Troubleshooting Manual
IMPORTANT SAFETY INFORMATION
READ AND FOLLOW ALL INSTRUCTIONS.
NOTE: This manual is for use by licensed electricians or trained pool professionals only. No other person is to
install, service or troubleshoot this C Series Chlorinator.
WARNING
!
Failure to heed the following warnings can result in permanent injury, electrocution
or drowning.
ELECTRICAL HAZARD
• To reduce risk of electrical shock
- Make sure all power to pool equipment area is off prior to any installation or removal of DuoClear components.
- Replace damaged power pack cord immediately.
- Do not bury cord. Locate cord to minimize abuse from lawn mowers, hedge trimmers and other equipment.
• Severe shock or injury will likely occur as a result of a drill or drill cord coming in contact with water. Never allow electric drill or cord to come
in contact with water. Only plug drill into a Class A (5 Milliampere Trip) protected Ground Fault Circuit Interrupter (GFCI) in accordance with
the National Electrical Code Section 680 (USA only). Please see your drill owner’s manual for further safety precautions.
• Install the power pack at least 10 feet from the inside walls of a pool to prevent any possibility of the unit coming in contact with water.
• Your DuoClear system has been designed with an electronic flow switch. This device automatically switches the chlorinator ‘OFF’ when
the water through the cell stops. To prevent cell damage and personal injury, do not in any way interfere with this system which has been
designed for your protection.
CHEMICAL USE HAZARD
• To avoid personal injury when working with pool chemicals, always wear rubber gloves and eye protection and work in a well-ventilated area. Use caution when choosing a location to open and use chemicals as they may damage any surface in which they come in contact.
• The addition of certain chemicals can reduce the effectiveness of chlorine. Always make sure that proper residual chlorine levels are
maintained to avoid personal injury.
• This product manufactures chlorine. Individuals with any type of chlorine sensitivity should take the appropriate precautions to avoid injury or illness.
EQUIPMENT WATER PRESSURE HAZARD
• Always turn pump off prior to installing or removing any DuoClear system. Your pump/filter system is operated under pressure and the
pressure must be released before you begin work. Please see your pump/filter owner’s manual for further instructions.
• To avoid vessel damage, water pressure in the cell must not exceed 45 psi.
PREVENT CHILD INJURY AND DROWNING
• To reduce the risk of injury, do not permit children to operate this product.
• Do not let anyone, especially small children, sit, step, lean, or climb on any equipment installed as part of your pool’s operational system. Unless otherwise stated, ALL components of your pool’s operational system should be located at least 3 feet from the pool so children
cannot use the equipment to gain access and be injured or drown.
CAUTION
!
Failure to heed the following warnings could cause damage to pool equipment
or personal injury.
•
•
•
•
Chlorinator must be installed and operated as specified.
Scratching or bending plates in vessel housing can reduce cell life. Power to the DuoClear system should be turned off before unplugging the vessel connectors to prevent cell damage and low voltage sparks.
Keep the cell terminals protected with a light coating of silicone grease to allow for a positive electric connection. Use of any other type of
grease may damage the terminal seals and ‘o’ rings. Do not immerse these terminals in acid wash solution, and avoid accidental contact
with salt water.
• Water above the temperature of 104 degrees F (40 degrees C) flowing through the vessel can cause plastic vessel to discolor.
• Power pack must not be installed directly above any other heat source such as filter, pump or heater. It must be at least 1 Ft. (300 mm) from the ground to allow free circulation of air around it. It must not be installed in a closed box. If the power pack is to be installed on
a post, then it must be centrally positioned on a flat panel of suitable waterproof material at least 10 inches (240mm) wide and 18 inches (440mm) high.
• Check the cell frequently to prevent the accumulation of pool debris that for any reason may have by-passed the pool filter.
2
Table of Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chlorine reading too high . . . . . . . . . . . . . . . . . . . . . . 12
Look /Feel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Calcium Build-up On Cell . . . . . . . . . . . . . . . . . . . . . . 12
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reversing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning/Replacing Cell . . . . . . . . . . . . . . . . . . . . . . . 13
Testing Power Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Touch Pad PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chlorinator Not Operating . . . . . . . . . . . . . . . . . . . . . . . 6
To Replace the Clear Cover . . . . . . . . . . . . . . . . . . . . 15
No chlorine reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PCB Replacement for DuoClear . . . . . . . . . . . . . . . . . 16
Output Lights will Not go to 100% . . . . . . . . . . . . . . . . . 8
Triac Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Output Lights will Not go Down . . . . . . . . . . . . . . . . . . . 9
Exploded Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Amber Output Light Blinking . . . . . . . . . . . . . . . . . . . . . 9
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
No Flow Light Is On . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Add Salt Light Is On . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Add Salt Light and/or No Flow Light Are On . . . . . . . . 11
Look/Feel
Before removing chlorinator cover, check the following:
1. Is the pool pump on?
2. Is the chlorinator turned on?
3. Do the indicator lights function? (If NO, see Output Lights pg. 8-9)
(If all of the above answers are “YES”, there is no problem with the chlorinator. Have the consumer bring a water
sample to their dealer for analysis.)
4. Is the circuit breaker tripped? (see Circuit Breaker pg. 4)
5. Is the output cord damaged or the plug cap not properly attached?
(see No Flow Light Is On pg. 10)
6. Is there calcium built-up on the cell? (see Calcium Build-up
on Cell pg. 12)
After checking the above items:
1. Turn off power supply.
2. Remove 4 screws to remove cover and hang cover
from venting with “S” hooks provided in kit.
Do not disconnect ribbon wire. Check the following:
• Are there any visible burn marks?
• Is there any visible water damage?
• Are there any loose wires or screws?
3
Circuit Breaker
Reset Circuit Breaker
1. Turn off power supply.
2. Find circuit breaker on bottom near power cord. Note: In some cases, insects may make nests
under edge of power pack – use caution.
3. Push button in.
4. Turn on power supply.
5. If breaker continues to trip, replace breaker and PC board.
Replace Circuit Breaker
1. Disconnect power supply.
2. Remove 4 screws to remove cover.
3. Disconnect ribbon wire connector from power PCB and set cover aside.
4. Remove 2 push-on wire connectors from back of circuit breaker.
5. Use pliers to squeeze base of circuit breaker and push through hole from the inside.
6. Push new circuit breaker through hole from the outside till it snaps in place.
7. Reconnect 2 push-on wires to back of circuit breaker.
8. Reconnect ribbon wire connector to power PCB.
9. Replace cover with 4 screws.
10. Replace chlorinator on wall.
11. Connect power supply.
Power Cord
Power Cord Replacement
1. Disconnect power cord from power source.
2. Remove 4 screws to remove cover.
3. Disconnect ribbon wire connector from power PCB and set cover aside.
4. Unscrew ground wire from back and disconnect the ground wire.
5. Unscrew posts that attach 3 input wires and remove the fourth wire from the circuit breaker.
6. Use pliers to squeeze base of power cord holder and push through hole from the inside.
7. Unclip power cord holder and transfer to new power cord.
8. Push power cord holder with new power cord through hole from the outside till it snaps in place.
9. Reconnect all wires and screw ground wire to back.
10. Reconnect ribbon wire connector to power PCB.
11. Replace cover with 4 screws.
12. Replace chlorinator on wall.
13. Connect power cord to power source.
4
Testing the Power Path
1. Turn off power supply.
2. Remove 4 screws to remove cover and hang cover from venting with “S” hooks provided in kit.
Do not disconnect ribbon wire.
3. Turn on power supply.
4. Use multimeter set on AC volts up to at least 250 VAC to test between L & M (All results should
be +/- 10%).
Results = 220V?
YES
NO
Have qualified electrician rewire chlorinator to
220V or determine
why no voltage.
Unit receiving power – continue testing.
6. Test between N & K = 220V?
YES
NO
Reset or replace circuit breaker.
(see Circuit Breaker pg. 4)
Transformer receiving power
circuit breaker OK (continue testing).
7. Test between H & F and H & D.
Results should be as printed on transformer (26.5V).
Both tests read OK?
YES
NO
Transformer is good.
Replace transformer.
(see Transformer pg. 9)
A B C
5
D E F G H
I JN K L M
Chlorinator Not Operating
Are there any lights visible?
YES
NO
Push On / Off Button.
See pg. 8.
Is the resettable circuit breaker tripped?
YES
NO
Reset circuit breaker.
(see circuit breaker pg. 4)
Is there power at timer or switch?
YES
*If breaker continues to trip
replace PC board (see pg. 16)
and circuit breaker (see pg. 4).
NO
Refer customer to a qualified
electrician to troubleshoot
power source.
Check for loose wires.
Trace power through transformer.
(see Testing Power Path pg. 5)
Check touch pad PCB.
(see Touch Pad PCB pg. 14)
Replace power PCB.
(see Power PCB pg. 16)
6
No Chlorine Reading
Are there any lights visible?
YES
NO
See pg. 6.
Will the output lights go all the way up?
YES
NO
Chlorinator is working properly. Recommend
to customer to have water sample checked by dealer.
1. Is salt level 4000 ppm?
YES
NO
Add salt according to chart in
Owner’s Manual.
2. Is unit wired 220V?
YES
NO
Have qualified electrician wire to 220V.
3. Is the water temperature above 65˚?
YES
NO
Add salt to compensate.
4. The cell is nearing the end of its life.
replace cell.
7
Output Lights Will Not Go To 100%
Is salt level 4000 ppm or higher?
YES
NO
Add salt according to chart
in Owner’s Manual.
Check there is 220V incoming power.
YES
NO
Have qualified electrician
rewire chlorinator to 220V.
Is water temperature below 65˚ F?
YES
NO
Add salt to compensate.
Cell may be nearing the end of its life. Check
cell age, run time & output setting. Replace cell. (see Cell pg. 13)
If unit is less than 1 year old check
the following:
Check touch pad PCB.
(see Touch Pad PCB pg. 14)
Replace power PCB.
(see Power PCB pg. 16)
8
Output Lights Will Not Go Down
Is Chlorinator in super-chlorinate mode?
YES
NO
Check touch pad PCB.
(see Touch Pad PCB pg. 14)
Press super-chlorinate button once to take
chlorinator out of super-chlorinate mode.
Amber Output Light is Blinking
Chlorinator is in a rest mode before it reverses polarity. Wait 5-10 minutes
and check again.
OR
Press and hold service button
(located 1” to the right of the ON/OFF switch
and the Nature2 Reset switch )
to speed up the reversing process.
(see Reversing Polarity pg. 13)
Transformer
Testing
(see Testing Power Path pg. 5)
Replacement
1. Disconnect power supply.
2. Remove chlorinator from wall.
3. Remove 4 screws to remove cover.
4. Remove ribbon wire connector from power PCB and set cover aside.
5. Disconnect the 5 wires from the transformer (keep track of each wire location for reassembly).
6. Turn over powerpack, remove screw from the center of the transformer and remove the transformer.
7. Mount new transformer using the nut & bolt.
8. Attach wires from new transformer to correct plastic terminals.
9. Attach ribbon wire connector.
10. Attach cover with 4 screws.
11. Replace chlorinator on wall.
12. Reconnect power supply.
9
No Flow Light is On
Is the pump moving water?
YES
NO
Is the flow restricted in the pool (improperly set valve)?
YES
There is a flow related problem
with pool equipment.
Disconnect the plug cap from the cell until the problem is corrected.
NO
There is a flow related
problem with the equipment.
Disconnect the plug cap from the cell until the problem is corrected.
Is the output plug properly attached and the cable in good condition?
YES
NO
Replace Power PCB.
Attach plug cap or replace output cable.
10
Add Salt Light is On
Is salt level 4000 ppm or higher?
YES
NO
Add salt according to chart
in Owner’s Manual.
Is water below 65 deg. F?
YES
NO
Test touch pad PCB.
(see Touch Pad PCB pg. 14)
Cell is nearing end of life.
Replace cell.
(see Cell pg. 13)
Ignore light till water warms up.
OR
Raise salt level to compensate
for cold water.
Only 1 or 2 Output Lights and/or Add Salt and/or No Flow Lights are Flickering
Is salt level 4000 ppm or higher?
YES
NO
Add salt according to chart
in Owner’s Manual.
Chlorinator is wired 110V. Have qualified
electrician wire chlorinator to 220V.
Cell is nearing end of life.
Replace cell. (see Cell pg. 13)
11
Chlorine Reading is Too High
Do the output lights go up and down?
YES
NO
Check touch pad PCB.
(see Touch Pad PCB pg. 14)
Reduce output setting.
Reduce pump run time.
Calcium Build-up on Cell
Is chlorinator reversing polarity properly?
Press and hold service button
(located 1” to the right of the ON/OFF switch
and the Nature2 Reset switch)
to speed up the reversing process.
(see Reversing Polarity pg. 13)
YES
NO
Check pH.
(per test kit instructions)
Check touch pad PCB.
(see Power PCB pg. 16)
Check calcium hardness.
(per test kit instructions)
Replace power PCB.
(see Touch Pad PCB pg. 14)
Clean cell manually.
(see pg. 13)
Note: New plaster pools will have a
continuous demand for acid for 6 months
or more.
High pH conditions and/or high calcium
hardness levels will make scale build-up more
likely. Maintain a pH between 7.2 and 7.6.
12
Reversing Polarity
1. With power on, be sure chlorinator is NOT in super-chlorinate mode.
2. Locate service button 1” to the right of the ON/OFF switch and Nature2 Reset switch.
3. Press and hold service button down.
4. You should hear a click and see the output lights flash once within 30 seconds (this indicates the polarity
has reversed).
5. Continue to hold service button down to hear and see polarity reversing every 10 – 15 seconds.
6. If it does not switch polarity or times are longer than above, check touch pad PCB (see pg. 14) or Replace power
PCB (see pg. 16).
Cell
!
WARNING
Cell is under pressure! Make sure that the pump is off and that the pressure has
been released by opening the air-bleed valve on top of the filter before removing
the cell.
Clean the Cell
CAUTION: Always wear rubber gloves
& eye protection when handling muriatic
acid. Always pour acid into water, NEVER
water into acid. Sodium bicarbonate
(baking soda) neutralizes muriatic acid.
1. Turn off pump and the DuoClear.
2. Close any applicable valves.
3. Remove yellow plug cap from DuoClear.
4. Unscrew locking ring and remove cell.
5. Hose off excess calcium.
6. Use a solution of 10 parts water to 1 part muriatic acid in a plastic pail
(stronger solutions will damage the cell and void the warranty). Submerse
only the cell portion and let sizzle for 10-15 minutes. If scraping is needed,
use a soft object like a popsicle stick (no metal).
7. Remove cell and rinse with fresh water. Repeat soaking as needed. Rinse
and replace.
8. Insure o-ring is in place.­­­­
9. Tighten locking ring and attach yellow plug cap.
10. Open any applicable valves.
During electrode
cleaning, only
immerse this
portion of the
electrode
11. Start pump and check for leaks.
Replace the Cell
1. Turn off pump.
2. Close any applicable valves.
3. Remove yellow plug cap from DuoClear.
4. Unscrew locking ring and remove cell.
5. Insure o-ring is in place.
6. Insert new cell and tighten lock ring.
7. Attach yellow plug cap.
8. Open any applicable valves.
9. Start pump and check for leaks.
13
Touch Pad PCB
Check / Replace
1. Note position of Nature2 reminder light and output setting.
2. Turn off power supply.
3. Remove chlorinator from wall if needed.
4. Remove 4 screws to remove cover.
5. Disconnect ribbon wire connector from power PCB (do NOT remove touch pad PCB from cover at this time).
6. Plug ribbon wire connector from new touch pad PCB into power PCB.
7. While holding edges of touch pad PCB, turn on power supply.
8. Push buttons and check all light functions.
Are all functions restored?
YES
NO
1. Disconnect ribbon wire connector of new
touch pad PCB and set aside.
Replace Touch Pad PCB
1. Turn off power supply.
2. Replace power PCB.
2. Disconnect ribbon wire connector of new
touch pad PCB and set aside.
(see Power PCB pg. 16)
3. Remove 4 screws to remove touch pad
PCB from cover.
3. Attach original ribbon wire connector to
power PCB.
4. Attach new touch pad PCB to cover with 4 screws. 4. Turn on power supply/push buttons and
check all light functions.
5. Attach ribbon wire connector to power PCB.
5. Replace chlorinator on wall.
6. Turn on power supply.
6. Turn on power supply.
7. Use button on touchpad labeled “Fast N2”
to adjust reminder light to previous setting.
Are all functions restored?
8. Replace cover with 4 screws.
YES
9. Replace chlorinator on wall.
NO
10. Reset output to previous setting.
Replace touchpad.
Note: If unit functions properly after replacing
touch pad, power PCB will NOT need to
be replaced.
1. Replace cover with 4 screws.
2. Replace chlorinator on wall.
3. Reset output to previous setting.
14
Clear Cover
Replace
1. Turn off power supply.
2. Remove the 4 cover screws, disconnect the ribbon wire and remove the cover.
3. From the inside, push the center pin out of the plasti rivet, remove (pliers may be needed).
4. Gently pull the plasti rivets out of the cover & remove the clear cover.
5. Lay paper down (to avoid scratching the replacement cover) and place the new cover on the paper.
6. Insert the plasti rivet thru the hole in the clear cover and push the anchor partially into the spacer (to hold the spacer
in place).
7. Set the metal cover into the clear plastic cover.
8. Insert the pins through the anchor to lock the cover in place.
15
PCB Replacement for DuoClear
Replacement
1. Disconnect power supply.
2. Remove chlorinator from wall if needed.
3. Remove 4 screws to remove cover.
4. Remove ribbon wire connector from power PCB and set cover aside.
5. Remove 3 triac screws “A”, “B” and “C”. (IMPORTANT: Read pg. 17) Note that screw “C” has a special insulating
washer and pad.
6. Remove the 4 screws holding the board on.
7. Lift power PCB away without removing wires and fold forward.
8. Place new PCB in position and replace 4 screws.
9. Replace 3 triac screws “A”, “B” and “C” and tighten securely (special insulating washer and pad on screw “C” MUST
be in place).
10. Transfer wires one at a time to avoid misplacement.
11. Remove the shunt from the old board and position onto the new board. The terminals are labeled. The shunt
hangs down and should not be touching any wires.
12. Attach ribbon wire connector.
13. Attach cover with 4 screws.
14. Replace chlorinator on wall.
15. Reconnect power supply.
16. Test all functions.
PCB
Mounts
PCB
Mounts
Disconnect wires
one at a time
and reconnect
to new board.
Shunt
IMPORTANT: See next page
concerning triac screws!
16
Triac Screws
The triac screws are the 3 screws at the base of the power PCB. It is imperative that these screws be tightened all the
way. The triac tabs are used to transfer heat from the power PCB to the back panel of the chlorinator.
If the triac screws are NOT tight, the power PCB will overheat and be damaged.
It is also imperative to have screw “C” insulated with the special washer and pad. This special washer and pad insulates
this triac tab while still allowing heat to transfer.
Triac screws “A”, “B”, & “C”. Note that screw
“C” has an insulating pad and washer that MUST
be replaced when the PC board is changed.
These screws must be tight in order to dissipate
heat from the board.
17
DuoClear
Powerpack
10
9
8A
11
8B
8C
14
7
5
2
12
13
6
3
4
18
17
22
19
15
21
20A
16
20B
1
25
DuoClear Vessel
24
23A
29A
29B
23B
23C
29C
28
27
26
18
DuoClear
DuoClear 220V S Power Pack
No.
DuoClear Vessel
Part #
Description
No. Part #
Description
1
W012381
Duoclear Perspex Cover
23A W202241
Duoclear 25 Electrode
2
W001281
Plasti Rivet (Duoclear Hinge)
23B W202251
Duoclear 35 Electrode
3
W042281
Nylon Spacer 4mm Hinge
23C W202261
Duoclear 45 Electrode
4
W173671
S Cover Label Duoclear
24
W042071
Nature2 Locking Ring
5
W012321
S Cover Duoclear
25
W042081
Electrode Locking Ring
6
W082462
Duoclear S Control PCB Assy
26
W042232
Vessel Assembly
7
W000351
Screw Pan Hd Phil M3*8 Wth Cap
27
W151201
Nature2 O-Ring
8A
W141441
Shunt Duoclear 25 150mm
28
W151211
Electrode O-Ring
8B
W141431
Shunt Duoclear 35 110mm
29A W26000
DuoClear 25K (4pk)
8C
W141421
Shunt Duoclear 45 130mm
29B W26001
DuoClear 35K (4pk)
9
W000351
Screw Pan Hd Phil M3*8 Wth Cap
29C W26002
DuoClear 45K (4pk)
10
W082441
Duoclear Power PCB Assy
11
W000351
Screw Pan Hd Phil M3*8 Wth Cap
12
W000651
Insulation Mounting Kit To 220
13
W001321
Ribbon Cable Clamp (Multicomp)
14
W052271
Duoclear Circuit Brkr Cable
15
W130671
Transformer (220 290va 54v Ct)
16
W052301
Duoclear UL Mains Cable USA
17
W111071
Circ. Break.W28-Xq1a03 Potter
18
W000661
Cord Grip Grommet HE1200 15 amp
19
W000021
Cord Grip Grommet HE1217 /6N-4
20A W052311
6’ Output Cable With Plug
20B W052313
12’ Output Cable With Plug (not shown)
21
W000261
Washer Shkproof Int 1/8 Z/P
22
W000581
M3 X 6mm Taptite Screw
19
ZODIAC POOL SYSTEMS, INC.
2620 Commerce Way
Vista, CA 92081
Tel: 800-822-7933
Fax: 877-327-1403
www.zodiacpoolcare.com
© 2007 Zodiac Pool Systems, Inc. All rights reserved. TL-2505 8/07
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