Pentair INTELLICHLOR COMSYS-4 User manual

IMPORTANT SAFETY INSTRUCTIONS
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INTELLICHLOR®SALT CHLORINATOR
COMMERCIAL SYSTEM
COMSYS-4 (520971)
INSTALLATION GUIDE

P/N 520981 Rev C- 5/2016
Customer Support
8 A.M. to 7:30 PM
Phone: [phone]
Fax: [phone]

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IntelliChlor Electronic Chlorine Generator COMSYS-4 Installation Guide
IntelliChlor®Electronic Chlorine Generator (SCG) COMSYS-4 Overview
The IntelliChlor COMSYS-4 commercial system consists of two IntelliChlor (SCG) cells (primary and
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 ORP system 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-4 (2-cell - 1 primary and 1 secondary) produces four 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-4 Installation Guide
Installation
Before installing the IntelliChlor CIC60 system, please read all SAFEYPRECAUTIONS below.
Kit Contents
-OnePrimaryPower Center
-One SecondaryPower Center
- One Primary CIC60P cell
-One Secondary CIC60S cell
-Installation Guide(this manual)
RequiredTools
-Medium phillips or flathead screwdriver(and fourscrews)
- Electric drill and 1/4" masonry drill bit. (To mount Power Center Bank)
SAFETY PRECAUTIONS - PLEASE READ BEFORE PROCEEDING
IMPORTANT SAFETY PRECAUTIONS.PLEASE READTHE 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
andgrounded.
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 cell. For high flow applications, use a
bypass loop.

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IntelliChlor Electronic Chlorine Generator COMSYS-4 Installation Guide
Mount Primary and Secondary Power CenterToWall
1. Locate a wall near the pool equipment area within 15 feet of the
IntelliChlorcells. Position theprimary and secondary power center
at eye level. Mount and secure the power center bank to the wall
using four (4) screws (not provided in kit). Note: The power
centers are pre-wired to each other.
2. Remove the cover retaining screw and remove the cover from
the PRIMARY power center.
Connect AC PowerWires and ORP SensorWires
1. Provide 208-260VAC power to the PRIMARYPOWER CENTER This power should be on its
own breaker for future servicing.A(knock-out) opening is provided on the bottom of the power
center for a conduit.
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.
2. Splice the incomingAC power wires onto the two wires labeled WIRED FOR 220V. Do not
applyAC power yet.
3. 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.
4. Replace the cover. Secure it using the retaining screw.
Connect these
wires to ORP
Mount power centers to wall
using four (4) screws
Connect these
wires to AC
power source
PRIMARY SECONDARY
Communication
wires

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IntelliChlor Electronic Chlorine Generator COMSYS-4 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.
DO NOT MIX OLD AND
NEW MANIFOLD PARTS.
MANIFOLD
DIMENSIONS MAY NOT
BE BACKWARDS
COMPATIBLE.
O-ring
Union coupling nut
Inlet
Outlet
Manifold
Coupling

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IntelliChlor Electronic Chlorine Generator COMSYS-4 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 thereceptacle, then twist theto lock in place.
2. Plug the SECONDARYcell power connector into the power center labeled SECONDARY using
same method as described in step 1.
PRIMARY SECONDARY
Secondary power
center receptacle
Primary (CIC60P)
power center receptacle
Secondary connector
Primary (CIC60P) connector
Communication wires

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IntelliChlor Electronic Chlorine Generator COMSYS-4 Installation Guide
Power Centers (Front View)
PRIMARY 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-4 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.

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IntelliChlor Electronic Chlorine Generator COMSYS-4 Installation Guide
Troubleshooting
TheIntelliChlor100% light does not come on when thechlorinecontrollercallsforchlorine
1. Verify the ORP controller is opening and closing the dry-contact output.
2. Remove the ORP SENSOR wires connection from the PRIMARY power center and the ORP
controller. Manually tie the ORP SENSOR wires together. This will turn on the cells at 100%. If
the 100% lights do not come on for each cell or only one cell, verify the communication wires are
connected, shown in POWER UP THE SYSTEM, step 3, page 7.
The IntelliChlor 100% light stays on after the chlorine controller says to stop
1. Verify the communication wires are connected, as shown in section 5, POWER UP THE SYSTEM,
step 3.
2. Verify the ORP SENSOR wires are not shorted together in the power center.
3. Verify the ORP controller dry contact output is opening and closing by using an ohmmeter.
Manually set this output open and closed using the controller menu system.
The CHECK SALT light is on
More salt needs to be added to the water.
1. Add salt to the water and bring up to 3600ppm. Allow it to mix for 24 hours.
2. The salt level will be automatically checked every 8 hours by the primary cell and displayed.
The LOW salt light is on
Not enough salt is in the water to produce chlorine, cell is OFF.
1. Add salt to the water and bring up to 3600ppm. Allow it to mix for 24 hours.
2. The salt level will be checked every 8 hours by the cells and displayed.
Not enough chlorine is produced
1. Ensure the ORP sensor probe on the chlorine controller unit is clean and working.
2. Verify the IntelliChlor cells do not have a flashing CELL light. If so, remove the cell and acid clean.
3. Verify no debris is in the cells. Remove if present.
4. Verify the FLOW light is green, for adequate water flow.
5. Verify the salt level lights are displaying either green GOOD or yellow CHECK SALT. If displaying
yellow CHECK SALT, add salt to the water, and allow to mix for 24 hours.
6. Verify the ORP controller sets the cells to 100% SANITIZER OUTPUT or 0%, by manually
controlling this output relay (done in the ORP controller, not the IntelliChlor) or by disconnecting the
ORP SENSOR wires from the power center and manually opening and closing the wires.
7. Verify the ORP probe is clean.
8. Verify the filter pump is not being turned off by a timer.