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Hayward AquaTrol Troubleshoot Manual

Hayward AquaTrol
33 pages
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AquaTrol®
Rev. 1.45
Troubleshooting
Guide
Turbo Cell
&
Control
Electronics
Copyright 2015 Hayward Industries Inc.
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Hayward AquaTrol Specifications

General IconGeneral
ModelAquaTrol
TypeSalt Chlorine Generator
Pool TypeAbove Ground
Voltage120V/240V
DisplayDigital
Salt Level2700-3400 ppm
Weight15 lbs
Warranty1 Year

Summary

Aqua Trol Diagnostics and Safety

High Voltage Electrocution Hazard

Warns about high voltage hazards and safety precautions for qualified technicians.

Switching from Metric to US Standard

Metric Mode Detection and Initiation

Initial display indicates Metric Mode; press 'Diagnostics' to start change.

Fahrenheit Conversion and Finalization

Temperature changes to Fahrenheit; finalize by cycling switch to 'Super Chlorinate' then 'Auto'.

Changing the Default Display Setting

Identifying 'Desired Output %' Mode

Display shows number followed by 'P', indicating 'Desired Output %'.

Restoring Average Salt Level Display

Adjusting switch to 'AL-0' and then '3400' to restore average salt level.

Check Salt & Inspect Cell LED Troubleshooting

LED Indicators and Salt Level Correlation

Explains when 'Check Salt' and 'Inspect Cell' LEDs flash or stay ON based on salt levels.

Turbo Cell Inspection and Cleaning Recommendation

Inspect cell for deposits; clean if necessary; check pages 17-19 for cleaning.

Salt Level Testing and Adjustment

Guidance on testing salt levels and adding salt if below the recommended range.

Resetting Average Salt for Cell Issues

Initial Salt Reset and Reading Access

Cycle switch to reset; press 'Diagnostics' to view instant salt reading.

Stabilizing and Finalizing Salt Reading

Move switch to 'Super Chlorinate' then 'Auto' when stable; verify new reading.

How to Reset Average Salt Level

Initiating Salt Level Reset

Resetting the average salt by cycling the switch from 'Off' to 'Auto'.

Displaying Instant Salt Level

Using the Diagnostics button to view the Instant Salt level.

Finalizing Reset Procedure

Cycling the switch to 'Super Chlorinate' and back to 'Auto'.

Adjusting Chlorine Output Level

Understanding Desired Output Percentage

Explains how the 'Desired Output %' dial controls cell operation time.

Adjusting Chlorine Production Levels

Rotate dial left to decrease, right to increase chlorine output.

Water Chemistry Impact on Output

Advises testing water chemistry if chlorine output doesn't increase.

High Salt LED ON Troubleshooting

High Salt LED and 'HI' Display Explanation

Explains when 'High Salt' LED is ON and 'HI' display condition due to amperage.

Salt Level, Cell Model, and Action Guidance

Verify salt, cell model; drain/refill for excessive salt levels.

Maximum Current Limit Information

Displays the maximum amperage before shutdown for the T-CELL-5 model.

Calculating Water Removal for High Salt

Formulas for Water Removal Calculation

Provides formulas to calculate water needed for removal and inches to drain.

Example Calculation and Water Level Advice

Demonstrates calculation and advises limiting water level reduction to six inches.

No Flow LED Flashing or ON Troubleshooting

'No Flow' LED Behavior and Causes

Explains 'No Flow' LED flashing on start-up vs. being ON due to flow detection issues.

Troubleshooting Flashing 'No Flow' LED

Steps for a flashing 'No Flow' LED: check pump priming and water flow.

Troubleshooting Solid 'No Flow' LED

Steps for a solid 'No Flow' LED: check flow switch connection and wire integrity.

Flow Switch and Control Box Checks

Flow Switch Plumbing and Orientation

Verifies 12" of straight pipe before the flow switch and orientation.

Control Box Corrosion or Damage Inspection

Instructions to check the control box for corrosion or damage before replacing the switch.

Display Only, Lights Only or Neither Troubleshooting

Verifying DC Voltage on Main Board

Measures 18-33 VDC between black and red wires on the main board.

Reseating the DSP Board

Procedure to remove and reseat the DSP board to resolve display issues.

Input Terminal TB1 Voltage Check

Checks 115-125 VAC at input terminal TB1.

Electrical Checks for Display Issues

Yellow Wire AC Voltage Measurement

Measures 20-24 VAC between yellow wires.

GFCI/Receptacle Power Verification

Verifies power at the GFCI or standard receptacle if TB1 voltage is incorrect.

Component Resistance and Fuse Checks

Measuring Wire Resistance for Transformer Fault

Measures resistance between Blue/White and Violet/Gray wires for transformer fault.

ATO Fuse Continuity Test

Tests continuity of the 20 amp yellow ATO style fuse.

Final Electrical Checks for Display Problems

Orange Wire to Ground Voltage Check

Verifies 10-14 VAC between the Orange wire and the Green Grounding lug.

PCB-Trol and Rectifier Identification

Identifies the PCB-Trol and Rectifiers (GLX-DRK) for potential replacement.

Low/High Cell Temperature Troubleshooting

Cell Operating Temperature Range and Indicators

Specifies operating range and explains LCD readings like 'COLD' and 'HOT'.

Sensor Failure Diagnosis and Output Scaling

Notes sensor failure causes high temp readings; output is scaled by temperature.

Cell Cleaning Instructions Overview

Cleaning Frequency Factors and Deposit Inspection

Discusses cleaning frequency factors and guide on inspecting for deposits.

Visual Inspection Technique and Safety Precautions

Technique for revealing deposits; safety warnings for acid cleaning.

Cell Cleaning Procedure Using a Container

Step 1: Dislodge Small Debris

Initial step to use a water hose to remove small debris from the cell.

Step 2: Muriatic Acid Soaking Process

Using a 1:4 acid to water solution for a 15-minute soak on each end.

Post-Soak Inspection and LED Reset

Inspecting the cell, repeating if needed, and resetting the 'Inspect Cell' LED.

Cell Cleaning Procedure Using a Cleaning Stand

Stand Usage and Soaking Process

Instructions for using the stand with acid solution for soaking and inspection.

Resetting LED Timer and Average Salt

Press diagnostic button to reset 'Inspect Cell' LED timer and average salt if needed.

Pump Not Turning On Troubleshooting

Understanding the Filter Pump Timer Operation

Explains the timer tabs representing 15-minute intervals for pump operation.

Filter Pump Timer Switch Modes

Describes 'Pump Timer Override', 'Auto Timer Mode', and 'Pump Timer Manual Off'.

Pump Not Turning On: Model and Continuity Checks

Verifying Correct Model Number Display

Checking if the displayed model number (AL-6 or AL-7) is correct.

Brown Wire Continuity Test

Verifying continuity between brown wires at J1 on the PCB.

Time Clock Replacement Recommendation

Recommends replacing the time clock if continuity is absent.

Pump Not Turning On: PCB and Receptacle Voltage Checks

PCB Voltage Verification

Verifying 115-124 VAC between terminals E5 and E6 on the PCB.

Pump Receptacle Voltage Verification

Verifying 115-125 VAC at the pump receptacle on the bottom of the Trol.

Receptacle or PCB Replacement Guidance

Guidance on replacing the receptacle or PCB based on voltage readings.

Check Salt & Inspect Cell Troubleshooting Flowchart

Salt Level, Cell Cleanliness, and Reset Steps

Assesses salt level, cell cleanliness, and guides on resetting average salt.

Salt Reading vs. Independent Test Verification

Checks salt reading against independent tests for customer's or new cell.

High Salt LED ON Troubleshooting Flowchart

Salt Level and Cell Cleanliness Check

Checks salt level and cell cleanliness for 'High Salt' LED issues.

Lowering Salt Level to Recommended Range

Action to lower salt level to 3200ppm if it exceeds the recommended range.

Average Salt Level Reset for High Salt

Procedure to reset average salt level as part of the troubleshooting process.

No Flow LED Flashing Troubleshooting Flowchart

Initial Wait, LED Status, and Flow Switch Checks

Wait after start, check LED, verify flow switch installation and connection.

Flow Blockage, Pressure, and Switch Replacement

Check for blockage/pressure; replace switch if issues persist.

No Flow LED ON Troubleshooting Flowchart

Pump/Valve Status and Flow Switch Plumbing

Check pump/valves; verify flow switch plumbing and arrow alignment.

Wire Damage, Switch Testing, and PCB Replacement

Check wire damage, test switch, replace PCB if necessary.

No LED's/LCD Display Troubleshooting Flowchart

DC Voltage, Input Voltage, and Yellow Wire Checks

Verify DC voltage, 120VAC input, and yellow wire AC voltage.

Transformer, Fuse, and Rectifier Checks

Ohm out transformer, check fuse continuity, replace rectifiers as needed.

Pump Not Turning On Troubleshooting Flowchart

Model Number, Wire Continuity, and PCB Voltage

Verify model, check brown wire continuity, and PCB voltage.

Pump Receptacle Voltage and Control Troubleshooting

Check pump receptacle voltage and troubleshoot pump control.

Salt Chart and Additive Instructions

Pounds of Salt Required by Pool Size

Table detailing pounds of salt needed for various pool sizes and target ppm.

Guidelines for Adding Pool Salt

Instructions on properly adding salt to the pool for distribution.

Chlorine Output and Salt Level Information

Chlorinator % Control and Salt Level Discrepancies

Control operation time with %; discuss calculated vs. actual salt level differences.

Adjusting Chlorinator Percentage and Super-Chlorinate

Increase % for aging cells; use Super-Chlorinate for production boost.

Understanding Serial Number Formats

Serial Number Breakdown (08-05-2011)

Explains the components of serial numbers starting from 08-05-2011.

Serial Number Breakdown (11-01-2001)

Explains the components of serial numbers starting from 11-01-2001.

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