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Hayward Aqua Plus® Installation Manual

Model: pl-plus installation
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Aqua Plus
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Automation and Chlorination
Installation Manual
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PL-PLUS
PL-PLUS-20
www.hayward.com

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Summary of Contents for Hayward Aqua Plus®

  • Page 1 Aqua Plus ® Automation and Chlorination Installation Manual for model PL-PLUS PL-PLUS-20 www.hayward.com...

  • Page 2: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS When using this electrical equipment, basic safety precautions should always be followed, including the following: READ AND FOLLOW ALL INSTRUCTIONS • • WARNING: Disconnect all AC power during installation. • WARNING: Water in excess of 100 degrees Fahrenheit may be hazardous to your health.

  • Page 3: Table Of Contents

    Table of Contents Introduction Before You Begin..............1 Installation Steps..............1 1. Preparing General Water Chemistry............. Pool/Spa Water Salt..................3 2. Mounting Aqua Plus Control Center............5 Equipment Temperature Sensors............. 5 Optional Chlorination .............. 5 Optional AQL-CHEM Sensing Kit......... 5 Optional AQL-CHEM2 CO Dispense Kit......

  • Page 4: Introduction Before You Begin

    Utility electrical outlet and weatherproof cover (for mounting on side of Aqua Plus) Mounting hardware (screws, etc.) for mounting Aqua Plus and remote display/keypad Valves (use standard Hayward, Pentair/Compool, or Jandy valves) Additional valve actuators Accessory Products - Order Separately AQL-CHEM ORP &...

  • Page 5: Preparing General Water Chemistry

    1. Preparing Pool/Spa Water General Water Chemistry Salt is required only if you are using the chlorinator features on the Aqua Plus Control. If you are NOT using the chlorinator, it is recommended that you follow all of the other chemistry recommendations besides salt. Refer to the description of the Aqua Plus configuration menu for information on enabling/disabling the chlorinator (see page 20).

  • Page 6: Pool/Spa Water Salt

    The pool’s chemistry must be balanced BEFORE activating the Aqua Plus’s optional chlorinator function. NOTE: If the pool does not have new water, add metal remover and non-copper based algaecide to the pool, per manufacturer’s instructions. This ensures a quick, troublefree transfer to the Aqua Plus system. Salt Salt Level Use the chart below to determine how much salt in pounds or (Kgs) should be added to reach the recommended...
  • Page 7 Pool Sizing Formula Liters Gallons (pool size in meters) (pool size in feet) Length x Width x Length x Width x Rectangular Average Depth x 7.5 Average Depth x 1000 Diameter x Diameter x Diameter x Diameter x Round Average Depth x 5.9 Average Depth x 785 Length x Width x Length x Width x...

  • Page 8: Mounting Aqua Plus Control Center

    2. Mounting the Equipment Aqua Plus Control Center The Aqua Plus is contained in a raintight enclosure that is suitable for outdoor mounting. The control must be mounted a minimum of 5 ft. (2 meters) horizontal distance from the pool/spa (or more, if local codes require). The Control Center is designed to mount vertically on a flat surface with the knockouts facing downward.

  • Page 9: Optional Remote Controls

    Note that the Aqua Plus is compatible with AQL2 wireless remote controls only. A single AQL2-BASE-RF Base Station must be installed on the Aqua Plus in order to use any of the Hayward wireless remote controls. With the Base Station installed, there is no limit on the number of wireless remotes that can used. The maximum distance between the wireless remotes and the base station on the Aqua Plus main control unit is 400 feet (120m) line of sight or 200 feet (60m) through walls, etc.

  • Page 10: Optional Base Station

    require the user to run the “Teach Wireless” routine in the Settings Menu. This information can be found in the Aqua Plus Operation Manual and the owner’s manual of each remote. AQL2-Tx-RF-P-4 The AQL2-Tx-RF-P-4 is a portable battery operated remote control designed to be used in a weather protected area (rain should never hit the unit).

  • Page 11: Plumbing Pool/Spa Configuration

    3. Plumbing Pool/Spa system configuration These systems use a single filter pump and filter. Pool or spa operation is controlled by two 3-way valves (suction and return). Refer to the diagram below. HIGH VOLTAGE LIGHTS High Voltage Relays Valve Outputs LOW VOLTAGE Filter Pump Pool/Spa Suction...

  • Page 12: Turbo Cell

    Turbo Cell The Turbo Cell (used for chlorine generation) should be plumbed AFTER the filter and heater. If installed on a pool/ spa combination system, the cell should be plumbed BEFORE the pool/spa return valve in order to allow proper chlorination of both the pool and the spa.

  • Page 13: Electrical Main Service

    4. Electrical Wiring Wireless Base AQL-CHEM Connector Receiver Connector Remote Keypad “Local” Display Temp Sensor Inputs External Input Heater Output Valve Connectors Flow Switch High Voltage Cell Connector Relays Subpanel Control Power Input pH Dispense Output Bonding Lug(s) Ground Bus Bar The Aqua Plus Control Center requires both high and low voltage connections.

  • Page 14: General Purpose Outlet

    General Purpose Outlet If desired, a duplex receptacle with weatherproof cover (supplied by installer) may be installed in the knockouts on the lower right side of the Aqua Plus enclosure. Per code, the receptacle should be a GFCI type. Alternatively, connect a standard receptacle to a GFCB.
  • Page 15 The Aqua Plus can control up to 2 Hayward TriStar VSPs and 4 EcoStar VSPs. Refer to the diagram below for proper input wiring to the VSP. Wiring from the 220V breaker must connect through the Aqua Plus’s Filter/Lights/Aux relay. Refer to VSP Address Setting on page 16 to determine which relays can be used with your pump.

  • Page 16: Low Voltage Wiring

    (Valve2) and return (Valve1) valves. Valve3 is for general purpose use (solar, water feature, in-floor cleaner, etc.). For installations with solar heating, Hayward offers the AQ-SOL-KIT-xx solar kit that contains a valve, actuator, and extra temperature sensor. The “xx” indicates the valve type from the 3 choices below: 1.5”...
  • Page 17 Fusible Link Hayward Heaters Refer to the instructions in the heater manual for “2-wire Remote Thermostat” operation under “Remote Control Connections” and the diagram below: 1. Turn off power to heater. 2. Wire Aqua Plus to terminals 1 & 2 (see diagram).
  • Page 18 Pentair/Purex/MiniMax 1. Turn power off to heater. 2. Remove factory installed jumper from the “Ext Switch” connector. 3. Wire the Aqua Plus to the “Ext Switch” connector as shown below. 4. The wires to the Aqua Plus must be separated from any line voltage wires. Failure to follow these instructions may cause erratic operation of the heater.
  • Page 19 Terminal Board STA-RITE Hayward Variable Speed Pump (VSP) Wiring and Address Setting Refer to your TriStar or EcoStar manual(s) for proper low voltage communication wiring between the Aqua Plus and the Hayward Variable Speed Pump. A pump address must be configured for each VSP used in the system. This address is entered into the VSP’s configuration menu.
  • Page 20 Temperature Sensors The Aqua Plus utilizes 10K ohm thermistor type sensors. Three sensors (water temperature, air temperature and solar temperature) are included. If the Aqua Plus is being used to control a solar heating system, the solar sensor is required. The sensors are provided with a 15 ft.
  • Page 21 Base Station Plug in the pigtail connector from the wireless base station into the “wireless” connector on the main PCB in the Aqua Plus control unit. Connector for Base Station Base Station (AQL2-BASE-RF) Main PCB Tighten nut AQL-CHEM ORP and pH Sensing Kit Plug in the connector from the AQL-CHEM into one of the “COMM”...
  • Page 22 Hayward Aqua Rite Chlorinator The Aqua Plus can control one or more Hayward Aqua Rite chlorinators when additional sanitizing capacity is re- quired. A 4 wire connection is used to communicate to the Aqua Rite and can be wired up to 500' apart. Any outdoor rated 4 conductor cable can be used.

  • Page 23: Configuration Configuration Menu

    5. Configuration Menu After plumbing and wiring are complete, the Aqua Plus MUST BE CONFIGURED before attempting to operate. Configuration information is entered at the keypad and “tells” the Aqua Plus what equipment is connected and how each should be controlled. Accessing the Configuration Menus Configuring the Aqua Plus requires that you navigate through the Configuration Menu and input various informa- tion.
  • Page 24 Pool/Spa Config. Push to access Pool/Spa options + to view/change Move to previous/next configuration menu Rotates between Pool Only (default), Spa Only and Pool/Spa Setup Pool and Spa Pool and Spa Move to next menu item if “Pool and Spa” is selected Spa - CountDn Adjust time setting (Manual On/Off, 0:05, 0:10, 0:15..., (default is 4:00)) 00:30...
  • Page 25 2-speed and variable speed pump operation. For the Hayward variable speed pump: The Filter relay is used to supply input power to the pump. The relay will be on when the filter pump output is on. When the filter pump output is off, the relay will be off.
  • Page 26 Freeze Protection Temperature Select the temperature to be used for freeze protection. Temperature is adjustable from 33ºF-42ºF (1ºC-6ºC). 38ºF (3ºC) is default. This threshold will be used for all outputs that have freeze protection enabled. External Input Interlock When enabled, the filter pump will be forced off when the external input is active. Note that freeze protection will have precedence over this feature.
  • Page 27 Solar Config. Push to access solar options + to view/change Move to previous/next configuration menu Toggle between Enabled and Disabled (default) Solar Solar Disabled Move to next menu item or previous/next configuration menu if “Solar” is enabled Toggle between Enabled and Disabled (default) Solar Extend Solar-Extend Disabled Move to next menu item...
  • Page 28 Lights Config. Push to access Lights options + to view/change Move to previous/next configuration menu Lights Name Rotates between all available names Pool Light Move to next menu item or previous/next configuration menu Rotates between Manual On/Off (default), Countdown Timer, Low Speed- Filter, Lights Function Timeclock, Solar, and Super Chlorinate Manual On/Off...
  • Page 29 If “VSP” is selected, the Lights relay is used to supply power to a Hayward Variable Speed Pump (VSP). The relay will be on when the Lights output is on and off when the output is off . On, off and speed are controlled by commands sent to the VSP.
  • Page 30 20% to 100% (default). The level is saved for the next time the aux1 output is turned from off to If “VSP” is selected, the Aux relay is used to supply power to a Hayward Variable Speed Pump (VSP). The relay will be on when the Aux output is on and off when the output is off.
  • Page 31 Valve3 Config. Push to access Valve3 options + to view/change Move to previous/next configuration menu Rotates Timeclock (default), Solar, In-floor Cleaner and Super Chlorinate Valve3 Function Solar Move to next menu item for all functions except solar and super chlorinate Toggle between Enabled and Disabled (default) Valve3 Interlock Valve3 Interlock...
  • Page 32 if AQL-SS-6B is connected 6B Spa Config. Push to access the 6 Button Spa Side Remote options + to view/change Move to previous/next configuration menu Select 6B Spa Rotates between all available remotes Move to next menu item Rotates between System Off, Pool/Spa, Filter, Lights, Heater1, 6B A, Button 1 Aux1 and Aux2 Pool/Spa...

  • Page 33: Maintenance Menu

    Reset Config. to Initiate reset of all configuration parameters Default Press + Move to previous/next configuration menu (config. not reset) Are you sure? Reset all configuration parameters + to proceed Move to previous/next menu (config. not reset) Config. reset Move to previous/next configuration menu Confirmed Use this function to erase all previous system configuration and reset all configuration parameters back to the factory default values.

  • Page 34: And Checkout Heater Checkout

    Heater Checkout Follow these instructions to verify that the Aqua Plus is properly controlling the heater. 1. Check that the Aqua Plus is calling for the heater to turn on as indicated by the “Heater” LED being illuminated. If the “Heater” LED is illuminated, go directly to step 2; if not, then check the following: •...

  • Page 35: Warranty Aqua Plus Limited Warranty

    (3) years. Hayward 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 purchase on private residential swimming pools in the US and Canada.
  • Page 36 6 button spa side remote remote menus 7-day or weekend/weekday timeclock 12 hour or 24 hour time format ºF or ºC vsp speed (% or rpm) reset to default 620 Division St. 092359D RevH Copyright © 2010 Hayward Elizabeth, NJ 07207...

This manual is also suitable for:

Aqua plus pl-plusAqua plus pl-plus-20

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