Aqua Plus Automation And Chlorination Operation Manual For .

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TESTIDEAL RANGEADJUSTMENT REQUIREDFree Chlorine1.0 - 3.0 ppmTurn output dial up to increase,down to decrease -OR- increaseor decrease pump filtration time.pH7.2 - 7.6Alkalinity80 - 120 ppmSaltAquaPlusAutomation and ChlorinationToo high - add muriatic acidToo low - add soda ash.Add baking soda to increase.Add acid as required to decrease.2700 - 3400 ppm Add salt as required to increase.Stabilizer60 - 80 ppmAdd cyanuric acid to increase.Calcium200 - 400 ppmAdd calcium to increase.Drain and add water to decrease.Electrolytic Cell inspect & cleanRefer to section in manual.(actuators, cell & remote display not included - order separately)Operation Manualfor modelAQL-PLUSAQL-PLUS-20GLDLINEGC ON TROLSNorth Kingstown, RI 02852 USA092149BCopyright 2008 Goldine ControlsLDLINEC ON TROLSwww.goldlinecontrols.com888-921-7665

LIMITED WARRANTY Goldline warrants its Aqua Rite, Aqua Rite Pro, Aqua Trol, Aqua Logic and Pro Logic products(products with Goldline part numbers starting with AQ-RITE-, AQ-RT-PRO, AQ-TROL-, AQ-LOGIC-, AQL-P-, AQL-PS-,AQL-CL-, PL-P-, PL-PS-, and HPC-2) to be free from defects in material or workmanship, under normal use and service:IMPORTANT SAFETY INSTRUCTIONSWhen using this electrical equipment, basic safety precautions should alwaysbe 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 behazardous to your health. !WARNING: To reduce the risk of injury, do not permit children touse this product unless they are closely supervised at all times.A green colored terminal marked “Earth Ground” is located inside the wiringcompartment. To reduce the risk of electric shock, this terminal must beconnected to the grounding means provided in the electric supply servicepanel with a continuous copper wire equivalent in size to the circuitconductors supplying the equipment. One bonding lug for US models (two for Canadian models) is provided on theexternal surface. To reduce the risk of electric shock, connect the localcommon bonding grid in the area of the swimming pool, spa, or hot tub tothese terminals with an insulated or bare copper conductor not smaller than 8AWG US / 6 AWG Canada. All field installed metal components such as rails, ladders, drains, or othersimilar hardware within 3 meters of the pool, spa or hot tub shall be bondedto the equipment grounding bus with copper conductors not smaller than8 AWG US / 6 AWG Canada. SAVE THESE INSTRUCTIONSFor three years from the date of the initial system installation on private, residential swimming pools within the USA or Canadaand one year from the date of initial system installation on commercial installations, installations outside of the USA or Canadaand for any replacement parts or accessory products, provided they are installed in accordance with the Goldline installationinstructions and specifications provided with the product. If written proof of the date of the initial system installation is notprovided to Goldline, the manufacturing datecode on the Aqua Rite, Aqua Rite Pro, Aqua Trol, Aqua Logic and Pro Logicelectronics unit will be the sole determinant of the date of the initial system installation.For residential installations in USA or Canada: If a product is defective in workmanship or materials and is removed and returnedfreight prepaid within three (3) years after the date of the initial system installation, Goldline will, at its option, either repair orreplace the defective product and return it freight prepaid.For commercial installations, installations outside the USA and Canada, and accessory products and replacement parts: If aproduct is defective in workmanship or materials and is removed and returned freight prepaid within one (1) year after the dateof the initial system installation, Goldline will, at its option, either repair or replace the defective product and return it freightprepaid.Contact any Goldline dealer or contact Goldline at 61 Whitecap Drive, North Kingstown, RI 02852 for warranty service. Thecosts incurred in removal and/or reinstallation of the product are NOT covered under this warranty. Some states do not allowlimitations on how long an implied warranty lasts, so the above limitation may not apply to you.WARRANTY EXCLUSIONS:1.Material supplied or workmanship performed by others in process of installation.2.Damage resulting from improper installation including installation on pools larger than the product rating.3.Problems resulting from failure to operate the product(s) in accordance with the recommended instructions containedin product’s owners manual(s).4.Problems resulting from failure to maintain pool water chemistry in accordance with the recommendations in theowners manual(s).5.Problems resulting from tampering, accident, abuse, negligence, unauthorized repairs or alternations, fire, flood,lightning, freezing, external water, degradation of natural stone used in or immediately adjacent to a pool or spa, waror acts of God.DISCLAIMER. THE EXPRESS LIMITED WARRANTY ABOVE CONSTITUTES THE ENTIRE WARRANTY OFGOLDLINE WITH RESPECT TO ITS POOL AUTOMATION AND CHLORINATION PRODUCTS AND IS IN LIEUOF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITYOR FITNESS FOR A PARTICULAR PURPOSE. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, ANDYOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. IN NO EVENT SHALL GOLDLINEBE RESPONSIBLE FOR ANY CONSEQUENTIAL, SPECIAL OR INCIDENTAL DAMAGES OF ANY NATUREWHATSOEVER, INCLUDING, BUT NOT LIMITED TO, PERSONAL INJURY, PROPERTY DAMAGE, DAMAGE TOOR LOSS OF EQUIPMENT, LOST PROFITS OR REVENUE, COSTS OF RENTING REPLACEMENTS, AND OTHERADDITIONAL EXPENSES, EVEN IF THE SELLER HAD BEEN ADVISED OF THE POSSIBILITY OF SUCHDAMAGES. SOME STATES DO NOT ALLOW THE EXCLUSION OF LIMITATION OF INCIDENTAL ORCONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.NO WHOLESALER, AGENT, DEALER, CONTRACTOR OR OTHER PERSON IS AUTHORIZED TO GIVE ANYWARRANTY ON BEHALF OF GOLDLINE.THIS WARRANTY IS VOID IF THE PRODUCT HAS BEEN ALTERED IN ANY WAY AFTER LEAVING THE FACTORY.36

System OverviewThe following statement is applicable if any of the wireless accessories are connected to the Aqua Plussystem.The Aqua Plus is a multifunction pool controller used to fully manage your pool/spa system. The Aqua Pluscan control pumps, valves, lighting, heaters, and chlorination. Although the Aqua Plus is easy to use, it isimportant to completely read through this operating manual before attempting to operate the control.FCC Statement(Compliance Statement, Part 15.19): This device complies with Part 15 of the FCC Rules. Operation issubject to the following two conditions: (1) This device may not cause harmful interference, and (2) thisdevice must accept any interference received, including interference that may cause undesired operation.WARNING (Part 15.21): Changes or modifications not expressly approved by the party responsible forcompliance could void the user’s authority to operate this equipment.OptionalWireless BaseReceiverIndustry Canada StatementOptionalRemote DisplayKeypadThe term “IC” before the certification/registration number only signifies that the Industry Canada technicalspecifications were met.Main DisplayKeypadInterference(maximum of three)Filter PumpLightsAux 1WaterTemperatureSensors120/240VRelaysAux 2Pool/Spa Suction &Return ValvesAirSolar24V ValveActuatorsValve 3This equipment has been tested and found to comply with the limits for a Class B digital device, pursuantto Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmfulinterference in a residential installation. This equipment generates, uses, and can radiate radio frequencyenergy and, if not installed and used in accordance with the instructions, may cause harmful interference toradio communications. However, there is no guarantee that interference will not occur in a particularinstallation. If this equipment does cause harmful interference to radio or television reception, which can bedetermined by turning the equipment off and on, then the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna.Increase the separation between the equipment and the receiver.Connect the equipment into a power source on different circuit than the receiver.Consult the dealer or an experienced radio/TV technician for help.HeaterOptionalFlow SwitchOptionalChlorinator Cell240 VACPowerCircuit BreakerSubpanelNOTE: This manual assumes that the Aqua Plus has been wired and configured according to the Installation Manual. Aspects of the Aqua Plus that pertain to system setup are not covered in this manual.AutomationThe Aqua Plus can control up to 4 high voltage (120/240V) pieces of equipment, up to 3 automatic valveactuators, and a conventional and solar heater. Both manual and automatic (programmed) operation areavailable. All of the control functions can be programmed at a display/keypad which is part of the main unit(typically located near the pool equipment) or at one or more remote display/keypads.134

Table of Contents35System OverviewBlock Diagram.Automation.Chlorination.Default Display.1122Manual SystemOperationFilter Pump.Lights and Aux Outputs.Pool/Spa Valves.Service.3444Automatic SystemOperation(Programming)Using the Programming Buttons.Programming Menu Flow Chart.Settings Menu.Timers Menu.Configuration Menu.5671013Quick “How To”GuideOperate the Spa - Manually.Operate the Spa - Automatically.Set the Heater Temperature.Set the Chlorinator Output .Start/Stop Superchlorination.Program a Timeclock.Program a Countdown Timer.Enter/Exit Service Mode.2222222223232324Chlorinator Operation/Water ChemistrySaturation Index.Salt Level.Type of Salt.How to Add or Remove Salt.25262626System MaintenanceServicing and Cleaning the Turbo Cell. 29Winterizing. 29Spring Startup. 29Troubleshooting &Diagnostic InformationService Mode .Check System Indicator.Diagnostic Menu.Chlorinator Diagnostics.Instant Salt.Flow Switch.Cell, Water, Air, Solar Temperature.Software Revision.WarrantyAqua Plus Warranty. 363031323232323333

Solar SensorShort circuit Air Sensor94ºF Water SensorOpen circuit Cell Temp Sensor77ºF No functionMove to previous/next menu item No functionMove to previous/next menu item No functionMove to previous/next menu item No functionMove to previous/next menu itemAvailable displays depend on configuration. If the sensor appears to operating properly,then the temperature will be displayed. If this temperature is not correct then check theplacement of the sensor. If the problem is not placement related, then the sensor will, mostlikely, require replacement. If the display is “Open Circuit” or “Short Circuit” then check thewiring to the sensor and also make sure that the wires are secure in the terminal block in theAqua Plus main unit. No functionMove to previous/next menu item No functionMove to previous/next menu item No functionMove to previous/next menu item No functionMove to previous/next menu itemAvailable displays depend on configuration. If you call the Goldline Technical ServiceDepartment for assistance, they may ask for the software revisions of both the main unit andeach of the display/keypads or other devices that are attached to the system. Note that it ispossible that different display/keypads have different software revision levels. For thisreason, it is advisable to check this diagnostic menu item on every display.With the use of the included AQL-CL chlorination kit, the Aqua Plus is also an automatic chlorine generation system for pool and/or spa sanitization. If enabled (see Configuration Menu), this operation requiresa low concentration of salt (sodium chloride) in the pool/spa water. The Aqua Plus automatically convertsthe salt into free chlorine which kills bacteria and algae in the pool/spa. Chlorine will revert back to sodiumchloride after killing bacteria. These reactions will continuously recycle, virtually eliminating the need toadd sanitizing chemicals to your pool/spa. The only time you may need to add more salt to the pool/spais when water is replenished due to backwashing, draining, or splashing (not evaporation).The Aqua Plus is designed to handle the purification needs of most residential swimming pools up to40,000 gallons (150,000 liters), or the needs of most commercial pools up to 25,000 gallons (95,000liters). The AQ-PLUS-20 should be used for pools up to 20,000 gallons (75,000 liters). Check localcodes for other restrictions. The actual amount of chlorination required to properly sanitize a pool variesdue to bather load, rainfall, temperature, and the pool’s cleanliness.For pools larger than 40,000 gallons, the Aqua Plus can control one or more Goldline Aqua Rite chlorinators to supplement chlorine production.NOTE: Before installing this product as part of a saline water purification system in a pool or spa usingnatural stone for coping or for immediately adjacent patios/decking, a qualified stone installation specialistshould be consulted regarding the appropriate type, installation, sealant (if any) and maintenance of stoneused around a saline pool with electronic chlorine generator in your particular location and circumstances.Default DisplayTurn power on at the main panel and turn the Aqua Plus control power circuit breaker on. The keypad willshow the default display. The default display alternates between the day/time, air and pool (or spa)temperature, pool/spa sanitizer setting, and salt level. Under certain circumstances, additional displaysmay be added to the default menu to inform you about system operation. Refer to the Programming MenuFlowchart on page 6 to view all possible displays. The Aqua Plus will automatically scroll through all ofthe available default menu displays or you can press “ ” or “ ” to manually scroll.Saturday11:45APool/Spa Service 6B Spa SoftwareRemote A r1.00 RF Base Softwarer1.20 ID:1234 Display Softwareremote-08 r3.10 Main SoftwareRevision 2.40Chlorination33MenuFilterLightsAux 1Aux 2 2

Diagnostic Menu 23.45Set Day and 6.75ATimeWednesday84 F3200PPM10:37P(Pool/Spa/Spillover)Filter PumpFilterCheck SystemIndicatorIf the current (amps) display is 0.00A, then the chlorinator is operating normally but is in theoff part of its normal operating cycle. Simply press either the “ ” or “-“ key to start a newcycle.(On/Off)Pool/SpaLightsThe Aqua Plus periodically reverses the polarity of the voltage applied to the cell in order toautomatically clean off any calcium deposits. It is important that you check the chlorinatoroperation in both polarities. To do this, press either the “ ” or “-“ buttons and the chlorinatorwill turn off, wait for 15 seconds and then turn on in the opposite polarity.(On/Off)LightsServiceAux 1Aux 2Service ButtonAux 1(On/Off)If a conventional or solar heater is operating, it is likely that the temperature of the water atthe cell is higher than the pool/spa water temperature displayed on the Aqua Plus defaultdisplay.Aux 2(On/Off)(main display only)Filter PumpSingle Speed Filter Pump: If the pump is currently off, press the FILTER button to turn on the pump.Pressing the FILTER button again will turn off the pump. However, if there is a heater in the system, andit is operating, and the “Heater Cooldown” feature is enabled (Configuration Menu) then: when you pressthe FILTER button to turn off the filter, only the heater will turn off, the Filter LED will flash and the displaywill indicate “Heater Cooldown”. At this point the filter pump will automatically turn off after 5 minutes ofheater cooldown operation. If you want to override the heater cooldown, simply press the FILTER buttonagain to turn off the filter pump.Two Speed Filter Pump: If the pump is currently off, simply press the FILTER button to turn on highspeed operation of the filter pump. The “Filter” LED will illuminate continuously. Pressing the FILTERbutton again will switch to low speed operation and the “Filter” LED will flash. If you attempt to switch tolow speed shortly after turning on high speed the filter pump will automatically remain in high speed for 3minutes before switching to low speed to allow the pump to prime and establish normal water flow.Freeze Protection: This function protects the pool, plumbing, and equipment against freeze damage. IfFreeze Protection is enabled and the AIR temperature sensor falls below the preset freeze protectiontemperature (see Filter Pump Configuration), the Aqua Plus will turn on the filter pump to circulate thewater.3Instant Salt3200 PPM ( save) Press to load the “Instant salt” into the averaged salt displayMove to previous/next menu itemThis display will be shown only if the chlorinator is enabled. This display shows “InstantSalt” or “Instant Minerals” (if Chlor. Config. is set for “Display Minerals”). The “InstantSalt” is calculated based on the voltage, current (amps), and water temperature at the cell.This is different than the “average salt” value which is displayed as part of the default menu.There are a number of reasons why instant and average salt readings may differ. Some ofthese include salt having just been added to the pool and not yet thoroughly mixed, calciumbuildup on the cell, and the cell aging.Flow SwitchFlow Valve 3IndicatorPress to switch chlorinator operation to opposite polarity (15 second delay)Move to previous/next menu itemThis display will be shown only if the chlorinator is enabled. For the chlorinator to beoperating, several other things must be happening: the filter pump must be running, the flowswitch must be detecting flow, the chlorinator setting must be set greater than 0%, the watertemperature at the cell must be between 50ºF and 140ºF, and the salt level must be within theoperating range. If any of these conditions are not met, the chlorinator diagnostic displaywill tell you the reason. It’s possible to have more than one reason, in which case after yourectify what was displayed the first time, a second display will appear.Pool/Spa ButtonSalt Level3200ppm /- 23.45V is the voltage applied to the chlorinator cell /-6.75A is the current (amps) through the cell84ºF is the water temperature at the cell3200PPM is the “instant” salt level at this timeDisplayHeater Indicator While the main objective of the Aqua Plus is to automate the operation of your pool/spa system, there maybe certain times when you want to override the automatic operation and control the equipment manually.To operate the pool equipment manually while keeping the automation active, perform the following procedures. Note that if you turn a relay on manually, it will remain on until either you turn it off manually, orthe next time the programmed automatic operation would normally turn that relay off. Example: the filterpump is programmed to run from 9:00A to 5:00P daily. If you turn the filter pump on manually at 8:00PM,it will run continuously until the next day at 5:00PM at which time it will turn off and follow the normalprogram from then on. Manually turning off a relay works in a similar fashion.To enter the Diagnostic Menu, press the “Menu” button repeatedly until the display shows “DiagnosticMenu”. At this point, you can use either the “ ” or “ ” buttons to scroll through the various menu itemswhich are described below: Manual System Operation No functionMove to previous/next menu itemThis display will be shown only if the chlorinator is enabled. The current status of the flowswitch is displayed. There is a short delay when transitioning from flow to no-flow and alonger delay on the transition from no-flow to flow. The delay time is displayed.32

Lights, Aux1 and Aux2 OutputsCheck System IndicatorThe “CHECK SYSTEM” LED will alert you when the Aqua Plus detects any of the following conditionsthat are abnormal and require attention for optimal operation of your pool. Inspect Cell -- for optimum operation, you will need to inspect the Aqua Plus chlorinator cell approximately every 3 months and clean the cell if necessary. The Aqua Plus will automatically remind youwhen it is time and display “Inspect Cell, to reset” as part of the rotating Default Menu. Clean the cell(see instructions, page 29) and then press the “ ” button during the “Inspect Cell” display to reset thetimer. Low Salt/Minerals or Very Low Salt/Minerals -- when the salt is too low the Aqua Plus willgenerate less chlorine and the life of the cell is degraded. Check the cell and clean if necessary (seeinstructions, page 29) before adding salt (see instructions, page 26). High Salt/Amps/Minerals -- the Aqua Plus will stop generating chlorine under certain high salt conditions in order to protect the internal electronics from damage. The only way to lower the salt level is topartially drain the pool and add fresh water.Standard Relay: Manual operation of all 3 relays is identical. Assuming that the relay is currently off,simply press the appropriate button to turn on the relay. If the relay does not turn on, it probably is due tothe “interlock” feature (which was set up in the Configuration Menu) being activated that requires the filterpump to be running and the valves to be in the pool-only position. This protects pumps and other equipment from possible damage. If the controlled output is on, pressing the appropriate button again will turnoff the relay. Manual turn off is disabled if the “Freeze Protection” feature is enabled and the air temperature is less than the selected freeze temperature threshold.Dimmer Relay: If Lights or an Aux output is configured as a dimmer, pressing the corresponding buttonwill generate a temporary display which shows the dimmer output level (Off - On 100%). Pushing the “ ”or “-” button changes the level in increments of 20%. When the desired output level is displayed, press thecorresponding button again to turn off the display and return to normal operation. When the Lights or Auxoutput comes on again (either manually or automatically), the dimmer output level will be the same as thelast time that it was set.Pool/Spa Valves Water Sensor -- if the water sensor is either an open or short circuit.Pool-only or spa-only systems: The POOL/SPA button has no function. Air sensor -- if the freeze protection feature is enabled (Configuration Menu/ Filter Config.) and the airsensor is either an open or short circuit.Pool and Spa systems without spa spillover: In pool-only mode, the left LED next to the POOL/SPAbutton is illuminated. Pressing the POOL/SPA button will switch the Aqua Plus to spa-only operation(right LED illuminated). Pressing the POOL/SPA button again will switch back to pool-only. Note thatthe filter pump will turn off while the pool/spa valves are turning. Solar Sensor -- if the solar sensor is either an open or short circuit. Chlorinator Cell Sensor -- if the chlorinator function is enabled (Configuration Menu/Chlorinator)and the cell sensor is either an open or short circuit. Low Volts -- if the chlorinator cell voltage is too low. No Cell Power -- if no chlorinator cell power is detected on the printed circuit board. Check Flow Switch -- if the flow switch input is invalid. Cell Power Error -- if a chlorinator cell power error is detected on the printed circuit board. Cell Missing -- if the chlorinator is enabled but no cell is detected.For helpful troubleshooting information on any of these issues, go to the Diagnostic Menu and then scrollthrough the various items until you see the cause for the “CHECK SYSTEM” LED being illuminated.Pool and Spa systems with spa spillover: In pool-only mode, the left LED next to the POOL/SPAbutton is illuminated. Pressing the POOL/SPA button will switch the Aqua Plus to spa-only operation(right LED illuminated). Pressing the POOL/SPA button again will switch to spa spillover operation (bothLED’s illuminated). Pressing the POOL/SPA button again will switch back to pool-only. Note that thefilter pump will turn off while the pool/spa valves are turning.ServiceThe main unit keypad has a SERVICE key. This button is used primarily during servicing of the poolequipment. If you want to completely disable the automatic operation and operate the system manually,you can put the system into Service or Service-Timed mode by pressing the SERVICE button. Pressingthe SERVICE button once will switch the system into service mode which means that all automatic functions are disabled, and the remote display/keypads are disabled (except for manual turn off for emergencies). The red SERVICE LED will be illuminated and the Aqua Plus will remain in this mode of operationuntil manually taken out of service mode.Pressing the SERVICE button again will cause the Aqua Plus to switch to service-timed mode which isvery similar to service mode, except that the Aqua Plus will automatically return to normal operation after3 hours. During service timed operation, the “Service” LED will flash and the time remaining will bedisplayed on the remote display/keypad(s).Pressing the SERVICE button again, will return the Aqua Plus to normal (automatic) operation. See Troubleshooting/Diagnostic Information (page 30) for more information about the service modes.314

Automatic System OperationThe Aqua Plus controls most of your pool equipment automatically in order to minimize the time spentworking on your pool. Most of the pool equipment can be programmed to operate on a timeclock basis.In addition, the desired pool and spa temperatures and pool and spa chlorinator settings can be programmed. This section will guide you on how to program the automatic operation for each function.The programming of automatic functions can be performed at either the main display/keypad located at thepool equipment pad or the in-home remote display/keypad.Using the programming buttonsThere are 5 buttons on each keypad that are used for programming (refer to diagram).DisplayTroubleshooting and Diagnostic InformationThe Aqua Plus provides 2 different tools to aid in troubleshooting any problems that may occur in yourpool and/or spa system. The Service mode will allow you to disable automatic operation and manuallycontrol most of the equipment (the heater and general purpose Valve3 output are the exceptions). TheDiagnostic Menu will provide some detailed information regarding system operation.While both of the features are primarily intended for the use of the professional service technician, theirfunction is fully explained below. If you believe your system is not operating properly or have questionsregarding the operation, call the Goldline Technical Service Department from Monday through Friday,8AM to 8PM EST at 888-921-7665.Service ModeThe main unit keypad has a SERVICE button that is used primarily during servicing of the pool equipment.If you want to completely disable the automatic operation and operate the system manually, you can putthe system into Service or Service-Timed mode by pressing the “Service” button. Pressing the “SERVICE” button once will switch the system into service mode which means that all automatic functions aredisabled, the optional remote display/keypads are disabled (except for manual turn off for emergencies).The outputs can be manually controlled by pressing the buttons on the local display/keypad. The red“SERVICE” LED will be illuminated and the Aqua Plus will remain in this mode of operation until manuallytaken out of service mode.SettingsMenuMenu ButtonSelect Desired Menu Pressing the “SERVICE” button again will cause the Aqua Plus to switch to service-timed mode which isvery similar to service mode, except that the Aqua Plu

provided to Goldline, the manufacturing datecode on the Aqua Rite, Aqua Rite Pro, Aqua Trol, Aqua Logic and Pro Logic electronics unit will be the sole determinant of the date of the initial system installation. For residential installations in USA or Canada: If a product is defective

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