Pentair INTELLICHLOR COMSYS-16 User manual

IMPORTANT SAFETY INSTRUCTIONS
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INSTALLATION GUIDE
INTELLICHLOR®SALT CHLORINATOR
COMMERCIAL SYSTEM
COMSYS-16 (P/N 520977)

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
IntelliChlor®Electronic Chlorine Generator COMSYS-16 Overview
The IntelliChlor COMSYS-16 commercial system consists of eight IntelliChlor cells and eight power centers
(1 primary and seven secondary).
Each cell can produce up to 2.00 lbs of pure chlorine per 24 hours of operation. These cells can sanitize either
a pool or spa, or combination of both. A commercial system requires an external ORP panel and sensor to
produce chlorine upon demand as needed. The ORPsystem is sold separately.
Features
• Each cell draws approximately 220 Watts.
• Dry contact wires on primary power center connect to chlorine controller panel (ORP system).
Closing these wires turns the Comsys system on with an output level of 100%. The system is now
producing chlorine. Opening these wires turns the Comsys system off with an output level of 0%, so
the system is not producing chlorine.
• Each cell produces 2.00 pounds of chlorine per 24 hours.
• Comsys-16 (8-cell - 1 primary and seven secondary) produces sixteen pounds of chlorine per day.
• The ORP system (not provided) is a separate device that monitors the available chlorine in the water
and, when needed, calls for chlorine to be produced by closing a dry contact output. An ORP
system consists of a panel, usually with an LCD display, that has the ORP sensor in the water.
Preparing the Site
1. Add salt to the water until it measures 3600 ppm. Use an electronic tester to measure salt, such as
the Extech EC400. DO NOT USE SALT TEST STRIPS AS THEY TEND TO BE INACCURATE.
Allow the salt to mix for 24 hours before using the IntelliChlor system.
2. Locate a clear spot on a wall, within 15 feet of the IntelliChlor manifold.
3. Locate a clear spot on the return line where the IntelliChlor manifold will be mounted. Be sure that
the user can readily see the lights and press buttons if needed.
4. Be sure 110VAC or 220VAC is available and on its own circuit breaker, to power the IntelliChlor
power centers. This separate breaker will make it easier to service the IntelliChlor.
5. Be sure 110VAC or 220VAC is provided to the power center bank in a conduit, for maximum safety
and NEC compliance.

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Installation
Before installing the IntelliChlor CIC60 system, please read all SAFETY PRECAUTIONS below.
Kit Contents
-EightPowerCenters (one primary,seven secondary)
-OneCIC60Pcell
-SevenCIC60S cells
-InstallationGuide(thismanual)
RequiredTools
-Mediumphillips or flathead screwdriver(andtwelvescrews)
- Electric drill and 1/4" masonry drill bit. (To mount Power Center Bank)
Mount Power Center BanksToWall
1. Locate a wall near thepool equipment area within 15 feet of the IntelliChlor cells. Positionthe
CPC104 POWER CENTER BANK on the wall at eye level. Mount and secure each the power
center banks to the wall using six (12) screws (not provided in kit). See illustration on next page.
2. Position the CPC204 POWER CENTER BANK on the wall at eye level either just below or to
the right of the CPC104.
3. Mount and secure the CPC204 power center bank to the wall using six (6) screws (not provided in
kit).Seenextpage for illustration.
SAFETY PRECAUTIONS - PLEASE READ BEFORE PROCEEDING
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 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. The Power Center 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.
CAUTION - Install the IntelliChlor cell 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 a minimum flow rate of 25 gpm per celll. For high flow applications, use a
bypass loop.

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Mount Power Center Banks ToWall (Continued)
4. Remove the cover retaining screw and remove the cover
from upper side left PRIMARYpower center and the
lower left side SECONDARYpower center.
Connect AC PowerWires and ORP Sensor Wires
1. Mount a JUNCTION BOX on the left side of the Power
Center Banks.
2. Run a CONDUIT(with 208VAC -
260VAC wires) from theAC
BREAKER to the junction box. Note:
ThisAC power should be on its own
breakerforfutureservicing.
Note: For 110VAC operations, each
power center will need to be re-
configured. A 110VAC wiring
diagram is provided on the inside of
each the power center covers.
3. Run conduit from thejunctionboxinto
each of the power centers located on
theleft side (PRIMARYand
SECONDARY).A(knock-out)
conduitopening is provided on the
bottom of each of power centers.
Mount power center bank
to wall using six (6)
screws
Remove cover screw and cover from
PRIMARY POWER CENTER
Remove cover screw and cover from
SECONDARY POWER CENTER
Mount power center
bank to wall using six
(6) screws
CPC204
CPC104
Knock-out opening for
conduit CPC104
CPC204

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Connect these
wires to ORP
PRIMARY SECONDARY SECONDARY SECONDARY
Connect these
wires to AC
power source
Connect AC PowerWires and ORP SensorWires (Continued)
4. Splice the incomingAC power wires onto the two wires labeled WIREDFOR220V. Do not
applyAC power yet.
5. Connect the two (2) twisted wires labeled ORPSENSOR to the ORP chlorine controller panel
(AcuTrol, etc., not included in kit). Carefully place the connection inside of power center.
6. Replace the cover on the upper Primary power center and lower Secondary power center. Secure
eachcover with the retaining screw.
PRIMARY Secondary Secondary Secondary
Secondary Secondary Secondary Secondary
CPC104
CPC204
CPC104
Splice in junction box
(see STEP 4)

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
7. Remove the cover retaining screw and remove the cover from the SECONDARY power center,
located on the top bank, far right side.
8. Route the communication cable from the CPC204 power center through the bottom hole of the
CPC104 Secondary power center.
9. Insert the two wires from the CPC204 into terminal block in same order as the wires already
connected. Be sure to match the wire colors. GREEN to GREEN andYELLOW toYELLOW.
10. Replace the cover on the upper Secondary power center (top far right side). Secure the cover with
theretainingscrew.
GREEN and
YELLOW wire
from CPC204
power center
Terminal screw
connector: Match
wires GREEN to
GREEN and
YELLOW to
YELLOW
(See step 9)
CPC104
PRIMARY SECONDARY SECONDARY SECONDARY
CPC104
Insert wires from
CPC204 into hole and
connect into terminal
connector

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Assemble the Manifold
1. Place an o-ring into groove on union coupling.
2. Place each cell on the manifold and tighten coupling nut securely. Be sure the o-ring stays
in place. Note: Cells labeled PRIMARY and SECONDARY can be placed anywhere in
the manifold, they do not need to be in a specific location.
3. Glue the manifold into the system plumbing at desired location, either horizontal or vertical.
Make sure the cells are readable and the buttons can be pressed if needed.
CAUTION: Do not install upside down!
4. Verify water flow direction See the FLOW arrow located on the IntelliChlor cell near the
input coupling.
IMPORTANT! MANIFOLD ASSEMBLY AND INTELLICHLOR CELL MUST BE
INSTALLED IN THE VERTICAL POSITION, AS SHOWN BELOW.
Glue the manifold
6. Glue manifold into system plumbing at the desired location. The manifold will sit on the floor. Be sure
the cells are readable and the buttons can be pressed if needed. Do not install upside down!
7. Verifywater flow direction.
O-ring
Union coupling nut
Coupling
Manifold
Outlet
Inlet
Stand
Drain
DO NOT MIX OLD AND
NEW MANIFOLD PARTS.
MANIFOLD
DIMENSIONS MAY NOT
BE BACKWARDS
COMPATIBLE.

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Connect the IntelliChlor Cells
1. Connect the cell power connector, labeled PRIMARY(CIC60P), into the receptacle on the
bottom of the power center labeled PRIMARY. While holding the connector on the receptacle,
turnit slowly until the plugpins are inserted into the receptacle, then twist the to lock in place.
2. Plug the two SECONDARYcell power connectors into each of the power centers labeled
SECONDARY using same method as described in step 1.
PRIMARY SECONDARY SECONDARY SECONDARY
Secondary power
center receptacle
Primary
(CIC60P)
power center
receptacle
Secondary connector
Primary (CIC60P) connector
CPC104
CPC204
SECONDARY SECONDARY SECONDARY SECONDARY

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Power Centers (Front View)
PRIMARY SECONDARY SECONDARY SECONDARY
Terminal
Screw
Connector
CPC204
CPC104
SECONDARY SECONDARY SECONDARY SECONDARY
Power Centers
The PRIMARYand SECONDARYpower centers have been pre-wired with communication wires as shown
below.
Power Center
communication wire
connection

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IntelliChlor Electronic Chlorine Generator COMSYS-16 Installation Guide
Operation
When the ORP system requests chlorine, it closes the dry-contact output that is connected to the ORP
SENSOR wires, and causes each cell to set its output level to 100%. The CELL light will turn on and
chlorine will be produced. If the ORP system is not requesting chlorine (ORP SENSOR wires open),
all lights in the SANITIZER OUTPUT section will be off, no chlorine is produced.
Chlorine will be produced only when:
• SANITIZER OUTPUT 100% light is on
• CELL is green and not flashing
• FLOW light is green
• Salt is FLASHING GOOD, GOOD, or CHECK SALT
Note: Verify each cell has a green FLOW light, to show that adequate water is flowing through the
cell.
• After power up, all cells will scroll the salt lights LOW, CHECK SALT and GOOD for 2 minutes
while waiting to check salt. If FLOW is red, these lights will scroll indefinitely.
• After 2 minutes of green FLOW, the salt will be read and all cells will now display the same salt
color.
• If the CELL light is flashing, the cell has become dirty and requires acid cleaning. Turn off the
circuit breaker to the power centers, disable water flow through the manifold (either an external
valve or turn off the filter pump), and remove the cell. Check the cell and acid clean if necessary.
Power Up the system
1. Switch the AC circuit breaker to ON to apply AC power to the system.
2. After the system is powered up for one minute, if any SECONDARY cell shows a red light,
the communications to that cell is not connected.
Open the power center covers and verify the two green and yellow wires on each terminal
block are connected and in the same order. Verify these connections from each
SECONDARY power center to the PRIMARY power center (see page 6).
3. Apply water flow to the cell manifold. When water flow is present, each cell's FLOW light
will go from red (no flow) to green (flow).
4. The GOOD, CHECK SALT and LOW salt lights on each cell will scroll back and forth for
two minutes before checking the salt level. If water flow is not present, this two minutes
will start over when flow is restored. Note: THE SALT LEVEL CAN NOT BE CHECKED
WHEN THE FLOW LIGHT IS RED.
5. After two minutes, the salt level will be read and displayed on all cells.