Hayward Pool Chlorinator Problems: Troubleshooting & Maintenance Guide

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The Hayward pool chlorinator, whether salt chlorine generator or inline feeder, helps maintain clean and sanitized pool water. But despite its simplicity, problems can arise—like low chlorine output, scale buildup, salt cell failure, and control panel errors. These issues, if unchecked, lead to cloudy water, algae growth, or damage to your pool system. This detailed guide covers common chlorinator issues, clear troubleshooting steps, and best maintenance practices to avoid unexpected breakdowns and keep your pool healthy year-round.

How Hayward Chlorinators Work

Hayward produces both salt chlorine generators (HCC series) and traditional inline feeders. Salt systems convert dissolved salt into chlorine via electrolysis in a salt cell. Inline feeders release chlorine tablets or granules into the flow. Both require accurate flow, proper voltage, and clean components. Most problems stem from malfunctioning salt cells, poor flow, electrical faults, or scaling.

Table of Contents

1. No or Low Chlorine Output

Answer: If your chlorinator is active but producing little to no chlorine, check salt levels, cell output, water chemistry, or flow issues.

  • Salt concentration: Must match recommended levels (typically 2700–3400 ppm). Test weekly with a digital meter.
  • Clean cell: Scale buildup reduces output—clean with acid per manufacturer directions.
  • Water chemistry: Imbalanced pH, low calcium hardness, or high phosphates impede chlorine production.
  • Flow pressure: Use the pump and valves to ensure strong circulation through the cell.

Fix: Adjust salt levels, balance water chemistry, boost flow rate, and clean cell plates to restore output.

2. Control Panel Error Codes

Answer: Hayward control panels display codes when issues occur. Common ones include FLO, LOC, HCL, and OL.

  • FLO – Flow alarm: Clean flow sensor, remove airlocks, and confirm proper circulation.
  • LOC – Lockout due to low salt or cell problem: Refill salt and inspect cell.
  • HCL – High chlorine: Usually a false alarm—check residual and reset panel.
  • OL – Overload: Electrical short or cell failure—inspect wiring and cell integrity.

Action: Refer to your manual for code translation, fix the cause, then reset the unit to clear errors.

3. Scale on Salt Cell Plates

Answer: Calcium and minerals build up on cell plates, interfering with electrolysis.

  • Inspect cell visually: Cloudy or white build-up indicates scaling.
  • Descale safely: Soak in a mixture of 1:4 muriatic acid and water. Rinse thoroughly after.
  • Use pre-filter: Reduce minerals entering the cell by adding a phosphate or scale inhibitor cartridge inline.
  • Balance calcium hardness: Maintain shim to 200–400 ppm to limit scale buildup.

Tip: Clean scaling every 3–4 months depending on water hardness and usage.

4. Flow Sensor & Pressure Problems

Answer: Chlorinators require sufficient flow through a flow sensor to operate. If flow is insufficient, the unit shuts off as a safety precaution.

  • Clean flow switch: Remove debris by flushing or removing the sensor for cleaning.
  • Check valves: Verify suction/fill valves and return valves are fully open.
  • Remove air pockets: Bleed air by backwashing or running pump with bleed valve open.
  • Pump strength: Lower pump speed or clogged impeller may reduce flow—clean impeller and return lines.

Reminder: Never force the chlorinator on with low or no flow—it risks overheating or tripping safety.

5. Salt Cell Doesn’t Age Properly

Answer: Salt cells degrade over time and lose effectiveness.

  • Track cell life: Hayward cells typically last 3–5 years. Monitor amp output and efficiency.
  • Watch for pitting: Check for pitted, eroded plates which require replacement.
  • Test voltage/amperage: Use a multimeter to confirm proper electrical output at the cell terminals.

When to replace: If efficiency drops by 30% or error codes persist after cleaning, it’s time for a new cell.

6. Electrical Failures & Power Issues

Answer: Power supply faults, wiring corrosion, or short-circuits can impact chlorinator function.

  • Inspect wiring: Look for corroded or loose wire connections from the power module to the cell.
  • Replace power module: Signs of overload, heat damage, or smell often indicate smart board failure.
  • Check GFCI fault: Reset and test GFCI outlet regularly.

Pro tip: Ensure all wiring is weatherproofed to avoid moisture intrusion.

7. Salt Spills & Corrosion

Answer: Salt is corrosive—spillage around chlorinators can damage plumbing and equipment.

  • Check plumbing for corrosion: Replace fittings or manifolds showing pitting.
  • Clean spill areas: Rinse with fresh water and dry to neutralize salt residue.
  • Upgrade fittings: Use corrosion-resistant PVC and stainless steel hardware rated for salt environments.

Tip: Treat piping and valve components with sealant to resist salt corrosion.

8. Routine Maintenance Tips

Keeping your chlorinator in top shape depends on routine upkeep. Here are key maintenance tasks:

  • Weekly: Test salt/Cl levels, inspect control panel for alarms or salt creep.
  • Monthly: Clean flow sensor, balance water chemistry, rinse cell to remove surface scale.
  • Quarterly: Deep clean cell plates, check amperage, and inspect wiring/valves.
  • Annually: Replace salt cell if output drops and conduct a full system inspection including piping and seals.

Pro tip: Document dates of salt additions, cleanings, and cell swap outs to track maintenance intervals.

9. Winterization & Shutdown

Answer: Proper winter prep preserves your chlorinator during idle months.

  • Drain salt cell or blow out with air hose.
  • Disconnect power and store module indoors to prevent moisture damage.
  • Cover connection points: Seal cable entry points against insects and moisture.
  • Resume process in spring: Check all components before refilling and restarting.

Conclusion & Next Steps

Hayward pool chlorinators reduce chemical handling and keep pools sanitized—but issues like low output, scaling, sensor faults, and salt corrosion can limit performance. Begin troubleshooting by verifying salt level, flow rate, and water balance. Clean the cell, inspect wiring and fittings, and track salt cell life to maintain efficiency. Coupled with regular maintenance, these steps can help avoid surprises and downtime, ensuring your chlorinator delivers reliable performance.

Need help interpreting a control panel code, finding a replacement cell, or understanding maintenance frequency? Drop a comment below or subscribe for expert walkthroughs, lifeless tracking tools, and pro tips designed for Hayward chlorinator owners.


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