Pentair Pool Products IntelliChlor PC100 User manual

IntelliChlor Power Center Installation Guide
Installation
and
User’s Guide
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
IntelliChlor®Power Center
(For use with IntelliChlor
model IC60, IC40 and IC20)
Patents
pending
Certified to NSF/ANSI 50

IntelliChlor Power Center Installation Guide
Technical Support
Sanford, North Carolina (8 A.M. to 5 P.M. ET)
Moorpark, California (8 A.M. to 5 P.M. PT)
Phone: [phone]
Fax [phone]
Web sites: visit www.pentairpool.com and staritepool.com
© 2009 Pentair Water Pool and Spa, Inc. All rights reserved
1620 Hawkins Ave., Sanford, NC 27330 • [phone] • [phone]
10951 West Los Angeles Ave., Moorpark, CA 93021 • [phone] • [phone]
IntelliChlor®, EasyTouch®, IntelliTouch®, SunTouch®and Pentair Water Pool and Spa®are 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 520590 Rev D - 11/13/09
IMPORTANT SAFETY PRECAUTIONS .......................................................... i
IntelliChlor Power Center Overview.................................................................. 1
IntelliChlor System Components ..................................................................... 2
Operating Instructions ..................................................................................... 2
Installation ................................................................................................ 2
Kit Contents ............................................................................................. 2
Required Tools .......................................................................................... 2
Installing the Power Center .............................................................................. 3
SAFETY PRECAUTIONS ............................................................................... 3
Troubleshooting ............................................................................................... 6
Electrical Specifications .................................................................................. 6
230 VAC Basic System Wiring ........................................................................ 6
110 VAC Basic System Wiring ........................................................................ 6
Contents

IntelliChlor Power Center Installation Guide
i
Most states and local codes regulate the construction, installation, and
operation of public pools and spas, and the construction of residential
pools and spas. It is important to comply with these codes, many of which directly
regulate the installation and use of this product. Consult your local building and health
codes for more information. Before attempting installation of service, ensure that all
power to the circuit supplying power to the IntelliChlor Power Center(s) is
disconnected/switched off at the circuit breaker.
SERIOUS BODILY INJURY OR DEATH CAN RESULT IF THIS
PRODUCT IS NOT INSTALLED AND USED CORRECTLY.
INSTALLERS AND POOL OPERATORS MUST READ THESE
WARNINGS AND ALL INSTRUCTIONS BEFORE USING THIS
PUMP AND SAND FILTER. To reduce the risk of injury, service
should only be done by a qualified pool service professional.
Before installing this product, read and follow all warning notices
and instructions in this Guide. Failure to follow warnings and
instructions can result in severe injury, death, or property damage.
Call [phone] for additional free copies of these instructions. Please refer to
www.pentaircommercial.com for more information related to these products.
IMPORTANT NOTICE - Attention Installer: This Installation and User’s
Guide (“Guide”) contains important information about the installation,
operation and safe use of this product. This Guide should be given to the
owner and/or operator of this equipment.
WARNINGS AND IMPORTANT SAFETY PRECAUTIONS
IMPORTANT SAFETY INSTRUCTIONS PERTAINING TO A RISK OF
FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS. READ AND
FOLLOW ALL INSTRUCTIONS.
CHLORINE GAS BUILDUP CAN OCCUR WITH IMPROPER WIRING:
To reduce the risk of personal injury the IntelliChlor® Electronic
Chlorine Generator (IECG) Power Center must be installed on and
wired to the load side of the time clock, electronically controlled switch,
or relay load side, so that it will receive power only when the pool
pump is on. 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.
To reduce the risk of injury, do not permit children to use or operate this
pump and sand filter.
When setting up pool water turnovers or flow rates the operator must
consider local codes governing turnover as well as disinfectant feed
ratios.
DO NOT increase pump size; this may increase the flow rate through the
system and exceed the maximum flow rate stated on the drain cover.
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.
Operate unit with minimum flow of 25 gpm. For high flow
applications, use a bypass loop.

IntelliChlor Power Center Installation Guide
ii
WARNINGS AND IMPORTANT SAFETY PRECAUTIONS
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. Operate unit with
minimum flow of 25 gpm. For high flow applications, use a bypass
loop.
Only use pipe couplings that meet Schedule 80, maximum pressure
150 psi at 70° F.
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 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
dissembled for storage and reassembled to its original integrity.
The IECG Power Centers must be interconnected with the pool
pump motor power source. This ensures the IECG and pool pump
will switch on and off together.
When mixing acid with water, ALWAYS ADD ACID TO WATER.
NEVER ADD WATER TO ACID.
Use of chemicals other than those recommended may be hazard-
ous. Follow the Chemical Manufacturer's Instructions.
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.
Install the IECG a minimum of three (3) feet away from the heater
outlet. Allow ample access to the IntelliChlor control panel buttons
and the IntelliChlor Power Center.
It is recommended to install a Pentair two (3) inch CHECK VALVE
(P/N 263060) between the input side of the IECG and the main
heater output pipe.
A solid copper, bonding conductor not smaller than No. 8 AWG
(8.4 mm) should be connected to all metal parts of the swimming
pool, spa, or hot tub structure and to all electrical equipment,
metal conduit, and metal piping.
Always disconnect power to the IntelliChlor salt chlorine generator
at the circuit breaker before servicing. Failure to do so could result
in death or serious injury to service person, pool users or others
due to electric shock.
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION:

IntelliChlor Power Center Installation Guide
WARNINGS AND IMPORTANT SAFETY PRECAUTIONS
For information about the Virginia Graeme Baker Pool and Spa Safety
Act, contact the Consumer Product Safety Commission at (301) 504-
7908 or visit www.cpsc.gov.
NOTE: Always turn off all power to the pool pump before installing the
cover or working on any suction outlet.
iii
When mixing acid with water, ALWAYS ADD ACID TO WATER.
NEVER ADD WATER TO ACID.
Do not operate electrolytic cell without proper flow or water
circulation. A build-up of flammable gases will result in
hazardous conditions.
When using IntelliChlor with an IntelliTouch system, it is recom-
mended to wire the IntelliChlor Power Center to the pump side of
the relay located in the IntelliTouch 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 connec-
tor 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 IntelliChlor chlorinator and pool pump will switch on and off
together.
Use of chemicals other than those recommended may be
hazardous. Follow the Chemical Manufacturer’s Instructions.
Install the IntelliChlor unit a minimum of two (2) feet from the
heater outlet.
It is recommended to install a Pentair Water Pool and Spa®
two ( 2) inch CHECK VALVE (P/N 263042) between the input
side of the IntelliChlor cell and the main heater output pipe.
Water temperature in excess of 100° F (37.7° C) may be hazardous to
your health. Prolonged immersion in hot water may induce
hyperthermia. Hyperthermia occurs when the internal temperature of
the body reaches a level several degrees above normal body
temperature of 98.6° F (37° C.). Effects of hyperthermia include: (1)
Unawareness of impending danger. (2) Failure to perceive heat. (3)
Failure to recognize the need to leave the spa. (4) Physical inability to
exit the spa. (5) Fetal damage in pregnant women. (6)
Unconsciousness resulting in danger of drowning. The use of alcohol,
drugs, or medication can greatly increase the risk of fatal
hyperthermia in hot tubs and spas.

IntelliChlor Power Center Installation Guide
1
IntelliChlor® Power Center Overview
The IntelliChlor electronic chlorine generator system comprises of a Power Center and
electrolytic Cell. The Power Center converts AC electrical current to a low voltage DC
current required by the IntelliChlor electrolytic cell to operate and create chlorine for the
swimming pool and spa. The Power Center is connected with the pool circulation pump
electrical source so that the electrolytic cell only operates when the pool pump is on. It is
recommended that a pool pump timer be used to save on energy and prolong the
service life of your pool pump and IntelliChlor. A timer is not included as part of the Power
Center kit. The IntelliChlor Power Center can be connected to an IntelliTouch,
EasyTouch or SunTouch system for automation control.
The Power Center enclosure can be mounted vertically on a flat surface such as a wall
or post no more than 15 feet away from the cell controller. The Power Center houses the
transformer, fuse, and connector to the cell. 110 VAC and 220 VAC wiring is connected at
this box, with 35 VDC output to the cell controller. A 10 AMP slo-blo fuse is mounted on
the bottom of the enclosure for additional protection. There are no other controls or lights
on the outside of the Power Center. A green power LED indicator is mounted on the
inside main board. When the Power Center is switched on, the power LED is lit.
Cell connector
Power LED
indicator
IntelliChlor Power Center (model PC 100)
(cover removed)
Transformer
Screw terminal to
EasyTouch and
IntelliTouch
systems
Attach incoming AC wire
to Power Center AC
power wires
(blue and brown)
Lug (Ground bonding)
Internal
Ground lug

IntelliChlor Power Center Installation Guide
2
Operating Instructions
When using a pool pump timer: The Association of Pool and Spa Professionals (APSP)
recommends that all water in a residential pool pass through the filtration system at least
once every 12 hours (referred to as pool water turnover). However, many factors have an
effect on actual pump and filter system run times. Pool size, source of water, direct sun
light, indoor/outdoor, screened and unscreened, filtration system, cold or hot weather,
swimmer load, rain, organic debris, algae, etc., are all factors which contribute to either
more or less pool pump and filter system run times. Because of these differences, it is
extremely difficult to set an initial run time (starting point) for the pool pump and
chlorinating system.
Try initially setting the pool pump timer to 12 hours. It will take a few days to get just the
right amount pool pump operating time. When the Chlorinator is wired with a pool pump
timer (see page 6) results will vary greatly from one pool installation to the next, so this
should be discussed with either the pool builder or your pool professional.
Installation
The following information describes how to install the IntelliChlor Power Center. Before
installing, review the IntelliChlor kit contents and required tools. For cell installation
instructions, see the “IntelliChlor User’s Guide” (P/N 520584).
Kit Contents
- One Power Center
- Installation Guide (this manual)
RequiredTools
- Phillips & Flathead Screwdrivers
- Voltmeter. (To determine AC line voltage to Power Center)
- Electric drill and 1/4" masonry drill bit. (To mount Power Center)
IntelliChlor System Components
An IntelliChlor Electronic Chlorine Generator IntelliChlor system consists of one or more
of the following:
• PC100 (P/N 520556): Power Center Kit. Provides power and control communication to
and from theIntelliChlor cell.
• IC20 Cell (P/N 520554): Designed for pools up to 20,000 U.S. gallons (75,000 liters).
The cell willproduce 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 willproduce 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 willproduce the equivalent of 2 lbs. of pure chlorine per 24 hours of continuous
pool pump run time.
• IntelliChlor “dummy” bypass cell (P/N 520588): For new pool start-up.

IntelliChlor Power Center Installation Guide
3
Install the Power Center at eye level as close to the IntelliChlor
pump and filtration as possible.
The Power Center must be installed more than 8 ft. (2.44 m) from
the pool edges.
Leave sufficient clearance on all sides of the Power Center.
Ensure that the 15 ft. (4.61 m) DC power cord from the Cell
assembly pipe location can reach the Power Center location. The
Power Center enclosure can be mounted on the wall up to 15 feet
away from the cell controller.
Note: For installation instructions about connecting the cell to
Power Center, see the “IntelliChlor User’s Guide” (P/N 520589).
IMPORTANT SAFETY PRECAUTIONS. PLEASE READ THE
FOLLOWING: Read all the safety precautions in this manual
before attempting any electrical wiring. Be sure to read and follow all safety
Instructions on page ii.Wiring should only be performed by a qualified
professional. When using electrical products, basic precautions should always be
followed, including the following:
RISK OF ELECTRIC SHOCK, WHICH CAN RESULT IN
SERIOUS PERSONAL INJURY OR DEATH.
Before attempting installation of service, ensure that all power to the
circuit supplying power to the system is disconnected/switched off at
the circuit breaker. When using IntelliChlor with an IntelliTouch
system, it is recommended to wire the IntelliChlor Power Center to
the pump side of the relay located in the IntelliTouch 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 IntelliChlor
chlorinator and pool pump will switch on and off together.
• Grounding (earth bonding) is required. The unit should be installed by a
qualified service person and grounded.
Install the IntelliChlor unit a minimum of two (2) feet from the
heater outlet.
• Allow ample access to the IntelliChlor control panel buttons and the
IntelliChlor Power Center.
• Pipe couplings: Schedule 80, maximum pressure 150 psi at 70° F.
• Operate unit with minimum flow of 20 gpm. For high flow applications,
use a bypass loop.
Installing the Power Center

IntelliChlor Power Center Installation Guide
4
Preparing the SiteMount the Power Center enclosure
1. Remove the screw securing the Power Center cover and remove the cover.
2. Mount the Power Center on a flat surface such as a wall or post and mark each
mounting bracket screw hole location. There are two (2) screw holes and a keyslot
for the top and lower bracket.
3. Drill six ¼ inch (6.35 mm) holes. Install anchors if necessary and one screw for
each bracket keyslot location.
4. Position each Power Center keyslot (top and lower) slot over the two mounting
screws just installed. Tighten the two screws to secure the enclosure.
5. Install and tighten four mounting screws (two in the top and two in the lower
bracket).
Bracket keyslot
Bracket screw hole
Bracket screw hole Bracket screw hole
Bracket screw hole
Bracket keyslot
Cover screw hole

IntelliChlor Power Center Installation Guide
5
Conduit knockout
for AC power cable
source
Attach incoming power
wires (12-14 AWG 3-wire)
to Power Center
AC power wires
Ground bonding lug
Connect incoming ground
wire to GROUND lug
Connect AC Power to the IntelliChlor® Power Center
6. Use 12-14 AWG three conductor insulated wire for the main AC power
connection. Connect the Power Center to pool pump AC power source. The
Power Center should be connected to the pump motor switch or automatic timer.
For system wiring information, see page 6.
7. Attach incoming GROUND wire to the ground lug inside the Power Center.
8. Earth Bonding (Grounding): Connect the earth wire to the GROUND BONDING
LUG located on the bottom of the Power Center enclosure. Earth bonding is
necessary to ensure personal safety and safety of equipment.
IMPORTANT: A number 8-gauge (8.4 mm) wire is recommended when connecting
the power supply to a Permanent Earth Ground connection that is acceptable to
the local inspection authority. Attach the bonding point located on bottom of the
Power Center to a Common Earth Bonding Point. Do not use the IntelliChlor as
the Common Bonding Point. Each piece of non-chlorinator pool equipment
requiring a ground should be bonded to the Common Approved Earth Bonding
Point. Never ground pool pump to Power Center.
9. Reinstall the Power Center cover and secure with the cover screw.
10. The Power Center installation is complete. For IntelliChlor operating information,
refer to the IntelliChlor User’s Guide (P/N 520589).