Zodiac DuoClear, Troubleshooting Manual

Page 1: ...Troubleshooting Manual ...

Page 2: ...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 pre...

Page 3: ...orinator 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 ca...

Page 4: ...t 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...

Page 5: ...be 10 Results 220V YES NO Unit receiving power continue testing Have qualified electrician rewire chlorinator to 220V or determine why no voltage Reset or replace circuit breaker see Circuit Breaker pg 4 Transformer receiving power circuit breaker OK continue testing 6 Test between N K 220V YES NO 7 Test between H F and H D Results should be as printed on transformer 26 5V Both tests read OK YES N...

Page 6: ...t breaker pg 4 If breaker continues to trip replace PC board see pg 16 and circuit breaker see pg 4 Refer customer to a qualified electrician to troubleshoot power source Is there power at timer or switch YES NO 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 Check for loose wires ...

Page 7: ...g properly Recommend to customer to have water sample checked by dealer Add salt according to chart in Owner s Manual 1 Is salt level 4000 ppm YES NO Have qualified electrician wire to 220V 2 Is unit wired 220V YES NO 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 ...

Page 8: ... NO 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 Have qualified electrician rewire chlorinator to 220V ...

Page 9: ...cess 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 t...

Page 10: ...until the problem is corrected Is the flow restricted in the pool improperly set valve YES 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 ...

Page 11: ...B see Touch Pad PCB pg 14 Is water below 65 deg F YES NO Cell is nearing end of life Replace cell see Cell pg 13 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 Chlorinator is wired 110V Have qualified electrician wire chlorinator to 220V Add salt according to chart in Owner s Manual Cell is nearing end of life Replace cell see...

Page 12: ...ally see pg 13 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 touch pad PCB see Power PCB pg 16 Note New plaster pools will have a continuous demand for acid for 6 months or more High pH conditions an...

Page 13: ...erse 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 11 Start pump and check for leaks Replace the Cell 1 Turn off pump 2 Close an...

Page 14: ...uch pad PCB from cover 4 Attach new touch pad PCB to cover with 4 screws 5 Attach ribbon wire connector to power PCB 6 Turn on power supply 7 Use button on touchpad labeled Fast N2 to adjust reminder light to previous setting 8 Replace cover with 4 screws 9 Replace chlorinator on wall 10 Reset output to previous setting Note If unit functions properly after replacing touch pad power PCB will NOT n...

Page 15: ...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...

Page 16: ...w 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...

Page 17: ...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 o...

Page 18: ...27 29B 29A 29C 26 28 23B 23A 23C 24 16 19 17 18 12 8B 8A 8C 14 7 6 5 4 3 2 1 22 21 20B 20A 25 11 10 9 13 15 18 DuoClear Powerpack DuoClear Vessel ...

Page 19: ...001321 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 ...

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