Hayward AQR940 AquaRite Troubleshooting Guide
Hayward AQR940 Manual
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- Hayward AQR940 | AquaRite Troubleshooting Guide - Page 1
AquaRite® Troubleshooting Guide Residential TSG-AQR159d Copyright 2017 Hayward Industries Inc. - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 2
Safety Precautions 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 • - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 3
How To: Change Metric to Standard & Change Default Reading Set TurboCell® Type & Reset Average Salt Adjust Chlorine Output & Clean TurboCell Troubleshooting: 1. Check Salt & Inspect Cell: flashing or ON 2. High Salt: LED ON 3. No Flow: LED flashing or ON 4. Display ONLY, Lights ONLY, or Neither - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 4
AquaRite: How It Works • The AquaRite Salt Chlorine Generator is designed to convert 99% pure salt into chlorine gas (HOCl). • The conversion occurs in the Electrolytic Cell, also known as the TurboCell® (used throughout this guide). • Power is sent from the AquaRite Control Center to the TurboCell, - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 5
B A 5 AquaRite: Main PCB Layout C D K E F G H I J A PCB Input Power (120/240VAC) B Transformer Input (120VAC & 120VAC) C External Control Jumper D Display Output (5-10VDC) E Rectifier Output (18-33VDC) F Comm Block - External Control (5-10VDC) G Transformer Output (12 VAC) H Chlorinator Fuse ( - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 6
AquaRite: Chemistry Requirements 6 - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 7
AquaRite® How To: - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 8
How To: Switch from Metric to US Standard If the first reading (average salt) is displayed in decimal form instead of a number represented in thousands, then the unit has been set to 'Metric Mode'. Step 1 Step 2 3.20 30 To - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 9
the default reading has been changed to express the 'Desired Output %'. Step 1 Step 2 77P AL-4 To change the default reading back to the average salt, start by pressing the 'Diagnostics' button two times. Step 3 AL-0 When the unit reads 'AL-4' move the switch up to 'Super Chlorinate' and back - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 10
must be configured to the correct TurboCell installed. "t-15" is the factory default. If the incorrect cell is chosen the salt level will be inaccurate and the system will likely suspend chlorination as a result. Step 1 Step 2 3200 t -15 Start with the main toggle switch in the 'Auto' position - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 11
for the relay to click (5 to 10 seconds). Step 3 -3200 Press Diagnostics button 5 times to display the Instant Salt level. Wait for the number to stabilize. Step 4 3200 When the instant salt level is stable (and the negative sign still present), slide switch to 'Super Chlorinate' and back to 'Auto - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 12
: If the chlorine level does not increase within 24 hours after increasing output, test water using an independent test kit to determine the current salt, stabilizer, phosphate, and nitrate levels. More information related to chlorine production on Pages 41-42). NOTE: Output is scaled back to 20% or - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 13
TurboCell appears clean, it may still require cleaning if salt accuracy is off AND/OR chlorine production has diminished. equipment. It is highly recommended to use a Hayward Cell Cleaning Stand as shown on the right (GLX AND RESPIRATORY PROBLEMS IF NOT HANDLED PROPERLY. REFER TO THE MANUFACTURER - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 14
grid; this in turn effects the salt reading and chlorination efficiency. Mix: 4 Parts H2O / 1 Part Muriatic Acid Step 3 1 Part: Muriatic Acid 4 Parts: Water Carefully Pour Solution into Cell HARMS WAY. When the solution is depleted, follow the manufacturer's instructions for proper disposal. 14 - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 15
Inspect Cell LED, when flashing alone, indicates that the system is recommending the TurboCell should be inspected and cleaned (if salt level prior to cleaning, the average salt may need to be reset. To reset the average salt level, follow the steps outlined on pg.11 or wait 24 hours for the system - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 16
AquaRite® Troubleshooting - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 17
is Clean? NO Clean the Cell Cell model YES matches display reading? NO Program correct cell type Section B Problem solved Reset Ave. Salt Are both readings YES within 500ppm of each other? Did LED YES Clear? NO NO Replace the TurboCell Contact Support (908) 355.7995 Jump to Section B 17 - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 18
1B. The TurboCell must be clean in order to report accurate salt readings. IF the cell looks like the image on the left, clean the cell (pg.13-15). IF cell is clean, proceed to step 1C. The system should be reading salt within 500ppm of an independent test. The cleanliness of the - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 19
TurboCell model (located on the label the wraps around the body) then compare it to what is programmed in the system. Correct Cell Programmed? Step 1C Reset the Average Salt Level Step 1D -3200 Side A Side B -3100 Verify the cell model programmed into the control center, matches the model listed - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 20
prior and then reset the average salt level (instructions on pg. 11). IF the "Check Salt" & "Inspect Cell" LEDs cleared, then the problem is solved. IF not please contact technical support directly by dialing: 908.355.7995 or email support via Hayward.com's support page. *NOTE: When replacing the - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 21
model matches display reading? YES NO NO Program correct cell type YES Cell is Clean? NO Clean the Cell Section B Problem solved Reset Ave. Salt Are both readings YES within 500ppm of each other? Did LED YES Clear? NO NO Replace the TurboCell Contact Support (908) 355.7995 Section B - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 22
AquaRite control center will shutdown all chlorine production until the problem is solved and the LED light clears. Test the Salt Level Step 2A Correct Cell Programmed? Step 2B Desired Salt Concentration: 3200PPM Test salt concentration of the water using an independent test, with a calibrated - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 23
clean the cell (pg.13-15). IF cell is clean, proceed to step 2D. Side B -3100 Reset the average salt level, twice, following the steps on pg. 11. Are the two instant salt level readings within 500ppm of each other? IF not go to step 2E. IF they are go to step - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 24
TurboCell Step 2E Did the High Salt LED clear? Step 2F Part Numbers: *T-Cell-15 OR GLX-CELL salt level (instructions on pg. 11). IF the "High Salt" LED cleared, then the problem is solved. IF not please contact technical support directly by dialing: 908.355.7995 or email via Hayward.com's support - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 25
LED ON (cont.) To calculate how much water will need to be removed from a pool, with too much salt, follow the formula provided below (Proportional Method): Step 2G Part I (Ave. Pool Depth" X 3200) Part 1: Take the average depth of the pool in inches and multiply that by 3200. Then divide that - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 26
Switch is preceded by 12" straight pipe? NO Consider moving switch YES Problem solved Flow switch YES orientation is correct? NO Turn pump OFF & rotate Pump basket & Filter No Flow LED YES still ON? NO Problem solved Install new switch & manually close YES With Pump ON, did LED clear? No Flow - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 27
reporting consistent flow. When the pump initially turns on, this LED should flash for 10-60 seconds while the system verifies consistent flow. Pump Running & Valves are Set? Step 3A Verify 12" of Straight Pipe Step 3B Verify pump run speed to ensure the flow rate is not causing the problem. 27 - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 28
3. No Flow: LED flashing or ON (cont.) The flow switch only works in one orientation. An arrow (molded into the top of the flow switch) indicates the direction water should be flowing through the switch. Verify Flow Switch Orientation Step 3C Unplug Connector & Inspect Step 3D Verify the arrows ( - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 29
3. No Flow: LED flashing or ON (cont.) The flow switch wire carries the signal between the AquaRite and the flow switch. If damaged, the switch reports as an open circuit, which will suspend chlorination. Inspect Flow Switch Wire Step 3E Inspect Filter & all Baskets Step 3F IF the flow switch - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 30
Step 3H Plug a confirmed (working) Flow Switch into the control center and hold it closed, manually, for 60 seconds. Monitor the "No Flow" LED. IF LED goes out, install this new " LED. IF the LED goes out, the problem is solved. IF the LED remains on contact technical support (908.355.7995). 30 - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 31
4. Display ONLY, Lights ONLY, or Neither Lights ONLY, Display ONLY, or Neither Resolve source power issue 120/240VAC present? Input power NO Section B Fuse blown? 24VAC YES between two yellow wires? NO NO Test rectifier Input 120VAC between YES Replace blue &white, Transformer violet & - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 32
center, displays LEDs ONLY, a Display reading ONLY, or Neither, then the system is exhibiting a power related symptom. First verify the incoming power. It power for 120/240VAC (+/- 15%). IF no/low voltage, then the problem resides in the power source and NOT the AquaRite control center. IF power - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 33
4. Display ONLY, Lights ONLY, or Neither (cont.) The display requires a minimum of 5VDC to function correctly. The rectifier output should provide 18-33VDC. Test Rectifier Output Step 4C Reseat & Test Display Power Step 4D Test for 18-33VDC between the red and black wires (located in the top - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 34
4. Display ONLY, Lights ONLY, or Neither (cont.) The rectifiers take AC voltage from the transformer and convert it to DC voltage for both main board and chlorination functions. Inspect Rectifier Wiring Step 4E Test Transformer Output Step 4F * *Cutoff Corner: * (Bottom Right) Make sure the - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 35
4. Display ONLY, Lights ONLY, or Neither (cont.) The transformer input is split into four wires. The blue and the white carry 120VAC from the main PCB to the transformer, as do the grey and violet. Test Transformer Input Step 4G Test the 20A Fuse Step 4H Disconnect the transformer input wires ( - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 36
4. Display ONLY, Lights ONLY, or Neither (cont.) The orange wire carries 12VAC of the rectifier voltage, from the main PCB to the top rectifier. Verify all connections before proceeding. Test Rectifier Input Step 4I 12 VAC Disconnect the orange wire and test for 12VAC on the board against ground ( - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 37
Is water temp YES Raise or lower above 139 or water temp to below 51? clear message NO Clean the Cell Did error clear? YES Problem solved NO Is the cell downstream of a running heater/chiller? YES Move Cell or bypass heater/chiller NO Replace the TurboCell 37 - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 38
Cell Clean Cell Inspect the cell for calcification. Clean the cell & reset the average salt reading (pg. 11). IF the message still appears AND the water temperature is not override the message for 24hours. If the system reads "HOT" it is possible the temperature sensor (within the cell) - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 39
AquaRite® Additional Information - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 40
Software Revision: Cell Compatibility Chart Cell Compatibility Chart Cell Type AquaRite AquaRite XL AquaTrol T-CELL-3 & GLX-CELL-3-W For residental 1.50 or later X pools up to 15,000 gallons T-CELL-5 & GLX-CELL-5-W For residental 1.50 or later X pools up to 18,000 gallons T-CELL-9 & - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 41
speed up the dissolving process. DO NOT allow the salt to sit in a pile at the bottom of the pool. Salt water is heavier than fresh water, so the salt water will tend to accumulate at the deepest part of the pool. Run the filter system with the suction coming from the main drain for - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 42
you set the 'Desired Output %' dial on the main panel this sets the level of salt cell operation as a percent of the operating time of each cycle. 50% is the the switch to 'Super Chlorinate' to enable. This will cause the system to produce chlorine at 100% output for 24 hours assuming the pump - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 43
level. This is an acceptable situation, assuming the level of free chlorine in the pool is appropriate. NEVER add additional salt in this circumstance. 4. If the free chlorine is not appropriate and the steps in item 2 have been followed and addressed as needed, then the 'Desired - Hayward AQR940 | AquaRite Troubleshooting Guide - Page 44
Reading Serial Numbers Beginning 08-05-2011 3A11284- 123456 Beginning 11-01-2001 3A0112- 123456 3A11284 = Standard Warranty Term 3A11284 = Product Family 3A11284 = Year of Manufacture 3A11284 = Day of Manufacture 123456 = Manufacturing ID 3A0112 = Standard Warranty Term 3A0112 = Product Family
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AquaRite®
Troubleshooting Guide Residential
TSG-AQR159d
Copyright 2017 Hayward Industries Inc.