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How to wire IntelliChlor salt chlorine generator
How to wire IntelliChlor SCG power center
How to wire iChlor TM Salt Chlorine Generator
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How to control IntelliChlor salt chlorine generator How to wire IntelliChlor salt chlorine generator How to wire IntelliChlor SCG power center How to wire iChlor TM Salt Chlorine Generator |
| Use only 600 volt wire. Lamp cord, extension cords are not rated 600 volt. Use copper wire only. Aluminum wire is fire risk and should be avoided or installed by professional. 30 amp breaker use 10 gauge / 120-240 volt 30 amp outlet can be installed on 30 amp breaker only/ use 10 gauge wire ... cannot be connected to 15-20-40 amp breaker.  Orange/ #10 gauge wire, with ground ... 30 amp capacity. Safe maximum: 30 x 80% = 24 amps. Buy: 10-2 gauge/ 30 amp 10-3/ 30 amp Southwire electric tools |
Yellow
12 gauge 20 amp 120 volt 20 amp outlet can be installed on 20 amp breaker, but not 15 amp breaker/ use 12 ga wire. ... cannot be connected to 30-40 amp breaker. 1  Yellow/ #12 gauge wire, with ground ... 20 amp capacity. Safe maximum 16 amps. Buy: 12-2 gauge/ 20 amp 12-3/ 20 amp NMB is house wiring UF is underground Rolls of stranded wire HOOK UP Wires |
White
14 gauge 15 amp 120 volt 15 amp outlet, AFCI, GFCI, timer, switch etc can be installed on 15 or 20 amp breaker. Never connect 15 gauge wire to 20-30-40 amp breaker.  White/ #14 gauge wire, with ground ... 15 amp capacity. Safe maximum 12 amps. Buy: 14-2 gauge/ 15 amp 14-3/ 15 amp NMB is house wiring UF is underground |
| 50-60
amp breaker use 6 gauge / 240 volt 50 outlet can be installed on 50 amp breaker only  Buy: 6-2 wire Southwire electric tools NMB is house wiring UF is underground |
40-50
amp breaker use 8 gauge / 240 volt 40 amp outlet can be installed on 40 or 50 amp breaker only  Buy: 8-2 wire Southwire electric tools NMB is house wiring UF is underground |
  Copper ground wire. Every device, load, metal enclosure etc must be grounded. Ground wire must be continuous throughout installation, never switched on-off, never used as a Neutral wire. Generally ... use same size as other wire in circuit Buy: 12 gauge copper ground wire Ground wire Green ground wire Ground pigtails Ground rods/ ground clamps at Amazon |
 Non metallic flexible cables must carry ground wire, but do not have hazard of short circuit causing injury from shock. Armored steel cable can be used as a grounded connection, and will protect wires from damage. Metal can be energized from an insulation failure. All conduit ...metal, plastic ... flexible and rigid ... must be attached to structure, and attached to enclosures, boxes. Movement, damage and deterioration are major cause of electrical failure. Buy: Non-metallic flexible conduit Power whip Armored cable Southwire armored cable cutter Pull boxes |
 Electrical tools must be insulated. Always best to disconnect power, but insulation failure, lack of proper grounding, grounded neutral, lack of GFCI, out-of-code wiring, generator operating without transfer switch, and other problems still pose a risk to anyone working on electric power ... even when breaker is off. Buy: Electrician tools kits KLEIN TOOLS Tools kits IRWIN tools KNIPEX Telephone cable knife Low Voltage Mounting Bracket for Telephone |
Push-on wire connectors in place of twist-on connectorsBuy:Push on wire connectors Amazon Red 3P connector for 10-14 gauge wire Lever connectors for stranded wire at Amazon HOOK UP Wires |
 Protect wiring from damage Use nipper instead of pliers or screwdriver for removing staples (and nails). Do not damage cable or wires inside cable. -Code says: Cable SHALL BE secured without damage to the outer covering. NEC sec. 336-15 Buy End cutting nippers at Amazon |
  Electrically insulated tools When removing insulation from wire, do NOT score or put cuts on surface of copper wire. Doing so increases resistance and heat on wire and creates possible weak point. Buy tools: KLEIN TOOLS Wire strippers at Amazon Electric Wire Stripping Machine Linesman pliers Utility knife at Amazon |
 Multimeters Voltage is tested across two separate wires. Ohms or resistance is tested across both ends of same wire. Amperage is tested along one or two points on same wire. Buy: Analog multimeter Multimeters at Amazon Klein multimeter Electric testers at Amazon Clampmeter for testing amp flow on line |
 GFCI circuit breaker A GFCI circuit breaker will protect all boxes on circuit. Circuit must be grounded. Ground wire must be continuous and connected to each piece of equipment. White wire on circuit breaker must be connected to Neutral busbar inside the breaker panel. Buy GFCI circuit breakers |
Push down 1" wide Push down breaker Plug-in breaker Buy single-pole: Choose from 15 to 60 amp Eaton CL series Siemens 15-60 amp Single-pole tandem breaker Tandem breakers |
Push down 2" wide Push down breaker Plug-in breakers Buy double-pole: Choose from 15 to 125 amp Choose from 15 amp to 200 amp Eaton CL series circuit breaker Siemens circuit breaker Double pole GFCI |
 IntelliChlor salt chlorine generator Buy: IntelliChlor Pentair IntelliChlor Acid Washing Kit Resources IntelliChlor power center 5209590/ pdf IntelliChlor manual ''Note: Before acid washing, remove the calcium buildup in cell: Use a garden hose on the jet setting and spray directly into both ends of the cell. Most of this calcium buildup has a slushy consistency and will be blown out of the cell. Once the majority of the calcium has been removed, continue with acid washing which will be more effective since most of the calcium has been removed.'' |
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| Don
emails: We have the IntelliChlor Salt Chlorine generator, or iChlor generator Our pool company didn't wire the iChlor generator like they say in the manual. The install manual gives numerous warnings  CHLORINE
GAS BUILDUP CAN OCCUR WITH IMPROPER WIRING: "To reduce the risk of personal injury the iChlor TM Salt Chlorine Generator (SCG) 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 SCG should never be energized when the pool pump is OFF and water is not flowing through the unit." IntelliChlor manual warning page/ pdf Internet says "chlorine is poisonous and swallowing or inhaling it can cause harm." ... " most frequent complaint headache, eye irritation, sore throat, vomiting ... more sever cases result in "asthma like symptoms, defects in pulmonary (lung) function test hat can be permanent in older people, healthy people effects can last months." Gene
responds:
All salt chlorine generators should be wired in parallel with pump, both on same circuit breaker, both routed through same timer. ... this is so the salt chlorine generator cannot turn on unless pump is operating ... |
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| Don
emails: Do you know of specifics with the NEC (national electric code) that say it's an infraction if you do not hook up a particular device as the specific instructions provide? I do hope there is some verbiage about this. We're dealing with a number of problems with this pool company. I guess these guys didn't crack the manual at all and don't know ANYTHING about this unit. They mounted it horizontally (instead of vertically), without the 12"-18" of straight pipe, and without the bypass, -when this system is capable of over 105 GPM. Ha! Anyway... well, yea, the plumbers and the electricians were the same guys. Gene
Responds:
The chlorine generator wired in parallel with pump is safety related ... and relative to the specific equipment being installed ... it does not fall under electrical code that I know of ... consult local electrician ... The wiring might meet local codes, but probably not if the installers weren't licensed electricians. That means somebody could come out and RED TAG your installation because it wasn't inspected... If the installation was very unprofessional, and dangerous to you ... I would gauge this is better reported to local BBB or through small claims court. Overall your complaint will probably have little effect unless damage or death resulted Recommend you use Fig-1 illustration below to have another electrician do the job, and possibly deduct the cost from final payment to company you're dealing with... of course they could put mechanic's lien on your property and cause more trouble than it's worth. |
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| Fig-1
illustration simplifies the wiring by adding details that
are missing from the iChlor product manual that shows 'MC Escher'
version of the
installation as you noted in earlier email. Why doesn't the salt chlorine manual clearly show the installation of the salt chlorine generator? Where is the 12-18" suppose to be? It's a confusing manual that requires additional 5209590 installation guide that shows timer and IntelliChlor SCG power center transformer. Fig-1 solves the problem hopefully. Resources IntelliChlor power center 5209590/ pdf IntelliChlor manual The timer and transformer part of Fig-1 are correct based on my understanding of timers and transformers (power supply) and wiring. Ground wire not shown, but must be installed. A proper ground wire must be continuous and connect to timer, iChlor transformer box, and motor. Metal enclosures must be grounded, but plastic enclosures are not. The 24 V line does not require ground wire.  |
|
 T100
series 40 amp outdoor timer120 volt and 240 volt models 24 hour dial up to 12 on-off per day  Buy: 240 volt 24-hour repeat cycle timer 120 volt timer Beige colored timer Resource: How to wire 240 volt series How to wire 120 volt series Compare box timers DPDT timers Control w/ Z-wave Control with wifi |
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| But
wait........ Don's pool pump has built in timer... there is no
stand-alone timer to wire into ** **As a safety measure against exposure to chlorine fumes, the timer ensures that salt chlorine generator is only able to operate if timer has turned pump ON .... so the chlorine goes into water, and does not get released into air,,, so how do you wire the iChlor TM Salt Chlorine Generator safely without a timer ? Don emails: .... with the latest variable speed pumps and their built-in electronics, and pump has a built-in timer, there's no need for an external timer in that setup. And this is what we have. The electrical rough-in only included the sub-panel and 1 low-voltage transformer (for pool light). But after they put the equipment in, we mentioned yea you guys didn't put the salt system in (it was a $1300 upcharge and we had already paid for it). So after some time they did put it in but they just jumped the salt low voltage transformer from the same 15 amp breaker supplying the light transformer (actually they just did a pass-through at the first transformer can). The VSP is wired to its own dedicated 15 amp breaker. Gene
responds
So the installation does not have a timer ... now it makes sense why they wired it wrong (and probably why they 'overlooked' it during initial installation). Safety
footnote about pool lights:
-All pool lights should be LOW voltage ... 12-13-14 volt AC, 300 watt transformer is typically used for power supply .... Buy: Pool light transformers. -Never connect household 120-240 volt light to a swimming pool. Overhead lights and equipment that do not come into contact with water or any part of pool can be 120-240. -Piping that goes through pump and filter and supplies water to pool should made of plastic to ensure that short circuit in equipment does not travel into water. |
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| Don
emails his solution: I'm gonna put a current sensing relay (current sensing switch) on the pump circuit so that can switch the salt system. I intend to use this current sensing relay to sense the pump circuit and relay the high volt line heading to the salt power center  Gene
responds.My website is amazon affiliate, enter through the following link and purchase amp relay and other materials Buy: Amp relay/ CSS or current switch/ current transducer Your plan seems solid. The current sensing relay is self-powered, and operates as single-pole switch. Check amp rating and range. The contact points are usually low amperage, and cannot be used to switch a pool pump etc, but can be used to switch voltage on-off to the transformer. More expensive amp relays can be very reliable ... they are susceptible to magnetic interference from nearby inductive loads like motors, pumps etc ... and do not substitute for good-ole hardwired magnetic relays and mechanical timers. Amp relays/ current switches/ current relays etc have flammability rating and can be installed inside electrical enclosure and come in contact with wires etc. Note that cheap amp relays (current sensing switches), are unreliable. |
|
 Fig-2 shows wiring diagram for current switch  The
current switch and connections MUST be made
inside metal or plastic enclosure that is rated for electrical.Do not use homemade wood box or plastic kitchen box etc. Buy: Current switch/ current transducer 6 x 6 enclosures Resources: Enclosures and boxes Current switches are installed on 1 Hot wire... Only 1 of the 2 wires going to pump is put through the amp relay. The relay turns ON when current of electrons start flowing through the wire going to pump. If the circuit is 240v then either wire can be used. With 120 volt, the black hot wire is used. If both wires going to pump are put through the amp relay, then the reverse flow of electrons on each leg (each wire) cancels the other out, and relay remains in OFF position. |
|
 Surge:Fig-3 shows how to add Type 1 surge protector directly to the equipment, without needing a circuit breaker. The closer the protection is located to the electronic motor, the better it protects. Multiple surge devices on one circuit are ok. Type 2 is different than Type 1. Type 2 surge requires circuit breaker and must be installed inside a breaker panel. ... best protection when Type 2 is located in a breaker slot nearest to source of power entering panel.... and Type 1 is installed at or near the pool equipment. Buy: PS3000 Type 1 Type 2 universal surge protection Pool and spa surge protection Resource How to wire surge protector GFCI Circuit should be GFCI protected, for example using GFCI breaker. Caution: only 1 GFCI per circuit. Resource How to wire GFCI circuit breaker Ground: Bond the panel to ground rod if code requires ... or if the conduit is metallic, the it works fine as a bond when conduit is run underground. Resources IntelliChlor power center 5209590/ pdf IntelliChlor manual Safe electric wiring |
|
 Wiring
notes:Metal boxes and conduit require grounding. Boxes, enclosures, wires, conduit etc must be attached to structure. Movement is major cause of wiring failures. Use 600 volt solid copper wire (not stranded). Always match wire and breaker size. When possible, locate electrical equipment out of direct sun exposure. High heat causes degradation and early failure of electrical installations Buy Southwire Resources Color code for wire Safe electric wiring |
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| Don's
experiences shows that the all-in-one pump is a less-than-best
'upgrade' offered by pump manufactures
... it is NOT right choice for professional pool installations, because
the professional installers in this installation could not do the
correct installation. There were evidently other problems, unclear what
they
were, but the complaint was not about total failure of equipment ... it
seems the pump and lack of a timer were the curve ball. The weakness of all-in-one pumps is clear to me because of my experience in the trades. For example, if the electronics inside pump go bad due to surge caused by the pump start-up, high summer temps, moisture, nearby lightning strike, poor manufacturing standards etc, the entire pump needs to be replaced. There won't be any repair parts ... and this type of pump will cost more in long run, aside from the $60 savings not buying a timer. It shows the strength of buying simple, reliable pumps that just pump water ... without need for electronics. And shows strength of assembling a group of devices that handle specific jobs ... that can be replaced separately.  Resource:Compare box timers DPDT timers Intermatic Control w/ Z-wave Control with wifi |
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