Pentair IntelliChlor® Plus40 IC40 Plus Replacement Salt Cell Instruction Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your Pentair IntelliChlor® Plus40 IC40 Plus Replacement Salt Cell. This unit is designed to sanitize pools up to 40,000 gallons by converting salt into chlorine, offering an alternative to traditional chlorine handling.

Figure 1: Pentair IntelliChlor® Plus40 IC40 Plus Replacement Salt Cell.

2. Key Features

• Direct Drop-in Replacement: Designed for seamless integration with existing Pentair salt chlorine generators, requiring no additional plumbing.
• High Capacity Sanitization: Capable of sanitizing pools up to 40,000 gallons, with a chlorine output of 1.40 lbs every 24 hours at 100% efficiency.
• Modular Design: Features new and improved modular designs for enhanced serviceability, accuracy, and value, allowing for simple replacements of electronics and sensors.
• Easy-to-Read Interface: Equipped with an LCD/LED interface that includes over 20 built-in diagnostics and warnings for simplified monitoring.
• Accurate Salt Level Readings: Incorporates a redesigned conductivity sensor for more precise salt level measurements.
• Integrated Cleaning Kit: An acid cleaning kit is provided with all units to facilitate routine maintenance and cleaning.
• Scale Prevention: Regular cycling helps prevent calcium and scale buildup, contributing to a maximized cell life.
• System Compatibility: Fully compatible with existing IntelliChlor Power Center and Pentair automation systems.

Figure 2: Exploded view illustrating the modular design for easy component replacement.

Figure 3: Close-up of the redesigned conductivity sensor for improved accuracy.

Figure 4: Acid washing kit for convenient cell cleaning.

3. Setup and Installation

The IntelliChlor® Plus40 is designed for straightforward installation as a direct replacement for previous IntelliChlor models. No additional plumbing is typically required, as it fits into the existing system.

Installation Tips:

1. Install the salt cell on the return line after the pump, filter, and heater.
2. Establish the required salt level according to the manufacturer's instructions.
3. Consider adding a swing check valve and zinc anode to protect equipment against corrosion.

Figure 5: Visual guide for proper salt cell installation.

Installation Video Guide:

4. Operating Instructions

Once installed and connected to your Pentair Power Center or automation system, the IntelliChlor® Plus40 will automatically begin producing chlorine to sanitize your pool. The unit features an easy-to-read interface with built-in diagnostics to monitor its operation.

Control Panel Overview:

The front panel provides visual indicators for salt level, cell status, water temperature, flow, and sanitizer output. Use the 'Info' and arrow buttons to navigate through diagnostic information and adjust settings.

Figure 6: Close-up of the IntelliChlor® Plus40 control panel with indicators and buttons.

Product Overview Video:

5. Maintenance

Regular maintenance is crucial for the longevity and optimal performance of your IntelliChlor® Plus40 salt cell. The unit features a self-cleaning cycle to minimize scale buildup, but manual checks and chemical balancing are still necessary.

Maintenance Schedule:

• Every 3 Months: Clean and inspect the salt cell. Use the provided acid cleaning kit as needed.
• Weekly: Test and balance pH levels.
• Seasonally: Maintain Cyanuric Acid (CYA) level at a minimum of 60 ppm. If the salt cell will not be used for long periods in winter, consider using a dummy cell.

Figure 7: Visual guide for routine salt cell maintenance.

Chlorine Solution Management Video:

6. Troubleshooting

The IntelliChlor® Plus40 features an easy-to-read interface with over 20 built-in diagnostics and warnings to assist in identifying and resolving operational issues. Refer to the unit's display for specific error codes or indicators.

Common Issues and Indicators:

• Low Flow: The 'Flow' indicator will illuminate or flash if insufficient water flow is detected. Ensure your pump is running and filters are clean.
• Low/High Salt: The 'Salt Level' indicator will show if salt levels are outside the ideal range (3600 ppm). Adjust salt levels as necessary.
• Cold Water: The 'Cold Water' indicator signifies that water temperature is too low for efficient chlorine production. The unit may automatically reduce or cease operation to protect the cell.
• Cell Status: A 'Cell' indicator may signal a need for cleaning or replacement.
• Warning: A general 'Warning' light, often accompanied by a specific code on the display, indicates a system fault. Press the 'Info' button for more details.

Troubleshooting and Review Video:

7. Specifications

8. Warranty and Support

For detailed warranty information, please refer to the official warranty document included with your product or visit the Pentair website. Maintaining proper pool water chemistry, as outlined in the product manual, is essential for ensuring the longevity of your salt cell and may be required to uphold warranty coverage.

For technical support or service inquiries, please contact Pentair customer service through their official channels. Ensure you have your model number (523735-EC) and purchase date available when contacting support.