Hayward Aqua Rite® Pro User manual

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Aqua Rite ProAqua Rite Pro
Aqua Rite ProAqua Rite Pro
Aqua Rite Pro
Pro LogicPro Logic
Pro LogicPro Logic
Pro Logic
Installation and Operation
Manual
AQL-CHEM-3-120
AQL-CHEM-3-240
and
for
TM
®
TM
Work less, play more
with chemistry automation.
092438ARevB
Copyright © 2010 Hayward www.haywardnet.com
620 Division St.
Elizabeth, NJ 07207
®

110
LIMITEDWARRANTY(effective04/01/09) Hayward/Goldlinewarrants itsProLogic
and E-Command pool automation products as well as its Aqua Rite, Aqua Rite Pro,
Aqua Plus and SwimPure chlorination products to be free of defects in materials and
workmanship, under normal use and service, for a period of three (3) years. Hayward/
Goldline also warrants its Aqua Trol chlorination products to be free of defects in
materials and workmanship, under normal use and service for a period of one (1) year.
These warranties are applicable from the initial date of installation on private residen-
tial swimming pools in the US and Canada.
Hayward/Goldline warrants all the above-identified pool automation and chlorination
products installed on commercial swimming pools and on swimming pools outside of
theUSand Canada foraperiod ofone(1) year. Likewise, Hayward/Goldlinewarrants
all accessories and replacement parts for the above-identified pool automation and
chlorination products for a period of one (1) year. Each of these warranties is not
transferable and applies only to the original owner.
Proof of purchase is required for warranty service. If written proof of purchase is not
provided, the manufacturing date code will be the sole determinant of the date of
installation of the product. To obtain warranty service or repair, please contact the
place of purchase or the nearest Hayward/Goldline authorized warranty service cen-
ter. For more information on authorized service centers please contact the Hayward/
Goldline Technical Service Support Center (61 Whitecap Road, North Kingstown RI,
02852) or visit the Goldline web site at www.goldlinecontrols.com or the Hayward
website at www.haywardnet.com.
WARRANTYEXCLUSIONS:
1. Material supplied or workmanship performed by others in process of installation.
2. Damage resulting from improper installation including installation on pools larger
than the product rating.
3. Problems resulting from failure to install, operate or maintain the product(s) in
accordance with the recommendations contained in the owners manual(s).
4.Problemsresulting from failuretomaintainpool waterchemistryinaccordance with
the recommendations in the owners manual(s).
5. Problems resulting from tampering, accident, abuse, negligence, unauthorized re-
pairsoralterations,fire, flood, lightning, freezing,externalwater,degradationofnatu-
ral stone used in or immediately adjacent to a pool or spa, war or acts of God.
DISCLAIMER. THEEXPRESSLIMITEDWARRANTIESABOVECONSTITUTE
THEENTIREWARRANTIESWITHRESPECTTOTHEABOVE-IDENTIFIEDHAY-
WARD/GOLDLINEPOOLAUTOMATIONANDCHLORINATIONPRODUCTS
ANDIS INLIEUOFALLOTHERWARRANTIES,EXPRESSORIMPLIED,IN-
CLUDINGWARRANTIESOFMERCHANTABILITYORFITNESSFORAPAR-
TICULARPURPOSE.THESEWARRANTIES GIVEYOUSPECIFICLEGAL
RIGHTS,ANDYOUMAYALSOHAVEOTHERRIGHTSOFEQUIPMENT,LOST
PROFITSORREVENUE,COSTSOFRENTINGREPLACEMENTS,ANDOTHER
ADDITIONALEXPENSES,EVENIFTHESELLERHADBEENADVISEDOFTHE
POSSIBILITYOFSUCHDAMAGES.SOMESTATESDONOTALLOWTHEEX-
CLUSIONOFLIMITATIONOFINCIDENTALORCONSEQUENTIALDAMAGES,
SOTHEABOVELIMITATIONOREXCLUSIONMAYNOTAPPLYTOYOU.
NOWHOLESALER,AGENT,DEALER,CONTRACTOROROTHERPERSONIS
AUTHORIZEDTOPROVIDE,SUPPLEMENTORMODIFYANYWARRANTYON
BEHALFOFHAYWARD/GOLDLINE.
THESEWARRANTIESAREVOIDIFTHEPRODUCTHASBEENALTEREDIN
ANYWAYAFTERLEAVINGTHEFACTORY.FORTHEABOVE-IDENTIFIED
CHLORINATIONPRODUCTS,THESEWARRANTIESALSOAREVOIDIF,DUR-
INGTHEWARRANTYPERIOD,YOUUSEAREPLACEMENTCHLORINATOR
CELLOTHERTHANANUNMODIFIED,NEWHAYWARD/GOLDLINECHLORI-
NATORCELLPURCHASEDFROMHAYWARD/GOLDLINE.IFAWARRANTY
BECOMESVOID,YOUSTILLMAYPURCHASESERVICEAND/ORTELEPHONE
TECHNICALSUPPORTATTHETHENCURRENTTIMEANDMATERIALRATES.
IMPORTANT SAFETY INSTRUCTIONS
Danger - tank will be filled with corrosive acid:
•Poison- may befatalifswallowed. Causessevere burns. Vapor harmful.
•Keepaway from childrenandpets.
•Fillingand service tobeperformedbypool service professionalonly.
•Readall manufacturer cautionsanddirectionsbeforeuse.
To homeowners and users:
•Thistank contains acidthatisdangerous to handle,andcanharm people
andequipment if notproperlycontained,transported,poured, stored, and
dispensed.
•Perform safety check before entering water each day! Check the pool
chemistryandpool controller alarm statuspriortoenteringthepoolor spa.
Resolveany issues priortoenteringthe water.
•Keepequipmentmaintained! Thepumptubemust be replaced annually to
avoid wear out and leaks. The system should be inspected annually.
•Don’t open the lid! Slightly tip tank to check for liquid level.
To service personnel:
•Performdilutionby adding watertotank-thenaddingtheacid. Toprevent
violent boiling and splashing, always add acid to water, and do so slowly.
•Alwaysdilute acidaccordingtomanufacturer’s specifications.
•Alwaysfollow chemical manufacturers’directionsandwarnings.
•Followtheinstallation checklist toverifyproperoperationupon installation
andat the beginningofeach pool season.
Safety precautions are required to ensure that an equipment malfunction is
detected.Greatcaremustbe taken when installing,maintainingandoperating
acid pump feed systems.
CAUTION: Equipment failure can potentially cause too much acid to be dis-
pensedinto the water, causing anequipmentand health hazardwhichwould
notbe detectable withouttheuseof independent pHmeasurement.

2
9
Before You Begin
Compatibility
TheAQL-CHEM-3-120(120VAC)andAQL-CHEM-3-240 (240VAC) arecompatible
with all Hayward Aqua Rite Pro and Pro Logic pool controls using an AQL-CHEM
Sense & Dispense system. TheAQL-CHEM-3 is not compatible withAqua Rite or
Aqua Logic controls.
Description
TheAQL-CHEM-3 is an automatic acid dispensing system which utilizes a Stenner
45MSeriesacid pump and15gallon tanktolower the pHlevelin your swimmingpool.
Whenusedwith a HaywardAQL-CHEMORPand pH SensingKit,the HaywardAqua
RiteProor Pro Logicpoolcontrol willmeasurethe pool's pHand,if toohigh,automati-
cally enable the AQL-CHEM-3 to dispense muriatic acid into the pool until the pH
reaches the desired level.
What'sincluded
Ensure that the following contents have been included in theAQL-CHEM-3 box:
•Stenner 45M Series acid pump and 15 gallon tank containing:
3 Connecting nuts
3 Ferrules
1 Weighted strainer (pre-installed)
1 20' Roll of suction/discharge tubing 1/4" UV black
1 Spare pump tube
1 Injection fitting (not used, may be discarded)
1 Mounting bracket (pre-installed)
1Rainroof
1 Stenner Installation Manual
•1FlowIndicator
•2 Injector Valves (short injector valve is not used and can be discarded)
•1 Hose clamp
•1AQL-CHEM-3 Manual
Safety
Refer to the Stenner manual included with the dispenser for specific safety informa-
tion related to that product. Because the AQL-CHEM-3 system uses muriatic acid,
refer to the additional information below:
•Always use the proper dilution in the acid feed system (4:1 dilution of 20° Baume
hydrochloric acid 31.45% by weight or equivalent).
•To prevent violent boiling and splashing, ALWAYS ADD ACID TO WATER;
never add water to acid to dilute it. Some use the rhyme “do as you oughta- add
acid to water”.
•Strictly follow the acid vendor’s safety and handling protocols including hand,
body and eye protection when transferring or handling acid.
•Fill the 15 gallon tank to the following levels:
5 gallons of 4:1 solution for pools up to 15,000 gallons of water
10 gallons of 4:1 solution for pools up to 30,000 gallons of water
15 gallons of 4:1 solution for pool above 30,000 gallons of water
This limits the available acid in the event that equipment malfunctions and emp-
ties the tank into the pool or spa.

3 8
•If acid is not diluted properly or the feed pump is oversized, it will overshoot the
pH correction.
•Periodically use an independent pH and chlorine test kit to verify that pH is at a
safelevel,and that chlorineisata safe level.IftheAQL-CHEM probes arebroken,
depleted, dirty, fouled with oils, lotions, or other contaminants, they can report an
inaccurate result to the system causing incorrect water chemistry, which at worst,
could harm people or equipment.
•Check the Aqua Rite Pro or Pro Logic’s display each day before entering the
water.Ifthere is any CheckSystemalarm,follow the troubleshooting guideinthis
manual to understand and rectify the condition. If the display is blank, or report-
ing a communications error, troubleshoot the equipment and rectify the failure
before entering the water.
•Use commercially available tie-down straps (not supplied) to fasten the tank, as
appropriate for your locality.
•Follow the installation checklist to verify proper operation upon installation and
at the beginning of each pool season.
Beforeyoubegin
•Properly balance the pool chemistry. TheAQL-CHEM-3 is designed to maintain
a pool's pH, not correct an out-of-balance pool.
•Plan the mounting location of theAQL-CHEM-3. Look for an easily accessible
location that is less than 20' (length of supplied hose) away from the existing pool
plumbing. Consider that the hole location must be on the underside of the return
plumbing pipe. The injector assembly (approximately 10" long) will be mounted
to this hole, so be sure that there is adequate clearance under the pipe before
drilling.
•Turn off the pool filter pump and drain the return line.
•Remove power to the control. If wiring to a Pro Logic, be sure to remove power at
the home's main panel.
Toolsneeded
The installation of theAQL-CHEM-3 requires the following:
•7/16"drillbit
•flat head screwdriver
Pro Logic
At the local display/keypad:
1. Press "Menu" until Configuration Menu is displayed.
2. Hold both "<" and ">" for three seconds.
3. Press ">" repeatedly until "Chemistry Config. Wizard" is displayed.
4. Push "+" to start Wizard.
5. Advance through the Wizard until pH Reduction Control is displayed. Use "+" or
"-" to set pH Reduction Control to "Forced On".
6. Continue through the Wizard and exit.
7. Verify that acid solution is visible at the flow indicator.
8. After the system is fully primed, return to the Chemistry Config. Wizard and set
the pH Reduction Control setting to "Auto Sensing".
Every pool is different and requires different acid feed rates. In most applications, the
pool controller will compensate for varying pool sizes and chemistries. If your pool is
overshooting (too much acid dispense) or timing out (not enough acid dispense), you
can adjust the pump rate as needed by turning the numbered collar on the pump.
Refer to Stenner pump manual for additional instructions relating directly to the pump
operation and service.
Troubleshooting
If the tank is full but the pool's pH is not adjusting or if the pool control continues to
show a “pH timeout” indication:
•Check flow indicator for proper flow.
•Ensure that the acid dilution is correct.
•Check for leaks (pump tube, suction tube, discharge tube, all fittings)
•Check pool chemistry (especially TotalAlkalinity)
•Check that suction line strainer is fully immersed
•Check timeout setting
•Adjust pump output higher
If the pool's pH is overshooting the pH setting:
•Ensure acid dilution is correct
•Check pool chemistry (especially TotalAlkalinity)
•Adjust pump output lower
•Pump not operating as expected
•See Stenner pump manual
SpareParts
GLX-SP-LP5TUBE–peristaltic (pumping)tube
GLX-SP-UVTUBE – UV-resistant suction/discharge tubing with nuts and ferrules
GLX-SP-STRAINER–weighted suction line strainer
GLX-SP-CHECKV–injectioncheckvalve
GLX-SP-FLO–flowindicator
GLX-SADDLE–injection fitting andclamp
GLX-SP-DB-replacementduckbill
GLX-SP-ROLLER-replacementrollerassembly
GLX-SP-PUMP-120-replacement pump- 120V
GLX-SP-PUMP-240-replacement pump- 240V

4
7
Installation
Overview
InstallationoftheAQL-CHEM-3 requires:
•Setup and installation of the Stenner pump/tank
•Installation of the Feed Tube and Injector assembly to the return plumbing
•Connection of theAQL-CHEM-3 to the pool control
•Programming the pool control for use with theAQL-CHEM-3
•Filling the Stenner pump/tank
Installation Checklist
Before the installation is finished, the following checklist should be completed.
•Pool is properly balanced and functioning correctly
•Unit is mounted securely and in accordance with local codes and regulations
•The recommended amount of properly diluted acid has been added to the tank
•The child-resistant cap is securely tightened
•The check valve is in place and oriented properly
•The flow indicator is in place, oriented properly, and mounted vertically
•The tubing has been filled by running the pump until the flow indicator shows
flow
•There are no leaks in the system
•The pump output has been set to “5”
•The homeowner has been instructed on the use and safety of the system
Operation
Enable the Stenner pump by putting the toggle switch in the ON position according to
the diagram below.
Reinstall the protective roof for normal operation.
Purge air out of the system by using the 15 minute force feed until the flow indicator
shows that the acid solution is flowing. To do this, use the following procedure:
Aqua Rite Pro
1. Press the "Settings" button.
2. Press ">" repeatedly until "Chemistry Config. Wizard" is displayed.
4. Push "+" to start Wizard.
5. Advance through the Wizard until pH Reduction Control is displayed. Use "+" or
"-" to set pH Reduction Control to "Forced On".
6. Continue through the Wizard and exit.
7. Verify that acid solution is visible at the flow indicator.
8. After the system is fully primed, return to the Chemistry Config. Wizard and set
the pH Reduction Control setting to "Auto Sensing".
FROM
POOL
TO
POOL
FROM
SPA
TO
SPA
Outpu tInput
Stenner Pump
Remove Roof
Switch must be
in “ON” position

56
SetupofStennerpumpandtank
Refer to the included Stenner manual for specific information on installing, securing
and use of the pump and tank.
InstalltheFeedTube andInjectorassemblyintothe return
pipe
1. Drill7/16"holeontheUNDERSIDEof thepool'sreturnpipeAFTERtheelectro-
lyticcelland flowswitch.
Be sure there is at least 10" of clearance under the pipe before drilling. Clear out any
PVC shavings and make sure there are no sharp edges within the hole.
OPTIONAL: The injector assembly (saddle fitting, check valve, short length of feed
tube, and flow indicator) should be installed on the underside of the plumbing to
ensure that the flow indicator maintains a vertical orientation. If there is not enough
space underneath the plumbing, the assembly may be mounted on the top or side of
the plumbing as long as the flow indicator is in a position that has enough feed tube
length to allow it to be oriented vertically when flow reading is required.
2.ConnecttheFlowIndicatortothe Injector
NOTE: Two injector valves are included with theAQL-CHEM-3. Discard the shorter
injector as it does not included a flow-check system and must not be used. The
correct injector has a flow direction indicator as shown in the diagram below.
Cut a 2" piece of 1/4" tubing to connect the injector to the flow indicator. With the
fittings loose, insert the tubing firmly into each component and handtighten fittings
until tubing is secure. Note that the flow Indicator and the injector are directional and
must be assembled in the proper orientation according to the diagram below.
Feed Tube
Stenner pump
Pool Return Pipe
Injector Assembly
Output
Input
3. FastentheInjectorassemblyto thereturnpipeandinstallthe FeedTube
Fasten the injector assembly to the return pipe by pushing the injector fitting into the
7/16" hole. Tighten the hose clamp until the assembly is snug against the return pipe.
Do not overtighten.
Cut the 20' feed tube to the desired length. Connect one end of the feed tube to the
injector assembly by firmly pushing it into the flow indicator and handtightening the
fitting. Connect the other end of the feed tube to the output side of the Stenner pump
as shown below.
Fillthe tank
Fill the tank with acid based on the guidelines provided in this manual and the Stenner
manual.
Use a diluted mixture of 4 parts water to 1 part Muriatic acid (20º Baume hydrochloric
acid31.45%byweight). Always add acidtowater,anddo so slowly. Fillthe15 gallon
tank to the following levels:
•5 gallons of 4:1 solution for pools up to 15,000 gallons of water
•10 gallons of 4:1 solution for pools up to 30,000 gallons of water
•15 gallons of 4:1 solution for pool above 30,000 gallons of water
Connect the AQL-CHEM-3 to the Aqua Rite Pro or Pro
Logiccontrol
Plug the Stenner pump's linecord into the pH Dispense pigtail of theAqua Rite Pro or
Pro Logic. This pigtail is provided with the AQL-CHEM. If the pigtail isn't already
installed, refer to theAQL-CHEM product manual for installation instructions.
Program theAqua Rite Pro or Pro Logic
Thepoolcontrolmust now beprogrammedto operate theAQL-CHEM-3. Refer to the
Aqua Rite Pro or Pro Logic operation manual for specific programming instructions.
Flow Indicator 2” length tubing Injector Valv
e
Flow direction
Flow direction
Insert tubing firmly into fittings
Ferrule
Connecting Nut