Pentair INTELLICHLOR COMSYS-6 User manual

IMPORTANT SAFETY INSTRUCTIONS

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INSTALLATION GUIDE

INTELLICHLOR®SALT CHLORINATOR

COMMERCIAL SYSTEM

COMSYS-6 (P/N 520972)

P/N 520982 REV. C 8/7/23

Customer Support

8 A.M. to 7:30 PM

Phone: (800)831-7133

Fax: (800)284-4151

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

IntelliChlor®Salt Chlorine Generator (SCG) COMSYS-6 Overview

The IntelliChlor COMSYS-6 commercial system consists of four IntelliChlor (SCG) cells and three power

centers (one primary and three 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. Acommercial system requires an external ORPpanel 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-6 (3-cell - 1 primary and 2 secondary) produces six 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.

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

Installation

Before installing the IntelliChlor CIC60 system, please read all SAFEY PRECAUTIONS below.

Kit Contents

-Four Power Centers (one primary, threesecondary)

-One CIC60P cell

-ThreeCIC60S cells

-Installation Guide(this manual)

RequiredTools

-Medium phillipsor flatheadscrewdriver (andsix screws)

- Electric drill and 1/4" masonry drill bit. (To mount Power Center Bank)

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 cell. For high flow applications, use a

bypass loop.

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

Mount Primary and Secondary Power CenterToWall

1. Locate a wall near the pool equipment area

within 15 feet of the IntelliChlor cells. Position

the primary and secondary power center at eye

level. Mount and secure the power center bank

to the wall using six (6) 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 WIREDFOR 220V. Do not

applyAC power yet.

3. Connect the two (2) twisted wires labeled ORPSENSORto the ORP chlorine controller panel

(AcuTrol, etc. not provided in kit). Carefully place the connection inside of power center.

4. Replace the cover. Secure it using the retaining screw.

Communication

wires

Mount power centers to

wall using six (6) screws

Connect these

wires to ORP

Connect these

wires to AC

power source

PRIMARY SECONDARY SECONDARY

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

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. The manifold MUST be

installed vertically. 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.

O-ring

Union coupling nut Inlet

Outlet

Manifold

Coupling

DO NOT MIX OLD AND

NEW MANIFOLD PARTS.

MANIFOLD

DIMENSIONS MAY NOT

BE BACKWARDS

COMPATIBLE.

Drain

Stand

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

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,

turn it slowly until the plug pins are inserted into the receptacle, then twist it to lock it in

place.

2. Plug the two SECONDARY cell power connectors into each of the power centers labeled

SECONDARY using same method as described in step 1.

Communication

wires

PRIMARY SECONDARY SECONDARY

Secondary power

center receptacle

Primary (CIC60P)

power center receptacle

Secondary connector

Primary (CIC60P) connector

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

Power Centers

The PRIMARYand SECONDARYpower centers have been pre-wired with communication wires as shown

below.

Power Centers (Front View)

PRIMARY SECONDARY SECONDARY

Power Center communication wire connection

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

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 theAC circuit breaker to ON to applyAC 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 SECONDARYpower

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 twominutes, the salt levelwill be read anddisplayed on all cells.

IntelliChlorSaltChlorineGeneratorCOMSYS-6InstallationGuide

Troubleshooting

TheIntelliChlor 100% light does not come on whenthechlorinecontrollercalls for chlorine

1. Verify the ORPcontroller 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 ORPcontroller, 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.

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