Hayward AquaRite 100 Technical Training Manual
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Hayward AquaRite 100 Technical Training Manual

Salt chlorine generator
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AquaRite 100®
Technical Training Guide
TSG-AQR100c
Copyright 2022 Hayward Holdings Inc.

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Summary of Contents for Hayward AquaRite 100

  • Page 1 AquaRite 100® Technical Training Guide TSG-AQR100c Copyright 2022 Hayward Holdings Inc.
  • 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 •...

  • Page 3: Table Of Contents

    Table of Contents How AquaRite® 100 Works Main Display/Function Layout Main PCB Layout Water Chemistry Requirements How To: 9-19 1. Input Voltage Configuration 2. Adjust Daily Chlorine Output 3. Clean Electrolytic Cell 12-13 4. Test/Replace Call Cable 14-19 Troubleshooting: 20-54 1.

  • Page 4: How Aquarite® 100 Works

    • The conversion occurs in the electrolytic cell, also known as the cell (used throughout this guide). • Power is sent from the AquaRite 100 control center to the cell when chlorine production is scheduled (based on time percentage). • When power is applied to the cell, conductive plates produce a field;...

  • Page 5: Main Display/Function Layout

    AquaRite 100: Display Layout Inadequate Water Flow LED Cell Life Low LED Problem Detected LED Standing By LED Generating Chlorine LED Super Chlorinating LED Minimum Chlorine Output LED (10%) DAILY CHLORINE OUTPUT LED’s Chlorine Output Adjustment Buttons Super Chlorinate Button...
  • Page 6 AquaRite 100: Display Function Illuminates when there is no flow or low flow through the cell Illuminates when cell has reached the end of its expected life Illuminates if there is a problem with the unit Illuminates when unit is waiting for...

  • Page 7: Main Pcb Layout

    AquaRite 100: Main PCB Layout Transformer Output (24 VAC) Rectifier Output (30-32 VDC) Chlorinator Fuse (20A – ATO style) Display Output Cell Input/Output Ground...

  • Page 8: Water Chemistry Requirements

    AquaRite 100: Chemistry Requirements • Pools 15k gal and below: 1500 – 2700 ppm Salt Levels • Pools up to 30k gal: 2800 – 4500 ppm (Ideal 3200 ppm) Free Chlorine 1.0 – 3.0 ppm • 7.2 – 7.8 ppm •...

  • Page 9: How To

    AquaRite 100® How To:...

  • Page 10: Input Voltage Configuration

    How To: Input Voltage Configuration The AquaRite 100 can be powered by 120 VAC or 240 VAC. Use a multi- meter to verify voltage in order to determine wire configuration. 240 VAC Wire Colors 120 VAC Wire Colors Line 1...

  • Page 11: Adjust Daily Chlorine Output

    How To: Adjust Chlorine Output The “Daily Chlorine Output” buttons set the level of production during the generating cycle. Generating cycles occur in 60 minute increments. Each led illuminated (from Min to MAX) represents 10%, or six(6) minutes of chlorine production time. Example: The first 4 LED’s being on implies the cell is producing chlorine 40% of the pump run time;...

  • Page 12: Clean Electrolytic Cell

    How To: Clean the Cell Cell cleaning frequency is dependent on several factors; pH & calcium levels have the greatest effect on how often cells requires cleaning. In pH environments between (7.2 - 7.8) cells typically require cleaning 3-4 times a year (with moderate calcium levels). Turn Pump Off &...
  • Page 13 How To: Clean the Cell (Cont.) The cell draws amperage when power is applied during chlorination. The amperage draw will be impaired when calcium and other debris exist within the cell’s electrolytic grid; this in turn effects the salt reading and chlorination efficiency. Mix: 4 Parts H O / 1 Part Muriatic Acid Carefully Pour Solution into Cell...

  • Page 14: Test/Replace Call Cable

    How To: Test/Replace Cell Cord Turn Power to AQR 100 Off Remove Access Screws Breaker should be OFF Turn AQR100 power off at the breaker. Remove the Use a magnetic Philips head screwdriver to remove the control box from wall and turn it over to access the back. 10 screws, then rotate control box onto it’s back.
  • Page 15 How To: Test/Replace Cell Cord (Cont.) Remove Front Cover Disconnect Cell Cable Remove cell cable from cell vessel Slowly separate the front cover from the back of the Remove cell cable from the cell vessel by turning the lock AQR100 and move it towards the top of the unit. Be nut counter clockwise and removing cable.
  • Page 16 How To: Test/Replace Cell Cord (Cont.) Test Cable Continuity Test Cable Continuity Top center terminalnot used Use a multi-meter to test continuity of cell cablewires. With lead in place at cell plug terminal, use other lead to Place one lead into a wire terminal. Make note of the test each terminal of the cell cable cap.
  • Page 17 How To: Test/Replace Cell Cord (Cont.) Remove Cable Strain Relief Remove Cell Cable Remove the 2 Phillips head screws that secure the strain Remove cell cable by slightly pulling it away from the relief bar. Remove strain relief bar by lifting up and control box and then pulling it out through the bottom.
  • Page 18 How To: Test/Replace Cell Cord (Cont.) Reinstall Cell Cable Reinstall Cable Strain Relief Prior to installing cell cable verify proper orientationof Reinstall the cable strain relief bar. Verify the bar is cable. The flat side of the cable should be to the right. positioned as show in the picture above.
  • Page 19 How To: Test/Replace Cell Cord (Cont.) Plug in Cell Cable Reassemble AQR100 Connect cell cable to cell vessel Connect cell cable to cell vessel by rotating the locknut Verify ribbon cable is positioned correctly. Gently place clockwise until snug. Plug cell cable back into the PCB as front cover onto the control box.

  • Page 20: Troubleshooting

    AquaRite 100® Troubleshooting For online troubleshooting visit www.Hayward-Pool.com click Tools, How to Guides & Demos, Do It Yourself & Swim or click link below AQR100/Salt https://www.hayward-pool.com/shop/en/pools/res-in-ground/res-sanitization/do-it-yourself-salt---swim...
  • Page 21 No LED’s On Display Reason Possible Action No power to AQR100 Turn power to the pump “ON”, check breaker Blown fuse Inspect internal 20 amp fuse No power to PCB Test transformer No power to display Test voltage from PCB to display *Pages 21-28 will walk you through the proper steps to diagnose this issue...
  • Page 22 Test rectifier Did LED’s Did LED’s output plug for Problem solved appear? appear? 30-32vdc Verify proper Replace Replace PCB input voltage and Rectifiers (GLXAQR100PCB) configuration (GLXDRK) Correct voltage or configuration issue *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 23 No LED’s On Display No LED’s indicate a loss of power to/within the AQR100 Verify Power to AQR100 Verify Proper AQR100 Wiring Step 1A Step 1B Breaker and timer should both be ON Verify breaker is not tripped, reset breaker by switching If the breaker and timer are ON, verify proper to the off position and then back to on.
  • Page 24 No LED’s On Display (Cont.) No LED’s indicate a loss of power to/within the AQR100 Turn Power to AQR 100 Off Remove Access Screws Step 1C Step 1D Breaker should be OFF Turn AQR100 power off at the breaker. Remove the Use a magnetic Philips head screwdriver to remove the control box from wall and turn it over to access the back.
  • Page 25 No LED’s On Display (Cont.) No LED’s indicate a loss of power to/within the AQR100 Remove Front Cover Check 20a Fuse Step 1E Step 1F Slowly separate the front cover from the back of the Remove yellow 20a fuse and test for continuity. If fuse is AQR100 and move it towards the top of the unit.
  • Page 26 No LED’s On Display (Cont.) No LED’s indicate a loss of power to/within the AQR100 Check Transformer Output Test Transformer Step 1G Step 1H Test the yellow transformer output wires for 24vac by Locate the transformer input plug as shown in the top removing the plug from the PCB and testing as shown.If photo.
  • Page 27 No LED’s On Display (Cont.) No LED’s indicate a loss of power to/within the AQR100 Test Transformer Test Input Voltage Step 1I Step 1J Use your meter to test the resistance (1.5-2.5 ohms) of Use a meter to test AC voltage on the power inputplug. the transformer input wires.
  • Page 28 No LED’s On Display (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 Check Rectifier Voltage Step 1KA Step 1KB *Cutoff Corner: (Bottom Right) YELLOW YELLOW OPEN...
  • Page 29 No LED’s On Display (Cont.) No LED’s indicate a loss of power to/within the AQR100 Re-assemble AQR100 Replace PCB Step 1M Step 1L Verify all cables and plugs are properly connected. If all else is correct replace the PCB (GLXAQR100PCB). Check that the display ribbon cable is attached as shown.
  • Page 30 LED’s On Display Display Ribbon Incorrectly Installed If the display ribbon cable is pluggedinto the PCB upside down the above series of LED’s will be illuminated when power is restored to the AQR100. Install ribbon cable correctly to remedy the issue.

  • Page 31: Inadequate Water Flow Led

    Check for obstructions or other flow cycle begins or cycle power related issues in plumbing. Verify filter is generating cycles flow detected to the AquaRite 100 clean. *Pages 30-32 will walk you through the proper steps to diagnose these errors...
  • Page 32 Flow obstructions? Turn off pump Remove power and clear Turn pump on for 2 mins then Obstructions re-apply Replace Cell Did error clear? Did error clear? (CCELL) Problem solved *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 33 If cell is then re-apply. If error still does not clear go to step 2B. clean, like the image above, go to step2C. The cleanliness of the cell plays a major role in the AquaRite 100’s ability to report salt levels accurately.
  • Page 34 Problem Detected and MIN LED These lights illuminated together indicate Low or No water flow through cell vessel Verify Moving Water Fully Covers Cell Plates S tep 2C Inspect cell vessel, verify cell plates are fully covered by moving water. If NOT fully covered by moving water, clear obstructions.

  • Page 35: Problem Detected With Led # 5,6,7, Or

    Bring water temperature between covered by moving water 65°F -104°F if necessary Remove power to the AquaRite 100 for two Remove power to the AquaRite 100 for two minutes, then re-apply to reset system minutes, then re-apply to reset system...
  • Page 36 11-12 obstruction Did error clear? Did error clear? Did error clear? Remove power for 2 mins then Problem solved re-apply Replace Cell Did error clear? (CCELL) *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 37 If cell is clean, like the image above, addition table pg. 54). If fine, go to step 3B. go to step 3C. The cleanliness of the Cell plays a major role in the AquaRite 100’s ability to report salt levels accurately.
  • Page 38 Problem Detected and MIN LED When these lights illuminate together, the cell reports salt levels below 1500. Verify Moving Water Fully Covers Cell Plates Remove Power From the AQR100 Step 3D Step 3C Turn power off for 2 mins, then back on Inspect cell vessel, verify cell plates are fully coveredby Remove power to the AQR100 for two minutes.
  • Page 39 (High Salt) below 104°F? Dilute salt level Wait until water to lower than temperature falls Did error clear? below 104°F 4500 Did error clear? Did error clear? Replace Cell Problem solved (CCELL) *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 40 Problem Detected: LED #2 When these lights illuminate together, the Cell reports salt levels above 4500. Test the Salt Level Verify Water Temperature is Within Range Step 3E Step 3F Desired Water Desired Salt Temperature Concentration: is between 1500-4500 PPM 104°F 65°F Test the salt concentration of the water using an...
  • Page 41 Problem Detected: LED #2 When these lights illuminate together, the cell reports salt levels above 4500. Remove Power From the AQR100 Step 3G Turn to off position for 2 mins, then turn back on Remove power to the AQR100 for two minutes. Re-apply power to reset the system.
  • Page 42 With LED #4 Reason Reason Possible Action Possible Action Remove power to AquaRite 100 for two Remove power to AquaRite 100 for two minutes, then re-apply to reset system minutes, then re-apply to reset system Temperature Inspect cell. If dirty (calcified) then follow the...
  • Page 43 Replace Did error clear? Transformer Problem solved (GLXAQR100XFMR) Is cell clean and Clean cell using Replace Cell Did error clear? free of debris or procedures on (CCELL) calcium? pg. 11-12 *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 44 Problem Detected: LED #3 When these lights illuminate together the AQR100 is registering Low Input Power. Remove Power From AQR100 Verify AQR100 Wiring Step 4A Step 4B Turn power off for 2 minutes, then backon Remove power from the AQR100 for two minutes. Wiring should be configured correctly for the applied Re-apply power to reset the system.
  • Page 45 Problem Detected: LED #4 These lights illuminated together indicate a Temperature Sensor Error. Inspect Cell Remove Power From AQR100 Step 4C Step 4D Remove calcium and other debris from the cell Turn power off for 2 minutes, then backon Remove power from the AQR100 for two minutes. Cell should be clean &...
  • Page 46 Problem Detected LED With LED #5 With LED #6 Reason Possible Action Remove power to the AquaRite 100 for two minutes, then re-apply to reset system Verify salt level is no Internal greater than 4500 ppm Verify water temperature is...
  • Page 47 Is water Did error clear? temperature below 104°F? Clean filter or Wait until water Does moving clear plumbing Did error clear? temperature falls water fully cover obstruction cell Plates? below 104°F *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 48 Problem Detected: LED #5,6,7, or 9 Problem Detected with any one of these LED’s illuminated indicates an Internal Error. Test the Salt Level Remove Power From the AQR100 Step 5B Step 5A Desired Salt Concentration: 1500-4500 PPM Turn power off for 2 mins, then back on Remove power to the AQR100 for two minutes.
  • Page 49 Problem Detected: LED #5,6,7, or 9 Problem Detected with any one of these LED’s illuminated indicates an Internal Error. Verify Water Temperature is Verify Moving Water Fully Within Range Covers Cell Plates Step 5C Step 5D Desired Water Temperature is between 65°F 104°F If water temperature is NOT within the proper range,...

  • Page 50: Problem Detected With Led # 8 Or Max Led

    Reason Possible Action Remove power to the AquaRite 100 for two Remove power to the AquaRite 100 for two (2) minutes and then re-apply to reset system minutes and then re-apply to reset system Turn on Super Chlorinate briefly then go back to...
  • Page 51 2 mins then Did error clear? and free of (GLXAQR100PCB) (CCELL) re-apply damage? Is cell cable Replace Cell Cable Replace Cell Cable Did error clear? secure and free (GLXAQR100CABLE) (GLXAQR100CABLE) of damage? *For verification of diagnosis contact Hayward Technical Support 908-355-7995...
  • Page 52 Problem Detected: LED #8 These lights illuminated together indicate there is no current to the cell. Super Chlorinate Remove Power From the AQR100 Step 6B Step 6A Turn power off for 2 mins, then back on Remove power to the AQR100 for two minutes. Press Super Chlorinate button to force generatingcycle Re-apply power to reset the system.
  • Page 53 Problem Detected: LED #8 These lights illuminated together indicate there is no current to the Cell. Verify Moving Water Fully Covers Cell Plates Inspect Cell Cord Step 6D Step 6C Verify cell cord is Inspect cell cord for damage or securely fastened to cell corrosion...
  • Page 54 Problem Detected: MAX LED These lights illuminated together indicate there is no current to the cell. Inspect Cell Cord Remove Power From the AQR100 Step 6E Step 6F Inspect cell cord Verify cell cord is for damage or securely corrosion fastened to cell Turn power off for 2 mins, then back on...

  • Page 55: Standing By Led Blinking

    Problem Detected: STANDING BY LED (Blinking) The AQR100 has shut down because the temperature of the pool/spa water is too high (120ºF) or too low (50ºF). The system will not resume operation until the water temperature returns to normal. Inspect Cell Cord Connection Confirm water temperature Step 1G Step 2G...

  • Page 56: Additional Information

    AquaRite 100® Additional Information...

  • Page 57: Salt Addition Table

    Salt Addition Chart: lbs. Required for 3200ppm Pool Size - Gallons Current Salt Level 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000 24,000 26,000 28,000 30,000 32,000 34,000 36,000 38,000 40,000 1013 1067 1000 1000 1200 1400 1600 1800 2000 2200 2400 2600...

  • Page 58: Salt Dilution Formula

    Salt Dilution Formula To calculate how much water will need to be removed from a pool, with too much salt, follow the formula provided below (Proportional Method): Part I Part 1: Take the average depth of the pool in inches and multiply that by 3200 (or desired salt level within 1500-4500ppm).

  • Page 59: Replacement Parts List

    Replacement Part Numbers Replacement Part Number Description CCELL Replacement Cell Only GLXAQR100CCABLE Cell Cable GLXAQR100PCORD Power Cord GLXAQR100CTL AQR 100 Control Center Only GLXAQR100DOOR Door Flap for Display GLXAQR100PCB Main PCB GLXAQR100VESNUT Vessel/ Cell Nut GLXAQR100XFMR Transformer GLXAQR100VESSEL Replacement Vessel (w/o cell) GLX-F20A-10PK Fuse Kit, 20A/Yellow (10 pack) SP3200UNKIT...

  • Page 60: Reading Serial Numbers

    Reading Serial Numbers 3A20284 Standard Warranty Term 3A20284 Product Family 3A20284- 123456 3A20284 Year of Manufacture 3A20284 Day of Manufacture 123456 = Manufacturing ID...

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