Powerline 30 User manual

Powerline 20 & 30
User Manual
for
PL Series Saltwater & Mineral
Chlorinators
User Manual - Hayward Powerline 2016.docx

Conditions

Page 1
Contents
Warranty Terms 2
Introducing the PL Series 4
How it Works 5
Installation Guide 6
Initial Pool Balance 10
Front Panel & Operational Buttons 11
Menu System 12
Timer Menu 13
Chlorine Output Menu 15
Operation Following a Power Failure 16
Status Indicator, Warnings and Safety Shutdowns 17
Troubleshooting 18
Maintenance 19
Cell Cleaning 20
IMPORTANT
If the power cord is damaged the unit must be returned to
Hayward for repair.
Always read the instructions and warnings on chemical
containers before using chemicals.
Serial Number........................................
Date of Installation................................
Installed by.............................................

Page 2
Standard Warranty –Professional Sales and Installation –Effective July 1st, 2016
To the original purchaser only, on-site warranty is provided at the discretion of Hayward Pool Products (Australia) Pty Ltd and is
available according to the following schedule and is subject to our standard warranty conditions.
Warranty- Standard Conditions
Hayward Pool Products (Australia) Pty Ltd (ACN 083 413 414) (”Hayward Pool Products (Australia)”) distributes
Hayward Pool Products in Australia and New Zealand and provides the following warranties:
STATUTORY RIGHTS
STATUTORY RIGHTS
1. The benefits to the consumer under this warranty are in addition to other rights and remedies of the consumer
under the laws in relation to the goods and services to which the warranty relates; and
2. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to
a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage.
You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure
does not amount to a major failure.
LIMITED WARRANTY
Hayward Pool Products (Australia) warrants that its products are free from defects in materials and manufacture for
12 months from date of supply by Hayward Pool Products (Australia) plus 90 days to allow for installation and supply
(unless otherwise specified). Hayward Pool Products (Australia) will at its discretion, except in the circumstances
described below, either replace or repair any product proven to be defective during the warranty period for either
materials or manufacture or alternatively pay the cost of repair or replacement within 90 days of the receipt of the
defective product, barring unforeseen delays. This warranty is personal to the original purchaser and does not pass to
any subsequent purchaser(s).
To the extent permitted by law, Hayward Pool Products (Australia) will not be liable for products which fail or become
Product Description
Sold and installed by an approved installer
Parts
In-field Labour
Powerline Control Box, Dosing System & Electrolytic Cell*2
3 Years
1 Year
Spare Parts*3
1 Year
1 Year
Eligibility to claim
To be eligible to claim warranty support available to the original purchaser, prior to repairs being undertaken you
must:
a. Provide proof or purchase and installation by an Authorised/ Qualified Professional Dealer.
b. Where warranty claim is made, supply and installation must be completed by an Authorised/ Qualified
Professional Dealer or Builder, warranty certificate must be completed including installer’s full business details, copy
of original receipt and signature of approved partner’s representative. Where proof of professional installation is not
provided, warranty is limited to 12 months- parts only.
c. Where proof of purchase cannot be provided you will not be entitled to warranty support.
d. Any item that is hard wired to a power supply cannot be serviced on site. In this case contact Hayward Pool
Products (Australia), an Authorised Service Agent or place of purchase for instruction.
Conditions
1. On-site support will only be provided for installations located within 10km of the Authorised Service Agent in the
metropolitan areas of Melbourne, Sydney, Brisbane and Perth, or within 20km of an Authorised Service Agent in
regional areas. For Installations outside the specified radius the customer may have to pay a travel fee. Warranty
does not cover damages resulting from incorrect installations, improper storage, improper operation, water chemistry
or freezing.
2. To claim warranty a history of water balance test records must be provided to show compliant water balance has
been maintained for the product.
3. Parts including mechanical seals, multiport valves, elements, pressure gauges, grids, cartridges, bearings, shoes,
wings and drive tracks are considered spare parts and therefore qualify for 1 year manufacturer’s defect warranty.
Warranty commences from date of original purchase and is not extended in the event of a repair or replacement.
Squeeze tubes on peristaltic pumps need to be replaced every 6 months

Page 3
defective during the warranty period as a result of freezing, accident, negligence, improper installation, water
chemistry, misuse or lack of care.
To the extent permitted by law, except as set out in this Warranty, Hayward Pool Products (Australia) excludes all
statutory or implied conditions and warranties and any other liability it may have to the Customer (including liability for
indirect or consequential loss) that may arise under statute or at law including without limitation for breach of contract,
in tort (including negligence) or under any other cause of action.
To the extent permitted by law, except as set out in this Warranty, Hayward Pool Products (Australia) limits its liability
under any condition or warranty which cannot be legally excluded in relation to the supply of Goods and Services to:
1. Replacing the Goods or supplying equivalent Goods or Services again;
2. Repairing the Goods;
3. Paying the cost of replacing the Goods or of supplying equivalent Goods or Services again; or
4. Paying the costs of repairing the Goods.
PRODUCTS REQUIRING QUALIFIED INSTALLATION
Some products due to their technical nature are only intended for sale by retail shops where local sales and technical
support can be provided or as a part of a new Pool Installation. Where installation has not been carried out in
accordance with this requirement, warranty labour and support will be the sole responsibility of the reseller supplying
the product. Warranty claims for such products will be limited to replacement of parts only, with faulty goods being
returned to place of purchase for processing.
The following products as well as those that may be designated by Hayward Pool Products (Australia) from time to
time, are not specifically intended for owner installation and are deemed to be technical products:-
• Heaters - All;
• Hayward Dosing and Chemistry Control;
• Hayward Pool and Spa Controls;
• Puresilk and Powerline Dosing and Chemistry Control;
Claims made for warranty, labour or infield support will not be accepted by Hayward Pool Products unless evidence is
provided that installation has been completed in accordance with standard warranty conditions. Please refer to
specific program document for details.
HEATING PRODUCTS
Please note that warranty claims for Heaters are handled directly by Hayward Pool Products (Australia) and are not
authorised for over the counter exchanges. These items are site specific and involve local conditions such as
placement, installation, water chemistry, fuel supply and electricity. Each unit needs to be evaluated on the site
utilising Hayward Pool Products (Australia)'s authorised service network. Hayward Pool Products (Australia) will not
be responsible for additional costs incurred where a heater has been installed at a location situated further than 20km
from an authorised service outlet. Advice must be sought in writing from Hayward Pool Products (Australia) to
determine appropriate service procedure on a case by case basis.
EXCLUSION FOR WEARING PARTS
This warranty does not extend to wearing parts, in particular the squeeze tubes fitted in peristaltic dosing pumps.
Squeeze tubes should be replaced every six months by a suitably qualified technician. Hayward is not liable for any
failure of its products or other damage caused by failure of a squeeze tube that has been used for more than six
months.
Hayward Pool Products (Australia) Pty Ltd
ABN 66 083 413 414
PO Box 4384, Dandenong South, VIC, 3164
Melbourne, Sydney, Brisbane, Perth
T ([phone] or 1300 POOLS1
F ([phone] or 1300 POOLS2
email: [e-mail] web: www.hayward-pool.com.au

Page 4
Introducing the PL Series®
What’s in the box?
The image above shows the main parts of the PL Series system (clockwise from top left):
PL Series® Cell and Cell Cable
PL Series® Power Supply and Mains Cable
Also included in the box, but not illustrated:
User Manual
Mounting hardware (raw plugs, screws and paper template)
40/50 bushes

Page 5
How it works:
A salt/mineral chlorinator works by putting a dc current through an electrolytic cell in a flow
of salted water. Salt/minerals are made up of sodium/magnesium and chloride ions.
Electrolysis of these salts produces chlorine gas, which dissolves almost instantly to form
free chlorine in the water. This free chlorine is a highly effective sanitiser for your pool.
The PL Series®constantly adds a dose of chlorine to the water over the operating period of
the system. The amount of chlorine added depends upon the cell output and the running
time.
Generally, a salt water / mineral pool is run for around 8 hours per day in summer and 2 to
4 hours per day in winter. The summer operating periods are usually in the early morning
and later evening. This allows a chlorine residual to build up for pool use during the day.
The filter system should always be running when the pool is being used.
Optional pH Control
When chlorine is added to water the pH always changes –this is because chlorine is not a
neutral chemical. The pH will slowly rise as chlorine is produced in a salt/mineral water
system. A rise in pH greatly reduces the effectiveness of the chlorine as a sanitiser, so it
is important to ensure that the pH remains in the correct range.
The pH of the water can be lowered by the addition of acid –and if your PL Series® has the
optional pH control, this can be done automatically. The PL Series® uses a sophisticated
algorithm to calculate how much chlorine has been produced by the cell, and how much
acid needs to be dosed to correct the resultant pH rise.
The algorithm can be adjusted if installed on a concrete/plaster pool. When adjustments
are made it should be in small values with the pool then monitored for effectiveness.
Note: while the algorithmic pH control is effective it does not measure pH.
pH measurement and checking must be done manually to make sure the pH is correct.

Page 6
Installation Guide
Installation Diagrams
For most installations, please refer to the installation diagram on page 8.
If your PL Series®has the optional pH control, refer to the installation diagram on page 9.
Choosing a good location
The PL Series®is manufactured from weather resistant materials and is designed for
operation in full sun and rain. However, your PL Series® will benefit if it is protected from
the weather.
Choose a well ventilated area to allow for efficient cooling. Installing the unit in a hot and
closed shed or box may lead to overheating and activate the internal protective thermal
cut-out.
The PL Series®Power Supply should not be mounted in areas where chemicals are stored
(eg acid and chlorine) as vapours from these chemicals are corrosive and may damage the
electronic controls within the unit.
Insect intrusion (particularly ants) can cause problems with all equipment. Ensure that the
pool equipment area is kept free of insects as much as possible. Insect intrusion is not
covered under the warranty.
Installing the PL Series®Power Supply
Locate the PL Series®Power Supply close to the Cell/Housing and filtration pump so that
both may be connected easily.
Connect the PL Series®Power Supply to the mains power outlet of the pool area and make
sure this outlet meets all applicable Australian Standard at the time of installation.
Mount the PL Series®Power Supply at least 1.5m above the ground and at least 3m from
the pool water. A mounting template is printed on the last page of the manual.
The PUMP socket outlet in the base of the PL Series®Power Supply is dedicated to the
filtration pump only. Do not use a double adaptor to connect another pump as this will
overload the system and void warranty.
Installing the PL Series®Cell
The PL Series® cell housing assembly should be plumbed into the pool return line after all
other accessories (and prior to any heating take-offs).
Remember that the cell will need to be removed from its housing periodically for cleaning –
do not place it where its removal will be obstructed.

Page 7
Note any water flow direction on the cell housing and insure the cell housing is installed so
that water will flow in this direction.
Connect the cell cable to the cell connector on the base of the PL Series®Power Supply.
Ensure that all 3 connections (2 for cell power and 1 for gas sensing) are colour matched
and not loose.
pH Control (optional)
Units with pH control have an injection fitting and a peristaltic pump which must be
installed. Refer to the installation diagram on page 9 for details. Mount the peristaltic
pump unit adjacent to the PL Series® Power Supply, as it is hard-wired to this power
supply.
Cut a length of tubing that will reach from the base of the peristaltic pump to the injection
fitting. Connect one end of the tubing to the outlet side of the peristaltic pump (the
direction of flow is indicated by an arrow on the front cover of the pump.) Connect the
other end of the tube to the injection point.
Cut another length of tubing that will reach from the base of the peristaltic pump to the
base of the acid drum. Position the acid drum in a safe and secure location, preferably
about 2 metres from the PL Series®.
Connect the one end of this tube to the inlet side of the peristaltic pump (the direction of
flow is indicated by an arrow on the front cover of the peristaltic pump.)
Drill an 8mm hole in the lid of the acid drum and pass the tubing through the hole in the
drum lid. Place a sinker on to the end of the tubing that will be in the drum and then attach
the drum filter. Note that the drum filter incorporates a non-return valve to prevent back-
flow into the chemical drum.
Before placing the tubing into the drum, measure the tubing against the outside of the drum
and wrap several turns of PVC tape around the tubing above the drum lid so that the drum
filter will be 10-15mm above the bottom of the drum. Lower the drum filter and sinker into
the drum and screw on the lid.
Pool Light Outlet
Your PL Series® has a light power outlet in the base –this can be used to run up to a 150W
pool light power supply. This outlet is timed, allowing pool lights to be set to come on and
turn off automatically.

Page 8

Page 9

Page
10
Initial pool balance
Before you begin using the Chlorinator, make sure your pool water is balanced as follows:
Salt and Minerals –only add salt/minerals after checking the levels
There should be between 3000 and 5000ppm of TDS in the pool ideally 4000ppm.
This is achieved by adding 4kg of salt for every 1000 litres (1m3) of pool volume. Note that
this amount of salt will take time to dissolve.
Minerals: the conductivity of minerals is different to pure salt. All TDS testers are
calibrated for sodium chloride salt. You will need less weight of minerals to achieve an
equivalent TDS to salt –follow the mineral instructions.
Note: keep salt/minerals below 7500ppm to avoid overloading the cell and causing
shutdown. Only add after checking the level.
Chlorine - If it is a new installation, add enough chlorine (liquid or granular) to achieve a
reading of 3ppm on an appropriate test kit.
Stabiliser - If the pool is outdoors, it is vital that stabiliser (also known as cyanurate and
cyanuric acid) be added and maintained at 50ppm. This compound reduces chlorine
destruction due to sunlight. However, too much stabiliser will reduce the effectiveness of
chlorine and can result in poor quality water so ensure stabiliser does not exceed 80ppm.
pH - For chlorine to be effective, the pH must be within a certain range. This is usually
between 6.8 (fibreglass/liner pools) or 7.2 (concrete/plaster) and 7.8.
Adjust pH down with acid –powder, liquid sulphuric or liquid hydrochloric. Be very careful
with acid as it can be harmful and corrosive.
Minerals: the magnesium in mineral salts can form a soft scale on the cell even though it
is reversing polarity. This is minimised by keeping the pH at the lower range for your pool
type. The use of hydrochloric acid is recommended for magnesium mineral systems.
Total Alkalinity (TA) - Total alkalinity is also known as carbonate hardness or TA for
short. The recommended level is between 80 and 120ppm.
TA is related to pH in that it stops the pH from varying quickly with small additions of acidic
or alkaline chemicals. When the TA is low it is almost impossible to control the pH. To
raise the TA, buffer (sodium bicarbonate) is added. This must be done slowly as buffer will
also cause the pH to rise. As an approximate rule every increase of 20ppm of TA will also
cause a 0.1 rise in pH. Once buffer is added it should be left to mix in the pool for a few
hours before reducing the pH.
Phosphates and Nitrates - Phosphate and ammonia nitrogen will make your garden
green –and they will do the same thing to your pool. Check for phosphates and add
phosphate remover if necessary. Don’t let fertiliser get into your pool! Ammonia nitrogen
has a very high chlorine demand. Phosphates are also in some cleaning products –check
the label if using around your pool.

Page
11
The PL Series Front Panel
PL Series®Display
The PL Series®uses a two line LCD display to provide the user with information.
The first line of the display shows the current time and the cell status and output.
In the example above the time is 10.15am and the Cell is “OFF”. If the Cell is on, the
output of the Cell will be displayed. If the output of the Cell has been set at lower than
100%, “CELL OFF” will be displayed intermittently even while the unit is running as the Cell
regulates output. (See Chlorine Output Menu on page 16 for more details)
The second line of the display shows the automatic timer status.
In the example above, the automatic timer status is “OFF” and the display is telling you that
the PL Series® will turn on again at 17:00 (5pm).
Note that the PL Series® displays the time using a 24 hour clock.
PL Series Operational Buttons
Your PL Series® has 5 buttons that allow you to control the various functions available via
the PL Series® Menu system.
ON Button
Turn the System On Manually
Press the ON button once to switch the PL Series® and the pool pump on manually. The
PL Series® will default back to AUTO and turn itself off automatically at the end of the next
programmed FILTER CYCLE (and this time will be displayed on the LCD).
Increasing Manual Run-time in Hourly Increments
Press the ON button repeatedly (or hold the button down) to increase the manual run time
in hourly increments. The run time is displayed on the LCD. When the desired run time
has been reached, press the ENT button to confirm your selection and the system will
commence operation.
Each button is labelled with its primary
function either on the button itself, or adjacent
to it. Secondary functions are labelled within
a curved white outline next to the relevant
button.
The buttons are backlit to show which are
active at any given time, although the
ESC/OFF button is always available to take
you back to the home screen.

Page
12
ESC/OFF Button
Turn the System Off Manually
If the PL Series® and pool pump are running, pressing this button will turn them off
manually. The PL Series® will automatically turn on again at the start of the next FILTER
CYCLE (and this will be displayed on the LCD).
Return to Home Screen
If you have unintentionally accessed a PL Series® Menu that you don’t actually require,
pressing the ESC/OFF button allows you to return to the home screen at any time.
ENT Button
Use this button to enter the PL Series® Menu system and to access the various options in
each Menu. Use the Y/UP and N/DOWN buttons to scroll through menu options and when
your desired menu option is displayed on the LCD, press ENT to access that option.
Y/UP Button and Optional Pool Light
If you have accessed the PL Series® Menu by pressing the ENT button, press the Y/UP
button to scroll upwards through the various menu options. Some menu options will
prompt a yes or no answer. If you wish to answer “yes”, press the Y/UP button.
If your PL Series® also controls your pool lighting (optional), you can turn the lights on or off
manually by pressing the Y/UP button. For multi-coloured lights, hold the Y/UP button
down to cycle through the various colours and release once the desired colour is reached.
Navigating the PL Series Menu System
There are two aspects to the general PL Series® Menu system –the Timer Menu and the
Chlorine Output Menu.
Access the PL Series® Menu system by pressing the ENT button and following the prompts
on the LCD. If you find you have ended up in a part of the Menu system unintentionally,
you can return to the Home Screen by pressing the ESC/OFF button at any time.
Use the Y/UP and N/DOWN buttons to scroll through the various menu options until the
desired option is displayed on the LCD. Use the ENT button to confirm that you wish to
select that option.
Once accessed, use the Y/UP and N/DOWN buttons to adjust operational settings up or
down –and confirm adjustments by pressing ENT. To cancel any adjustments, simply
press ESC/OFF to return to the Home Screen.

Page
13
Timer Menu
Setting the time
Once you have installed your PL Series® and turned it on, you will need to set the correct
time on the PL Series’24 hour clock.
First, access the Menu System by pressing the ENT button. The LCD will display the word
TIMER MENU. Select this by pressing the ENT button once more.
Line 2 on the LCD will now read SET TIME HOURS. Press ENT to select this option and
then use the Y/UP and N/DOWN buttons- to adjust the hours on the LCD. Confirm the
correct hours value by pressing ENT again.
The LCD will now show SET TIME MINUTES. Adjust the minutes using the Y/UP and
N/DOWN buttons. When complete, press ENT to return to normal operation.
Filter Cycles Menu
Your PL Series® has two filter cycles pre-programmed as factory defaults as follows:
Filter Cycle 1: ON at 7:00 (7am) OFF at 11:00 (11am)
Filter Cycle 2: ON at 18:00 (6pm) OFF at 22:00 (10pm)
You can change the start and finish times of each filter cycle to meet your sanitiser
requirements and to suit your lifestyle.
To adjust filter cycle start and finish times, press ENT to access the PL Series® Menu
system. Press ENT again to select the TIMER menu and then scroll down using the
N/DOWN button until ADJUST CYCLES is displayed on the LCD.
Select this option by pressing ENT and the LCD will show the start (ON) time of the filter
cycle being adjusted. Use the Y/UP and N/DOWN buttons to adjust the start time. Press
ENT to confirm your selection and then the LCD will show the end (OFF) time for that filter
cycle. Adjust the OFF time in the same way as the ON time and press ENT to confirm.
After ON and OFF times for the first filter cycle have been adjusted, the ON time for the
second filter cycle is shown on the LCD. This can be adjusted in the same way, or if you
do not wish to make any changes, simply press ENT to confirm the time shown on the
LCD. Follow the same process to either adjust or confirm the OFF time for the second
filter cycle, and once this has been confirmed the LCD will display the home screen.

Page
14
Running Times
We recommend your system be operated for at least 8 hours per day and always run
the system when using the pool. The amount of chlorine being added to the pool each
day is determined by the cell size, the chlorine output settings (See Chlorine Output Menu
below) and the number of hours that the PL Series®is operated. As sunlight destroys
chlorine, it is recommended that the PL Series®be run mostly in the evening.
Chlorine is added for sanitation but the filter is needed to remove pollutant particles (dust,
sand etc) and keep the water looking good. The filter must operate for a reasonable
number of hours per day to remove pollutants.
In very hot weather and/or with large bather loads, the pool may need to run for even
longer and if necessary, extra chlorine should also be added manually. If there are
adverse local conditions –such as windborne dust and debris - the chlorine demand will be
higher than normal and you will likely need to operate the system for longer periods to
adequately filter the water.
Light Timer Menu
You can use your PL Series® to turn your pool or garden lighting on and off automatically,
you can set the ON and OFF times using the light timer menu.
Press ENT to access the PL Series® Menu system. Press ENT again to select the TIMER
menu and then scroll down using the N/DOWN button until LIGHT MENU is displayed on
the LCD.
Line 2 on the LCD will now read “AUTO? Y/N”. To enable automatic light operation press
the Y/UP-button. Line2 will read “Auto ON” for short period before displaying “ON hh:mm”.
Adjust the ON time using the Y/UP and N/DOWN-buttons and confirm by pressing ENT.
The LCD will now prompt you to set the OFF-time, which is accomplished using the Y/UP
and N/DOWN-buttons as before. Press ENT-to confirm the new OFF-time and the LCD
will return to the home screen.
To disable automatic light operation, access the LIGHT menu in the way described above
and when asked “AUTO? Y/N” - press the N/DOWN button. Line 2 will read “Auto OFF” for
short period then the system will return to normal operation and the light can only be
operated manually (see below for how to do this).
Manual Light Operation
If the PL Series® is turned on, the light can be turned on or off manually by pressing the
Y/UP-button.
If you have multi-coloured LED lights that cycle through different colours and requiring a
power pulse to change effects, you can hold down the Y/UP-button to cycle through the
options and release when the desired colour or effect is achieved.

Page
15
Controlling the Chlorine Residual
There are two ways of controlling the amount of chlorine entering the pool –by altering the
running times and by reducing the PL Series®Output. If the pool chlorine residual tests
high you can reduce the operating time and/or decrease the Output. If the chlorine residual
tests low and the output is already at maximum you will need to increase the operating
time and/or add supplementary chlorine.
PL Series®Output Control
The LCD display usually shows the amount of chlorine being produced by the Cell as a
percentage of its maximum.
However, this is the not the same as the PL Series®Output. The Output Control turns the
Cell ON/OFF over a short period of time. The Output setting determines how long the ON
time is –for example if the Output setting is 60% the Cell will be ON for 60% of the period
and OFF for 40% of the period. This is why the Cell will turn ON/OFF if the PL Series®
Output is below 100%.
Chlorine Output Menu
To adjust the chlorine output on your PL Series, press ENT to access the PL Series® Menu
system. Scroll down using the N/DOWN button until CHLORINE OUTPUT is displayed.
Press ENT again to select this menu and then used the Y/UP and N/DOWN buttons to
adjust the output level. Confirm the adjusted settings by pressing ENT once more.
Superchlorination
When bathers enter a pool there is a reaction between nitrogen/ammonia compounds from
the bathers and the chlorine in the pool. These reactions form chloramines (also called
combined chlorine) which are responsible for the “chlorine” odour and for some minor
irritations.
These compounds can be broken down by adding free chlorine to a level above 5ppm by
the addition of a shock dose of chlorine –also known as superchlorination.
Levels of chlorine immediately adjacent to the PL Series®Cell anodes far exceed 5ppm
and so a lot of chloramines are destroyed as water passes the Cell.
If the chloramine levels still become high, simply add a shock dose of chlorine or run the
PL Series®for a long period overnight.

Page
16
Operation Following a Power Failure
The PL Series®unit comes with a timer function built into the operating software. The timer
is a 24-hour type with quartz-crystal control. This Timer is backed-up by a Real-Time Clock
(RTC) similar to those found in computers.
During a power failure the PL Series®will keep time and maintain AutoMode functions.
If a Filter Cycle is active when power is returned the pump will be turned ON within 1
minute. The PL Series®will keep all its settings and will not need to be re-programmed.
The PL Series®is ideal for use in systems where repeated power cuts occur, such as off-
peak power circuits and Queensland’s Tarriff33 system.

Page
17
PL Series Status Indicator, Warnings and Safety Shutdowns
There is a STATUS indicator on the front panel that simply shows green (OK) and red
(WARNING). The reason for any WARNING will be written on the LCD display. Possible
warnings are explained below.
Low Water Temperature & Salinity
Low water temperature and lower than recommended salt/mineral levels can both cause
low conductivity of the water to be detected.
The PL Series® will, however, continue to function and will display this without a red
warning indication. Simply check the salt level and make sure it is well above 3000ppm
(ideally around 4000ppm).
Check the temperature of the water, and if it is lower than 20ºC, you may wish to adjust the
Water Temperature setting using Advanced Settings Menus (information on Advanced
Settings available via www.hayward-pool.com.au or by calling Hayward Service on
1300POOLS1.
Gas Detection & Dry-Run Pump Shutdown
This is an important safety feature of the PL Series® as a build-up of chlorine gas can be
dangerous.
The display above left shows the Cell being turned OFF after chlorine gas is detected for
approximately 10 seconds. If gas is still detected after approximately 2 minutes the pump
will also be turned OFF –and the display will read as shown above right.
To re-start the pump, simply press the ON-button (as instructed by the display). This will
reset the warnings and allow the pump to run (for a maximum of 3 minutes if gas is still
detected).

Page
18
High Salt
Too much salt/mineral in the water results in high conductivity and the PL Series®
Cell may overheat. The PL Series® will shut down to prevent this.
If the above warning is present, the PL Series® will have shut down to avoid an overload
(mandated by electrical standards).
Check the salinity/TDS and water temperature. Salinity/TDS should be kept below
7,500ppm, and ideally will be above 3000ppm.
The PL Series®is not designed for operation in seawater or brine.
Trouble-shooting
Before requesting service, you may wish to run through the check list below but feel free
to call Hayward Service on 1300POOLS1 or log a service call via our website –
www.hayward-pool.com.au.
If there appears to be low or no Chlorine Residual:
1. Check stabiliser level is 40ppm –60ppm. Add if necessary and wait for it to dissolve.
2. Have you added any chemical additives recently?
3. Check pool for phosphates and remove if necessary
4. Is the unit turned on and operating the filter pump?
5. Are the operating hours sufficient?
6. Is the Output set to 100%?
7. When running is the Cell ON? Is it reading 100?
8. Is there enough salt in the water? (4000ppm)
9. Is the temperature of the water low?
10.Is the Cell scaled heavily?
If the Cell is ON but not reading 100, check the Temperature Compensation setting in the
WATER TEMP MENU (located in Advanced Settings –see www.hayward-pool.com.au for
Advanced Settings Manual). Also check the pool salinity is within correct range.
If the unit is not running at all check the fuse in the lower section of the unit.
Danger: ensure to remove the unit's power chord from the power point (GPO) before
removing the fuse.