Entrapment is a pool safety issue that is gaining considerable public, regulatory, media and industry attention. A number of states have introduced or are poised to introduce various forms of entrapment avoidance safety regulations. It is likely that other states and regulations will follow.

A variety of factors have helped to contribute to the escalating attention on the issue of entrapment. There is also much confusion over this issue, with a variety of avoidance methods written into a variety of standards and construction techniques since the 1980’s. It was with this thought that the APSP released the recent ANSI approved standard, ANSI/APSP-7 covering suction entrapment avoidance. According to the APSP, it is the first comprehensive standard for engineering swimming pools and spas to avoid suction entrapment hazards.

According to the ANSI/APSP-7 standard, the five entrap-ment hazards associated with submerged suction outlets are:

Hair Entrapment – Hair becomes knotted or snagged in an outlet cover.

Limb Entrapment – A limb is sucked or inserted into an opening of a circulation outlet with a broken or missing cover.

Body Entrapment – Suction is applied to a large portion of the body.

Evisceration/Disembowelment – Suction acts on the intestines through an unprotected sump or suction outlet with a missing or broken cover.

Mechanical Entrapment – Jewelry, swimsuit, hair decorations, finger, toe or knuckle is caught in an opening of an outlet or cover.

It must be understood that there is currently no single product or device that can singly prevent all of the listed entrapment hazards. Thus, entrapment avoidance requires a layered solution – a blend of prod-ucts, devices and/or construction techniques.

Hayward has recently introduced the StratumTM VRS, a product designed to reduce the risk for Body Entrapment. Stratum is unique in the industry because it simultaneously powers the pump off and vents the suction line to atmosphere (releasing the vacuum).

Warranty claim process now onlineIntuitive system designed fordealer ease, convenience

Hayward champions entrapment safety with StratumTM VR1000

A technical publication for Hayward dealers and service providers

See ‘Warranty’ on page 6

Hayward warranty claims can now be submitted for processing online at www.haywardnet.com.

“Servicers who participated in the beta testing of our online warranty claims process are very pleased with it,” said Angela

Wagoner, primary administrator of our web-based warranty claims process, which is now available to all Hayward Authorized Service Centers (HASC’s).

To utilize our web-based warranty claims program, HASC’s simply log into their Totally Hayward partner program, click on the Tech Services tab, then click on the Warranty tab.

“After submitting a claim online, servicers can check on a claim’s status at any time,” Wagoner said, “Dealers will greatly benefit from the speed and simplicity this online tool brings to the warranty claim process.”

StratumInstallation, Page 4

—— Also Inside ——

Match pump’s flow rate, not its power(GPM vs HP)

pg 3

Cleaner bearings must be aligned

pg 5

More thanquality: Product reliability

pg 6

HASC’s can click on Tech Services, then select Warranty Claims to access the online Warranty Claims program at

Haywardnet.com.

New training series DVD distributedHayward dealers should have received the second installment of our popular new training series, Training for the Future, in January.

After reviewing its contents, technicians can receive APSP credit by completing the course test online. For details, see ...

— Page 2

Phantom, Viper ManifoldEnhancements

PhantomTM and ViperTM will be greeting the new year with manifold and gearbox improvements to ensure

more durable and robust operation, with less sensitivity to debris that may have inadvertently found its way into the pressure line.

— Page 2

Volume 4 Issue 1 SP703

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In addition to illustrating how easily the IDL2 heat exchanger can be rotated for left-hand or right-hand installation, the IDL2 Service & Diagnostics DVD outlines and walks viewers through heater troubleshooting keys – valuable training not just for the Hayward IDL2 but for heater servicing in general.

“Safe and efficient heater maintenance and servicing depends on technicians being able to identify the heater’s major components, its major systems, and how those systems interact with each other,” said John Murray, Hayward National Training Manager.

“Technicians armed with this knowledge can isolate installation and operation issues in a quick, efficient manner – whereas technicians lacking this knowledge are simply guessing and replacing parts blindly, which drives up costs and erodes customer trust.”

The DVD also covers all of the IDL2’s fault codes, and shows where to look for the problem(s) that can trigger each code.Finally, in addition to being a valuable addition to a dealer’s training library – an enduring reference tool that staff

members can utilize for new or refresher training at any time – the IDL2 Service & Diagnostics DVD also includes a course examination, which technicians may complete online for APSP credit (go to www.haywardnet.com/techtraining).

Any Hayward Pool Products dealer who did not receive “Training for the Future” DVD in January is encouraged to contact their Hayward representative for a copy or e-mail your request to us at Splash@Haywardnet.com.

Please send comments or suggestions to:

SplashHayward Pool Products1 Hayward Industrial Dr.Clemmons, N.C. 27012

or e-mail us at:Splash@Haywardnet.com

SP703

© Hayward Pool Products, Inc., 2007

IDL2 Service & Diagnostics

The new Phantom and Viper manifolds feature a new piston dimension. Plus, the dual vent openings were relocated and changed to a radial vent design, and the inlet now includes a sec-ondary debris protection screen.

All of these improvements add up to better debris protection, which is further enhanced with two more notable improvements:

• the new manifold incorporates radial vents for self-cleaning of the manifold, and

• the new pistons are more forgiving of very fine debris – resulting in a more robust and trouble-free manifold.

Latest edition released in Hayward‘Training for the Future’ DVD Series

New year rings in manymanifold enhancements

PhantomTM and ViperTM will be greeting the new year with manifold and gearbox enhancements. The 2007 model year production of the Phantom and Viper will include several modifications to the manifold and gearbox to ensure more durable and robust operation, with less sensitivity to debris that may have inadvertently found its way into the pressure line.

Gearbox improvements include

• a material change to the gears for more strength,

• better sealing at the bottom cover to keep out fine debris, and

• a more definitive alignment of the gear stacks by creating a better locating design to the bottom cover.

The new gearbox is easy to distinguish from the older version, as the new gearbox post (to which the cam attaches) is white, whereas the older post more of an aqua color.

ABOVE: New gearbox(is easily identified by its white cam-alignment post).

BELOW: Self-cleaning openings (lower)

(dual self-cleaningradial vents

have been relocated for easier

self-cleaning).

BELOW: New manifold notch(The new Phantom & Viper manifolds are easily identified by the presence of this notch).

ABOVE & BELOW: Secondary

filter screen(can be removed for

cleaning by pulling on the center rib).

PhantomTM manifold kit................ 6000 MA 3

ViperTM manifold kit ..................... 5500 MA 3

Hayward dealers should have received their IDL2 Service & Diagnostics training DVD in January. As the second installment of Hayward’s acclaimed new DVD training series, “Training for the Future”, this disc is a perfect complement to our inaugural training DVD, which covered IDL2 gas heater installation.

TWOPAGE

Information presented in ‘Splash’ is abridged due to space and may NOT be thorough in certain aspects.

Supplemental precautions and details may be omitted, so always consult product own-er’s manuals and other technical publica-tions for complete details and procedures.

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power, (3) similarly excessive electrical costs for other system components, and (4) potential additional repair costs that may arise as the whole system strains to handle increased head loss and flow demands.

Reliable rules re-examinedAs pump technology improves, many of the service technician’s other

long-standing rules of thumb are also changing.For example, an old pump-sizing rule-of-thumb suggested a pool

pump should generate about 1/4 horsepower for every pool jet. Another way of saying that is a pump could accommodate about four (4) jets per horsepower. Hence, a pool with 12 jets would need a 3 hp pump.

But that’s the old rule. With today’s high-flow, low-energy pumps, each horsepower might accommodate six (6) or even (8) jets instead of just four (4). That’s because newer pumps move much more water with the same effort (same hp).

This is a critical point for pool installers and service technicians – not just when sizing pumps for a new pool, but especially when replacing older pumps in an existing system.

Re-assess before replacingPool systems today are commonly paired with spas, fountains and

water features galore – meaning today’s more efficient pumps are practi-cally a necessity to handle all those jets. Plus older systems retrofitted with new features and new components may need more water flow than the original pump and plumbing delivered.

Therefore, when replacing an older pump in most situations, the professional pool technician’s prudent course of action is to reassess the entire pool system, determining the system’s current hydraulic resistance (total dynamic head loss) and required water flow (gallons per minute).

For a refresher on pump sizing basics, refer to page 5 in the December 2005 edition of Splash ...

... and learn why head loss is not linear (constant) when we discuss the “system curve” in a future edition of Healthy Hydraulics.

When replacing a pump, first obtain pump curves or tables for both the existing and potential new pumps. Using the current pump curve, determine the plumbing system’s necessary FLOW rate (GPM) and RESISTANCE (feet of head loss).

These can be obtained:

a) Using the 6-step method outlined in the Dec. 2005 edition of Splash, or

b) Arbitrarily selecting a moderate resistance level along the existing pump’s curve.*

Compare the pump curves: A suitable replacement pump must intersect the resis-tance level (horizontally) at about the same place as the old pump.

*Today’s “best practices” (the accepted standard) in pool maintenance dictates that technicians calcu-late or otherwise determine the pool system’s total dynamic head (resistance) and necessary flow rate (GPM) when selecting a suitable replacement pump.

Let’s say we need to replace a 2 hp Super Pump (black curve in chart above) and we’ve determined or arbitrarily selected 60 feet of head loss.

The “compatible pump window” area (where the 2 hp Super Pump intersects with 60 feet of head loss) is spotlighted with a large green dot in the chart above.

As indicated by the green curves above, the correct size Super II pump would be the 1.5 hp model, while the correct size TriStar pump would also be the 1.5 hp model.

and finding which pump model (size) delivers the necessary GPM at that head loss (the point where A and B intersect).

In short, the system’s head loss (FEET) and necessary flow (GPM) largely determine which pump size (HP) is the best fit for a given system.

New pump often needs to be smaller!Technological differences between brands can also be a critical factor. While the effects of these differences are

reflected in manufacturers’ pump curves and pump tables, it’s safe to assume older model pumps of any brand will likely need to be downsized when being replaced by more efficiently engineered newer models.

To illustrate how technological improvements dramatically affect pump selection, we arbitrarily highlighted

Match pump’s GPM, not its HPIf a homeowner understands just one thing about selecting a pump for their pool, make sure they understand this:

The more critical aspect is the pump’s flow rate, not its horsepower.In fact, whether sizing a new pump or replacing an old one, horse-

power ranks third among three pivotal selection factors.The first two factors are:(A) system head loss, and (B) required flow rate (at that head loss) to achieve

complete turnover.Armed with those facts, optimal horsepower for the new pump is then

determined by looking at manufacturers’ pump curves or pump tables ...

HEALTHYHYDRAULICS

Healthy Hydraulics examines the principles, challenges and techniques for installing and maintaining healthy hydraulic systems.

In short, a needlessly oversized pump typically costs more in many ways, including (1) the higher cost of a larger pump, (2) wasted energy generating unneeded horse-

60 feet of head loss and a required flow rate of 65-70 GPM in the adjacent three pump tables. If we need to replace an older 2 hp Super Pump, these tables show us that the Super Pump’s 67 GPM flow rate (at 60 feet of head loss) is attained with less horsepower by the newer Super II or TriStar pumps, which need only 1.5 hp for the same production.

What would happen if (instead of downsizing to the 1.5 hp Super II or TriStar) we replaced the older 2 hp pump with a new 2 hp model? Since the older model pump was (hopefully) sized to fit the existing system, the newer 2 hp pump’s higher flow demand and added resistance (head) might simply exceed the capacity of the existing plumbing configuration. The new pump would have a thirst for increased water flow, and must also overcome extra head. As a result, the new pump and other system components are more likely to malfunction or possibly suffer premature failure.

THREEPAGE

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Stratum stops pump AND breaks vacuum

One of the favorite harpings of coaches and business leaders alike has always been the value of teamwork. Even if you’re not particularly fond of sports, you can probably rattle off a half-dozen teamwork clichés simply because they’re so ingrained in our culture.

Steve Gorlin certainly preaches teamwork – and was doing so before he opened Gorlin Pools in Lakehurst, N.J., seven years ago.

A seasoned pool technician with tons of experience and energy, Gorlin recognized that when it came to the business end of the business, he had a lot to learn as he ventured into the entrepreneurial world. So he hired a business coach, immersed himself in management training, business courses, and other educational opportunities –drawing on the expertise of others to help him build

organizations over the years.“Business, technology and

safety training have been particu-larly valuable,” Gorlin said, “but the most important training we receive every year is in cus-tomer service. Most people think they’re great at customer service, but the reality is, most of us need to focus on customer service much more than we do.

“If you’re a technician out on the job, you are the company. The way you speak with the customer, the way you dress and handle yourself while changing a filter or while simply walking around the yard – those are the

a stronger team.His business’s rapid growth – both

in volume and breadth of services – is testament to the dividends of Gorlin’s commitment. Today, training and teamwork are the linchpins of Gorlin Pools, which means the best place to spot Gorlin and staff members this time of year will be in a classroom, or at a pool & spa expo, or at some other type of training event.

“We spend the entire winter training,” said Gorlin, who not only preaches the value of training, but

also backs up that message with his wallet.“The employee has to pay part of the cost – otherwise they won’t be com-

mitted to the training. But Gorlin Pools will pay part of the cost if the training directly impacts their job here,” said Gorlin, who finds himself on the opposite side of the lectern these days.

The immediate past president of the NorthEast Spa & Pool Association (NESPA), Gorlin takes particular pride in his newest training venture – devel-opment of the Certified Hot Tub Technician course and accreditation process he is overseeing as chairman of the APSP Hot Tub Council.

Gorlin’s tremendous involvement and leadership in the APSP (and its regional affiliate, NESPA) was a natural evolution, considering how much valuable training Gorlin and his staff had acquired from those leading trade

Training, teamwork are linchpins of success

images and impressions a customer will remember.“Great customer service starts with hiring the right people – employees who

are motivated and will therefore smile and embrace the training.”For this type of employee, annual refresher courses not only raise awareness

of customer service importance, every refresher course usually arms students with a fresh or additional set of memorable queues for enriching customer service efforts.

“We tap into a variety of sources for all our different types of training, though we rely most heavily on the two trade organizations (APSP and NESPA) and their 70-plus courses during the first quarter or so,” Gorlin said. “The courses and other benefits these organizations provide help you to build a strong team.

“We don’t have any stars at Gorlin Pools. We have a team of motivated, trained professionals – each of us with our own strengths. Because we’ve built a strong team, we can send any technicians out on any job, and the customer can count on receiving the same great service and attitude every time, regardless of who we send out.”

Driven by this passion for training and teamwork, Gorlin Pools is a glistening reflection of a highly popular modern business axiom, which holds:

Steve Gorlin now finds himself providing as well as receiving training.

Steve Gorlin proudly accepts the first ‘Service Company of Excellence’ award from NESPA President Ann Janowicz.

e.*

-e

Power is supplied to the Stratum from the local electrical disconnect. Incoming power can be either 240 or 120 VAC.

The Stratum can be programmed to operate on either voltage.

Power to the pump is supplied from the Stratum.

Note: Stratum acts as a switch to turn the pump on and off.

A tap is installed into the common suction line.

When a change in vacuum occurs:

• Power to the pump is shut off, and

• The vacuum is broken as the line is instantly vented to the atmosphere.

Basic Operation

Stratum Installation

FOURPAGENone of us is as strong as all of us.

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Suction Cleaner Repair Technique

Align bearing notches with keys on turbine shaft, housing

The bearing has a U-shaped outer

notch (below) that locks onto

the housing key in the bearing well (above).

With a successful inaugural tour under our belts, Hayward rolled out its second Mobile Training Center (MTC 2) in November at the International Pool and Spa Expo in Las Vegas.

Shortly after a quick tour through Arizona in December, MTC 2 will christen the new year with a protracted tour through California.

Meanwhile, Hayward’s tech services and training team unveiled MTC 3 in February, with its grand debut coming at the Florida Pool & Spa Show while our original MTC headed north to the Atlantic City show, where it captured the Best Booth award for its category.

Immensely popular and well received by Hayward partners, each MTC is a virtual classroom on wheels, allowing Hayward to bring our industry-leading training to the dealer.

Each MTC training trailer is fully plumbed, wired and specially fit with hands-on product demonstration, installation and training stations that provide insight to key Hayward and pool industry technologies.

With each unit hosting up to three training sessions a day, Hayward will be expanding our on-site train-ing stops throughout the West Coast, Midwest and New England areas in 2007. And of course, we’ll also be increasing our MTC appearances throughout the Southeast and Southwest as well.

“The MTC provides a great setting and wonderful tools for sales and service training,” said John Murray, Hayward National Training Manager. “If you’re a Hayward partner in the United States, one of our Mobile Training Centers will probably be making an appearance near you.

“If you’re interested in seeing what all the excitement is about, we encourage you to ask your Hayward sales or technical representative when and where the nearest MTC appearance will be. L-R: John Murray, Dennis Willis and Stan Taylor

work on the IDL2 heater station in one of the new Hayward Mobile Training Centers that will be hitting the highways in 2007.

Mobile Training Centers multiplying

Raised KEY in housing’s bearing well

(underside of cleaner housing)

Both the inner ring and outer ring of the turbine bearing have small notches which need to be aligned with the protruding “key” on the turbine shaft (pictured below left) as well as the protruding “key” molded into the turbine housing in the middle body assembly (pictured at right).

Properly aligning both notches to slide onto their respective keys when reassembling the middle body assembly will lock the bearing assembly into its correct position.

When performing routine maintenance involving the turbine bearings inside Hayward suction-side pool cleaners, please pay special attention to proper alignment of the turbine bearing assembly.

NOTE: If the turbine does not spin freely after reassembly, one or both of the bearing notches may be misaligned. When properly aligned, the bearing will slide snugly onto the turbine shaft and will never need to be forced onto the shaft. Likewise, when the outer notch is properly aligned a tight seal will be ob-tained (without force) when closing the middle body assembly, with the bearing assembly snugly encased inside.

Turbine bearings may be all black or red & white (as shown here).

If bearings do NOT spin freely after reassembly, the most likely culprit is improper bearing alignment restricting bearing movement, resulting in erratic cleaner performance and premature wear.

Technicians should pay particular attention to bearing alignment when replacing or servicing a turbine bearing kit or propulsion kit on the Hayward suction-side cleaners, including Navigator®, Pool Vac Ultra®, AquaBug®, Diver DaveTM, or Wanda the WhaleTM and older models.

HousingAlignment

Raised KEY on Turbine Shaft

The bearing (left) has a square-grooved inner notch that slides onto the turbine shaft key (above).

TurbineShaft

Alignment

FIVEPAGE

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Not Just Quality … Product ReliabilityQuality Assurance (QA) programs are standard

fare for manufacturers today, contributing to better product development, better manufacturing pro-cesses, and lower product costs.

Hayward takes these efforts a step further with an extensive “product reliability” program.

“While QA programs focus on products being made correctly,” explained Hayward Product Reliability Manager Doug Philhower, “our product reliability program goes beyond that, ensuring that Hayward products not only deliver superior perfor-mance, but that they in fact fulfill customer needs in the way we envisioned during product development.”

With the Tri-Star pump we recently introduced, for example, part of our product development pro-cess automatically launched early product reliability processes, including beta field testing many months before the product went to market,” Philhower said.

“We made numerous product improvements based on those tests – things likes motor modifica-tions, fastening system changes, and assembly and test process modifications.”

Continual assessment of the monitoring processes themselves is critical during early stages.

“We have to make sure we’re measuring the right things, and that we’re not overlooking factors that turn out to be more important than anticipated,” Philhower explained. “Certain aspects of reliability assurance are predictable and merely need to be monitored. It’s the dynamic aspects, the unexpected or atypical findings that you really have to look for.”

Numbers and charts aren’t enough in many cases. Those tools can call attention to unexpected occur-rences. To determine what’s really going on, however, may require digging a little deeper.

That’s why product and component failures go to engineering to be examined first. Hayward also employs an “Early Detection Field Evaluation” reli-ability program to quickly identify potential surprises. Hayward partners with key dealers around the country to help with the early detection program, in which dealers replace working units that have been up and running in the field, then ship those units to Hayward for thorough inspection.

The early detection program allows Hayward to spot problems that arise in “real world” usage – and to spot them before the products go to market.

“The goal with all of these product reliability programs,” Philhower said, “is to help us predict and prevent problems before they impact customers.”

Product Reliability Manager Doug Philhower inspects a bank of Tri-Stars in our poolside pump lab.

Splashback Quiz

Splashback winner gets TriStarDarlene at Creative Leisure in Davison, Mich., will be receiving

a brand new TriStar pump after being selected from all the correct respondents to last issue’s Splashback quiz.

Each issue, Hayward draws the name of one person who correctly answers all the Splashback Quiz questions, and awards that person a nice prize.

Be sure to enter this issue’s contest ... and encourage others in your store to enter as well. There’s no limit on how many people can enter from each business.

This issue’s winner will receive two prizes: a Jet Action Clean-ing Wand (EC2024) and a FunSpray water fountain (SP7410).

1. Why are today’s pumps more efficient than older pumps?A. Impeller design.B. Volute design.C. Engineering

improvements.D. All of the above.

2. What actions does a Stratum take when it senses an entrapment?A. Cuts power to the pump.

B. Breaks vacuum by injecting air.

C. Closes all suction valves. D. Only A & B.

3. The online warranty claim process helps our service centers by ...A. Saving time and money, reducing the turnaround time for

parts replacement.B. Allowing anytime access for filing or checking the status of

claims.C. Preventing incomplete claim submissions.D. All of the above.

Send your answers to:Splashback Quiz

Hayward Technical Services1 Hayward Industrial DriveClemmons, NC 27012

OR E-mail your answers to:Splash@Haywardnet.

“Putting the warranty claims process online not only saves Hayward and our servicers time and money,” Wagoner said, “it’s been efficiently designed so that it helps prevent servicers from accidentally submitting an incomplete form.

Wagoner said the online claim form has many dynamic safeguards built in – such as intuitive drop-down menus of acceptable answers based upon other selections entered.

For example, the online form cannot be submitted with missing serial numbers, model numbers and dates. Once a model number is entered, any serial number that is outside ac-ceptable ranges for that model will be rejected before the claim is submitted.

“Even those who may not be computer-savvy will quickly realize the time and money saved through online processing – not to mention the shorter time it takes to get replacement parts and labor payments.” Wagoner said. “Any system that helps prevent incomplete or incorrect claim submissions directly translates into servicers receiving their money faster.”

Over the last two years Hayward has invested many resources into improving the war-ranty claim process for our dealers. This online warranty claim process is another huge step in this effort, utilizing today’s latest technology solutions to reward our dealers for their loyalty and support.

Continued fromfront page

The winning name randomly selected from the correct entries in the Hayward Technical Challange at the Atlantic City Pool Show was Tim Leggour of ACQUA Pools in Midland Park, NJ. Hayward congratulates all of those who rose to the challenge and submitted entries.

For those keeping score, here are the 18 faults found on our Technical Challenge pool pad:1. Plumbing size too small for system

requirements.2. Suction line to pump too short.3. Plumbing into filter reversed.4. Flow sensor for cell installed in reverse.5. Booster pump inlet line plumbed in after

pump, should be after heater.6. Propane heater on a natural gas installation.7. Using non-CSA (or BTU sized/rated) flex

line.8. Natural gas meter too small for 400 heater.9. Heater not bonded.

10. Temperature sensor placed in heater outlet line

11. Line/load wires reversed on relay in PS8 for filter pump.

12. Booster pump suction/outlet lines reversed.

13. No GFI breaker on pool light.14. Teflon tape used in gas connection-not

gas approved.15. Actuator position incorrect, suction from

spa return to pool (draining spa).16. No ground wire on pool light.17. Booster pump wired @ 120V.18. No ground wire on heater.

Leggaur wins Hayward Technical Challenge in Atlantic City show

Warranty on the web

SIXPAGE

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