 1 GENERAL INFORMATION
1a Product Information and Contact Numbers........................................................... 1
1b Important Safety Instructions................................................................................... 2
1c Table of Contents....................................................................................................... 3
Section 2 INSTALLATION
2a Main Components...................................................................................................... 4
Control Box Connections........................................................................................... 5
Electrical Connections
Cell Cord and Tri-Sensor Connections
Remote ORP Connections
2b Cell and Manifold Installation.................................................................................. 6
Verification of Flow Switch Protection.................................................................... 6
Section 3 OPERATION
3a Key Features – Display Panel ................................................................................... 7-9
3b Pool Water Preparation ............................................................................................10
Salt Requirement Chart
Start-Up Procedures
3c Monitoring and Maintenance ...................................................................................11
Water Chemistry Parameters
Saturation Index
Section 4 SERVICE and MAINTENANCE
4a Control Box and Fuse Locations............................................................................... 12
Tri-Sensor Assembly.................................................................................................. 12
4b Cell............................................................................................................................... 13
Removal and Inspection
Maintenance and Cleaning
Filter Backwashing .................................................................................................... 13
4c Parts Explosion........................................................................................................... 14
Section 5 TROUBLESHOOTING
5a Troubleshooting ......................................................................................................... 15
3

Section 2a – INSTALLATION
Main Components
Tri-Sensor Assembly
DIG 60 = RC13Cell
union
Flow In Flow Out to pool
Control Box Flow Bypass Manifold Assembly
CONTROL BOX converts incoming ELECTROLYTIC CELL TRI-SENSOR ASSEMBLY
AC power to a Low Voltage DC current, receives Low Voltage DC current from ensures that adequate flow,
which energizes the Cell(s). Set the the Power Circuit Board, which initiates 94.5 L/min. (25 US Gallons/min.)
Control Box on a vertical surface away the electrolytic process. This process minimum; salt, 2.8 – 3.2 gm/l
from excessive exposure to heat and converts ordinary table salt (Sodium (2800–3200 ppm) ideal range; and
moisture. Use the template to mark and Chloride) to 100% Pure Sodium water temperatures, above
drill the (4) mounting holes and insert Hypochlorite (Chlorine Bleach) or 15.6 °C (60°F) are satisfactory to
the screws, leaving a ¼ in. gap. Hang the Bromine (with the addition of Sodium prevent abusive conditions for the
control box on the screws and level. Bromide), which in turn sanitizes your cell to operate. See page 12 for
Remove the cover by following the steps pool or spa. instructions to remove and inspect
on page 12 to access the mounting See page 10 for salt requirements. the tri-sensor assembly.
holes to tighten the screws.
RATINGS:
Input Power: 115 VAC (3.0 AC amps) Maximum Output:Equivalent to 0.88 kg (1.92 lbs) of free available chlorine/day
230 VAC (1.5 AC amps) RC13 Cell@ Power Level 3 (8 amps DC)
50/60 Hz Cell Life Expectancy: A minimum of 15,000 ampere/hours
Output Power: Cell Power 1 (5.0* DC amps) Agency Approvals: NSF, ETL us, ETL c, CE
Cell Power 2 (6.5* DC amps)
Cell Power 3 (8.0* DC amps) Internal Pump Relay is rated for 30-amp max.
*Indicates nominal amperage output. The dual axis controller will slightly vary the amps to optimize the power to the cell.
The cell and tri-sensor are located in a Flow Bypass Manifold Assembly. 3.6 m (12 ft.) of Cell and Tri-Sensor cords are
provided with the unit. Ensure that the manifold is located within that distance from the control box with enough slack to
allow for removal for service or maintenance.
The Digital display provides full information and diagnostic for maintenance and operation of your system. The programmable
settings are retained on a microprocessor chip with the clock setting backed-up with a CR-2025 lithium battery.
CAUTION: It is suggested to locate the cell downstream of all other equipment and on the pool return line only to avoid
over-saturation conditions of your spa. For applications other than as recommended, contact the factory.
4

Section 2b – INSTALLATION
Control Box Connections
Electrical Connections
Bio-Lab recommends that a licensed electrician or certified electrical contractor perform the electrical connections.
DANGER: ensure that the electrical panel or filter pump circuit breaker is turned OFF before wiring this unit.
Your Pool Pilot™ Digital Control Box comes pre-wired from the factory for 230VAC (1.5 amps max draw) and can also
operate on 115 VAC, (3.0 amps max draw) at 50/60Hz. 1.8 m (6 ft.) of AC lead wires are provided with the unit and are
located on the bottom base plate of the control box along with the Cell, Tri-Sensor and optional ORP Interface connections.
Converting to 115VAC is accomplished by accessing the circuit board, rewiring, and attaching the included jumper as shown
below. Remove the cover (see page 12) to access and ensure that the Jumper Connections on the circuit board marked
“TRANSFORMER PRIMARY” are matched to the LINE IN voltage. Follow all state/local codes for electrical installations.
►An additional jumper is Power Circuit Board
provided with your
Installation Kit for 115VAC. Transformer
Location of the
Input Jumper Connections
TRANSFORMER PRIMARY TRANSFORMER PRIMARY
230 VAC 115 VAC
INNER CONTROL PANEL FACTORY SETTING WIRING DIAGRAM
Top terminals factory wired – do not disturb.
TAB 7
TAB 9
115VAC
115VAC
TAB 5
TAB 3
TAB 7
TAB 9
230VAC TAB 5
TAB 3
TAB 8
TAB 10
TAB 6
TAB 4
TAB 8
TAB 4
TAB 6
TAB 10
AC to PCB Bonding 6-pin Tri-sensor
Lug connector
Pump Relay trigger
Ground Ground Conduit
Lugs Lug (to Low Speed) connector
Internal Relay provided
(Gr/Yel) (Br) (Bl) Pump Ground Lug Pump conduit 2-pin ORP Cell Cord
AC
Line In
Plug
Plug
Pool Pilot AC Line IN Load wires out to Single Speed Pump Plugs Connector Connectors
(or Brown to High Speed) CONTROL BOX BASE PLATE
Pump AC Line IN Pump AC Line OUT
AC Line IN
for Filter Pump
AC Line OUT
to Filter Pump
#2 #3 #4 #5 #6#1
AC LINE IN (Wiring diagram also located on inside of cover):
For 230 VAC; Brown (Br) = Line 1, Blue (Bl) = Line 2, Green w/Yellow Tracer (Gr/Yel) = Earth Ground
For 115 VAC; Brown (Br) = Line, Blue (Bl) = Neutral, Green w/Yellow tracer (Gr/Yel) = Earth Ground
The AC Line IN wiring is pre-set for connection to the LOAD SIDE of your time clock, electronic controller switch or relay to
work in conjunction with your circulation pump.
For control of your main circulation pump (single or two speed) through the Pool Pilot™ Digital’s Internal Relay, cut and strip
the pre-wired Line In wires, and jump #1 to #3 and #2 to #4 (Gr/Yel can be discarded). Route a new set of Pump AC Line IN
wires from the circuit breaker/electrical panel into #3, #4 and Pump Ground Lug. Connect Pump AC Line OUT to #5, #6 and
Pump Ground Lug. This relay is rated for 30-amp max. Ensure that the Line In and Line Out wire sizes are according to
electrical guidelines. Follow the menu program, pages 8 & 9, to program the Digital to your particular application. Ensure
that the Pool Pilot™ Digital Control Box is properly bonded to a grounding circuit.
Cell Cord.Each Cell Cord contains (2) Banana Plugs that attach to the (2) Banana Jacks on the bottom of the Control Box.
Polarity does not matter. The other end of the cell cord has a three-position plug that connects to the cell in any direction. See
page 13 for service instructions.
Tri-Sensor Cord.The Tri-Sensor Cord connects to the keyed 6-pin harness on the Control Box Base Plate. The opposite
end of the cord connects to the Tri-Sensor Assembly with a locking ring quick connect. Align the grove and keyway on the
connector and twist the locking ring to ensure a proper connection. Refer to the instructions on pages 12 & 14 for diagrams
and additional instructions.
ORP Connection. When an ORP Chemical Controller is interfaced to your Pool Pilot™ Digital, the Chemical Controller
will remotely control the sanitizer Output. Adjust the output level to 0% and connect the ORP controller to the 2-pin connector
on the Control Box Base Plate. When the ORP is activated, the output will indicate ON with the display showing 0%.
WARNING: THE ORP CONNECTIONS ARE DRY CONTACT INPUTS, DO NOT ENERGIZE THESE
INPUTS! DAMAGE TO THE CONTROL BOX WILL OCCUR AND WILL VOID THE WARRANTY.
5

Section 2b – INSTALLATION
Cell and Manifold Installation
Your MINERAL SPRINGS System is adaptable for use with the 13 blade (RC13) cell. The manifold must be located as the
last accessory in the POOL RETURN LINE only. For special plumbing configurations, please contact your representative for
assistance in locating the manifold.
Standard Manifold Assembly:
Bypass flow rate should be set at 94.5 L/min. (25 US Gallons/min.).Tri sensor
DIG60 = RC13 Cell
union
flow in flow out to pool
For other plumbing configurations, please contact your representative for assistance.
Verification of Flow Switch Protection:
It is important to ANNUALLY inspect and verify the safe and proper operation of the Tri-sensor’s Flow Switch protection
device. We recommend following this procedure to verify that the flow switch is working as designed, which is to halt power
from being sent to the cell in the presence of insufficient flow. A defective Flow Switch could cause serious personal and/or
equipment damage. Using either a GOLF BALL or small plastic wrap (saran wrap, food wrap or zip lock bag), block off flow
to the upper portion of the manifold by placing the golf ball in the strainer screen union or by wrapping the strainer screen with
the plastic wrap and placing it back in the union and tightening. Operating the system on with this blockage should detect a
FLOW obstruction, indicated on the digital display and activating a red flashing CHECK SYSTEM light. Once this protection
feature has been verified, remove the plastic wrap or golf ball, replace the strainer screen and resume operation. Turn the
output dial to OFF and contact the factory if the flow switch protection is not working properly.
Golf Ball Plastic Wrap
C LEAN UNION
SCREEN
REGULARLY
OR
union
6

Section 3a – OPERATION Key Features
The Pool Pilot Digital display will show the SANITIZER OUTPUT LEVEL (in percent %) and whether the system is in
BOOST or SUPER-BOOST Mode on the first line of the two line alphanumeric display. The second line will display the
current TIME in either 12 or 24-hr mode, the TEMPERATURE in either Fahrenheit or Celsius, whether the cell is powered
or not, shown as ON or OFF and Polarity Direction, shown as a “.” or blank. Easy touch pads allow for adjusting and
programming the unit. A Check System visual alarm indicator works in conjunction with the display to advise of any
problems. All Menu, Select and Pump functions as well as any “Error messages” will be displayed on both lines of the
alphanumeric display.
POOL PILOT
Digital
Sanitizer 100%
12:00P 80F ON Check
System
Boost Menu Select Pump
The SANITIZING OUTPUT LEVEL is adjustable from 0% (OFF) to 100 % (MAX) by pressing the Up/Down Arrows to
obtain the desired Sanitizer Output Level. Little adjustment is needed once the initial setting is established.
Note: The Pool Pilot Digital does not test for sanitizer levels nor automatically adjust to maintain a desired sanitizer
level. This is done by periodically testing the water and adjusting the output levels up or down, as needed.
The Pool Pilot Digital is designed with an AUTOMATIC TEMPERATURE COMPENSATION feature, which
automatically adjusts the output level setting based upon changes in seasonal water temperatures only. This unique feature
conveniently compensates for warm (more sanitizer needed) or cold (less sanitizer needed) water conditions.
The BOOST Button increases the sanitizer output level to 100% for up to 72 hours, regardless of the initial output level
setting. The sanitizing agent is produced, continually; throughout the normal On/Off cycles of the pump and throughout all
power line disturbances until the end of the cycle or when manually discontinued. When Boost is activated with External
Timer setting programmed, the time remaining for the boost cycle is held in memory and will start up in Boost mode until
expired. With Pump Program or 2-Speed Pump setting programmed, the time clock will be over ridden, producing
sanitizer until the end of the boost cycle. The display will indicate the BOOST Mode on the second line when the boost
Button is pressed once. Once activated, the system will produce the sanitizing agent for 24 hours. The sanitizing agent can be
produced for 72 hours by pressing and holding down the Boost Button for 5-seconds from the Boost-Off position. This is
called the SUPERBOOST Mode. The display will indicate that the system has successfully entered the Super Boost mode.
To discontinue operation of Boost mode or Super Boost mode, pressed the Boost Button once more. The pool/spa pump must
be turned on during the whole boost cycle. Do not let the pump run on a timer during that period.
The Menu and Select Buttons allows you to view the TEST mode, program the functions and time clocks. See the following
pages for description of the menu tree.
* The PUMP Button allows you to over ride the pump timer to temporarily turn the pump on or off (depending on its status of
operation), or to manually turn the pump off, indicated by the display “OFF FOR MAINTENANCE”. In “OFF FOR
MAINTENANCE” mode, the pump is prevented from restarting by the time clock and is only reactivated only by manually
programming it to turn the pump back on. Not applicable with “EXTERNAL TIMER” selection.
The CHECK SYSTEM light will flash if there is a problem with the system. The nature of the problem will be indicated by
the display through various error messages. See the Troubleshooting section, page 14, for repair solution.
FREEZE PROTECTION: this protective feature allows the pump, when programmed for One-Speed Pump, to override the
program cycle and run continually (30-minute minimum) when the water temperature falls below 4.4°C (40°F). This prevents
any damage to the PVC due to water expanding as it freezes.
7

Section 3a – OPERATION
Key Features – continued
POOL PILOT
Digital
Sanitizer 100%
12:00P 80F ON Check
System
Boost Menu Select Pump
The MENU Button allows you to enter the programming and monitoring functions.
Use UP/DOWN ARROW and SELECT to scroll through the Main menu and Sub-menu:
Main Menu
1.0 Test Pool Pilot
2.0 Owner Options
3.0 Maintenance Menu
4.0 Installer Menu
5.0 Exit Menu Mode
SUB-MENUS
1.0 TEST POOL PILOT
The display will automatically cycle through this program, then return to normal operation. The display shows as follows:
1.1 Salt in grams per liter (gm/l) or parts per million (PPM)
1.2 Add Salt indicates the amount of salt needed to add to establish 3.0 gm/l (3000 ppm) based upon pool volume
1.3 Temperature in Celsius or Fahrenheit.
1.4 Cell Volts and Amps
2.0 OWNER OPTIONS
Use UP/DOWN ARROW and SELECT to scroll through the sub-menu. After completing a step, it displays the next step:
2.1 English/Metric: displays volume in gallons or cubic meters; salt additions in lbs or kg; Back – Main Menu (2.0)
2.2 Temperature Units: displays the water temperature in Fahrenheit or Celsius; Back - Main Menu (2.0)
2.3 12/24-hour Time: displays the current time in 12-hour Time or 24-hour Time units; Back – Main Menu (2.0)
2.4 Set Time of Day: sets the time as follows: Set Hours; Set Minutes
2.5 *Pump Program 1: allows you to program the pump on/off cycle through the on-board program
2.6 *Pump Program 2: allows you to program a secondary pump on/off cycle through the on-board program
* Only applicable with Pump Config. (4.6) selection of One-Speed Pump or Two-Speed Pump
* Pump Program 1 or 2 will show the previous time set. Otherwise, Not Programmed will display,
then automatically step to display -Prog. -Delete SELECT-No Change
Selecting -Prog steps to Pump ON at Set Hours “12”:00 P; Pump ON at Set Mins 12:“00” P
then Pump OFF at Set Hours “12”:00 P; Pump OFF at Set Mins 12:“00” P
2.7 Back – Main Menu (returns to MAIN MENU)
8

Section 3a – OPERATION
Key Features – continued
POOL PILOT
Digital
Sanitizer 100%
12:00P 80F ON Check
System
Boost Menu Select Pump
Use UP/DOWN ARROW and SELECT to scroll through the sub-menu. After completing a step, it displays the next step:
3.1 Test: same as 1.0 above plus cell Amp-hrs – then returns to Main Menu (3.0)
3.2-3.4 Set Time of Day: same as 2.4 above
3.5 Force Reverse: allows you to check cell volts and amps in the opposite direction (verifies reversing feature)
3.6 Set Reverse Time: allows adjustable self-cleaning reverse rate of 2, 4, 8or 16 hrs; Back – Main Menu (3.0)
Cell reversal is set on 4-hrs from the factory for ideal cell life. For conditions such as high calcium levels that can
cause the cell to scale quicker than the self-cleaning cycle can control, change the setting to “2” hours.
For vinyl liner pools or optimum water chemistry balance according to the Saturation Index, see page 10, changing the
REVERSING cycle to “8” or “16” hours will extend the life of the cell.
If the Reverse Time is set to the “16” hours setting, check the cell weekly for the first month to ensure no scale
develops. If there is scale development, change the setting to “8” hours.
Note: changing the Reversing Time to “2” hours will affect the cell life. However, operating with scale
development on the cell is more damaging to the life of the cell and changing the reversing time is suggested
3.7 Calibrate Salt: allows you to calibrate the salt display. Contact the factory for calibration solution
3.8 Replace Cell: Only used when replacing cells. May be used to zero the amp-hour counter. Consult Bio-Lab Canada
Inc. for details.
3.9 Back – Main Menu (returns to MAIN MENU)
4.0 INSTALLER MENU
(Hold Select for 10 seconds to enter this mode)
Use UP/DOWN ARROW and SELECT to scroll through the sub-menu. After completing a step, it displays the next step:
4.1 English/Metric: displays volume in gallons or cubic meters; salt additions as lbs or kg; Back – Main Menu (4.0)
4.2 Temperature Units: displays the water temperature in Fahrenheit or Celsius; Back - Main Menu (4.0)
4.3 12/24-hour Time: displays the current time in 12-hour Time or 24-hour Time units; Back – Main Menu (4.0)
4.4 Set Pool Volume: displays the volume of the pool in either Gallons or Cubic Meters
4.5 Set Cell Power: allows you to set the Power Level = 1, 2 or 3. Warning: Operating on “1” reduces cell power
but extends cell life, “3” increases cell power but reduces cell life. Back – Main Menu (4.0)
4.6 Set Pump Config: allows you to select from External Timer, One-Speed Pump or Two-Speed Pump configuration
4.7- 4.9 Set Time of Day: same as 2.4 – 2.6 above
4.10Back – Main Menu (returns to MAIN MENU)
Error Messages:
If the message “Sanitizer Off” is shown, the system halts sanitizer production. This is shown when the unit is at rest or when
the salt level is extremely low.
If the message “Warning!” is shown, the system will continue to produce sanitizer but at a reduced efficiency. This is
associated with a warning message to check the system.
9

Section 3b – OPERATION
Pool Water Preparation
Salt Requirements
It is important that with typical pools, a salt residual of 2.8 – 3.2 gm/l (2800 to 3200 ppm) be maintained at all times for peak
efficiency.
NOTE: Maintaining high salt levels above recommended range can contribute to corrosion of pool/spa equipment. Salt levels
exceeding the recommended concentration can be reduced by diluting the pool/spa with fresh water.
The amount of salt required depends on the size of the pool and the present salt level. Broadcast the salt around the perimeter
of the pool. DO NOT add salt directly into any skimmer or gutter device. As the salt is being added, we recommend running
the circulation pump continually for 24 hours with the main drain opened. Brushing the salt towards the bottom main drain
will assist in the dissolve rate and prevent possible staining with certain types of salt.
We recommend the use of a specialty blended salt product that does not contain Yellow Prussiate of Soda (YPS) or Iodine
which could cause a localized tint to the water or brown staining on the cementitious finish if allowed to rest undissolved on
the finish for extended periods of time.
Granular Salt, Table Salt, Solar Salt or Water Conditioner Pellets can also be used but will have different dissolve rates. If the
salt you use contains Iodine or YPS, constant brushing may help the dissolve rate and minimize staining due to the additives in
the salt. Ensure that ANY salt you use contains a minimum purity of 99% Sodium Chloride (NaCl).
NOTE: Do not use Rock Salt due to its high levels of impurities.
TEST YOUR WATER FOR SALT LEVEL FIRST with the provided salt test strips,
and then use the chart below to determine the amount of salt to add.
SALT REQUIREMENT CHART
KILOS (LBS.) OF SALT NEEDED FOR 3000 PPM RESIDUAL
Pool Volume in Liters (US Gallons)SALT Level
Before Addition 3,780
(1,000) 9,430 (2,500) 18,900 (5,000) 28,300 (7,000) 37,780 (10,000) 56,700 (15,000) 75,600 (20,000) 113,600 (30,000)
0 ppm 11.3 (25) 28 (63) 57 (126) 85 (175) 113 (252) 175 (378) 227 (504) 340 (756)
500 ppm 9.5 (21) 24 (53) 48 (106) 73 (147) 95 (212) 145 (318) 191 (424) 286 (636)
750 ppm 8.6 (19) 22 (48) 43 (96) 66 (133) 86 (192) 130 (288) 173 (384) 259 (576)
1000 ppm 7.7 (17) 19 (43) 39 (86) 54 (119) 77 (172) 116 (258) 155 (344) 232 (516)
1500 ppm 5.9 (13) 15 (33) 30 (66) 41 (91) 59 (132) 89 (198) 119 (264) 178 (396)
2000 ppm 3.6 (8) 9.5 (21) 19 (42) 30 (56) 38 (84) 57 (126) 76 (168) 113 (252)
2250 ppm 2.7 (6) 7 (15) 14 (30) 19 (42) 28 (60) 41 (90) 54 (120) 81 (180)
Note: The above chart is based on 120 grams of salt added to 1000 Liters of water (1 lb. per 1,000 gallons) to increase your salt
residual 120-ppm.
Start Up Procedures
Keep the Output Setting on your Pool Pilot Digital on 0% (OFF) until you get your water clear, blue and properly balanced.
1. After balancing your water chemistry according to the Water Chemistry Parameters shown on page 10, add the proper
amount of salt (see Salt Requirement Chart above) and circulate 24-hours prior to starting your Pool Pilot Digital.
2. The following day set your Output Level to 50% and operate normally. Test water as required to conform with local
health code. Raise or lower output control setting as needed.
3. Once your Output Level has been established, you will only need to adjust your level according to increased bather usage.
10

Section 3c – OPERATION
Monitoring and Maintenance
Water Chemistry Parameters - VERY IMPORTANT NOTE! Your Pool Pilot Digital is designed to provide Sanitizer on a daily
basis. We recommend the following water chemistry ranges and periodic checks to monitor your systems efficiency. Always
follow local health requirements. Check the expiry date of the test kit as test results may be inaccurate if used after that date.
Daily Checks: Monthly Checks:
Free Chlorine: 1.0 – 3.0 PPM(pool) Calcium Hardness: 200-300 PPM (Pool) 150-200(spa) Salt Residual: 2800 – 3200 PPM
Or Bromine: 1.0 – 3.0 PPM(pool) Total Alkalinity: 100-120 PPM (Pool & Spa) Saturation Index: ± 0.3 pH of saturation
Free Chlorine: 3.0 – 5.0 PPM(spa) Cyanuric Acid: 30 – 100 PPM (Pool & Spa) Visual Cell Inspection for wear, scale or debris
Or Bromine 3.0 – 5.0 PPM(spa)
pH: 7.2 – 7.8
CHLORINE/BROMINE REQUIREMENTS: During Peak Sanitizer Demand (rainy season or heavy bather usage) it may be
necessary to increase your sanitizer level by increasing your Output Level setting and/or pump run time. Conversely, during
Low Sanitizer Demand, you can decrease your Output Level to a lower setting. For extremely Heavy Sanitizer Demand or to
boost your sanitizer levels quickly, you can Boost the system or supplement with a Potassium Monopersulfate based shock.
NOTE: During cold-water conditions, below 15.6°C (60°F), Sanitizer demand is reduced significantly. For colder
climate regions with freezing temperatures, contact your local pool professional for proper pool winterizing instructions.
CAUTION: Excessive chlorine levels can cause corrosion damage to stainless steel rails, ladders, heater heat exchangers, light
faceplates and other metallic equipment. Avoid over saturation of chlorine levels. The output setting must be sufficiently high
to maintain the recommended chlorine residual in the swimming pool/spa water. Provincial and/or municipal regulation must
be followed.
pH: When your pH falls below the accepted range, your Sanitizer is used up very quickly and can be damaging to your
equipment. For pH levels higher than the accepted range, your Sanitizer becomes much less effective and will work harder to
keep your pool sanitized. Improper pH also contributes to the strong smell, red eyes, dry itchy skin and brittle hair conditions
usually associated with “too much Chlorine”.
CALCIUM HARDNESS AND TOTAL ALKALINITY: Your Pool Pilot Digital provides 100% pure sodium hypochlorite
and does not affect the calcium hardness or total alkalinity levels. Maintain and balance only as needed.
CYANURIC ACID (STABILIZER/CONDITIONER): This chemical goes by either trade name and allows your chlorine
residual to last longer by protecting it from the UV degradation of the sun. In outdoor pools/spas with low or no Cyanuric acid,
the chlorine being produced will be used up as quickly as it enters the pool. Check and maintain your cyanuric acid levels at
the same time as your salt level, as these tend to deplete at the same rate. Regulations may exist regarding the use of cyanuric
acid; please consult your local authority. NOTE: For Bromine or indoor pools, it is not necessary to add stabilizer.
SALT RESIDUAL: Your Pool Pilot Digital works most efficiently with salt levels between 2.8 – 3.2 gm/l (2800- 3200 ppm).
If it falls below 2.8 gm/l (2800 ppm), determine the salt level and adjust according to the SALT REQUIREMENT. Low salt
will cause premature deterioration of the Cell blades. Maintaining high salt levels above recommended range can contribute to
corrosion of pool/spa equipment. Salt levels exceeding the recommended concentration can be reduced by diluting the
pool/spa with fresh water.
BROMINE RESIDUAL: Along with the normal Salt level, add 0.45 kg (1 lb) Sodium Bromide (NaBr) per 7500 L (2000
gallons) of water. Your Pool Pilot Digital will now generate Bromine to sanitize your pool. Maintain your bromine level by
checking your salt level. Once your salt falls below the recommended range, we suggest you add 0.45 kg ( 1 lb) sodium
bromide with every 22.5 kg (50 lbs) of salt added. NOTE: Always use a registered or scheduled source of sodium bromide.
SATURATION INDEX (Si): a formula used to ensure that your total water chemistry does not fall into a scale forming or
corrosive condition. Either condition can cause premature damage to the Cell, equipment and exposed pool/spa surfaces.
Have your water professionally tested periodically according to the Saturation Index or use this chart to determine your water
balance. Si = pH + TF + CF + AF – Constant
Temperature TF Calcium Hardness CF Total Alkalinity AF TDS Constant
15.6C 60F 0.4 150 1.8 75 1.9 0 – 1000 12.1
18.9C 66F 0.5 200 1.9 100 2.0 1001 - 2000 12.2
24.4C 76F 0.6 250 2.0 125 2.1 2001 - 3000 12.3
28.9C 84F 0.7 300 2.1 150 2.2 _____
34.4C 94F 0.8 400 2.2 200 2.3 _____
39.4C 103F 0.9 600 2.4 250 2.4
Test your water for pH, Calcium Hardness, Total Alkalinity and TDS levels. Use the equivalent Factor in the Si equation.
Si = +0.3, balanced Si above + 0.3, scaling, staining or cloudy water conditions.
Si below -0.3, corrosive to metals, etches/deteriorates plaster finishes or skin irritating conditions.
DO NOT add pool/spa chemicals directly to the skimmer. This may damage the cell.
11

Section 3c OPERATION (cont’d)
Additional notes:
a) For proper sanitation, spa must be completely drained periodically. The number of days between COMPLETE SPA
DRAINAGE is equal to the volume of spa water in liters, divided by 10 times the maximum number of daily spa
users.
b) Maximum spa usage temperature is 40°C (104°F). Duration in spa water at 40°C should not exceed 15 minutes.
c) Heavy use of the spa (excessive contamination) may require longer recovery times (A return to a minimum of 3 ppm
chlorine/bromine). Recovery time may be reduced by adding a shock compound to the water.
d) Hot weather, heavy pool usage, and rain may require a higher output to maintain proper sanitizer residual.
Section 4a –SERVICE and MAINTENANCE
CONTROL BOX
There are very few serviceable parts on the Pool Pilot Digital Control Box except the fuses. For any other problems with the
Control Box, please contact your representative or Authorized Dealer/Service Center.
To remove the Control Box Cover and access the fuses, follow these steps.
DANGER: TURN OFF THE AC POWER FROM THE CIRCUIT BREAKER OR PANEL BEFORE SERVICING
THIS UNIT.
POOL PILOT f
Digital Control Circuit Board
F3 F2
Front of Unit ’Wire Harness Connection Inner Metal
Top Cover Inside Top Cover Cover
F1
Loosen (4) knobs Lift off cover and disconnect Remove (3) screws and Access is gained to
(you do not need to) wire harness (Control Circuit lift off metal cover. electrical connections
(remove these). board removes with cover). and fuses.
Fuse Location and Ratings F1 Main AC Power Fuse 6 Amps 250 VAC
F2 Control Panel Circuit Board Fuse 3 Amps 250 VAC
F3 Cell Fuse 10 Amps 250 VAC
TRI-SENSOR ASSEMBLY
The Tri-sensor assembly tests for Flow, Salt and Water temperatures. A minimum flow rate of 94.5 L/min. (25 US
Gallons/min.) is required to activate the flow switch. As the water flow closes the paddle, a magnet activates a micro switch to
verify proper flow. The Salt sensor protects against low salt levels and the temperature sensor protects against cold water
temperatures. Both of which can contribute to accelerated cell failure.
Remove the Tri-Sensor as follows (with pump off):
Remove both screws from the side of the Tee Assembly. Firmly grip
he Tri-Sensor assembly and twist to loosen the compression o-ring.
With the aid of large Channel-lok® (or similar) pliers, twist
back and forth while removing the Tri-Sensor from the tee. directional
Inspect the thin metalic paddle for erosion and straightness. arrow screw(s)
Take care not to twist or tweek this paddle, which can cause one on each side
inaccurate flow readings. Inspect the salt sensor blades for scale
and debris and clean if necessary. See page 12 for cleaning
instructions. Follow the directions for Manual Cell Cleaning.
Check the tri-sensor assembly for any damage to the plastic
housing and replace if needed.
12

Section 4b –SERVICE and MAINTENANCE
Cell
The Cell is installed with Unions on each end of the cell to allow quick and easy removal. Loosen the unions and remove the
cell from the plumbing.
RC13
Side View of Cell and Unions
VISUAL CELL INSPECTION:
The titanium Cell blades, seen inside the Cell body, should be straight and clear of any debris between the blades. Your Pool
Pilot Digital is designed to automatically self-clean scale build-up within the Cell. However, imbalanced water chemistry and
certain conditions can cause a heavier scale build up that exceeds the self-cleaning capability and would need to be cleaned
manually by the method described below.
Periodically inspect both ends of the cell.
A White Flaky or Crusty build-up on the
edge or between the blades will prematurely
deplete the life of the cell. Immediately End View of cell
clean the cell and determine the cause of Looking at the Titanium Blades
scaling. See Troubleshooting Section, page 14.
MANUAL CELL CLEANING:
With the Cell removed as described above, use a high-pressure hose nozzle to spray off as much loose, soft scale and debris as
possible. Any remaining calcium scale can be treated with a mixture of one (1) part Muriatic Acid into four (4) parts water.
Mix the solution in a container high enough to cover the Cell blades. You may also use non-fuming/pre-mixed cell cleaner, per
label directions.
Remove the Cell cord and immerse the Cell so that the blades are completely covered in the solution for up to 15 minutes. An
effervescences action indicates the calcium is being neutralized and cleaned. Drain the cell, flush with fresh water and re-
inspect. Repeat the immersion if necessary. Once the cell has been cleaned and rinsed; it may be re-installed in-line. BE
SURE THAT THE CELL “PINS” ARE CLEAN AND DRY BEFORE ATTACHING THE DC CORD FROM THE POWER
SUPPLY. WARNING: ALWAYS ADD ACID TO WATER, never water to acid.
When replacing the cell, only use replacement cells having a label that clearly states that it is a replacement cell for the chlorine
generating device MINERAL SPRINGS Digital Model DIG60, REGISTRATION NUMBER 28065, PEST CONTROL
PRODUCTS ACT.
NEVER USE ANY SHARP OR METALLIC OBJECTS TO REMOVE SCALE. Scraping or scratching the titanium
blade’s edge or surface will allow chemical attack of the blade, cause premature failure of the Cell and will void your
warranty.
Hacksaw Blades Screwdrivers Forks Knives
FILTER BACKWASHING:
NOTE: The Control Panel Output setting must be set to 0% (OFF) when backwashing the filter.
13

Section 4c –SERVICE and MAINTENANCE
Parts Explosion
Manifold Assembly: Manifold Union w/Strainer:
(#941) (#19065)
TRI-SENSOR Union Nut
Union O-Ring (#19014)
Strainer (#19064)
CELL w/ UNIONS
MANIFOLD
UNION
w/Strainer MANIFOLD BASE w/Check Valve
Electrolytic Cell:
(Cell Unions and Cord ordered separately)
12 ft. (3.6m) Cell Cord (# 952-1)
Union O-Ring (#19013)
Cell RC13
Nut Half only (2 pcs) for 2 in. (50 mm) S x S Union Thread Half Only for 2 in. (50 mm) S x S Union
Tri-Sensor Assembly:
(Cord Ordered Separately)
Directional Flow Indicator View of locking
Quick connect heads 12 ft. (3.6m) Tri-Sensor Cord (# 956-DIG)
Tri-Sensor O-Ring (#19028)
Direction of Water Flow
Temperature Sensor Post
Salt Sensor Blades
Flow Paddle
Tri-Sensor
(#909-GO1.5)
14

Section 5a – TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
1) Insufficient Sanitizer Production.
A) The test kit reagents or test strips are old or expired. A) Retest with new Reagents or Strips.
B) The unit is set too low in relation to sanitizer demand. B) Increase the Sanitizer % output.
C) The circulation run time is insufficient. C) Increase your pump run time.
D) The bather load has increased. D) Same solution as (B) and/or add a Non-Chlorine Shock
containing Potassium Monopersulfate to supplement.
E) The body of water being sanitized leaks. E) Repair the leak and rebalance as needed.
F) Low Salt. F) Check the residual salt level and adjust as needed.
G) “Cell Type” selection not matched to the cell installed. G) Follow the INSTALLER SETUP instructions, see page 8.
H) Sanitizer loss due to intense sunlight H) Check your stabilizer level and adjust if needed.
2) Scale Build-up within the Cell.
A) The water being sanitized contains high pH, total A) Calculate Langelier’s Index to assure balanced water.
alkalinity and calcium hardness levels. Adjust chemicals and clean the Cell. See pages 12 & 13.
(Cell scales within 2 – 3 weeks)
B) Power Supply not reversing polarity. B) Contact Representative or Authorized Service Centre.
(Cell constantly scales within 3 – 5 days)
3) DC Plug and Cell Terminals Burned.
A) The Cell terminals are wet due to a leaking cell body. A) Contact Representative or Authorized Service Centre.
B) The Cell plug is not securely pushed onto the cell B) Ensure the Cell cord plug is pressed completely onto the
terminals, allowing moisture to seep into the plug. Cell terminal. Check the terminals and clean with a dry
cloth to remove all dirt and corrosion.
4) Premature Cell Failure (Requires Replacement Cell).
A) Abnormally high Cell usage due to an insufficient A) Check the stabilizer level and adjust to recommended levels.
Stabilizer (Cyanuric acid) level.
B) Excessive Scale/Debris in the Cell. B) See Section 2 above.
C) “Cell Type” selection not matched to the Cell installed. C) Follow the INSTALLER SETUP instructions, see page 8.
5) White Flakes in the Water.
A) This occurs when excessive calcium hardness is A) Adjust your water chemistry, visually inspect Cell for scale
present. Usually due to water chemistry imbalance. build-up and clean the cell as described on pages 11 & 13.
6) No Power to the Control Box.
A) Internal Fuse blown. A) Check and replace fuse. See page 11.
B) Circuit Breaker tripped. B) Check the power going to the Control Box. Reset the
Circuit Breaker.
7) SERVICE Light Flashing.
MESSAGED DISPLAYED “CHECK FLOW”
A) Tri-Sensor Defective. A) Contact Representative or Authorized Service Centre.
B) Insufficient Flow(Min 94.5 L/min.)(25 USGallons/min)B) Ensure your Filter and Cell are clean of debris.
Check all valves that might divert flow away from the cell.
MESSAGE DISPLAYED
“LOW AMPS – CELL?”
A) Extremely Low Cell Amperage. A) Cell heavily scaled. If cell is already clean, replace cell.
B) Extremely Low Salt Level. B) Salt level below 1,5 gm/l (1500 ppm).
C) The Cell Cord is Loose C) Ensure that the cord is firmly pressed into the cell and
the wires properly connected into the banana plugs.
D) Power Supply has failed. D) Contact Representative or Authorized Service Centre.
MESSAGED DISPLAYED “CHECK/CLEAN CELL” (Sanitizer still producing)
A) Excessive Cell Voltage A) Check cell for calcium or scale build-up.Clean as req’d.
Water Temperature too cold. Raise above 15.6°C/60°F
MESSAGE DISPLAYED “LOW SALT - ADD XXX lbs (or kg)”
A) Salt level Low (below 2,2 gm/l/2200 ppm). A) Add the amount of salt shown on the displays
15

Imported to Canadafor
BIO-LAB CANADA INC.
1005 Copperstone Drive
Pickering, ON. L1W 4A5
REGISTRATION NO. 28065 PEST CONTROL
PRODUCTS ACT MINERAL SPRINGS MODEL
DIGITAL 60 Chlorine Generating Device
One DIG60 unit can treat a maximum of
190,000 Liters of swimming pool water.
Notice to User: This control product is to be
used only in accordance with the directions
on this label. It is an offence under the Pest
Control Products Act to use a control product
under unsafe conditions.
For swimming pools, a minimum of 1 ppm of
free available chlorine or bromine must be
maintained. For spas, a minimum of 3 ppm
of free available chlorine or bromine must be
maintained.
Controls Bacteria and Algae in Swimming
Pool Waters.
Maximum output equivalent to .88 kg of
Free Available Chlorine per day
WARNING: Operating theMINERAL
SPRINGS MODELDIGITAL 60 without water
flow through the cell can cause a build up of
flammable gases which can result in FIRE
OR EXPLOSION
DOMESTIC
READ THE LABEL AND THE INSTALLATION
AND OPERATION MANUAL BEFORE USING
Imported to Canadafor
BIO-LAB CANADA INC.
1005 Copperstone Drive
Pickering, ON. L1W 4A5
REGISTRATION NO. 28065 PEST CONTROL
PRODUCTS ACT MINERAL SPRINGS MODEL
DIGITAL 60 Chlorine Generating Device
One DIG60 unit can treat a maximum of
190,000 Liters of swimming pool water.
Notice to User: This control product is to be
used only in accordance with the directions
on this label. It is an offence under the Pest
Control Products Act to use a control product
under unsafe conditions.
For swimming pools, a minimum of 1 ppm of
free available chlorine or bromine must be
maintained. For spas, a minimum of 3 ppm
of free available chlorine or bromine must be
maintained.
Controls Bacteria and Algae in Swimming
Pool Waters.
Maximum output equivalentto .88 kg of
Free Available Chlorine per day
WARNING: Operating theMINERAL
SPRINGS MODELDIGITAL 60 without water
flow through the cell can cause a build up of
flammable gases which can result in FIRE
OR EXPLOSION
DOMESTIC
READ THE LABEL AND THE INSTALLATION
AND OPERATION MANUAL BEFORE USING
Imported to Canadafor
BIO-LAB CANADA INC.
1005 Copperstone Drive
Pickering, ON. L1W 4A5
REGISTRATION NO. 28065 PEST CONTROL
PRODUCTS ACT MINERAL SPRINGS MODEL
DIGITAL 60 Chlorine Generating Device
One DIG60 unit can treat a maximum of
190,000 Liters of swimming pool water.
Notice to User: This control product is to be
used only in accordance with the directions
on this label. It is an offence under the Pest
Control Products Act to use a control product
under unsafe conditions.
For swimming pools, a minimum of 1 ppm of
free available chlorine or bromine must be
maintained. For spas, a minimum of 3 ppm
of free available chlorine or bromine must be
maintained.
Controls Bacteria and Algae in Swimming
Pool Waters.
Maximum output equivalent to .88 kg of
Free Available Chlorine per day
WARNING: Operating theMINERAL
SPRINGS MODEL DIGITAL 60 without water
flow through the cell can cause a build up of
flammable gases which can result in FIRE
OR EXPLOSION
DOMESTIC
READ THE LABEL AND THE INSTALLATION
AND OPERATION MANUAL BEFORE USING
Imported to Canadafor
BIO-LAB CANADA INC.
1005 Copperstone Drive
Pickering, ON. L1W 4A5
REGISTRATION NO. 28065 PEST CONTROL
PRODUCTS ACT MINERAL SPRINGS MODEL
DIGITAL 60 Chlorine Generating Device
One DIG60 unit can treat a maximum of
190,000 Liters of swimming pool water.
Notice to User: This control product is to be
used only in accordance with the directions
on this label. It is an offence under the Pest
Control Products Act to use a control product
under unsafe conditions.
For swimming pools, a minimum of 1 ppm of
free available chlorine or bromine must be
maintained. For spas, a minimum of 3 ppm
of free available chlorine or bromine must be
maintained.
Controls Bacteria and Algae in Swimming
Pool Waters.
Maximum output equivalent to .88 kg of
Free Available Chlorine per day
WARNING: Operating theMINERAL
SPRINGS MODELDIGITAL 60 without water
flow through the cell can cause a build up of
flammable gases which can result in FIRE
OR EXPLOSION
DOMESTIC
READ THE LABEL AND THE INSTALLATION
AND OPERATION MANUAL BEFORE USING
10-JUN-2005

Cell Model RC-13
This is a replacement cell for the chlorine generating devices MINERAL SPRINGSModel DIG ITAL 60
REGISTRATION NUMBER 28065, PEST CONTROL PRODUCTS ACT, and MINERAL SPRINGS
Model Soft Touch ST60 REGISTRATION NUMBER 28069, PEST CONTROL PRODUCTS ACT. This
cell must only be used on these models of chlorine generating device.
Read the Label and the Installation and Operation Manual of the chlorine generating device MINERAL
SPRINGSModel DIGITAL 60 orMINERAL SPRINGSModel Soft Touch ST60 before using.
BIO-LAB CANADA INC., 1005 Copperstone Drive, Pickering, ON. L1W 4A5
(MINERAL SPRINGS Cell Label for DIG,ST 60 ENG.)

******************************
This label transcript service is offered by the Pest Management Regulatory Agency to provide
efficient searching for label information. This service and this information do not replace the
official hard-copy label. The PMRA does not provide any guarantee or assurance that the
information obtained through this service is accurate, current or correct, and is therefore not
liable for any loss resulting, directly or indirectly, from reliance upon this service.