🌊 Pool Pilot Digital Nano Plus Salt Chlorinator – Automated Salt Water Chlorination System

Automated Salt Water Chlorination for Crystal Clear, Low-Maintenance Pool Water

💧 Product Overview

The Pool Pilot Digital Nano Plus is a sophisticated salt chlorination system designed for residential swimming pools and spas. Manufactured by AquaCal AutoPilot, Inc., this advanced system automatically converts dissolved salt in your pool water into chlorine — providing continuous, automated sanitisation with minimal chemical handling. The system supports programmable pool volumes from 2,000 to 500,000 litres, making it suitable for a wide range of residential pool sizes.

Unlike traditional chlorine dosing, the Nano Plus generates chlorine directly from salt dissolved in your pool water. The salt is constantly recycled during normal operation, meaning minimal salt loss throughout the swimming season. The result is softer, more comfortable water with reduced eye and skin irritation, no harsh chlorine odour, and significantly lower long-term chemical costs.

The system features a patented temperature compensation algorithm, self-cleaning electrolytic cell technology, a digital control panel with multi-language display, and comprehensive diagnostic monitoring. It is suitable for both new pool installations and retrofitting to existing pools with integration into your current filtration system.

⭐ Key Features

• ✅ Automated Salt Chlorination – Converts dissolved salt to chlorine automatically, no manual dosing required
• ✅ Programmable Pool Volume – Supports 2,000 to 500,000 litres (500 to 125,000 US gallons)
• ✅ Self-Cleaning Electrolytic Cell (PPC2) – Automatic polarity reversal prevents calcium scale buildup
• ✅ Patented Temperature Compensation – Automatically adjusts chlorine output as water temperature changes (13°C–52°C)
• ✅ Digital LCD Control Panel – Programmable with multi-language display (English, Spanish, French, German, Italian, Czech)
• ✅ Tri-Sensor Technology – Monitors water flow, temperature, and salt concentration simultaneously
• ✅ Boost Mode – 24-hour or 72-hour boost to 100% output for heavy bather loads
• ✅ Automatic Flow Bypass Manifold – Optimises water flow through the cell for maximum chlorine generation efficiency
• ✅ Optional CoPilot Ozone Upgrade – Add ozone treatment to reduce chlorine demand and extend cell life
• ✅ Retractable Cover Detection – Optional feature automatically reduces output when pool cover is closed (requires 863A Expansion Board)
• ✅ Certified Safety Standards – UL1081, CAN/CSA-C22.2#218.2, FCC compliant

🔧 Technical Specifications

Specification	Detail
Model	Pool Pilot Digital Nano Plus
Model Numbers	75043A, 75043A-xx
System Type	Salt water chlorination (electrolytic)
Programmable Pool Volume	2,000–500,000 litres (500–125,000 US gallons)
Factory Default Pool Volume	60,000 litres (15,000 US gallons)
Standard Cell	PPC2
Compatible Cells	PPC1 or PPC2
Max Chlorine Output (PPC2)	20.0 g/hr (1.06 lb/day)
Max Chlorine Output (PPC1)	15.1 g/hr (0.8 lb/day)
Manifold Models	PPM2, PPM2M
Input Power (Factory Default)	220–240 Vac, 1.0 A
Input Power (Field Convertible)	110–120 Vac, 2.0 A
Manifold Flow Rate (Min)	76 L/min (20 US gpm)
Manifold Flow Rate (Max)	265 L/min (70 US gpm)
CoPilot Ozone Flow Rate (Min)	95 L/min (25 US gpm)
Maximum Manifold Pressure	586 kPa (75 psi)
Programmable Pool Volume	2,000–500,000 litres
Cell Self-Cleaning Cycle	Automatic polarity reversal (2, 4, 8, or 16 hours programmable)
Temperature Compensation Range	13°C–52°C (55°F–125°F)
Control Display	LCD digital display with multi-language support
Languages	English, Spanish, French, German, Italian, Czech
Tri-Sensor Cable Length	3.6 m (12 ft)
Cell Cable Length	3.6 m (12 ft)
Fuse (230V Operation)	250 Vac, 1 A Slo Blo
Fuse (115V Operation)	250 Vac, 2 A Slo Blo
Certifications	UL1081, CAN/CSA-C22.2#218.2, FCC Class B
Manufacturer	AquaCal AutoPilot, Inc.

⚡ Electrical Requirements

Electrical Spec	Requirement
Supply Voltage (Factory Default)	220–240 Vac
Supply Voltage (Field Convertible)	110–120 Vac
Amperage (230V)	1.0 A
Amperage (115V)	2.0 A
GFCI/RCD Protection	Required (mandatory)
Bonding	8 AWG (8.4 mm²) solid copper bonding conductor required
Minimum Distance from Pool (230V)	1.5 m (5 ft)
Minimum Distance from Pool (115V)	3 m (10 ft)
Disconnect Device	Required in fixed wiring (circuit breaker, time clock, or relay)
Conductors	Copper only

⚠️ IMPORTANT:

All electrical work must be carried out by a qualified, licensed electrician in accordance with local wiring regulations. The Pool Pilot must be connected to a supply circuit protected by a ground-fault circuit-interrupter (GFCI) or RCD. In the UK, all pool electrical installations must comply with BS 7671 wiring regulations and include 30mA RCD protection.

🧪 Water Chemistry Requirements

The Pool Pilot Digital Nano Plus requires specific water chemistry parameters to operate safely and effectively. Maintaining balanced water chemistry is essential for optimal chlorine production, cell longevity, and swimmer comfort.

Pool Water Parameters

Parameter	Minimum	Ideal	Maximum
Free Chlorine	1.0 ppm	2.0–4.0 ppm	5 ppm
Combined Chlorine	0.0 ppm	0.0 ppm	0.2 ppm
pH	7.2	7.4–7.6	7.8
Total Alkalinity	60 ppm	80–100 ppm	180 ppm
Calcium Hardness	150 ppm	200–400 ppm	1,000 ppm
Salt	2,000 ppm	3,500–4,500 ppm	6,000 ppm (recommended)
Cyanuric Acid (Stabiliser)	0 ppm	30–50 ppm	80 ppm (typical)

Spa Water Parameters

Parameter	Minimum	Ideal	Maximum
Free Chlorine	2.0 ppm	3.0–4.0 ppm	10 ppm
Combined Chlorine	0.0 ppm	0.0 ppm	0.5 ppm
pH	7.2	7.4–7.6	7.8
Total Alkalinity	60 ppm	80–100 ppm	180 ppm
Calcium Hardness	100 ppm	150–250 ppm	1,000 ppm
Salt	2,000 ppm	3,500–4,500 ppm	6,000 ppm (recommended)
Cyanuric Acid (Stabiliser)	0 ppm	30–50 ppm	80 ppm (typical)

💡 Salt Notes:

• The unit can operate with salt levels up to 35,000+ ppm, but levels above 6,000 ppm are not normally recommended as corrosion issues may result
• Salt levels below 2,000 ppm will reduce efficiency and chlorine production
• Extremely low salt levels below 1,900 ppm will activate the low salt safety cutoff and halt chlorine production
• Use sodium chloride (NaCl) salt greater than 99% pure — food grade granular, pool salt, water softener pellets, or solar salt flakes
• Do NOT use rock salt, iodised salt, or salt with rust preventatives

🔬 How Salt Chlorination Works

Step 1: Salt Dissolves – Food-grade sodium chloride salt is added to the pool water at a low concentration (3,500–4,500 ppm), well below the taste threshold.

Step 2: Electrolysis – As water passes through the electrolytic cell, a controlled electrical current splits the salt (NaCl) molecules, generating chlorine (hypochlorous acid) — the same sanitiser used in traditional pool treatment.

Step 3: Sanitisation – The generated chlorine sanitises the pool water, destroying bacteria, algae, and other harmful organisms.

Step 4: Recycling – After treating the water, the chlorine reverts back to salt. The salt is constantly recycled, meaning minimal loss during a swimming season.

Step 5: Temperature Compensation – The patented algorithm automatically adjusts chlorine output based on water temperature. Warmer water requires more chlorine; colder water requires less. This prevents over-chlorination and premature cell depletion.

The result: Clean, sanitised water with softer feel, reduced chemical odour, and lower ongoing costs — all managed automatically.

🎛️ Digital Control Features

The Pool Pilot Digital Nano Plus features a comprehensive digital control panel with intuitive programming:

Feature	Description
Purifier Output Control	Adjustable from 0%–100% in 1% increments
Boost Mode	Press once for 24-hour 100% output; hold 8 seconds for 72-hour boost
Salt Level Display	Real-time salt concentration reading with “Add Salt” quantity guidance
Water Temperature Display	Fahrenheit or Celsius (can be hidden or shown)
Check System LED	Flashes red to indicate attention required, with diagnostic messages
Audio Alarm	Optional audible alert for low flow, low salt, or temperature issues (auto-silences after 10 minutes for flow issues)
Diagnostic Test Mode	Displays salt level, temperature, cell voltage/amperage, and accumulated amp-hours
View Setup	Review all programmed parameters including software version and serial number
Multi-Language Display	English, Spanish, French, German, Italian, Czech
Purifier Off Delay	Delay chlorine production 1–28 days for new plaster curing (requires 863A Expansion Board)
12/24 Hour Clock	Time display with timezone adjustment (requires 863A Expansion Board)
Cover Detection Display	Shows “Cover Closed” with automatic output reduction to 20% (requires 863A Expansion Board and cover switch)

Not Included (Required for Installation)

Item	Notes
Power service electrical wire	Supplied by installer
Bonding wire	8 AWG (8.4 mm²) solid copper
Pool cover controller and switch	Optional, requires 863A Expansion Board

Optional Upgrades

Option	Description
863A Expansion Board	Adds cover detection, 12/24 hour clock, and 1–28 day purifier off delay
CoPilot Ozone System	Adds ozone treatment to reduce chlorine demand and extend cell life
PPC1 Cell	Smaller replacement cell (15.1 g/hr output vs 20.0 g/hr for PPC2)

🛠️ Installation Requirements

Mounting

Requirement	Specification
Mounting Position	Vertical on flat surface, wiring inputs facing downward
Minimum Height Above Ground	30 cm (1 ft) for proper air circulation
Distance from Pool (230V)	Minimum 1.5 m (5 ft)
Distance from Pool (115V)	Minimum 3 m (10 ft)
Cable Reach	Control unit must be within 3.6 m (12 ft) of manifold assembly
Ventilation	Do not mount in tightly enclosed area — top and bottom of enclosure must not be blocked
Indoor/Outdoor	Suitable for both

Plumbing

Connection	Specification
Connection Size	2″ PVC slip socket (63 mm metric adapters included for metric models)
Position in Pipework	After heater and spa diverter valve — last component in pool return line
Manifold Orientation	Must be installed vertically (upright)
Flow Direction	Must follow marked direction on manifold
Minimum Flow Rate	76 L/min (20 US gpm)
Maximum Flow Rate	265 L/min (70 US gpm)
Flow Rate Over 265 L/min	External bypass must be installed

Installation Notes

⚠️ For pool/spa combination systems, the manifold must be located as the last component in the pool return line to avoid over-sanitisation of the spa.

⚠️ For two-speed or variable speed pumps, ensure the pump provides sufficient flow at the low speed setting (minimum 76 L/min).

⚠️ For newly constructed or resurfaced plaster pools, do not operate the Pool Pilot with newly poured or resurfaced plaster. Wait 30 days after construction to allow proper curing before adding salt and operating the chlorinator.

⚠️ For new vinyl liner pools, contact the liner manufacturer for recommended instructions before adding salt and operating the chlorinator.

🔄 Maintenance Guide

Routine Maintenance

Task	Frequency	Notes
Test free chlorine level	Weekly	Maintain 1–3 ppm (pool) or 3–4 ppm (spa)
Test pH level	Weekly	Maintain 7.2–7.8
Test salt level	Monthly	Maintain 3,500–4,500 ppm
Test total alkalinity	Monthly	Maintain 80–100 ppm
Test calcium hardness	Monthly	Maintain 200–400 ppm (pool)
Test cyanuric acid (stabiliser)	Monthly	Maintain 30–50 ppm (outdoor pools)
Check Saturation Index	Monthly	Keep between -0.3 and +0.3
Inspect manifold strainer screen	As needed	Remove debris, clean if dirty
Inspect Tri-sensor	As needed	Check for scale, damage, or debris
Inspect cell	As prompted or periodically	Check for calcium scale buildup
Check cell voltage and amperage	Periodically	Use Test Pool Pilot diagnostic menu

Cell Cleaning

If calcium scale builds up on the cell blades (indicated by “Warning! Check/Clean cell” message):

1. Turn off circulation pump and shut off all power
2. Unscrew unions at both ends of the cell and slide out
3. Place a cleaning plug on one end
4. Fill with water to 2 inches from top of blades
5. Fill remaining space with muriatic acid (approximately 1:4 acid-to-water ratio)
6. Always add acid to water, never water to acid
7. Allow solution to sit for 15 minutes or until bubbling stops
8. Dispose of solution safely (pouring into pool is recommended)
9. Rinse cell with light water pressure and re-inspect
10. Repeat if necessary

⚠️ NEVER use sharp or metallic objects to scrape the titanium blade surfaces — this will damage the catalyst coating and void the warranty.

Tri-Sensor Cleaning

If salt sensor blades develop calcium scale:

1. Mix one part muriatic acid into four parts water (always add acid to water)
2. Immerse salt sensor blades for up to 15 minutes
3. Rinse with fresh water and re-inspect
4. Repeat as necessary

Winterising

For areas with sustained freezing conditions:

• During brief freezing periods, run the filtration system continuously — circulating water will not freeze
• For sustained freezing, drain all water from the manifold assembly, cell, Tri-sensor, pump, filter, and all supply/return lines
• The manifold assembly, cell, Tri-sensor, and cables may be stored indoors
• The control unit is not affected by cold and does not need to be removed

⚠️ Equipment damage due to freezing conditions is NOT covered under the equipment warranty.

Spring Start-Up

1. Manually chlorine-shock the pool water
2. Test water and add chemicals to balance per recommended levels
3. Check salt and cyanuric acid levels — bring up to recommended levels
4. Inspect cell, manifold screen, and test Tri-sensor flow switch
5. Clean and/or replace components as necessary

🎯 Ideal Applications

Application	Suitability	Notes
🏊 Residential swimming pool	✅ Excellent	Primary designed application — programmable for 2,000–500,000 litres
♨️ Spa / hot tub	✅ Good	Suitable with adjusted water chemistry parameters
🏊 Pool/spa combination	✅ Good	Install as last component in pool return line
🏊 Vinyl liner pool	✅ Good	Contact liner manufacturer before adding salt
🏊 Plaster/rendered pool	✅ Good	Wait 30 days after plastering before operation
🏢 Commercial pool	⚠️ Consult local regulations	Follow local regulatory guidelines for commercial applications

⚙️ Troubleshooting Quick Reference

Display Message	Meaning	Action
“Error purify off / Check flow”	Insufficient water flow	Check pump is on, clean skimmer/pump baskets, clean manifold screen, check for air leaks
“Error purify off / Add salt xxx lb”	Salt below 2,000 ppm	Add salt as indicated on display
“Warning! Add salt xxx lb”	Salt between 2,000–2,300 ppm	Add salt to bring to 3,000 ppm
“Warning! Check/Clean cell”	Reduced water conductivity	Check salt level, inspect/clean cell, check water temperature
“Warning! Low Amps: Cell?”	Cell may be depleted or scaled	Inspect cell for wear/scale, check cable connections, acid wash if scaled
“Warning! Low cell volts”	Possible power board issue	Contact AutoPilot Service Centre
“Warning! Bad temp sensor?”	Temperature out of range	Check Tri-sensor cable connection
“Cell inspect due”	Maintenance reminder	Inspect cell and filter screen — this is advisory only, unit continues operating
“Cell is cleaning”	Polarity reversal in progress	Normal operation — production resumes shortly
“Cooling”	Internal temperature exceeded shutoff	Unit pauses for 5 minutes; consider relocating to shaded area
“Purify off ## Day(s)”	Purifier off delay active	Feature activated intentionally — unit will start automatically when countdown expires

❓ Frequently Asked Questions

Q: What size pool can the Nano Plus handle? A: The Pool Pilot Digital Nano Plus supports a programmable pool volume range of 2,000 to 500,000 litres (500 to 125,000 US gallons), covering a wide range of residential pool sizes. The factory default is set to 60,000 litres (15,000 US gallons) and must be programmed to your specific pool volume during installation for accurate salt calculations.

Q: How much salt do I need to add? A: The ideal salt level is 3,500–4,500 ppm. Once programmed with your pool volume, the controller automatically calculates and displays exactly how much salt to add. Use food-grade granular salt, pool salt, water softener pellets, or solar salt flakes — always greater than 99% pure NaCl.

Q: Will my pool water taste salty? A: No. The recommended salt concentration of 3,500–4,500 ppm is normally maintained below the taste threshold. For comparison, seawater contains approximately 35,000 ppm of salt — your pool will have roughly one-tenth of that.

Q: How often do I need to add salt? A: Salt is constantly recycled during normal chlorine generation. Loss is minimal and mainly occurs through filter backwashing, rainwater overflow, splashing, and leaks. Salt does not leave the pool through evaporation. Most pools only need occasional salt top-ups.

Q: Does the cell clean itself? A: Yes. The Pool Pilot uses automatic polarity reversal (self-cleaning cycle) to prevent calcium scale buildup. The default cycle is every 4 hours, programmable to 2, 4, 8, or 16 hours. However, unbalanced water chemistry can cause scaling that exceeds self-cleaning capability, requiring periodic manual cleaning.

Q: What is the Boost mode? A: Boost mode temporarily increases chlorine output to 100% for either 24 or 72 hours. Use this before or after heavy bather loads, pool parties, or heavy rainfall. The unit automatically returns to its normal setting when the boost period expires.

Q: Can I retrofit this to my existing pool? A: Yes. The system is designed for both new installations and retrofitting to existing pools. The manifold is plumbed into your pool return line after all other equipment. Professional installation is required.

Q: What voltage does this system require? A: The unit ships configured for 220–240V operation (1.0 A). It can be field-converted to 110–120V operation (2.0 A) by a qualified electrician. GFCI/RCD protection is mandatory.

Q: Does the system work in winter? A: The temperature compensation feature automatically reduces chlorine output as water temperature drops. At 13°C or below, the controller adjusts to a fixed 1% output. For areas with sustained freezing, the system must be winterised — drain all water from the manifold, cell, and Tri-sensor.

Q: What is the CoPilot option? A: The optional CoPilot system adds ozone treatment to complement salt chlorination. It reduces chlorine demand, extends cell life, and provides an additional layer of water purification. It is available as an upgrade to existing Pool Pilot systems.

Q: How long does the cell last? A: Cell life depends on water balance, usage, and maintenance. Maintaining properly balanced water chemistry is the single most important factor in maximising cell life. Water maintained in a scaling condition will shorten cell life significantly.

Q: Can this system be used with a pool cover? A: Yes. With the optional 863A Expansion Board and a retractable cover switch installed, the system automatically reduces chlorine output to 20% of the normal setting when the cover is closed, preventing over-chlorination.

📥 Downloads & Resources

📄 Installation & Operation Manual (PDF) – Complete installation, programming, operation, maintenance, and troubleshooting guide

🏆 Why Choose the Pool Pilot Digital Nano Plus

• ✅ Automated Chlorine Generation – Set it and let it maintain your pool water automatically
• ✅ Patented Temperature Compensation – Intelligent output adjustment prevents over or under-chlorination
• ✅ Self-Cleaning Cell – Automatic polarity reversal reduces manual maintenance
• ✅ Wide Pool Volume Range – Programmable from 2,000 to 500,000 litres with 20.0 g/hr chlorine output
• ✅ Comprehensive Diagnostics – Tri-sensor monitoring with clear digital display messages
• ✅ Low Running Costs – Salt is recycled, dramatically reducing ongoing chemical purchases
• ✅ Softer Water – Reduced eye and skin irritation, no harsh chlorine smell
• ✅ Expandable – Optional CoPilot ozone system and 863A Expansion Board for additional features
• ✅ Certified Safety – UL1081, CAN/CSA, FCC Class B compliant
• ✅ Multi-Language Support – Six languages built in

🤝 Why Buy From Parts4Tubs

• ✅ UK-based company with local support
• ✅ Fast UK delivery
• ✅ Expert advice from pool and spa equipment specialists
• ✅ Competitive pricing
• ✅ Full warranty support
• ✅ Easy returns within 30 days
• ✅ Secure payment options
• ✅ Related salt chlorinator spares and accessories available

✨ Summary

The Pool Pilot Digital Nano Plus is a professional-grade salt chlorination system for residential pools and spas. It automatically generates chlorine from dissolved salt, providing crystal clear, soft-feeling water with dramatically reduced chemical costs and maintenance. Featuring a patented temperature compensation algorithm, self-cleaning PPC2 electrolytic cell producing up to 20.0 g/hr chlorine output, Tri-sensor monitoring (flow, temperature, salt), digital LCD control panel with six languages, and Boost mode for heavy usage periods. The system supports programmable pool volumes from 2,000 to 500,000 litres and is expandable with the optional CoPilot ozone system and 863A Expansion Board for cover detection and delayed start features. Certified to UL1081, CAN/CSA, and FCC standards.