Hayward AquaTrol User manual

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

Table of Contents
Important safety
instructions Pg. 1
Display Only, Lights Only or Neither
Pg. 12-15
Switching from Metric to US
Standard Pg. 2
Low/High Cell Temperature
Pg. 16
Changing the Default
Reading Pg. 3
Cell
Cleaning instructions Pg. 17-19
Check Salt/Inspect
Cell LED flashing or ON Pg. 4-5
Pump not
turning on Pg. 20-22
How to Reset Average
Salt Level Pg. 6
Troubleshooting flow charts
Pg. 23-28
Adjusting Chlorine Output
Pg. 7
Salt Chart
Pg. 29
High Salt LED
ON
Pg. 8-9
Important
Information –Chlorine
Output and Salt
Pg. 30
No
Flow LED flashing or ON Pg. 10-11
Reading
Serial Numbers Pg. 31

Aqua Trol Diagnostics
Page 1
!
Warning
High Voltage Electrocution Hazard
Hazardous voltage can shock, burn, cause serious injury
and or death. To reduce the risk of electrocution and or
electric shock hazards:
•Only qualified technicians should remove the panel
•Replace damaged wiring immediately
•Insure panel is properly grounded and bonded

Immediately the temperature reading should change to reflect
a Fahrenheit value. If it does not repeat step 2.
Page 2
If the first reading (average salt) is showing in decimal form instead of as a
number represented in thousands, then the unit has been set to ‘Metric Mode’.
Step 1
Step 2
Step 3
Step 4
To change the unit from Metric mode to standard, start by
pressing the ‘Diagnostics’ button one time.
Once showing the temperature in Celsius, move the switch up
to ‘Super Chlorinate’ then back to auto. It takes about 30 seconds for the unit to settle back to the
default reading. The reading should now reflect a number is
thousands.
Switching from Metric to US Standard

Changing the Default Display
Page 3
Step 1
Step 2
Step 3
Step 4
If the first reading is showing as a number followed by a ‘P’, then the default
reading has been changed to express the ‘Desired Output %’.
Continue moving the switch up to ‘Super Chlorinate’ and back
to ‘Auto’ until the unit reads ‘AL-0’.
To change the default reading back to the average salt, start by
pressing the ‘Diagnostics’ button one time.
When the unit reads ‘AL-4’ move the switch up to ‘Super
Chlorinate’ and back to ‘Auto’. It takes about 30 seconds for the unit to settle back to the default reading. The reading should now reflect the average
salt level.

The ‘Check Salt’ & ‘Inspect Cell’ LED’s will flash when the cell reports the salt
level is between 2400-2700ppm. In this condition chlorine is still being produced.
The ‘Check Salt’ & ‘Inspect Cell’ LED’s will be ON when the cell reports the salt
level is 2300ppm or less. In this condition, chlorine production is interrupted.
Test the salt level in the pool using an
independent testing method. If the salt level is
between 2700-3400ppm, go to step 1B. If salt
level is below the recommended range, add
enough salt to achieve a salt level of 3200ppm.
(Refer to Salt Chart, Page 29).
Inspect the turbo cell.
If cell looks like 4A, go to step C. If cell looks
like 4B, clean cell. (Refer to Pages 17 thru 19).
After the cell is clean go to step 1C to reset.
Page 4
NOTE: ‘Check Salt’ & ‘Inspect Cell’ LED’s may also be ON if the
control is set for the wrong Cell type or the cell is unplugged.
Step 1A Step 1B
1. Check Salt & Inspect Cell
LED flashing or ON

1. Check Salt & Inspect Cell
LED flashing or ON
With the number stable (and the negative sign still
present) move the switch to ‘Super Chlorinate’ then
back to ‘Auto’.
Starting with the average salt reading. Turn the
switch to ‘Off’, then back to ‘Auto’. Wait for the relay
to click (about 5 to 10 seconds).
Press the ‘Diagnostics’ button 5 times, this will
bring up the instant salt reading. The instant salt
reading will start as -0. It will then fluctuate. Wait
for the number to stabilize.
When the negative sign disappears, this number will
reflect the new average salt reading. If value is not
reading within 500ppm of independent test, then
replace cell. If number is reading within 500ppm of
the independent test and the ‘Inspect Cell’ LED is
flashing, add salt until level is above 2700ppm.
Step I
Step II
Step III
Step IV
Note: Resetting the average salt must be done within 60 seconds after starting the process. To ensure both polarities are
reading salt accurately (within 500ppm of the independent test), conduct this reset two times consecutively.
Step 1C
Page 5

Page 6
How to Reset Average Salt Level
The Average Salt level needs to be reset for start up, when a board is replaced, when major adjustments are made to the
pool water and when a cell is replaced. Note: new boards will display a factory default of 2800ppm.
Press Diagnostics button 5 times to display the Instant Salt level.
Wait for the number to stabilize.
When the instant salt level is
stable (and the negative sign
still present), cycle slide switch
to ‘Super Chlorinate’ and back
to ‘Auto’.
To reset, move the switch to ‘Off’ and then back to ‘Auto’. Wait
for the relay to click (5 to 10 seconds).
Step I
Step II
Step III

Adjusting Chlorine Output
Desired Output % Dial 1 to 100% sets the level of cell operation in % of operating
time. Example: 50% (factory default) cell is operating and generating chlorine
50% of the total pump/filter operating time.
Note: If the chlorine level does not increase within 24 hours after increasing output, test water with
independent tests to determine current salt, stabilizer, phosphate, and nitrate levels. More information
related to chlorine production on Page 30).
Note: Output is scaled back to 20% of desired output setting at 60 ° F and output stops at 50 ° F.
Page 7
Rotate dial to the
left to lower
chlorine production.
Rotate dial to the
right to raise
chlorine production.

Page 8
2. High Salt LED ON
The ‘High Salt’ LED will be ON when the cell amperage is above the maximum limit. The ‘High Salt’ LED may also
be ON if the wrong Turbo Cell is being used. The Aqua Trol systems are designed to only work with the t-5 model.
The LCD display will read ‘HI’ when the amperage is above 6.40.
Verify salt level is 2700-3400ppm and check
with independent test to ensure accuracy.
If salt level is above the range, partially drain pool and/or spa and refill
with fresh water to achieve a salt level of 3200ppm, refer to page 9,
Step D. If the salt level is not high, verify the correct cell is being used
then reset (follow steps on page 6).
Maximum Current (Amps)
before shutdown
Unlike low salt the system does
not shut the chlorinator down
when a specific salt level is
reached. Instead the unit will
suspend chlorination when the
cell’s amperage draw exceeds a
certain value.
T
-CELL-5
6.40

Page 9
2. High Salt LED ON
Part I
(Ave. Pool Depth X 3200)
Actual Salt level in Pool
Part 1: Take the average depth of the pool in inches and
multiply that by 3200. Then divide that number by the actual
salt level in the pool (based on the independent test).
Part 2: Subtract the Ave. Pool Depth by the answer from part
1. This will give you the total number of inches to drain and
replenish with fresh water to achieve a salt level of 3200.
Part II Ave. Pool Depth - Answer from Part 1 = Amount of Water to Drain
To calculate how much water will need to be removed from a pool with
too much salt, follow the formula provided below:
Example: a pool has an ave. depth of 54” and the salt level is 4500ppm
54 X 3200 = 172800
4500 38.4
Example: Part I
54 –38.4 = 15.6”
Example: Part II
Note: It is recommended to reduce the water level no more than six inches at a time before replenishing with
fresh water. Failure to due so may result in damage to the pool structure or surface.
Step 2A

Page 10
3. No Flow LED flashing or ON
‘No Flow’ LED will flash for up to 60 seconds on start-up (when continuity through the switch is being detected).
‘No Flow’ LED will be ON if there is a problem with flow detection (when continuity through the switch is not being detected).
If the ‘No Flow’ LED is flashing, make sure pump is primed and an adequate amount of water is
passing through the flow switch element for at least 60 seconds (the required flow rate is 11 gpm). If
after 60 seconds the LED does not go out proceed to step 3B.
If the ‘No Flow’ LED is ON make sure flow switch is plugged into the bottom of the control box and the
wire is not damaged. If the wire or connector is damaged replace the switch, if not proceed to step 3B.
Step 3A

Page 11
3. No Flow LED flashing or ON
Verify the flow switch has 12” of straight pipe before it. If the flow switch
is installed too close to an outlet/bend, re-plumb the switch to a location
where it will not experience as much turbulence. Rotate the flow switch
until the raised surface (on the hexagonal nut) is oriented against the
flow of water. If this does not correct the problem (after 60 seconds) of
consistent flow, proceed to Step 3C.
Verify that the control box (where the
flow switch plugs in) is not corroded or
damaged. If no damage is present on
the board then replace the switch and
repeat the 60 second filter delay after
the pump is activated, if after 60
seconds the ‘No Flow’ LED does not go
out replace the board.
Step 3B Step 3C

Page 12
4. Display Only, Lights Only or Neither
Reseat DSP Board
Remove and/or reseat DSP board. Pins may be
shorted together or not making contact with
connector. If pins are good, if volts are below 5VDC
replace main board (GLX-PCB-TROL-(HP or RJ).
Verify 18-33 VDC between
black & red wires on main board
If no/low voltage, verify each wire is attached
according to the instructions. If wire orientation is
correct go to step 4C. If voltage OK, go to step 4B.
Step 4A
PINS
1 2 3 4 5 6
Step 4B

Page 13
If voltage is correct, go to step 4D. If no voltage, verify
that the GFCI or standard receptacle has power. If voltage is good go to step 4F. If no/low voltage go to step 4E.
Verify 115-125 VAC at
input terminal TB1.
Step 4C
Verify 20-24 VAC
between yellow wires
Step 4D
4. Display Only, Lights Only or Neither

Page 14
Test for continuity between
the two legs of the 20 amp
yellow ATO style fuse
Shut off power to the control box.
Disconnect the blue, white, gray and
violet wires from the main board and measure
the following:
Insert probes and measure resistance between the Blue & White
wires and the Violet & Gray wires. The readings should be 2.0-
2.9 Ohms.
If the readings of either of the two measurements are not
2.0 –2.9 Ohms, the transformer is faulty and should be replaced
(GLX-XFMR). If measurements are OK, reconnect wires and go
to step 4F.
Replace fuse if blown. If fuse OK, go
to step 4G.
Step 4E Step 4F
4. Display Only, Lights Only or Neither

Page 15
If no/low voltage, replace the main circuit
board (GLX-PCB-TROL-XX). If voltage is
correct, replace the rectifiers (GLX-DRK).
Verify 10-14 VAC between the Orange
wire and the Green Grounding lug. PCB-Trol (GLX-PCB-TROL-XX)
Step 4G
Rectifiers (GLX-DRK)
4. Display Only, Lights Only or Neither

Page 16
5. Low/High Cell temperature
The operating temperature range for the cell is 50o F to 140o F.
Verify actual water temperature
LCD display will read “COLD” when the water temperature is below 50oF
LCD display will read “HOT” when the water temperature is above 140oF
If the water temperature reads an erroneously high number, the cell temperature sensor is shorted
and the cell needs to be replaced.
Cell Temperature
Sensor
Output is scaled back to 20% at 60°F and output stops at 50°F

Page 17
Cell cleaning frequency is dependent on several factors; pH and calcium levels in the water are the two that have the greatest effect
on how often the cell requires cleaning. Maintaining pH at the levels recommended in the Operating Instructions (7.2 - 7.8) should
result in the cell being cleaned 3-4 times a year in areas with hard water. Cells may be cleaned less frequently in soft water areas.
After removing the Turbo Cell from the plumbing of your pool; inspect the cell for white deposits between the plates inside of the
cell. Please remember that even if you cannot see deposits on the cell it still may need cleaning. If no deposits are found (4A), the
cell may have to be held towards ample amounts of light and angled in different directions to reveal smaller white deposits deeper
within the nest of the cell.
Hold to light to
look for small deposits Cell is dirty.
Note the deposits.
! CAUTION
4A 4B
ALWAYS ADD ACID TO WATER, NEVER WATER TO ACID. ALWAYS WEAR PROPER EYE
PROTECTION AND PROTECTIVE GLOVES. USE IN A WELL VENTILATED AREA. MURIATIC
AND OTHER ACIDS CAN CAUSE SEVERE INJURY, BURNS AND RESPIRATORY PROBLEMS IF NOT
HANDLED PROPERLY. REFER TO THE MANUFACTURER’S DIRECTIONS FOR SAFE HANDLING.
Cell Cleaning Instructions

Page 18
Cell Cleaning Instructions
We strongly recommend using a Goldline Controls cell cleaning stand. (GLX-CELLSTAND)
Step 1: Use a water hose to dislodge small debris.
Step 2: Use a solution of water and Muriatic acid. Stand the cell vertically in the solution. Mix 1 part acid to 4 parts water. The
level of the solution should be slightly over the product label. Let the cell stand in the solution for 15 minutes (Fig. 6A below), then
flip the cell over and let stand on the other end (Fig. 6B below) for an additional 15 minutes. Although the cord can be
submerged, be sure that the connector does not come in contact with the solution.
Inspect the cell after both sides have soaked. If there are no deposits after soaking, rinse with water and reinstall. If there are still
deposits after soaking, repeat the soaking procedure until clean. The water/muriatic acid mixture can be stored for later use or it
can be disposed. Follow chemical manufacturer’s recommendations when storing or disposing the water/acid solution.
After you inspect the cell (and clean, if necessary) press the small "diagnostic“ button next to the display for 3 seconds to stop
the flashing "Inspect Cell" LED and reset the countdown timer for another 500 operational hours.
Cleaning instructions
using a container.
5