6
With the vacuum in place; all we need is atmo- spheric pressure. At sea level the atmospheric pressure on the surface of the water will be 14.7 psi (pounds per square inch). At 5000 feet above sea level, it will be 12.0 psi. This is why a pump at sea level will pull a prime at about 8 feet, while one installed at 5000 feet will pull prime at about 5 feet. Now that we have a vacuum and a vacuum wants to not exist, all we need to generate water flow is the atmospheric pressure, which pushes on the surface of the water. Therefore, with the vacuum and atmospheric pres- sure working in tandem, water from the pool rushes to fill the vacuum – creating a cycle that will continue unless we have a leak in the suction side that would eliminate the vacuum. Without the vacuum, a pump will loose prime and quit pumping water. Many people make the comment that “my pump lost prime and isn’t sucking water.” Well, believe it or not, a centrifugal pool pump does not suck water from the pool. A centrifugal pump uses two kinetic principles – atmospheric pressure and vacuum – to create water flow. Of course, it’s usually easier to tell customers that the pump “sucks” water from the pool, but there are times when it’s helpful to know the actual engineering principles that allow a centrifugal pump to be primed and pump water. To prime a pump, remove the lid from the pump pot (a.k.a. trap) and fill the pot with water. It will be impossible to fill all the way since the water will start flowing through the suction pipe. Replace the lid onto the pot and secure tightly. When the pump is turned on, the impeller will evacuate the water from the pump pot, creating a vacuum situation on the suction side of the impeller. will be 12.0 level will one inst about 5 Now vacuum w generate wate which pushes on Therefore, wit sure working in t p be rt o A su sq water o m lt Pump Up Profits Page 4 How Do Centrifugal Pumps Work? A technical publication for Hayward dealers and service providers —— Also Inside —— Troubleshooting the most common heater fault code: ‘IF’ pages 2-3 Tr m fa Vacuum & Atmospheric Pressure Create Water Flow Near-blizzard conditions couldn’t deter our training team. e shooting the e System Curve Provides Insight page 5 v System Cur r 5 most common pump ailments page 4 Mobile Training Centers Showcase Newest Products, Technology See ‘Mobile’ on page 6 In addition to MTC on-site training being highly personal and technically revealing, dealers have commented on the timely nature of key products and technology featured. A staggered schedule of regular maintenance stops allows Hayward to continually re- equip our trainers and the mobile units themselves with new products, new technology, and new state-of-the-art training tools. For example, new Hayward products recently joining the list of products and technologies our mobile units are equipped to spotlight include the Tiger Shark robotic pool cleaner by AquaVac and the Aqua Pod wireless, handheld, personal control unit (pictured at right) for AquaLogic™ systems by Goldline. With our three mobile With three Mobile Training Centers (MTC’s) now roaming the country, bountiful turnouts and positive responses are piling up for Hayward’s novel approach to field training. “The dealers have really appreciated having the training brought to their door,” said John Ott, western technical training manager. “They have been so impressed with every- thing about the training, immediately after finishing their training many Another packed class enjoys on-site training in our west coast Mobile Training Center. dealers turn around and ask to get on the schedule for our next visit.” Volume 4 Issue 2 SP708 If gas supply is insufficient, these are the most likely culprits to troubleshoot: 1. Too small a gas meter (natural gas); 2. Tank size too small or gas level too low (propane gas); 3. One or more gas valves (including the heater’s) are not turned ‘on’; 4. Gas feed line is not the right size (refer to charts in owner manual); 5. Lead pipe from meter or heater is wrong size (improper flex line or length); 6. Plugged gas line; or 7. Air was not bled from the line on a new installation. Inside, we review the keys to resolving an “IF” fault code in a single service trip. — Page 2 If l l ii Using a manometer, conduct Static and Load tests to verify that proper gas flow is reaching the gas valve. Then conduct a Manifold test to verify proper gas flow is exiting the valve. Verify proper gas supply Before troubleshooting and replacing parts on a pool heater, always verify that the heater system’s gas supply is properly functioning. One-Trip Heater Service

Splash - A technical publication for Hayward dealers and ... technical publication for Hayward dealers and service providers ... For openers, many technicians’ ... • Safety Routines,

Embed Size (px)

Citation preview

With the vacuum in place; all we need is atmo-spheric pressure.

At sea level the atmospheric pressure on the surface of the water will be 14.7 psi (pounds per square inch). At 5000 feet above sea level, it

will be 12.0 psi. This is why a pump at sea level will pull a prime at about 8 feet, while one installed at 5000 feet will pull prime at about 5 feet.

Now that we have a vacuum and a vacuum wants to not exist, all we need to

generate water flow is the atmospheric pressure, which pushes on the surface of the water.

Therefore, with the vacuum and atmospheric pres-sure working in tandem, water from the pool rushes to fill the vacuum – creating a cycle that will continue unless we have a leak in the suction side that would eliminate the vacuum. Without the vacuum, a pump will loose prime and quit pumping water.

Many people make the comment that “my pump lost prime and isn’t sucking water.” Well, believe it or not, a centrifugal pool pump does not suck water from the pool. A centrifugal pump uses two kinetic principles – atmospheric pressure and vacuum – to create water flow.

Of course, it’s usually easier to tell customers that the pump “sucks” water from the pool, but there are times when it’s helpful to know the actual engineering principles that allow a centrifugal pump to be primed and pump water.

To prime a pump, remove the lid from the pump pot (a.k.a. trap) and fill the pot with water. It will be impossible to fill all the way since the water will start flowing through the suction pipe.

Replace the lid onto the pot and secure tightly. When the pump is turned on, the impeller will evacuate the water from the pump pot, creating a vacuum situation on the suction side of the impeller.

will be 12.0level willone instabout 5

Now vacuum w

generate watewhich pushes on

Therefore, witsure working in t

p be rt

o

Asusq

water o

m l t

PumpUp

ProfitsPage 4

How Do Centrifugal Pumps Work?A technical publication for Hayward dealers and service providers

—— Also Inside ——

Troubleshooting the most common heater fault code: ‘IF’

pages 2-3

Trmfa

Vacuum & Atmospheric Pressure Create Water Flow

Near-blizzard conditions couldn’t deter our training team.

eshooting thee

System Curve Provides Insight page 5

vSystem Curr

5 most common pump ailments page 4

Mobile Training Centers ShowcaseNewest Products, Technology

See ‘Mobile’ on page 6

In addition to MTC on-site training being highly personal and technically revealing, dealers have commented on the timely nature of key products and technology featured.

A staggered schedule of regular maintenance stops allows Hayward to continually re-equip our trainers and the mobile units themselves with new products, new technology, and new state-of-the-art training tools. For example, new Hayward products recently joining the list of products and technologies our mobile units are equipped to spotlight include the Tiger

Shark robotic pool cleaner by AquaVac and the Aqua Pod wireless, handheld, personal control unit (pictured at right) for AquaLogic™ systems by Goldline.

With our three mobile

With three Mobile Training Centers (MTC’s) now roaming the country, bountiful turnouts and positive responses are piling up for Hayward’s novel approach to field training.

“The dealers have really appreciated having the training brought to their door,” said John Ott, western technical training manager. “They have been so impressed with every-thing about the training, immediately after finishing their training many

Another packed class enjoys on-site training in

our west coast Mobile Training Center.

dealers turn around and ask to get on the schedule for our next visit.”

Volume 4 Issue 2 SP708

If gas supply is insufficient, these are the most likely culprits to troubleshoot:

1. Too small a gas meter (natural gas);

2. Tank size too small or gas level too low (propane gas);

3. One or more gas valves (including the heater’s) are not turned ‘on’;

4. Gas feed line is not the right size (refer to charts in owner manual);

5. Lead pipe from meter or heater is wrong size (improper flex line or length);

6. Plugged gas line ; or

7. Air was not bled from the line on a new installation.

Inside, we review the keys to resolving an “IF” fault code in a single service trip.

— Page 2

If ll i i

Using a manometer, conduct Static and Load tests to verify that proper gas flow is reaching the gas valve. Then conduct a Manifold test to verify proper gas flow is exiting the valve.

Verify propergas supplyBefore troubleshooting and replacing parts on a pool heater, always verify that the heater system’s gas supply is properly functioning.

One-Trip Heater Service

(3,1) -1- Splash 708 v824.indd 8/24/2007 12:50:24 PM(3,1) -1- Splash 708 v824.indd 8/24/2007 12:50:24 PM

HP_Administrator
Typewritten Text
v824

Sequence of Operation: 5 systems in 1

TWOPAGE

Heater service calls invariably present the biggest diagnostic drain on pool technicians’ time. Consequently, efficient heater diagnostics and repairs represent the big-gest area of opportunity for most pool technicians to improve profit-ability – simply by reducing time spent on the work they do.

For openers, many technicians’ first on-site heater service call is spent simply diagnosing the problem. After a trip back to the shop to pick up (or order) the necessary replacement parts, technicians then return to the pool site, frequently more than once, to complete repairs and repeat diagnostic routines to ensure that the heater issue has, indeed, been resolved.

Bottom line: Technicians armed with the Hayward heater fault code and the right tools (see story at left) can usually resolve heater issues with a “one-trip service call.”

To properly service a heater system, techni-cians must first understand that each heater system is actually an integrated combination of five different systems:

1. The Gas system (natural or propane) 2. The Water Path system 3. The Venting and Clearance system 4. The Electronics system 5. The User Interface system

These five systems are tightly intertwined with each other to form a single “Sequence of Operation.”

The precise Sequence of Operation (and corresponding Troubleshooting Sequence) varies somewhat from one heater to the next – though each Sequence is always governed by a logical sequence of priorities.

Those priorities can be grouped into three categories:

• Safety Routines, • User Commands, and• Command Overrides.Safety is always the top priority, therefore tasks

ensuring safe operation are usually addressed first overall and first within each stage of the Sequence of Operation.

Meanwhile, user commands are generally the last priority, with override routines occurring before a com-mand is actually executed.

Override routines prevent or delay execution of user commands that do not need to be, or should not be, executed.

For example, if a user command instructs the heater to fire up and raise the water temperature to 65°, an override routine would prevent* any action if the water temperature is already higher than 65°.

*In this case, the override would prevent or delay the action until the temperature dropped below 65°.

Hayward introduced heater fault codes with the IDL series, and has continued to refine and expand auto-mated diagnostic capabilities with the ED2 and IDL2 series – though the most essential, or core, fault codes are fairly consistent among all of Hayward’s electronic

gas heaters. These fault codes provide technicians two powerful benefits:

1. They help technicians instantly and accurately pinpoint the precise source of heater problems, and

The fact that five different systems are actually woven into a pool’s heater system probably explains why some other heaters lack this type of comprehen-sive diagnostic panel. That also explains why the automated LED panel displaying these fault codes is such a valuable aid found on Hayward electronic gas heaters.

2. They help minimize service calls, greatly facilitating “one-trip service calls” for even the most problematic heater issues.

By simply having pool owners read to them the fault code displayed on the heater, technicians can know what parts and repairs are likely needed before ever visiting the pool site (see example in adjacent story). This step greatly improves the technician’s chances of resolving the heater problem on a single service call.

NOTE: Technicians can encourage pool owners to read the fault code to them by informing them it could greatly reduce the amount of time (and cost) it takes to troubleshoot and resolve the issue.

In addition to speeding up the heater repair process, Hayward heater fault codes also improve accuracy and efficiency by helping pinpoint the source of heater problems. Experienced heater technicians can attest to the value of this benefit, because the amount of time and resources wasted can escalate much quicker with improper heater diagnostics (and faulty repairs) than with any other service area.

mply having pool owners read to them the fault splayed on the heater technicians can know

Speed, accuracy both improve

TrLED panel is tech’s best friend

most rrofofitit--me

nns’s

nd re that

n resolved.ed with the Hayward heater

se iries – araree fafairirlyly

gas hetwo p

1 1. T Taccsou

2. Tcsp

code disBy sim

code dis

SpeeSpeeElectronic Gas Valve

Recognizing there was a tremen-dous opportunity to improve our dealers’ profitability, our engineers worked out a method to equip Hay-ward heaters with a digital system of diagnostic codes (fault codes) that identify the specific source of any interruption in heater operation.

er service calls invariably present the biggest ddrarainin oonn popoolol ttecechnhniciciaiansns’ titimeme.. CCononseseququenentltly,y,

Hayward introduced heater fault codes with the IDL seseririeses,, anandd hahass cocontntininueuedd toto rrefefininee anandd exexpapandnd aaututo-o

Heatenonoststicic

Hayward Fault Codes EnaPlease send comments or suggestions to:

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

or e-mail us at:[email protected]

SP708

© Hayward Pool Products, Inc., 2007

rManometer,Multimeter

“One-Trip Service Calls” start with having the pool owner read to you the fault code displayed on the heater’s LED display (on the operation panel).

In addition to the standard assort-ment of wrenches, wire strippers and other tools, a heater technician’s toolbox must be equipped with a manometer and multimeter for measur-ing gas supply and electrical voltage levels, respectively.

A manometer is particularly critical, as 60% of all heater calls involve the gas system.

Toolbox essentials:

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

Supplemental details & precautions may be omitted, so always consult product owner’s manuals and other technical publications for complete details and procedures.

Manometer

Fault Code Provides Starting Point

Each heater’s Troubleshooting Sequence is based on its unique Se-quence of Operation, and can be found in the heater’s owner manual.

Technicians can obtain heater owner manuals directly from Hayward – or ac-cess these items online at www.haywardnet.com.

PAGEP

five diffferent systems:

1. The Gas systtem (n 2. The Water PPath sys 3. The Venting and C 44. The Electronnics sys 5. The User Intterface

Theese five systems are tigwith eaach other to forrm a sinOperattion.”

Thee precise Sequeence of correspponding Troublleshootvaries ssomewhat fromm one hethoughh each Sequencce is alwogical sequence of prrioritieslogical

ovides

ce e-d can bener manual.n heater owner ayward – or ac-t www.haywardnet.com.

Multimeter

Se

e facinto

omeiagnmatuch hea

ng tu tyunityfitaba mrs wtic cify trup

S

eTheeTen wove

oy soowhyde ddsivemutomauus suuissgassg

nizinnRecogniuo tuudous oppo uortuudous oppofroffdealers’ paut aworked ouraterrward heatosttof diagnoientiithat iderterrrany int

ur-

Manometerrr

Fault codes provide technicians a starting point to use with each heater’s unique Troubleshooting Sequence.

ndnd

trip

(1,1) -2- Splash 708 v824.indd 8/24/2007 12:52:55 PM(1,1) -2- Splash 708 v824.indd 8/24/2007 12:52:55 PM

Using one of the most common heater fault codes – “IF” – the following IDL2 example illustrates how the fault code and proper tools (see story at far left) allow technicians to accomplish the “One-Trip Service Call.”

A pump comprises two main components: the drive end (motor), and the wet end (which handles the water).

Homeowners often use these terms interchangeably – not knowing any better – so when speaking with an owner, clarify whether they are referring to the motor and electrical operation or the wet end.

Often referred to as the Insufficient Fuel code – since the most common reason for an “IF” code is inadequate gas supply to the heater – the Ignition Failure code actually occurs any time the heater passes all safety checks but the heater fails to ignite.

Without the proper gas/air mixture, the IDL2 will not light. Since the heater has gone through most of the steps within the Sequence of Operation, the problem is most likely gas supply or a faulty ignition board, flame sensor, ignitor or gas valve.

Many a gas valve has been needlessly changed resulting in no improvement – and frustration for service technicians, who should be aware that the statistical chance of a gas valve being faulty is less than 1%.

TO ACCOMPLISH A ONE-TRIP SERVICE CALL WITH AN IF CODE, be sure to bring a properly equipped toolbox (see story at far left) and the following items – as they are the items that may need to be replaced:

1. Ignitor 2. Flame Sensor 3. Gas Valve 4. Ignition Board

THREEPAGE

HaexpHa

exp

FIRST, VERIFY PROPER GAS SUPPLY

When “IF” appears on the LED panel the first thing we want to do is determine if the gas valve or gas supply is the culprit. So, as summarized on the front page, verify proper gas supply. All heaters should have minimum, maximum and mani-fold gas pressures listed on a data label affixed to the heater. If this label is not avail-able, refer to the heater’s operation and troubleshooting manual. Past Splash articles (available online at Haywardnet.com) have also addressed gas-testing procedures, including illustrated examples of manometer hookups for the following tests.

First, with the gas valve closed and your manometer attached to the incoming side of the valve, determine the STATIC gas pressure. This reading should be at or below the maximum listed gas pressure.

Then, with the same setup, try to fire up the heater to obtain the LOAD reading (the gas valve should stay open 4-6 seconds even if the heater does not fire – long enough for the manometer to obtain a “load” reading).

Load pressure should stay below the maximum listed gas pressure and at or above the minimum listed gas pressure. If these readings exceed the maximum or fall below the minimum, the problem is with the gas supply to the heater. If the readings are within minimum and maximum thresholds, the incoming gas pressure has been confirmed as correct.

Finally, move the manometer to the manifold side of the valve. Try firing the heater and note the MANIFOLD pressure reading when the valve opens.

A clicking sound should be audible when the valve opens. If the gas valve does not open, grab a voltage meter or multimeter and test for voltage at the gas valve during the ignition sequence. Attach the voltage meter leads to the white and orange wires on the gas valve (see photo below). Set the meter to test for 24vac (volts AC) and attempt to fire up the heater again.

If the meter confirms proper voltage (24vac, ±10%) during the ignition attempt, the gas valve is faulty. Replace the valve and recheck.

If the test reveals no or low voltage at the gas valve, then thoroughly check the wiring between the valve and the ignition board for any breaks, burn-outs or bad

The motor mounting plate, which may or may not be a separate part but is the interface that connects the wet end to the motor.

The impeller, which rotates, accelerates the movementof water, and is threaded onto the motor shaft.

The pump seal assembly, which seals the wet end and the motor, preventing water from leaking into the motor and destroying the front bearing.

The diffuser, which collects and channels the evacuated air and water

1. Remove and clean all orifices on the manifold.2. Check all burners for spider webs or other obstructions.3. Make sure all air orifices are open and unobstructed.

If the “IF” code persists and the heater does not light, the ignitor needs to be checked, beginning with connections between the ignitor and ignition board. If the connections are OK, remove the ignitor for testing. Look for breaks or corrosion while removing the ignitor. If corrosion is found, clean it off, and reinstall the ignitor.

To test the ignitor, set the multimeter to test ohms, then place one lead on the ignitor

connection and the other to ground. The IDL2 ignitor should register between

10.9 and 19.7 ohms at 75oF (room temperature). If the

ohms reading is out-of-range, replace the ignitor and recheck.

If the heater fires but immediately shuts down, flame recognition could be the problem. As with the igniter, check the wire and connections. Remove the flame sensor, checking for breaks or corrosion. If necessary, replace the flame sensor and recheck.

To ensure there are no internal problems within the heater that could be affecting the performance of the ignitor and flame sensor, make sure there are no water leaks from the exchanger that could be compromising these parts.

If the source of our heater problem is still undetermined at this point, it’s time to look at the ignition board as the possible suspect. It often is not easy to see a problem with the ignition board, so carefully check all connections on the board for broken, burned or missing parts. The board may need to be replaced to determine if that indeed is where the problem exists. Be observant as the problem could be something not easily seen. This is what separates the everyday technician from the expert.

wwill not light. Sincce the heater has

IF (Ignition Failure)

All centrifugal pool pumps have the same fundamental design. The way the pump connects to the motor may be different, along with volute specs and assorted features – but the list of essential components are virtually identical among pumps. They include:Voltage

Test

connections (on the ignition board as well as the gas valve). If no wiring or connection problems are found, replace the ignition board and recheck.

If the gas valve reading is not cor-rect, refer to the IDL2 manual for details on adjusting the gas valve.

Never adjust the gas valve if mini-mum and maximum inlet readings have not been confirmed as correct.

ms –

termine age, mani-ot avail-h articles ures,

To test the ignitor, setest ohms, thenn place one

connectioon and the oIDL2 ignitor sho

10.9 an(room

ohmrep

Iflame recogniition couldand connectionss. Removecorrosion. If neecessary, re

To ensure theere are no i

IDL2 Ignitor

Ignitor Test

(NOTE: Parts of this gas valve were maskedto enhance clarity of the Voltage Test setup.)

tooblem n, at thing

Flame Sensor

Using one of the most commmon heater fault codes – “IF” – thee following IDL2 examplle illustrates howw the fault code and proper tools (seee story at far

Troubleshooting the Most Common Code: ‘IF’ Hayward

IDL2 heater

Hayward

IDL2 heaterTROUBLESHOOTING BEYOND GAS SUPPLY

After verifying proper gas supply, perform the following steps to ensure that gas flow is unobstructed:

Troubleshooting the Most Common Code: ‘IF’ dddddHaywardHaHaHaHaHaywywywywywywwararararararrdddddddHayward

able One-Trip Service Call

A pump comprises ttwo wo mmain components: the drive end (motor), and the wet end (which handles the water)

Pump Primer

(2,1) -2- Splash 708 v824.indd 8/24/2007 12:52:55 PM(2,1) -2- Splash 708 v824.indd 8/24/2007 12:52:55 PM

Following are the five most common conditions for techni-cians to consider when evaluating pump failures.

First verify that the pump is not too large for the system.Then, using a multimeter, verify that the incoming volt-

age to the motor is correct. If the voltage is OK, consider that most motors have an internal thermal overload that will turn the pump off if it gets too hot. This can be caused by improper voltage, bearing failure, or restricted ventilation.

Many times the motor will shut off and start back up after cooling down. Improper voltage and hard-turning (worn) bearings will cause excessive amp draw, thus caus-ing the excessive heat. If left unchecked, these conditions can lead to motor failure.

INTERMITTENTMOTOR OPERATION

PROBABLE INDICATORS: Pump shuts off intermittently

PROBABLE CAUSES: Improper voltage, worn bearings

or oversized pump (too large for system) (All three can lead to excessive amp draw.)

FOURPAGE

Following are the five most common conditioons for techni-ans to consider when evaluating pump failuress.

Five Most Common Pump Ailments VACUUM LEAK

PROBABLE INDICATORS:Air bubbles in pump basket (pump loses prime)

PROBABLE CAUSES:Strainer lid o-ring (gasket) failure ... or suction-side plumbing leakAs long as the skimmer and other points along

the suction line are free from debris and the pump and plumbing are sized correctly, the pump basket should be filled completely with water. If air bubbles are observed in the basket, there may be a suction-side vacuum leak.

The most common cause is a bad strainer lid gasket (o-ring). This o-ring seals the top of the pump strainer and aids in creating a vacuum so the pump can draw water. If this seal is compromised, air is drawn into the basket and makes a full prime almost impossible. If not corrected, this condition can lead to seal failure.

If the o-ring looks to be in good condition and has not lost its elasticity, applying some lubricant (we recommend Jack’s 327) may fix the problem.

Another possible cause could be a slight break (vacuum leak) in the suction-side plumbing.

A great service trick for locating a suction leak above ground is to run water from the garden hose over each section of exposed suction-side plumbing. Once water hits the leak, the pump should start priming (a decrease in the pitch of the motor will likely be audible as well). NOTE: Be careful not to accidentally spray water onto the motor!

There are many places for air to enter the suction side. These are the most likely conditions:

1. Water level in the pool is too low – causing the skimmer to suck air.

2. The o-ring (gasket) for the pump strainer lid (pump pot) is bad.

(In this scenario, the gasket needs to be lubricated or may need to be replaced and lubricated.)

3. Stem or cover leak on suction valve.4. Suction-side plumbing fitting is loose or

warped from heat.5. Cracked pipe.6. A leaky condition with any item attached

within the suction-side plumbing.Once the location is determined, perform neces-

sary repairs.

MOTOR BEARING FAILURE

PROBABLE INDICATORS: Loud, grinding or clanking noise

– though this could also indicate the cooling fan is loose, OR water is leaking into the motor

PROBABLE CAUSES: Seal leak … or normal wear on bearings

With pools becoming more automated and owners not visiting the pool pad on a regular basis, seal leaks can go unnoticed for quite a while. If audible telltales go undetected, problems are often left unat-tended, causing pump motors to eventually seize.

Therefore, technicians should encourage owners to occasionally visit the pad and listen for any unusual sounds – sounds that may prompt proactive mainte-nance measures to prevent damage (or further dam-age) to the motor and subsequently the entire pump.

Loud noises, particularly grinding, usually indicate the motor bearings are failing. However, since it is impossible to know if a bearing replace-ment alone is enough to fix the problem, the more practical step financially is to simply replace the pump motor – an action that will prevent the worst-case scenario, a motor failure that is catastrophic to the entire pump.

SEAL FAILUREPROBABLE INDICATORS:

Water leaking from pump volute or housingPROBABLE CAUSES:

Debris, overheating, or other damage to sealMany seal failures can be traced to construction

debris which prevented a proper seal from forming because the debris was not flushed out prior to startup in a new installation.

Most pumps have a two-piece pump seal or pump seal assembly that prevents water from reaching the motor. One portion of the seal is mostly carbon and the other is ceramic. As one surface rotates against the other, a watertight seal is formed. Then, as long as the seal stays well lubricated and cooled with water, the pump will retain the seal for a good long life.

However, if the pump operates with insufficient water, impeller friction will heat up and boil away any water left in the pump housing.

As that water boils, it evaporates as steam instead of cooling the pump. As a result, heat builds up even more, weakening the seal, which eventually fails.

Prolonged exposure to this condition could eventually:A. melt the pump basket (beyond recognition in

severe cases), andB. melt threaded fittings, causing water leaks to

develop at the discharge port.When seal failure is detected, both pieces of the

seal must be replaced. On Hayward (and most other) pumps, the ceramic part is closest to the motor and the carbon is closest to the impeller. Prior to reassembly, it is important to clean each surface with a clean cloth so that they are free of dirt and grease.

Hayward TriStar pump exploded parts diagramHayward TriStar pump

exploded parts diagram

away from the impeller, creating a vacuum which makes water flow possible.

NOTE: Above-ground pumps do not have a diffuser, which is why they must be lower than the water level and is why they are called “flooded suction pumps.”

As that water bboils, it evapoooraof cooling the pummp. As a ressultmore, weakening tthe seal, whiccch

Prolonged expoosure to this connndA. melt thee pump basket (((

severe ccases), andB. melt thrreaded fittings, c

develop at the dischargWhen seal faiilure is detected

seal must be replaaced. On Haywpumps, the cerammic part is closescarbon is closest too the impeller. is important to cleean each surfacethat they are free oof dirt and grea

DEAD MOTOR ORINCONSISTENT MOTOR

PROBABLE INDICATORS: Dead or humming motorPROBABLE CAUSES: Incorrect voltage or starting capacitor failure

A humming motor could indicate a bad starting capacitor or incorrect voltage.

Using a multimeter, first verify that the incoming voltage to the motor is correct.

Then, with the power off, try to turn the motor shaft from the back of the motor. If the shaft will not turn, the bearings may be seized, which means the motor probably needs replacement.

If the shaft easily turns, the most likely culprit is the starting capacitor (if there is one). If a new starting capacitor does not resolve the issue, then the motor windings are most likely bad, which means the motor needs to be replaced.

Finally, the most familiar (to the pool owner) part of a pump

is the strainer basket, which traps debris to prevent it from clogging

the impeller.

c

P

P

(3,1) -2- Splash 708 v824.indd 8/24/2007 12:52:55 PM(3,1) -2- Splash 708 v824.indd 8/24/2007 12:52:55 PM

FIVEPAGE

System Curve Gives InsightTo Hydraulic Fingerprint

HEALTHYHYDRAULICS

Healthy Hydraulics examines the principles, challenges and techniques for installing and

maintaining healthy hydraulic systems.

System CurveThough not pragmatic because of the time

it would take installing and removing pumps, it is possible to measure the actual performance (GPM) for each pump (in a pump family) on a given system. Overlaying the results on a chart with those pumps’ pump curves would give us a SYSTEM CURVE (see adjacent charts).

Every system has its own system curve – a unique fingerprint – yet all system curves share some common characteristics. Most notably, observers will notice that system curves run perpendicular to pump curves.

This perpendicular relationship is particularly useful in illustrating two important points.

First, as illustrated in system curves chart B, increasing or decreasing pipe diameter has a profound impact on system performance.

Second, as the magnified section of a system curve in the adjacent chart C shows, obtaining a relatively small per-formance gain with an oversized pump comes at quite a price!

Aside from being more expensive, larger pumps dramatically increase elec-tric bills and system head pressure.

In fact, the upward curve illustrates that as pump size increases, the system’s dynamic head increases at a faster rate than the pump’s flow rate – leading to potential pump cavitation, premature wear and damage to the pump and other system components.

This point is extra important for Cali-fornia pool technicians/installers whose systems must comply with stringent Title 20 pump efficiency regs.

System Curve

LEARNtheLINGO

Like fingerprints, every pool & spa circulation system is unique.The cumulative length, diameter and type of pipe varies from one system to the next – as does each sys-

tem’s unique assortment of pipe fittings and limitless combination of elements connected by all this piping.Most of these elements restrict or

reduce water flow to some degree. Collectively, the cum-ulative impact of these restrictions can be calculated or estimated, and is collec-tively referred to as the system’s total dynamic head (aka friction loss / resistance to flow).

To offset the cumulative restric-tions and generate enough water flow for the system to function, the system needs a pump ... and for the system

and its components to function properly, the pump needs to be the correct size for that particular system. Using too small of a pump can prevent adequate water turnover, while using too large of a pump will strain

the system and its components, leading to poor performance, frequent repairs and shortened life expectancy. Previous editions of Splash

(available online at Haywardnet.com) have detailed how to select the right size pump.

Three general concepts are key to understanding the selection process.

First, a system’s dynamic head (resistance to flow) increases as components are added ... OR as pipe size is reduced (see adjacent Chart B).

Second, as dynamic head increases, a pump’s performance (GPM) decreases.

Finally, selecting the right pump is a simple matter of calculating or estimating the system’s dynamic head and the optimum GPM for system performance. Then, using pump curves (published by pump manu-facturers), find the point where those two figures (dynamic head and GPM) intersect, and select the pump whose curve comes closest to that intersection.

When that intersection of the system’s head and optimum flow falls between two pump curves, rounding up to the larger pump may be a good idea, allowing for occasionally dirty filters and modest system growth (see Chart A above). But never round up too far, for selecting too large of a pump can have harsh effects on the pump and other system components – particularly on systems with smaller pipe sizes.

(1,1) -1- Splash 708 v824.indd 8/24/2007 12:50:24 PM(1,1) -1- Splash 708 v824.indd 8/24/2007 12:50:24 PM

Send your answers to:Splashback Quiz

Hayward Technical Services1 Hayward Industrial DriveClemmons, NC 27012

OR E-mail your answers to:[email protected]

SIXPAGE

units, this spring we were simultaneously able to tour the northeast, southeast, southwest and west. Together, our fleet attended each region’s major pool shows and racked up more than 200 seminars during the first quarter.

With Ott at the helm, our newest MTC circuit included a nine-month tour through the states of Texas, Louisiana, Oklahoma, New Mexico, Arizona, Nevada and California.

Providing customized training sessions for each region and each audience, the west coast mobile unit racked up dozens of seminars with distributors, deal-ers, and builders – not to mention dozens of industry association meetings and trade show appearances in that inaugural western voyage.

Each MTC typically conducts four to six on-site seminars every week on the road. Dealers and dis-tributors are encouraged to call their local Hayward representative and reserve seat(s) in the next MTC training session in your area.

Continued from front page

1. Why are today’s pumps more efficient than older pumps?D. All of the above.

2. What actions does a Stratum take when it senses an entrapment?

D. Only A & B.

3. The online warranty claim process helps our service centers by ...D. All of the above.

Quiz Answers(for last issue)

Contest Winner to Get Choice: Manometer or Multimeter

Sun Devil grows with ‘Hayward credibility’When industry veteran Craig Broderick opened his own store five years ago, he

envisioned a three-prong approach to distinguish Sun Devil Pool Supply from the eclectic mix of mom-and-pop stores dotting the Phoenix landscape.

First, Broderick said, “We wanted a clean, professional look to the store – a consistency through-out the inside and outside of the store – like you would find in a franchise store.”

Second, he said, “To draw customers into the store, we stocked the shelves with lots of fun, recreational pool toys – competitively priced toys you can’t find at the grocery store.”

And finally, he said, “Instead of sending a mixed message with pumps and filters from lots of different manufacturers, we chose one line, Hayward, to be our primary line for pool system equipment.

“Making Hayward our full line brands us, gives us credibility. When consumers see us, they see the Hayward name, and everything Hayward represents. What they don’t see,” Broderick said, “is a smorgasbord of pumps and filters, like you find at most the mom-and-pop stores. All that variety is confusing to customers, and is also costly to stock.”

With Broderick’s clean, con-sistent approach, Sun Devil was instantly successful and quickly expanded to five stores … with two more on the way. Sun Devil also

recently joined a local buyers’ group (Arizona Pool Dealers Association), whose 16 mem-bers are primarily Hayward platinum dealers, allowing them to pool resources and

Hayward Pool Products cannot endorse specific independent dealer business prac-tices shared in Splash, but we encourage readers to view this publication as a dealer forum for sharing service tips and business success stories.

realize other economies of scale for training and advertising as well as product purchases.

“We use the group advertising for brand awareness. We do our own advertising to target potential customers for each of our stores – and get a

lot of help from Hayward on that, too,” Broderick said.

“In fact, Hayward has worked with us in so many ways, they’ve been a great resource for us,” Broderick said. “Their customer service, sales and tech people are very attentive, providing insight and answers whenever we need them. The support they provide us helps keep our people from getting bogged down in unproductive matters,” Broderick said.

“There’s no question, a great relationship with Hayward is one reason we’ve been successful and have grown as quickly as we have.”

Share Your Wisdom!Do you have a great time-saving tip or pearl of

wisdom you’d like to share with other technicians? This is your opportunity to share your insight and be published in a national trade publication. Send your idea to us at

Tech Tip Hayward Technical Services 1 Hayward Industrial Drive Clemmons, NC 27012

OR E-mail your idea to [email protected].

Sun Devil owner & GM Craig Broderick

Glen Butler of Fiesta Pools & Spas in Jamestown, N.Y., won a TriStar pump as the winner of our Splashback Quiz in the previous edition of Splash. Butler’s name was ran-domly selected from among all the correct entries submitted for last issue’s contest.

This issue’s contest is printed below, and the winner will receive their choice of a manometer or multimeter. As the prizes suggest,

readers may improve their chances of answering all the questions correctly by absorbing all the

valuable troubleshooting, maintenance and repair information regarding heaters

and gas supply presented in this issue.There are no entry limitations, so en-

courage everyone in your shop to enter by submitting their answers to the postal ad-

dress or e-mail address listed below.,

the questiovaluable and repap

and gas suThere a

couragge evesubmitting

dress or e-maa uggesst,

Splashback Quiz1. What is the first step in reducing heater service calls to a single trip?

A. Including a manometer and multimeter in your toolbox.

B. Getting the customer to tell you what fault code is being displayed on the heater.

C. Using the fault code to determine what parts may need to be replaced on site.

D. All of the above.

2. What tool is needed to determine if a pump is receiving proper voltage?A. Manometer.B. Magnet.C. Multimeter.D. All of the above.

3. Which of the following will have the most positive impact on a pool system’s hydraulic performance?

A. Oversizing the pump to accommodate potential system growth.

B. Increasing pipe diameter throughout the system.C. Installing a pool heater on the suction side of the pump.D. All of the above.

units this spring we were simultaneously able toContinued from front page

Mobile Training

(2,1) -1- Splash 708 v824.indd 8/24/2007 12:50:24 PM(2,1) -1- Splash 708 v824.indd 8/24/2007 12:50:24 PM