®
INTELLICHLOR POWER CENTER
FOR USE WITH INTELLILCHLOR CHLORINE GENERATOR
MODEL IC20, IC40 & IC60
INSTALLATION AND USER’S GUIDE
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
INTELLICHLOR® Salt Chlorinator Installation Guide
Technical Support
Sanford, North Carolina (8 A.M. to 4:30 P.M. ET)
Moorpark, California (8 A.M. to 4:30 P.M. PT)
Phone: (800) 831-7133
Fax (800) 284-4151
Web sites: visit www.pentairpool.com and staritepool.com
Contents
IMPORTANT SAFETY PRECAUTIONS ..........................................................
IntelliChlor Power Center Overview ..................................................................
IntelliChlor System Components .....................................................................
Operating Instructions .....................................................................................
Installation ................................................................................................
Kit Contents .............................................................................................
Required Tools ..........................................................................................
Installing the Power Center ..............................................................................
SAFETY PRECAUTIONS ...............................................................................
Troubleshooting ...............................................................................................
Electrical Specifications ..................................................................................
230 VAC Basic System Wiring ........................................................................
110 VAC Basic System Wiring ........................................................................
IntellliChlor Power Center with ORP Controller ..........................................
Connecting AP Power Wires to ORP Controller .....................................
Certified to NSF/ANSI 50
P/N 520590 REV. F 1/2015
INTELLICHLOR® Salt Chlorinator Installation Guide
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6
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9
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IMPORTANT WARNINGS AND SAFETY INSTRUCTIONS
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.
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 Salt Chlorine Power Center(s)
is disconnected/switched off at the circuit breaker.
IMPORTANT SAFETY INSTRUCTIONS PERTAINING TO A RISK OF
FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS. READ AND
FOLLOW ALL INSTRUCTIONS.
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.
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 (800) 831-7133 for additional free copies of these instructions. Please refer to
www.pentaircommercial.com for more information related to these products.
CHLORINE GAS BUILDUP CAN OCCUR WITH IMPROPER WIRING:
To reduce the risk of personal injury the IntelliChlor® Salt Chlorinator
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 IntelliChlor Salt
Chlorinator 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 Salt Chlorinator 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® Salt Chlorinator Installation Guide
ii
IMPORTANT WARNINGS AND SAFETY INSTRUCTIONS
Never operate the IntelliChlor® Salt Chlorinator 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.
RISK OF ELECTRICAL SHOCK OR ELECTROCUTION:
Always disconnect power to the IntelliChlor Salt Chlorinator 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.
IntelliChlor Salt Chlorinator 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 IntelliChlor Salt Chlorinator Power Centers must be interconnected with the pool pump motor power source. This ensures the
IntelliChlor Salt Chlorinator 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 hazardous. Follow the Chemical Manufacturer's Instructions.
To reduce the risk of electric shock, install IntelliChlor Salt
Chlorinator a minimum of five (5) feet away from the inside wall of
the pool.
Install the IntelliChlor Salt Chlorinator 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.
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.
INTELLICHLOR® Salt Chlorinator Installation Guide
iii
IMPORTANT WARNINGS AND SAFETY INSTRUCTIONS
For information about the Virginia Graeme Baker Pool and Spa Safety
Act, contact the Consumer Product Safety Commission at (301) 5047908 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.
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® Salt Chlorinator with an IntelliTouch
control 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.
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.
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® Salt Chlorinator Installation Guide
1
IntelliChlor® Salt Chlorinator Power Center Overview
The IntelliChlor Salt Chlorinator 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 Salt Chlorinator 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 Salt Chlorinator. A timer is
not included as part of the IntelliChlor Salt Chlorinator Power Center kit. The IntelliChlor
Salt Chlorinator Power Center can be connected to an IntelliTouch® , EasyTouch® or
SunTouch® Control 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 contains the
transformer, fuse, and connector plug to the IntelliChlor Salt Chlorine cell. 110 VAC and
220 VAC wiring is connected at this box, with 35 VDC output to the cell controller.
A 10 AMP replaceable fuse is mounted on the electronic circuit board 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 green power LED is lit.
Transformer
Internal
Ground lug
Attach incoming AC wire
to Power Center AC
power wires
(blue and brown)
Lug (Ground bonding)
(not shown)
10 AMP
replaceable fuse
Power LED (Green)
Screw terminal
(RS-485) (connect
to EasyTouch and
IntelliTouch Control
Systems
Cell connector
IntelliChlor Salt Chlorinator Power Center
(Model PC 100) (Cover removed)
INTELLICHLOR® Salt Chlorinator Installation Guide
2
IntelliChlor® Salt Chlorinator System Components
An IntelliChlor Salt Chlorinator system consists of one or more of the following:
• PC100 (P/N 520556): Power Center Kit. Provides power and control communication to
and from the IntelliChlor cell.
• 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.
• IntelliChlor “dummy” bypass cell (P/N 520588): For new pool start-up.
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 InteliChlor Salt Chlorator 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 Salt Chlorinator Power
Center. Before installing, review the IntelliChlor Salt Chlorinator kit contents and required
tools. For cell installation instructions, see the “IntelliChlor User’s Guide” (P/N 520584).
Kit Contents
- One Power Center enclosure
- Installation Guide (this manual)
Required Tools
- 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® Salt Chlorinator Installation Guide
3
Installing the IntelliChlor® Salt Chlorinator Power Center
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 Salt Chlorinator with an
IntelliTouch® Control System, it is recommended to wire the
IntelliChlor Salt Chlorinator Power Center to the pump side of the relay located in the
IntelliTouch Control System 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 Salt 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 Salt Chlorinator enclosure a minimum of two (2)
feet from the heater outlet.
Allow ample access to the IntelliChlor Salt Chlorinator control panel
buttons and the IntelliChlor Salt Chlorinator 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.
Install the Power Center at eye level as close to the IntelliChlor Salt
Chlorinator pump and filtration as possible.
The IntelliChlor Salt Chlorinator 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).
INTELLICHLOR® Salt Chlorinator Installation Guide
4
Installing the Power Center
Install the Power Center at eye level as close to the IntelliChlor pump and filtration as
possible. CAUTION: 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
(4.57 m) “Type Z” 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 ft (4.57 m) away from the cell controller. Note: For installation instructions about
connecting the cell to Power Center, see the IntelliChlor User’s Guide (P/N 520848).
Mount the Power Center enclosure:
1.
2.
3.
4.
5.
Remove the screw securing the Power Center cover and remove the
cover.
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.
Drill six ¼ in (6.35 mm) holes. Install anchors if necessary and one screw
for each bracket keyslot location.
Position each Power Center keyslot (top and lower) slot over the two
mounting screws just installed. Tighten the two (2) screws to secure the
enclosure.
Install and tighten four (4) mounting screws two (2) in the top and two in
the lower bracket.
Bracket key slot
Bracket screw hole
Bracket screw hole
Cover screw hole
Bracket screw hole
Bracket screw hole
Bracket key slot
IntelliChlor Power Center (Model PC 100)
(Cover removed)
INTELLICHLOR® Salt Chlorinator Installation Guide
5
Connect AC Power to the IntelliChlor® Power Center
Note: This Power Center is wired as an “All Pole Disconnect” System. Therefore a 3
mm 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.
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- guage (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 520848).
Connect incoming ground
wire to GROUND lug
Attach incoming power
wires (12-14 AWG 3-wire)
to Power Center
AC power wires
Conduit knockout
for AC power cable
source
INTELLICHLOR® Salt Chlorinator Installation Guide
Ground bonding lug
6
Troubleshooting
Note: Turn off power to unit before attempting to service or repair.
Problem
Possible Cause
Corrective Action
The IntelliChlor green
power light on the
control panel is not on.
Fuse in Power Center is open.
Replace 10 AMP fuse, located on the main
circuit board.
No AC power to Power Center.
Verify time clock is providing 110 VAC or 220
VAC to Power Center when active.
Tansformer leads not wired correcly in Power
Center.
Verify transformer leads wired to AC source by
referring to wiring diagram decal on inside of
Power Center cover.
Electrical Specifications
Circuit Protection: Two-pole 20 AMP device at the electrical panel.
IntelliChlor Salt Chlorinator Model IC20
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 @ 7.3 AMPS maximum from the Power Center.
IntelliChlor Salt Chlorinator 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 @ 7.3 AMPS maximum from the Power Center.
IntelliChlor Salt Chlorinator 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 @ 7.3 AMPS maximum from the Power Center.
IMPORTANT: When using IntelliChlor ® Salt Chlorinator with an
IntelliTouch ® Control System, EasyTouch® Control System or
SunTouch® Control System, it is recommended to wire the
Power Center to the PUMP SIDE OF THE RELAY located in the
automation control system load center. This method does not
require a ground fault circuit-interrupter (GFCI) to protect the
circuit.
INTELLICHLOR® Salt Chlorinator Installation Guide
7
110 VAC and 220 VAC Transformer Wiring
115 VAC Basic System Wiring
230 VAC Basic System Wiring
INTELLICHLOR® Salt Chlorinator Installation Guide
8
IntelliChlor Salt Chlorinator SPower Center 230 VAC and 115 VAC
Transformer Wiring
INTELLICHLOR® Salt Chlorinator Installation Guide
9
IntellliChlor Power Center with ORP Controller
Connect AC Power Wires and ORP Controller Wires
1. Provide 208-260VAC power to the POWER 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 the power center cover.
2. Splice the incoming AC power wires onto the two wires labeled WIRED FOR 220V. Do not
apply AC power yet.
3. Connect the two (2) twisted wires labeled ORP CONTROLLER to the ORP chlorine
controller (AcuTrol). Carefully place the connection inside of power center.
Note: The Acu-Trol Controller (sold separately), contains an oxidation reduction potential (ORP)
sensor that is placed in the water stream to detect the sanitizing ability of the water and according to a
user-preset set point, calls for chlorine when low, and cancels chlorine when satisfied. This Controller
provides a dry-contact output that connects to the Power center with ORP input. When the dry-contact
terminals are closed, chlorine is required. When the dry contact terminals are open, no chlorine is
required. The Acu-Trol Controller is not used for a stand-alone-No ORP system.
4. Replace the cover. Secure it using the retaining screw.
Connect wires to
ORP CONTROLLER
Connect wires
to AC POWER
SOURCE
Power Center (Bottom View)
INTELLICHLOR® Salt Chlorinator Installation Guide
10
System Diagram
Note: For best flow sensing,
provide at least 12 - 18
inches of straight pipe in front
of the CELL INLET
Troubleshooting
Problem:
The IntelliChlor 100% light does NOT come on when the ORP controller calls for chlorine
Actions:
1. Verify the ORP controller is opening and closing the dry-contact output.
2. Remove the ORP CONTROLLER wires connection from the power center and the ORP controller.
Manually tie the ORP CONTROLLER wires together. This will turn on the cells at 100%. If the 100%
lights do not come on, verify the communication wires are connected.
Problem:
The IntelliChlor 100% light stays on after the chlorine controller says to stop
Actions:
1. Verify the ORP SENSOR wires are not shorted together in the power center.
2. 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.
More and Less Output Buttons on Intellichlor cell.
These buttons control the output setting and only operate in a single-cell system where the cell is
connected to the standard 520556 power center, no ORP. When an ORP system is used, these buttons
are disabled. Chlorine demand is controlled by the ORP controller.
INTELLICHLOR® Salt Chlorinator Installation Guide
1620 HAWKINS AVE., SANFORD, NC 27330 • (919) 566-8000
10951 WEST LOS ANGELES AVE., MOORPARK, CA 93021 • (805) 553-5000
www. pentairpool.com
All Pentair trademarks and logos are owned by Pentair or one of its global affiliates. Pentair
Aquatic Systems™, IntelliChlor®, SunTouch®, IntelliTouch®, EasyTouch®, 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 expressly noted, names and brands of third parties
that may be used in this document are not used to indicate an affiliation or endorsement between
the owners 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 third parties. Because we are
continuously improving our products and services, Pentair reserves the right to change specifications
without prior notice. Pentair is an equal opportunity employer.
© 2015 Pentair Water Pool and Spa, Inc. All rights reserved.
This document is subject to change without notice
*520590*
.
P/N 520590 REV. F 1/2015
INTELLICHLOR® Salt Chlorinator Installation Guide
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