Pentair Pool Products IntelliChlor IC40 Installation Manual
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Pentair Pool Products IntelliChlor IC40 Installation Manual

Pentair Pool Products IntelliChlor IC40 Installation Manual

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2022-5790
2022-12-04
IntelliChlor Salt Chlorine Generator Model IC40
CONTROLS BACTERIA AND ALGAE In Swimming Pool Waters DOMESTIC
A maximum of 150,000 L of water can be treated with one IC40 unit.
Maxim um output of hypochlorous acid equivalent to 0.45 kg of free available chlorine per day.
For swimming pools, a minimum of 1 ppm of free available chlorine must be maintained.
READ THE LABEL AND OPERATING MANUAL BEFORE USING
KEEP OUT OF REACH OF CHILDREN
REGISTR ATION NO. 28365 PEST CONTROL PRODUCTS ACT
WARNING: Operating IC40 without water flow through the cell can cause a build up of flammable gases
which can result in FIRE OR EXPLOSION.
Pentair Water Pool and Spa, Inc.,
1620 Hawkins Ave., Sanford, NC 27330
(919) 566-8000
10951 West Los Angeles Ave., Moorpark, CA 93021
17228R1

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  • Page 1 2022-5790 2022-12-04 IntelliChlor Salt Chlorine Generator Model IC40 CONTROLS BACTERIA AND ALGAE In Swimming Pool Waters DOMESTIC A maximum of 150,000 L of water can be treated with one IC40 unit. Maxim um output of hypochlorous acid equivalent to 0.45 kg of free available chlorine per day. For swimming pools, a minimum of 1 ppm of free available chlorine must be maintained.
  • Page 2 INTELLICHLOR IC40 Replacement cell for the chlorine generating device IntelliChlor Salt Chlorine Generator Model IC40 REGISTRATION NO. 28365 PEST CONTROL PRODUCTS ACT This cell must only be used on this model of chlorine generating device. Read the Label, the Installation Manual and Operation Manual of the IC40 chlorine generating device before using.
  • Page 3 ™ IntelliChlor Power Center ™ (For use with IntelliChlor model IC40) Installation Guide ETL Listed Pentair Water Pool and Spa, Inc. Conforms to 1620 Hawkins Avenue UL Standard 1081 Sanford, NC 27330 3077230 (919) 566-8000 Patents Pending Registration No. 28365 Pest Control Products Act DOMESTIC IMPORTANT SAFETY INSTRUCTIONS READ THE LABEL AND OPERATING MANUAL...
  • Page 4 © 2006 Pentair Water Pool and Spa, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 • (800) 553-5000 Trademarks and disclaimers IntelliChlor and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa, Inc.

  • Page 5: Table Of Contents

    Contents IMPORTANT SAFETY PRECAUTIONS ......................ii Installation Steps Summary .......................... iii Technical Support ............................iii Introduction ................................. 1 Power Center Overview ............................. 1 IntelliChlor Models ............................1 Operating Instructions ..........................2 Installation ..............................2 Kit Contents ..............................2 Required Tools ................................... 2 SAFETY PRECAUTIONS ..........................

  • Page 6: Important Safety Precautions

    IMPORTANT SAFETY PRECAUTIONS SAVE THESE 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. WARNING - IMPORTANT SAFETY INSTRUCTIONS PERTAINING TO A RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS.

  • Page 7: Installation Steps Summary

    Installation Steps Summary The recommended Power Center installation steps are Review Important Safety Precautions (page ii and 2) : Review this important information. Review Power Center Overview (page 1) : Review the Power Center overview information Installing the IntelliChlor Power Center (page 2) : Installation information.

  • Page 8: Introduction

    Introduction Power Center Overview The IntelliChlor™ 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.
  • Page 9 IntelliChlor Power Center Installation Guide...

  • Page 10: Operating Instructions

    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.

  • Page 11: Installing The Power Center

    Installing the Power Center 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 2.44 m (8 ft.) from the pool edges. CAUTION: Leave sufficient clearance on all sides of the Power Center. Ensure that the 4.57 meters (15 ft.) “Type Z” DC power cord from the Cell assembly pipe location can reach the Power Center location.
  • Page 12 Connect AC power to the Power Center Note: This Power Center is wired as an “All Pole Disconnect” System. Therefore a 3mm spacing is required for all AC wiring entering the unit. 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.

  • Page 13: Troubleshooting

    Troubleshooting Note: Turn off power to unit before attempting to service or repair Problem Possible Cause Corrective Action The IntelliChlor green Fuse in Power Center is open. Replace 10 AMP (3AG Style) fuse, located at power light on the bottom of Power Center. control panel is not on.

  • Page 14: Electrical Specifications And 110 Vac And 220 Vac Wiring

    Electrical Specifications and 110 VAC and 220 VAC Wiring Circuit Protection: Two-pole 20 AMP device at the electrical panel. IntelliChlor Model IC40 Input: 90-130 VAC, 50/60 Hz, 220 Watts (2 AMP) or 220-240 VAC, 50/60 Hz, 220 Watts (1 AMP). Output: 22-39 VDC @ 6 AMPS maximum from the Power Center.
  • Page 15 Notes IntelliChlor Power Center Installation Guide...
  • Page 16 Notes IntelliChlor Power Center Installation Guide...
  • Page 17 LIMITED WARRANTY Pentair Water Pool and Spa, Inc. ("Pentair Water") manufactures its products with the highest standards of workmanship using the best materials available through state of the art process. Pentair Water warrants its products as follows: Limited Warranty: Pentair Water warrants its products to be free from defects in material and/or workmanship for a period of three (3) years or 8,000 hours (parts only) from the original date of installation.
  • Page 18 P/N 520845 - Rev A...
  • Page 19 ™ IntelliChlor Salt Chlorine Generator (Model IC40) User’s Guide DOMESTIC REGISTRATION NO. 28365 3077230 PEST CONTROL US Patents Pending PRODUCTS ACT IMPORTANT SAFETY INSTRUCTIONS Pentair Water Pool and READ THE LABEL AND OPERATING MANUAL Spa, Inc. 1620 Hawkins Avenue BEFORE USING Sanford, NC 27330 SAVE THESE INSTRUCTIONS (919) 566-8000...
  • Page 20 © 2005 Pentair Water Pool and Spa, Inc. All rights reserved This document is subject to change without notice 1620 Hawkins Ave., Sanford, NC 27330 • (919) 566-8000 10951 West Los Angeles Ave., Moorpark, CA 93021 • (805) 523-2400 Trademarks and disclaimers IntelliChlor and the Pentair Water Pool and Spa logo are trademarks of Pentair Water Pool and Spa, Inc.
  • Page 21 Contents System Description ......................1 Features ............................1 IntelliChlor model ........................1 Electrolytic Cell Controller ....................2 Power Center..........................3 System Diagram........................3 Loop Plumbing Diagram......................4 IntelliChlor Plumbing Diagram ....................4 Section 1: IntelliChlor Control Panel ..............5 Salt Level Status LEDs ......................5 Status LEDs .........................
  • Page 22 IMPORTANT SAFETY PRECAUTIONS 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. Follow all aspects of the local and National Electrical Code(s) when installing the IntelliChlor Salt Chlorine Generator IC40.
  • Page 23 IMPORTANT SAFETY PRECAUTIONS Canada - Industry Canada (IC) - This device complies with RSS210 of Industry Canada. (1999). 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.
  • Page 24 Installation Steps Summary The recommended IntelliChlor installation steps are Review Chemistry You Need to Know (page 12) : Review this important information. Review Optimum Pool Water Conditions (page 13) : Review this important information. Review Pool Water Preparation (page 17) : Review this important information.

  • Page 25: System Description

    • Cell hours meter reports current usage to determine how many hours remain. • The IntelliChlor IC40 model produces 0.45 kg of free available chlorine per day. • Salt level bar graph shows the amount of salt in pool. •...

  • Page 26: Electrolytic Cell Controller

    Electrolytic Cell Controller The electrolytic cell controller includes a control panel with buttons and LED indicators to fully control and produce chlorine. The cell controller measures the water temperature and salt level to optimally produce chlorine. If the salt level 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.

  • Page 27: Power Center

    Power Center The Power Center converts AC electrical current to a low voltage DC current which is required by the cell to perform the electrolysis. The power supply is connected with the pool circulation pump electrical source so that the electrolytic cell only operates when the pool pump is on. The enclosure can be mounted vertically on the wall up to 4.57 Meters (15 feet) away from the cell controller.

  • Page 28: Loop Plumbing Diagram

    Loop Plumbing Diagram The IntelliChlor will operate in water flow rates from 56.78 liters (15 gallons) per minute up to 416.40 liters (110 gallons) per minute (the limit of 5.08 cm (2”) plumbing). For flow rates over 303 liters (80 gallons) per minute, it is recommend that you use a bypass loop (shown below) for best chlorine production.

  • Page 29: Section 1: Intellichlor Control Panel

    Section 1 IntelliChlor Control Panel This section describes the IntelliChlor control panel status LEDs and the More, Less and Boost/On/Off control buttons. Salt Level Status LEDs The salt level is checked daily and is displayed on this section of the unit. •...

  • Page 30: Sanitizer Output Led Indicators

    Operator Control Panel (continued) Sanitizer Output LED Indicators The five LED indicators display as a bar graph to show in 20% increments, the amount of time the chlorine is produced per hour. In BOOST mode, these LEDs scroll in a pattern. Note: If no LEDs are lit •...

  • Page 31: Section 2: Operating Intellichlor

    Section 2 Operating IntelliChlor This section describes the start up procedure and operating instructions for IntelliChlor Initial Start up Period For the first 30 days of cell operation, the self-cleaning cycle will be set to 2 hours. After 30 days has elapsed the unit will automatically set itself to four hour self-cleaning cycle.

  • Page 32: Startup Procedure(Super Chlorination)

    Startup Procedure (Super Chlorination) Shocking (Super Chlorination) is recommended before pool startup. Start out with clean pool water from the beginning. IntelliChlor will build up a sufficient level of chlorine for sanitation in several hours. However, if pool water has a high demand from the start-up IntelliChlor will not be able to produce enough chlorine to reach break-point chlorination.

  • Page 33: Section 3: User Maintenance

    Section 3 User Maintenance This section describes how to maintain the IntelliChlor chlorination system Daily service 1. pH Level Test: Test the pH level of your pool with a test kit. The pH should be between 7.2 and 7.8. If necessary, adjust within this range. Note: Never use dry acid to adjust pH in arid geographic areas with excessive evaporation and minimal dilution of pool water with fresh water.

  • Page 34: Monthly Service

    Monthly Service To ensure that the correct chemical balance is maintained in your pool, it is important to perform the following recommended salt and pool water tests every month. 1. Salt Level Test: Check salt display lights on the unit and check that the green “GOOD” light is on. •...

  • Page 35: Electrolytic Cell Cleaning

    Electrolytic Cell Cleaning 1. Automatic Cleaning. This unit has an automatic cell-cleaning feature (Cell Reversing) that removes scale deposits from the electrolytic cell. Note Automatic Cleaning does not interrupt Chlorine Production. “Scale” is a white crusty deposit that forms in excessively hard water or from pool water that is out of balance and in a scaling condition.

  • Page 36: Chemistryyou Need To Know

    Chemistry You Need to Know 1. Chlorine Stabilizer (cyanuric acid) is needed in outdoor pools to maintain proper levels of chlorine. Most unstable chlorine is destroyed by the UV radiation from the sun within 2 hours. Chlorine stabilizer should be maintained between 50 - 75 PPM. See Table 3, page 16. 2.

  • Page 37: Optimum Poolwater Conditions

    Optimum Pool Water Conditions It is recommended that the following water balance conditions be maintained on an on going basis to protect the pool finish and equipment and ensure the pleasing appearance of the water. IntelliChlor is warranted to operate properly only if these conditions aremet. Free available chlorine: 1.0 - 3.0 PPM.

  • Page 38: Chlorine Testing

    Chlorine Testing It is recommended that chlorine test samples be taken from two places. Compare the samples. A higher level should be found at the pool return line. The higher level at the pool return line indicates IntelliChlor is producing chlorine.

  • Page 39: How To Add Salt To The Pool

    How to Add Salt to the Pool Do not operate IntelliChlor with newly poured pool plaster; salt damage can occur Wait at least CAUTION: 1 MONTH to allow new pool plaster to cure before operating IntelliChlor. 1. Switch on the pump to circulate the pool water. 2.
  • Page 40 Table 2. Approximate Kilograms (Pounds) of Salt Needed to Maintain 3,000 PPM Salt concentration Salt addition required Salt concentration Salt addition required per 3785.41 liters (1000 gallon ) per 3785.41 liters (1000 gallon ) before addition before addition pool capacity pool capacity 0 ppm 11.6 kg (25.6 lbs)

  • Page 41: Pool Water Preparation

    Pool Water Preparation Determining Pool Size in meters (liters of Water in Your Pool • Rectangular Pools: Length x width (meters) x average depth x 1000 • Circular Pools: Diameter x diameter x average depth x 785 • Oval Pools: Length x width (meters) x average depth x 893 •...

  • Page 42: Intellichlor Model Size

    IntelliChlor model size IntelliChlor Model IC40 Chlorine Production 0.45 kg of free available chlorine per 24-hour period. Residential Pools One unit per 150,000 L pool. IntelliChlor User’s Guide...

  • Page 43: Section 4: Installation

    Section 4 Installation This section describes how to install the IntelliChlor electrolytic cell assembly into the pool plumbing system. Also, included are connection instructions for an IntelliTouch system. Before installing, review the IntelliChlor kit contents and requiredtools. Note: For Power Center installation instructions, see the “IntelliChlor Power Center Installation Guide” P/N 520590.

  • Page 44: Installing The Cell Assembly

    Installing the Cell Assembly Install the IntelliChlor cell assembly no closer than 0.91 Meters (three (3) feet) from the heater outlet, if use Note: After new pool construction has been completed, in order to prevent debris from entering the IntelliChlor cell assembly, it is recommended that the IntelliChlor pass-through cell (P/N 520588) be installed before installing the IntelliChlor cell.
  • Page 45 Connecting the Cell Assembly to the IntelliTouch System To operate IntelliChlor via the IntelliTouch Indoor Control Panel, connect a four wire cable from the IntelliChlor Power Center to the Personality board located in the IntelliTouch Load Center. An alternate connection can be made by splicing the Indoor Control Panel connection wire connected to the Personality board.

  • Page 46: Connecting To The Intellitouch Load Center

    Connecting to the IntelliTouch Load Center To connect the four wire cable from the IntelliChlor Power Center to the Personality board located in the IntelliTouch Load Center: WARNING Switch OFF main system power to the Load Center before making any connections. 1.
  • Page 47 4. Route the four conductor cable up through the low voltage raceway in the Load Center to the Personality board. 5. Strip back the cable conductors 6.35 mm (¼ in.). Insert the wires into the screw terminals (provided in the kit). Secure the wires with the screws. Make sure to match the color coding of the wires; Red = +15, Yellow = +DT, Green = -DT, and GND = Black.

  • Page 48: Section 5: Troubleshooting

    Section 5 Troubleshooting Use the following troubleshooting information to resolve possible problems with the IntelliChlor system Note: Switch power off to unit before to attempting service or repair. Table 1: Troubleshooting Problem Possible Cause Corrective Action Low or no chlorine Low stabilizer (cyanuric acid) level in pool Add stabilizer to maintain 50 - 75 PPM per pool professional's recommendations.
  • Page 49 Table 1: Troubleshooting (Continued) Problem Possible Cause Corrective Action Red ADD salt light is Pool water needs salt. No chlorine is being Add salt as described on pages 14, 15, and produced. Yellow LOW salt light is Not enough salt in pool. Add salt to pool to achieve 3200 ppm to 3500 ppm.
  • Page 50 Table 2: Troubleshooting the Power Center Problem Possible Cause Corrective Action IntelliChlor unit does Fuse in Power Center is open. Replace AC fuse, located at bottom of Power not have green power Center. light. No AC power to Power Center. Verify time clock is providing 110 VAC or 220 VAC to Power Center when active.

  • Page 51: Electrical Specifications And 110 Vac And 220 Vacwiring

    Electrical Specifications and 110 VAC and 220 VAC Wiring Circuit Protection: Two-pole 20 AMP device at the electrical panel. Note: Spacing of 3 mm should be met by the all-pole disconnect. IntelliChlor Model IC40 Input: 90-130 VAC, 50/60 Hz, 220 Watts (2 AMP) or 220-240 VAC, 50/60 Hz, 220 Watts (1 AMP). Output: 22-39 VDC @ 6 AMPS maximum from the Power Center.
  • Page 52 LIMITED WARRANTY Pentair Water Pool and Spa, Inc. ("Pentair Water") manufactures its products with the highest standards of workmanship using the best materials available through state of the art process. Pentair Water warrants its products as follows: Limited Warranty: Pentair Water warrants its products to be free from defects in material and/or workmanship for a period of three (3) years or 8,000 hours (parts only) from the original date of installation.
  • Page 53 P/N 520844 - Rev A...

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