Pentair Pool Products IntelliChlor IC60 User manual

IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
Installation and User’s Guide
Electronic Chlorine Generator
(Model IC60, IC40, IC20 and IC15)
Patents pending
Certified to NSF/ANSI 50
®
IntelliChlor

© 2010 Pentair Water Pool and Spa, Inc. All rights reserved
This document is subject to change without notice
1620 Hawkins Ave., Sanford, NC 27330 • [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone] • [phone]
IntelliChlor®, IntelliTouch®, EasyTouch®, SunTouch® and Pentair Water Pool and Spa® are trademarks and/or
registered trademarks of Pentair Water Pool and Spa, Inc. and/or its affiliated companies in the United States and/
or other countries. Unless noted, names and brands of others that may be used in this document are not used to
indicate an affiliation or endorsement between the proprietors of these names and brands and Pentair Water Pool
and Spa, Inc. Those names and brands may be the trademarks or registered trademarks of those parties or others.
P/N 520589 Rev J - 06/11/10
WARNING - Salt is an inherently corrosive material. While the levels of salt required for proper operation
of the IntelliChlor Electronic Chlorine Generator are relatively low when compared to sea water and other salt
solutions, placing any amount of salt in your pool increases the likelihood of corrosion or other deterioration of
pool equipment and any surfaces used in and around your pool. Metal parts (including metal pools) and certain
natural and man-made surfaces are particularly susceptible to corrosion and deterioration when used in and
around salt water pools. Pentair Water Pool and Spa®(“Pentair”) does not represent or otherwise guarantee that
the proper use of the IntelliChlor Electronic Chlorine Generator will prevent corrosion or other deterioration of
pool equipment and any surfaces used in and around your pool. Consult your experienced pool professional,
who should be able to advise you on the proper material selection, installation techniques for those materials,
and the proper use, care and maintenance of those materials for your specific pool type and location in order to
minimize the corrosion and deterioration that is inherent in and around salt water pools.

i
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Contents
Important Warnings and Safety Instructions .................................................................................... iii - iv
IntelliChlor and Controller System Part Numbers ......................................................................................... ii
Technical Support ........................................................................................................................................ ii
IntelliChlor®Electronic Chlorine Generator Overview.................................................................................... 1
Features .................................................................................................................................................. 1
IntelliChlor System Components .................................................................................................................. 2
IntelliChlor Electronic Chlorine Generator Control Panel and Cell Description ............................................... 2
IntelliChlor IC20, IC40, IC60 Power Center and IC15 Power Supply ............................................................. 3
System Schematic Diagram ........................................................................................................................ 4
Install Chlorine/Bromine Feeders after the Intellichlor cell ............................................................................ 4
Loop Plumbing Diagram ............................................................................................................................... 5
IntelliChlor Plumbing Diagram ...................................................................................................................... 5
Section 1: IntelliChlor Control Panel .........................................................................................7
Salt Level Status LEDs ............................................................................................................................... 7
Status LEDs ................................................................................................................................................ 7
Sanitizer Output LED Indicators .................................................................................................................. 8
More and Less Output Buttons .................................................................................................................... 8
Self-Cleaning ............................................................................................................................................... 8
Section 2: Pool Water and Chemistry, Conditions and Precautions .......................................9
Pool Water Chemistry, Conditions and Precautions ...................................................................................... 9
Optimum Pool Water Conditions for Salt Water Pools (using the IntelliChlor Electronic Chlorine Generator) 10
Covered Pools and Vinyl Liner Pool and Lowering Chlorine Output Levels .................................................. 10
Chlorine Testing ......................................................................................................................................... 11
What Type of Salt to Use ........................................................................................................................... 11
How Much Salt to Use? ............................................................................................................................. 11
Calculating the Saturation Index ................................................................................................................ 12
Saturation Index Factors ....................................................................................................................... 12
How to Add Salt to the Pool ....................................................................................................................... 13
Table 1. Approximate Pounds (Kg) of salt needed to obtain 3,400 ppm in pool ...................................... 13
Table 2. Approximate Pounds (Kg) of salt needed to maintain 3,000 ppm in pool .................................. 14
Table 3. Approximate amount of cyanuric acid to obtain 75 ppm in pool ................................................ 14
Pool Water Preparation ............................................................................................................................... 15
Determining Pool Size (Gallons of Water inYour Pool) ........................................................................... 15
Determining Pool Size (liters of water in your pool) ................................................................................ 15
Section 3: Operating IntelliChlor .............................................................................................17
Initial Start up Period ................................................................................................................................. 17
Operation .............................................................................................................................................. 17
Use of an external Pool Pump Timer is not required .............................................................................. 17
If you use a Pool Pump Timer ............................................................................................................... 17
Startup Procedure (Super Chlorination) ...................................................................................................... 18
Sanitizer Output Settings and Adjustments ............................................................................................... 18
Operating in Winter .................................................................................................................................... 18
General Recommendations ................................................................................................................... 19
General Cautions .................................................................................................................................... 19
Section 4: User Maintenance....................................................................................................21
Daily service .............................................................................................................................................. 21
Weekly service .......................................................................................................................................... 21
Monthly Service......................................................................................................................................... 21
IECG Usage Hours Meter .......................................................................................................................... 22
Cleaning the IECG Cell Blades .................................................................................................................. 22
Winterizing ................................................................................................................................................. 23

ii
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Section 5: Installation ...............................................................................................................25
Kit Contents .............................................................................................................................................. 25
Required Tools ........................................................................................................................................... 25
IntelliChlor “Dummy” Cell ........................................................................................................................... 26
Selecting Model Size - IntelliChlor Model IC20, IC40, IC60 ........................................................................ 26
Installing the IntelliChlor Cell Assembly ..................................................................................................... 26
Connecting the Cell Power Cable to the Power Center ........................................................................... 27
Connecting the Power Supply Cable to the IC15 Cell ............................................................................. 27
Connecting IC20, IC40, IC60 Power Center to IntelliTouch, EasyTouch or SunTouch System ................ 28
Wiring AC Power from IntelliChlor and IntelliFlo pump to
IntelliTouch, EasyTouch and SunTouch Automation Control System ...................................................... 29
Connecting IntelliChlor to an SunTouch System .................................................................................... 30
Wiring AC Power from IntelliChlor and IntelliFlo to Automation Control System
(IntelliTouch, EasyTouch and SunTouch Automation Control System) ........................................................ 30
Section 6: Troubleshooting ......................................................................................................33
Table 1: Troubleshooting ............................................................................................................................ 33
System Specifications - 110 VAC and 220 VAC Wiring ..............................................................................35
220 VAC Basic System Wiring ............................................................................................................... 35
110 VAC Basic System Wiring............................................................................................................... 36
IC15 System Specifications and Wiring ...................................................................................... 37
Warranty Information ................................................................................................................... 38
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Technical Support
Sanford, North Carolina (8 A.M. to 5 P.M. Eastern Time)
Moorpark, California (8 A.M. to 5 P.M. Pacific Time)
Phone: [phone]
Fax: [phone]
Download the IntelliChlor User’s Guide (PDF)
http://www.pentairpool.com/pdfs/IntelliChlorOM.pdf
http://www.pentairpool.com/pdfs/IntelliChlorIC15IG.pdf
IntelliChlor®IC20/IC40/IC60 and Controller System Part Numbers
Refer to the following part numbers when configuring the IntelliChlor Electronic Chlorine Generator and the
IntelliChlor Power Center with an IntelliTouch®, EasyTouch® or SunTouch® system.

iii
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
IMPORTANT WARNINGS AND SAFETY INSTRUCTIONS
Important Notice: Attention Installer: This manual contains important information about the
installation, operation and safe use of this product.This information should be given to the owner and/or
operator of this equipment. When installing and using this electrical equipment, basic safety precautions should
always be followed, including the following:
WARNING: IMPORTANT SAFETY INSTRUCTIONS PERTAINING TO A RISK OF FIRE, ELECTRIC
SHOCK, OR INJURYTO PERSONS. READ AND FOLLOW ALL INSTRUCTIONS.
Before installing this product, read and follow all warning notices and instructions which are
included. Failure to follow safety warnings and instructions can result in severe injury, death,
or property damage. Call [phone] for additional free copies of these instructions, or
obtain a copy of these instructions at:
http://www.pentairpool.com/misc/owners_manuals/sanitizers/
IntelliChlor_Owners.pdf
WARNING: To reduce the risk of injury, do not permit children to use this product.
WARNING: CHLORINE GAS BUILDUP CAN OCCUR WITH IMPROPERWIRING: To reduce the risk of
personal injury the IntelliChlor®Electronic Chlorine Generator (IECG) Power Center must be installed on and
wirded 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 IECG
should never be energized when the pool pump is OFF and water is not flowing through the unit.
WARNING: To reduce the risk of injury, service should only be personnel by a qualified pool
service professional.
WARNING: Never operate the IntelliChlor Electronic Chlorine Generator (IECG) without proper flow or
water circulation. A build-up of flammable gases will result in hazardous conditions.
CAUTION - IntelliChlor Electronic Chlorine Generator (IECG) is for use with permanently-installed pools
and may also be used with hot tubs and spas if so marked. Do not use with storable or steel pools. A
permanently-installed pool is constructed in or on the ground or in a building such that it cannot be readily
disassembled for storage. A storable pool is constructed so that it is capable of being readily disassembled for
storage and reassembled to its original integrity.
CAUTION - When using the IntelliChlor Electronic Chlorine Generator (IECG) with an IntelliTouch®,
EasyTouch®or SunTouch®system, always wire the IECG Power Center to the pump side of the relay located in
the IntelliTouch, EasyTouch or SunTouch load center.This wiring method does not require a ground fault circuit-
interrupter (GFCI) to protect the circuit. A green colored terminal (or a wire connector marked “G”, “GR”,
“Ground” or “Grounding”) is provided within the terminal compartment in the Power Center transformer
enclosure.To reduce risk of electric shock, connect this terminal or connector to the grounding terminal of
your electric service or supply panel with a conductor equivalent in size to the circuit conductors supplying
this equipment.The power supply must be interconnected with pool pump motor power source. This insures
the IECG and pool pump will switch on and off together.
SAVE THESE INSTRUCTIONS

iv
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
IMPORTANT WARNINGS AND SAFETY INSTRUCTIONS
CAUTION - Use of chemicals other than those recommended may be hazardous. Even proper use of the
recommended chemicals can be hazardous. Follow the Chemical Manufacturer’s Instructions.
CAUTION - To reduce the risk of electric shock, install IntelliChlor Electronic Chlorine Generator (IECG)
a minimum of five (5) feet away from the inside wall of the pool.
CAUTION - Install the IECG a minimum of three (3) feet away from the heater outlet.
CAUTION - A solid copper, bonding conductor not smaller than No. 8 AWG (8.4 mm) should be connected
from the accessible wire connector on the unit to all metal parts of the swimming pool, spa, or hot tub structure
and to all electrical equipment, metal conduit, and metal piping within five (5) feet (1.5 m) of the inside walls of a
swimming pool, spa, or hot tub, when the unit is installed within five (5) feet of the inside walls of the swimming
pool, spa, or hot tub.
Canada - Industry Canada (IC) - This device complies with RSS210 of Industry Canada. (1999)
FCC Standard - 47 CFR Part 15, Subpart C (Section 15.247). This version is limited to chapter 1 to chapter 11
by specified firmware controlled in the U.S.A.
Federal Communications Commission (FCC) - This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this
device must accept any interference, including interference that may cause undesired operation of the device.
Interference Statement - This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television reception, which
can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference
by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Note: Modifications not expressly approved by the party responsible for FCC compliance could void the user’s
authority to operate the device.
SAVE THESE INSTRUCTIONS
WARNING: When mixing acid with water, ALWAYS ADD ACID TO WATER. NEVER ADD
WATER TO ACID.
CAUTION - The IC15 Power Supply must be interconnected with pool pump motor power source.This
ensures the IECG and pool pump will switch on and off together. When the IC15 (IECG) is installed in Europe,
IC15 (IECG) power supply fuses should ONLY be obtained from the manufacturer.
WARNING - The IC15 Power Supply is only intended for use with the IC15 cell, DO NOT PLUG ANY
OTHER INTELLICHLOR CELL INTO THIS POWER SUPPLY, SEVERE DAMAGE WILL RESULT.

1
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
IntelliChlor®Electronic Chlorine Generator Overview
The IntelliChlor Electronic Chlorine Generator (IECG) salt chlorinator uses a process known as electrolysis to
produce chlorine gas which immediately dissolves into a solution to create Hypochlorite (a pool and spa water
sanitizer) from a low concentration of salt added to the pool water. Hypochlorite kills bacteria, oxidizes organic
material, and kills algae, then reverts back to salt. The IECG then reuses the salt and the process starts over
again. The IntelliChlor system is comprised of the IECG and Power Center.
CAUTION - The IntelliChlor Electronic Chlorine Generator (IECG) is designed only to produce chlorine.The
IECG does not monitor or control chlorine levels in the pool or spa water. It is the pool owner’s responsibility for
monitoring and maintaining free chlorine levels at the APSP recommended range of 2.0 to 4.0 parts per million
(ppm). It is the pool owner’s responsibility to check, on a regular basis, the free chlorine level while the pool
pump is running, and adjust the IntelliChlor Electronic Chlorine Generator accordingly.
WARNING - Salt is an inherently corrosive material. While the levels of salt required for proper operation
of the IntelliChlor Electronic Chlorine Generator are relatively low when compared to sea water and other salt
solutions, placing any amount of salt in your pool increases the likelihood of corrosion or other deterioration of
pool equipment and any surfaces used in and around your pool. Metal parts (including steel pools) and certain
natural and man-made surfaces are particularly susceptible to corrosion and deterioration when used in and
around salt water pools. Pentair Water Pool and Spa (“Pentair”) does not represent or otherwise guarantee that
the proper use of the IntelliChlor Electronic Chlorine Generator will prevent corrosion or other deterioration of
pool equipment and any surfaces used in and around your pool. Consult your experienced pool professional,
who should be able to advise you on the proper material selection, installation techniques for those materials,
and the proper use, care and maintenance of those materials for your specific pool type and location in order to
minimize the corrosion and deterioration that is inherent in and around salt water pools.
Features
• Superior design combines cell and control panel as one assembly.
• Cell blades are made from a titanium metal base and coated with precious metal Ruthenium oxide.
• Cell blades are capable of producing chlorine for at least 10,000 hours, when the IECG is used properly.
• The IECG can be installed horizontally or vertically.
• Separate Power Center mounts to wall at equipment pad, for easy AC wiring.
• Electronics run cool for long, reliable life.
• Cell hour meter reports current usage to determine how many hours remain in the life of the unit.
• IC60 model produces up to 2 lbs of chlorine per day, IC40 model produces up to 1.40 lbs. per day, the
IC20 model produces up to 0.70 lbs per day and the IC15 produces up to 0.60 lbs. of chlorine per day.
• Salt level LED indicators show four ranges for the amount of salt in pool.
• Red and green LED indicators show system status for power, water flow, and cell status.
• MORE and LESS output buttons control how much chlorine is produced.
• BOOST cycle sets the unit to maximum chlorine output for 24 hours of pump run time.
• UL listed to UL1081 standards for swimming pool chlorinators.
• Approved NSF regulatory standards, and CE certified.
CAUTION - FOR ALL NEWLY CONSTRUCTED OR RESURFACED PLASTER POOLS: Do not operate
the IECG with newly poured or resurfaced pool plaster. Salt is a corrosive element and severe salt
damage can occur to your pool. Wait at least ONE (1) MONTH after construction to allow plaster to cure
before adding salt and operating IECG. Follow the pool surface manufacturer’s guidelines for your
specific pool.
FOR NEW VINYL LINER POOLS, contact the manufacturer for recommended guidelines before
adding salt and operating the IECG.

2
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
IntelliChlor System Components
An IntelliChlor Electronic Chlorine Generator IntelliChlor system consists of one or more of the following:
•IC15 Cell (P/N 520888): Designed for pools up to 15,000 U.S. gallons (56,000 cubic meters). The cell
will produce the equivalent of 0.60 pounds of pure chlorine per 24 hours of continuous pool pump run
time.
•IC20 Cell (P/N 520554): Designed for pools up to 20,000 U.S. gallons (75,000 liters). The cell will
produce the equivalent of 0.70 lbs. of pure chlorine per 24 hours of continuous pool pump run time.
•IC40 Cell (P/N 520555): Designed for pools up to 40,000 U.S. gallons (150,000 liters). The cell will
produce the equivalent of 1.40 lbs. of pure chlorine per 24 hours of continuous pool pump run time.
•IC60 Cell (P/N 521105): Designed for pools up to 60,000 U.S. gallons (227,124 liters). The cell will
produce the equivalent of 2 lbs. of pure chlorine per 24 hours of continuous pool pump run time.
•PC100 (P/N 520556): Power Center Kit. Provides power and control communication to and from the
IntelliChlor cell. Used for IC20, IC40 and IC60 IntelliChlor cell.
•IntelliChlor “dummy” bypass cell (P/N 520588): For new pool start-up.
Note: For IntelliChlor and IntelliTouch, EasyTouch and SunTouch controller parts numbers, refer to
“IntelliChlor and Controller System Part Numbers” on page v.
Note: The salt sensor reading is within +/- 500 ppm accuracy.
IntelliChlor Electronic Chlorine Generator Control Panel and Cell Description
The IntelliChlor Electronic Chlorine Generator (IECG) includes a control panel with buttons and
LED indicators to control the IECG and produce chlorine. The IECG measures the water
temperature and salt level to produce chlorine at the defined output. If the salt level in the pool
water is too low (red on salt display), the cell is turned off until salt is added to the pool. The
controller has a self-cleaning cycle which reverses the cell polarity, reducing calcium buildup. This
feature turns the cell on and off at regular intervals to minimize calcium and scale buildup and
further maximizes cell life.
The IECG contains the control electronics and bipolar electrodes that electrically produces chlorine
when energized with DC current. Chlorine is generated as pool water containing salt passes
through the cell. The chlorine production can be varied by either adjusting the sanitizer output level
on the control panel and/or by varying the number of hours the IECG is on each day. The IECG
automatically reverses the cell electrode blades every few hours to help clean the cell. This
process does not interrupt the production of Chlorine. The IECG also contains a mechanical
flow sensor to ensure the proper amount of water is passing through the cell to allow chlorination to
occur. The IECG automatically measures the water salinity and temperature and displays four (4)
salinity ranges on the control panel using LED indicators. The IECG includes a 15 ft. UL approved
four conductor 16-gauge cable for connection to the Power Center.
•Flow Sensor: A flow sensor assures that there will always be adequate water flow
through the IECG. If the IECG is not properly plumbed and/or does not receive adequate
water flow, no chlorine will be produced.
•Temperature Sensor: To protect the IECG from operation and potential damage when
the temperature of the pool water falls below 52° F, ±3° F (11° C, ±1.67° C), the
temperature sensor switches the IECG off, and no chlorine will be produced.
•Salt Sensor: Two (2) salt sensor probes in the IECG are activated each time the IECG is
switched on and again during every 12 hours of continuous running. At each of those
times, the salt level LED indicator lights flash in a scrolling sequence for two (2) minutes
to indicate that the IECG is in analysis mode. After two (2) minutes, the LED indicators
lights will signal one (1) of four (4) salinity ranges. For more information, see “Salt Level
Status LEDs” on page 7.

3
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
IntelliChlor Power Center (IC20, IC40 IC60)
The IntelliChlor Power Center converts AC electrical current to a low-voltage DC electrical current which is
required to produce chlorine. The power supply is connected with the pool circulation pump electrical source
so that the IECG only operates when the pool pump is on. The Power Center should be mounted vertically on
the wall up to fifteen (15) feet away from the IECG. The Power Center contains the transformer, fuse,
connector to the cell and the AC electrical current wiring configuration with the DC electrical current output
cable to the IECG. A fuse holder is mounted on the bottom of the Power Center for additional protection.
There are no other controls or lights on the Power Center. For information about installing and proper use of
the Power Center, see the “IntelliChlor Power Center Installation Guide,” (P/N 520590).
IntelliChlor IC20, IC40 IC60 Power Center (Model PC 100)
CAUTION - The IntelliChlor
Power Center does NOT control
the pump.The IntelliChlor
Electronic Chlorine Generator
only produces chlorine when the
pool pump is on.
CAUTION - Before plugging or
unplugging the IntelliChlor Electronic
Chlorine Generator to the Power Center,
first switch off the AC power to the Power
Center.
IntelliChlor Electronic Chlorine Generator
Clear sliding
cover
Control Panel
status LEDs
MORE and LESS
output buttons
IntelliChlor Power Supply
The IntelliChlor Power Supply converts AC electrical current to a low-voltage AC electrical current which is
required to produce chlorine. The Power Supply is connected with the pool circulation pump electrical source
so that the IECG only operates when the pool pump is on. A 15 ft. cord connected to the IC15 unit plugs into
the Power Supply which plugs directly into a 110VAC outlet. The Power Supply can be mounted vertically on
the wall up to fifteen (15) feet away from the IECG.. The Power Supply contains the transformer, fuse (1
AMP 250 V, 3 AG), connector to the cell and the AC electrical cord with plug. There are no other controls or
lights on the Power Supply. The Power Supply must be connected to a GFCI protected outlet.
CAUTION - The
IntelliChlor Power Supply
does NOT control the pump.
The IntelliChlor Electronic
Chlorine Generator, model
IC15 only produces chlorine
when the pool pump is on.
CAUTION - First
switch OFF AC power to
the Power Supply before
plugging or unplugging
the IntelliChlor IC15.
IntelliChlor IC15 External Power Supply

4
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
System Schematic Diagram
The following schematic diagram shows a typical IntelliChlor system installation.
Note: This schematic diagram is not drawn to scale. Refer to the relevant portions of this Installation
and User’s Guide for information regarding proper placement and spacing of all equipment depicted in
this diagram.
NOT TO SCALE
Install Chlorine/Bromine Feeders after the IntelliChlor Cell
CAUTION - To avoid permanent damage to the IntelliChlor cell, automatic in-line chlorine/bromine feeders
(such as Pentair Water Pool and Spa® Rainbow models) MUST be installed AFTER the IntelliChlor cell as
shown below. When using the IntelliChlor with an in-floor cleaner pressure system, it is recommended that a
separate return line be used for the cleaner to reduce the increased water pressure stress on the IntelliChlor
cell.
Note: For best flow
sensing, provide at least
12"-18" of straight pipe in
front of the cell inlet.

5
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
IntelliChlor Plumbing Diagram
Plumbing the IntelliChlor Electronic Chlorine Generator (IECG):
• Always install the IntelliChlor Electronic Chlorine Generator AFTER the filter and heater (see
“System Diagram” on page 4). The ICEG should be no closer than three (3) feet away from the
heater outlet.
• If the IECG is installed on a pool/spa combination system, install (see diagram below) the IECG
BEFORE the pool/spa return valve to allow proper chlorination of both the pool and spa and also to
avoid creating gas traps in the pipes.
Loop Plumbing Diagram
The IntelliChlor Electronic Chlorine Generator is designed to operate with water flow rates from 25 gallons per
minute (gpm) up to 105 gpm. Do not exceed 105 gpm or pipe manufacturers recommended flow rate,
whichever is less. For flow rates over 80 gpm, it is recommend that you use a bypass loop (as shown below)
for best chlorine production. Installations with flow rates over 80 gallons per minute are those that have
in-floor cleaning systems or booster pumps. These systems MUST use a bypass loop with the IECG with a
flow control valve that assures that the flow through the IECG is maintained within its designed operating
water flow rates.
Flow control valve
Bypass loop
NOT TO SCALE
NOT TO SCALE
Note: For best flow
sensing, provide at
least 12"-18" of straight
pipe in front of the cell
inlet.

6
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
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7
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Section 1
IntelliChlor Control Panel
Salt Level Status LEDs
The IECG salt level checks the pool water daily and displays the levels as follows:
Green LED: Good salt. The pool water salt level is between 2800 ppm
and 4500, and the IECG is producing chlorine. IECG salt LED should
always be showing GREEN level for better results.
Green LED (Flashing): Salt level is above 4500 ppm. Chlorine is being
produced but the salt level is too high which increases the risk of
corrosion and deterioration of pool equipment and surfaces in and around
the pool. Pool water needs to be drained and refilled one (1) foot at a
time until the salt level is below 4500 ppm.
Red LED: Low salt. The water salt level is below 2800 ppm. The IECG
will be producing chlorine at reduced efficiency. It is highly
recommended to add salt. See (*) Note below.
Red LED: Very low salt. The water salt level has fallen below 2600 ppm.
The IECG will not produce chlorine until salt is added. The IECG is OFF.
See (*) Note below.
Status LEDs
Pwr: Shows the IntelliChlor Electronic Chlorine Generator power status:
•Red: An error is occurring in the IECG. Service is needed.
•Green: The IECG is operational and ready.
Cell: Shows the status of the IECG.
•Green (flashing): The IECG needs to be inspected.The blades
may have calcium buildup. The IECG is not producing chlorine.
•Green: IECG is good and producing chlorine
No Light: IECG is off and not producing chlorine. It may be in an
off-period of the sanitizing cycle and will return on shortly. This
light will also be blank if the water temperature is below
52° F +/-3° F (11° C +/ 1.67° C). This cold water cutoff mode
extends the blade life.
Flow: This light indicates the status of water flowing through the IECG.
•Red: Insufficient water flow through the IECG, no chlorine is being produced.
•Green: Sufficient water flow to produce chlorine.
NOTE (*): Salinity readings will be accurate after the first power up of
the IECG, following a 24 hour period. After every salt addition, proper
dilution and salinity readings should be done after the pump has been
running for at least 24 hours.
DO NOT take salinity readings when the “LOW SALT” Red LED is
flashing or during the 24 hrs. dilution period. Otherwise, readings WILL
NOT be accurate.

8
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Operator Control Panel (continued)
Sanitizer Output LED Indicators
The five (5) LED indicators display as a bar graph to show in 20% increments, the percentage of time the
chlorine is produced per hour of pump run time. In BOOST mode, these LEDs (blink from left to right).
More and Less Output Buttons
The More and Less buttons control the percentage of time of each hour that the IntelliChlor Electronic
Chlorine Generator is producing chlorine while the pump is on (see Sanitizer Output LED indicators above).
The lights act as a bar graph: the more lights that are on, the more that chlorine is produced. Slide the panel
cover up to access the More, Less and Boost On/Off buttons. To exit Boost mode, press and hold both the
More and Less buttons. Note: When a IC20, IC40 or IC60 is connected to an IntelliTouch®,
EasyTouch® or SunTouch® system, the Less and More buttons are disabled and IntelliChlor Sanitizer
Output is controlled externally.
More: Increases the time the cell produces chlorine, in 20% increments. Example: The Sanitizer Output
display is showing 20%. Pressing the MORE button once will turn on the 40% light. The unit will produce
chlorine 40% of each hour the IECG is on. Pressing MORE again will turn on the 60% light, and so on until
all five (5) lights are on.
Less: Decreases the time the cell produces chlorine, in 20% increments. Example: The Sanitizer Output
display is showing 40%. Pressing the LESS button once will turn off the 40% light, leaving only the 20%
light. The unit will produce chlorine 20% of each hour the IECG is on. Pressing LESS again will turn off the
20% light, leaving no lights on, no chlorine is produced.
Boost On/Off: Press and hold both the More and Less buttons together to activate Boost mode on or off.
Boost mode sets the sanitizer output to run 100% for the next 24 hours of pool pump run time. If the time
clock switches off the pump cycle, then switches power back on the next day, Boost mode will continue until
24 hours has elapsed since Boost mode was turned on or Boost mode is canceled by the user. The Sanitizer
Output display will show a pattern LED display to indicate Boost mode.
Note: If connected to an IntelliTouch, EasyTouch or SunTouch system, these lights may slowly flash
when the output is set to a value not exactly 20%, 40%, 60% 80% or 100%. Example: 21% output
setting from the IntelliTouch, EasyTouch or SunTouch will flash the 20% light.
Note: If no LEDs are lit, the output is set to 0% and the IntelliChlor Electronic Chlorine Generator is
not producing chlorine.
Self-Cleaning
The self-cleaning feature reduces scale buildup on the blades of the IECG. The self-cleaning cycle tends to
reduce the life of the IECG, therefore, it should be used only to the extent necessary to minimize the scale
buildup on the blades. The self-cleaning cycle can be adjusted to run every 2, 3, 4, or 5 hours, whichever is the
optimal for your particular pool conditions in order to minimize scale buildup but maximize the life of the IECG.
It is factory set to two (2) hours for the first 30 days of operation, then automatically switches to three (3)
hours. To change the self-cleaning cycle, press and hold the LESS button for three (3) seconds. The sanitizer
output display will show the number of hours in a bar graph style. The number of output LEDs lit is the number
of reverse hours. Pressing More or Less button will change this setting. Example: The self-clean cycle is set to
run for four (4) hours and the pool owner chooses to change it to three (3) hours to optimize the blade cleaner cycle for
your particular pool conditions. Press and hold the LESS button for three (3) seconds. The sanitizer output display will
blank, then light up the 20%, 40%, 60% and 80% lights, four (4) total. This is a four (4) hours reverse setting. Pressing
the LESS button once within ten (10) seconds will switch off the 80% light, leaving only three (3) lights on, now at a three
(3) hours reverse setting. Wait ten (10) seconds and this mode will end automatically, returning to the original sanitizer
output display.
• 0% - No LEDs lit - No chlorine produced - IntelliChlor Electronic Chlorine Generator is off.
• 20% - 1 LED lit - Produces chlorine 20% of each hour of pump run time, 12 minutes on, 48 minutes off.
• 40% - 2 LEDs lit - Produces chlorine 40% of each hour of pump run time, 24 minutes on, 36 minutes off.
• 60% - 3 LEDs lit - Produces chlorine 60% of each hour of pump run time, 36 minutes on, 24 minutes off.
• 80% - 4 LEDs lit - Produces chlorine 80% of each hour of pump run time, 48 minutes on, 12 minutes off.
• 100% - 5 LEDs lit - Produces chlorine almost 100% of each the hour of pump run time, 59 minutes on, 1 minute off.

9
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Section 2
Pool Water Chemistry, Conditions
and Precautions
This section describes the start up procedure and operating instructions for IntelliChlor Electronic Chlorine
Generator.
Pool Water Chemistry, Conditions and Precautions
1. New Pool Water: A recently filled or newly-refinished pool may contain undesirable matter. This
undesirable matter could interfere with IntelliChlor’s ability to chlorinate properly. Make sure the
water is tested by a pool professional and properly balanced before switching on the IntelliChlor
Electronic Chlorine Generator.
WARNING - Salt is an inherently corrosive material. While the levels of salt required for proper operation of
the IntelliChlor Electronic Chlorine Generator are relatively low when compared to sea water and other salt
solutions, placing any amount of salt in your pool increases the likelihood of corrosion or other deterioration of
pool equipment and any surfaces used in and around your pool. Metal parts (including steel pools) and certain
natural and man-made surfaces are particularly susceptible to corrosion and deterioration when used in and
around salt water pools. Pentair Water Pool and Spa (“Pentair”) does not represent or otherwise guarantee that
the proper use of the IntelliChlor Electronic Chlorine Generator will prevent corrosion or other deterioration of
pool equipment and any surfaces used in and around your pool. Consult your experienced pool professional,
who should be able to advise you on the proper material selection, installation techniques for those materials,
and the proper use, care and maintenance of those materials for your specific pool type and location in order to
minimize the corrosion and deterioration that is inherent in and around salt water pools.
2. Super Chlorination burns out the swimmer waste that has combined with chlorine. This frees the
chlorine for sanitizing. This is accomplished by raising the chlorine level quickly and dramatically.
When the chlorine level is raised to ten (10) times the amount of combined chlorine (usually 5 to 10
ppm) the pool water is said to have been super chlorinated. As pool water is continuously passed
through the IECG while the unit is powered on, all pool water inside the IECG is being super
chlorinated. When the IntelliChlor Electronic Chlorine Generator is used on pools, the pool water
sparkles and does not burn the eyes because of the absence of chloramines.
Note: On initial start-up of a pool, it is best to super chlorinate using an outside source, i.e.,
use a shock treatment available at your local pool supplier.
3. Chloramines should not be present in pool water. Chloramines are formed when ammonia (which is
found in urine and sweat) combine with free chlorine. This ties up the free chlorine in your pool and
does not allow the chlorine in your pool to disinfect. Chloramines also burn the eyes and are foul
smelling. Super Chlorinate to remove chloramines at the initial start-up of the pool and as needed to
maintain proper levels of free chlorine.
4. Cyanuric acid is needed in outdoor pools to help to stabilize and maintain proper levels of chlorine.
90% of unstabilized chlorine is destroyed by the UV radiation from the sun within two hours.
Cyanuric acid stabilizes chlorine in water from UV degradation. When using the IECG, the cyanuric
acid level should be maintained between 50-80 ppm. See Table 3, on page 14. NOTE: DO NOT USE
CYANURIC ACID IN INDOOR POOLS.
5. Total Dissolved Solids (TDS): Adding salt to pool water will raise the TDS level. While this does
not adversely affect the pool water chemistry or clarity, the pool water professional testing for TDS
must be made aware salt has been added to the IntelliChlor system. The individual performing the
TDS test (see page 22) may then subtract the salinity level to arrive at a TDS level that would be
compatible to a TDS reading for a non-salt water pool.

10
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
6. Metals - Some metals, i.e. copper and iron, can cause loss of chlorine. Also, metals can stain your
pool. Metals can also damage the IntelliChlor Electronic Chlorine Generator. Have your local pool
professional check for metals and recommend methods of removal.
7. Nitrates and Phosphates can cause extremely high chlorine demands and will deplete chlorine from
your swimming pool. In some cases nitrates may even lower your chlorine levels to zero. Your local
pool professional can test for nitrates and phosphates. While a 0 ppm level of nitrates is the ideal, the
pool owner should make sure that nitrates DO NOT exceed 10 ppm. Phosphates should not exceed
125 parts per billion (ppb).
Optimum Pool Water Chemistry Conditions for Salt Water Pools
(using the IntelliChlor Electronic Chlorine Generator)
In accordance with the Association of Pool and Spa Professionals (APSP) standards, it is recommended that
the following pool water chemistry conditions be maintained on an on going basis to help protect pool users,
pool related equipment and surfaces in and around the pool. These values are important to maintaining the pool
equipment in proper operating condition and preventing corrosion, liming or other problems. The IntelliChlor
Electronic Chlorine Generator is warranted to operate properly only if these conditions are met. For more
information, refer to your local agency having jurisdiction, NSPI (National Spa and Pool Institute), the CDC
(Centers for Disease Control), or the WHO (World Health Organization).
Free Chlorine: 2.0 - 4.0 ppm. Above 4.0 ppm may cause corrosion of metal components
Combined Chlorine (Chloramines): None (super chlorinate to remove all chloramines)
pH: 7.2 - 7.8 (USE MURIATIC ACID to lower pH and Soda Ash to raise pH.)
Cyanuric Acid: 50 - 80 ppm
Total Alkalinity: 80 - 120 ppm
Calcium Hardness: 200 - 400 ppm
TDS (includes salt): 3000 minium to 5700 to 6000 maximum ppm
Salt: 3000 - 4500 ppm (ideal 3400 ppm)
Metals (Copper, Iron, Manganese): None
Nitrates: None
Phosphates: Less than 125 ppb
Covered Pools and Vinyl Liner Pool and Lowering Chlorine Output Levels
When using the IntelliChlor Electronic Chlorine Generator with covered pools and/or vinyl liner pools, less
chlorine is needed. It is recommend to lower the chlorine output level while the pool is covered. For more
information about chlorine output levels, see “More or Less Output Buttons” page 8.

11
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Chlorine Testing
It is recommended that chlorine test samples be taken from two (2) locations in the pool. Compare the
samples. A higher level should be found at the pool return line. The higher level at the pool return line indicates
the IECG is producing chlorine. Take chlorine samples for testing at:
• The pool return line.
• 18 inches (457 mm) below the surface and well away from the pool return line.
What Type of Salt to Use
The purer the salt, the better the life and performance of the IntelliChlor Electronic Chlorine Generator. Use
salt that is at least 99.8% pure NaCl, sodium chloride. The preferred and recommended salt is an evaporated,
granulated, food quality, non-iodized salt with no additives. Consult your salt supplier.
• Avoid using salt with anti-caking agents (sodium ferrocyanide, also known as YPS or yellow prussiate
of soda). Filling agents can cause some discoloration of fittings and surface finishes in pool.
• Water conditioning salt pellets are compressed forms of evaporated salt and may be used, but will
take longer to dissolve. Such pellets could damage pool plaster and other surfaces in and around the
pool.
• Do not use calcium chloride or potassium chloride as a source of salt. (Use sodium chloride only).
• Do not use Rock salt (insoluble impurities mixed with the rock salt can shorten the life of the IECG).
How Much Salt to Use?
Use the Table 1 chart (page 13) to determine how much salt will be needed. Most pools contain some salt,
depending on the water source and chemicals used for sanitizing. Therefore, the pool owner must always test
salt levels before adding salt. A hand held meter calibrated for NaCl (salt) can be used to determine the salt
levels of the pool water. After the IntelliChlor Electronic Chlorine Generator is powered on, the LED salt level
lights will blink from bottom to top for two (2) minutes while it analyzes the pool water, then the LED
indicators will show one (1) of four (4) salt level ranges. This solid light indicates the salt status of the pool.
• 3000 to 3500 ppm of salt is recommended for optimum water conditions.
• Low salt concentration below 2600 ppm will cause the unit to turn off
• High salt concentration above 4500 ppm may cause excessive corrosion or deterioration to pool
equipment and surrounding surfaces in and around the pool.
Note: Salt measurements will vary between measuring devices (salt test strips, electronic testers, and
titration). The salt sensor reading is within +/- 500 ppm accuracy. For more troubleshooting
information about high salt levels, see “Troubleshooting,” on page 33.
CAUTION - FOR ALL NEWLY CONSTRUCTED OR RESURFACED PLASTER POOLS: Do not operate
the IECG with newly poured or resurfaced pool plaster. Salt is a corrosive element and severe salt damage can
occur to your pool. Wait at least ONE (1) MONTH after construction to allow plaster to cure before adding salt
and operating IECG. Follow the pool surface manufacturer’s guidelines for your specific pool.
FOR NEW VINYL LINER POOLS, contact the manufacturer for recommended guidelines before adding salt
and operating the IECG.

12
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Calculating the Saturation Index
The saturation index is a formula that relates pH, calcium and alkalinity in the pool water. A well balanced
pool water will have a formula result range between -0.3 and 0.3 Outside this range, the pool water is out of
balance, potentially damaging pool equipment or scaling the IECG. The equation to calculate Si is:
Cyanuric acid in the form of cyanurate ions contribute to alkalinity. Thus, a correction must be made to total
alkalinity. We subtract 1/3 of the cyanuric acid level from the reading obtained in the total alkalinity test.
Total Alkalinity - 1/3 Cyanuric Acid = Corrected Alkalinity
This correction can be considerable in established pools with high cyanuric acid levels; for example, at 240
ppm cyanuric acid, the correction amounts to 80 ppm (240 ÷ 3 = 80).
Saturation Index Factors
SI = pH + CHF + AF + TF + TDSF
Saturation
Index pHas
tested Calcium
Hardness
Factor
Alkalinity
Factor Tempera-
ture
Factor
TDS
Factor

13
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
How to Add Salt to the Pool
CAUTION - FOR ALL NEWLY CONSTRUCTED OR RESURFACED PLASTER POOLS: Do not operate
the IECG with newly poured or resurfaced pool plaster. Salt is a corrosive element and severe salt damage can
occur to your pool. Wait at least ONE (1) MONTH after construction to allow plaster to cure before adding salt
and operating IECG. Follow the pool surface manufacturer’s guidelines for your specific pool. FOR NEW VINYL
LINER POOLS, contact the manufacturer for recommended guidelines before adding salt and operating the
IECG.
1. Check salt level in pool water before adding any salt to pool.
2. Determine the amount of salt from the following charts.
3. Slowly pour in the salt around the outer perimeter of the pool for quick and even distribution. To
avoid clogging the filter or damaging pool related equipment and surrounding surfaces, do not
add salt through the skimmer or surge tank.
4. Brush the pool bottom and allow water to circulate for 24 hours to dissolve salt completely.
5. After 24 hours, verify correct salt level reading by checking the LED indicators on the IntelliChlor
Electronic Chlorine Generator and by a separate reliable test method.
6. Power on the IntelliChlor Electronic Chlorine Generator and set the Sanitizer Output level to the
proper setting to maintain the appropriate free chlorine levels in the pool water (i.e., within the
2.0 - 4.0 ppm, APSP recommended range).
Table 1. Approximate Pounds (Kg) of salt needed to obtain 3,400 ppm in pool
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gk231gk121gk111gk001gk78gk67gk66gk55gk54gk23gk12
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23bl292bl562bl032bl202bl471bl641bl811bl48bl65
gk851gk541gk331gk021gk401gk29gk97gk66gk45gk83gk52
000,41
bl604bl473bl143bl903bl86
2bl632bl302bl171bl831bl79bl56
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000,61
bl464bl724bl093bl353bl603bl962bl232bl59
1bl851bl111bl47
gk112gk491gk771gk061gk931gk221gk501gk88gk27gk15gk43
000,81
bl225bl084bl934bl793bl543bl303bl162bl912bl871bl521bl
48
gk732gk812gk991gk081gk651gk731gk811gk99gk18gk75gk83
000,02
bl085bl435bl784bl144bl383bl733bl092bl442bl791bl931bl39
gk362gk24
2gk122gk002gk471gk351gk231gk111gk98gk36gk24
000,22
bl836bl785bl635bl584bl124bl073bl913bl862bl712bl351bl201
gk092gk662gk342gk02
2gk191gk861gk541gk221gk89gk96gk64
000,42
bl696bl146bl585bl925bl064bl404bl843bl292bl732bl761bl111
gk613gk192gk562gk042gk802gk38
1gk851gk331gk701gk67gk15
000,62
bl457bl496bl436bl375bl894bl834bl773bl713bl652bl181bl121
gk243gk513gk782gk062gk622gk891gk171gk4
41gk611gk28gk55
000,82
bl218bl747bl286bl716bl635bl174bl604bl143bl672bl591bl031
gk863gk933gk013gk082gk342gk412gk481gk551gk521gk
88gk95
000,03
bl078bl108bl137bl266bl475bl505bl534bl663bl692bl902bl931
gk593gk363gk233gk003gk162gk922gk791gk661gk431gk59gk36

14
IntelliChlor Electronic Chlorine Generator Installation and User’s Guide
Table 2. Approximate Pounds (Kg) of salt needed to maintain 3,000 ppm in pool
Table 3. Approximate amount of cyanuric acid to obtain 75 ppm in pool
NOTE: The cyanuric acid reading should be maintained at 50 - 80 ppm.
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