Hayward AquaLogic Troubleshooting Manual Download

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ProLogic: Main PCB Layout

Remote DSP comm (RS485 – 10VDC)

Temp sensor terminal block (5VDC)

Heater 1&2 terminal block (dry contacts)

Valves 1-4 & 4Amp fuse ( 24VAC)

Cell Plug for chlorination

High Voltage Relays (top – Filter, Lights,
AUX1, AUX2; bottom (AUX 3-6).

Flow Monitor (flow switch connector)

Transformer Input (120VAC X 2)

System Input Power (120VAC from breaker)

Rectifier input (24VAC for Chlor. circuit)

Transformer Output (24VAC)

20Amp Fuse (protects Chlor. circuit)

Rectifier Output (18-33VDC – Chlor. circuit)

Sense & Dispense output (120VAC)

Local Display power (11VDC)

Plugs for accessory equipment (11VDC)

Transformer

Rectifiers

Air/Water Sensor

Summary of Contents for AquaLogic

Page 2: ...zardous voltage can shock burn cause serious injury and or death To reduce the risk of electrocution and or electric shock hazards Only qualified technicians should remove the dead front Replace damaged wiring immediately Insure panel is properly grounded and bonded ...

Page 3: ...ean the Turbo Cell 13 15 Troubleshooting Pg 16 43 ProLogic vs AquaLogic SKUs 17 1 No Cell Power Low Volts 18 20 2 Blank Display 21 24 3 CSM Comm Error 25 27 4 Chlorinator Off High Salt Amps 28 31 5 Comm Error 1 or 2 32 34 6 Heater Not Firing 35 38 7 Auxilariry Not Running 39 43 Additional Information Pg 44 50 Cell Compatibility Chart Air Sensor Chart 45 46 Salt Addition Chart Chlorine Output 47 49...

Page 4: ...d Pumps ColorLogic Lighting Sense Dispense AquaConnect Homenet as well as a wide variety of remotes The panel features an 8 slot 100amp subpanel Equipment can be programmed to run off daily schedules and or based on manual commands Equipment such as heaters can be programed to operate only on demand Safety features such as interlocks and freeze protection can help protect pool pad equipment 4 ...

Page 5: ...bottom AUX 3 6 G Flow Monitor flow switch connector H Transformer Input 120VAC X 2 I System Input Power 120VAC from breaker J Rectifier input 24VAC for Chlor circuit K Transformer Output 24VAC L 20Amp Fuse protects Chlor circuit M Rectifier Output 18 33VDC Chlor circuit N Sense Dispense output 120VAC O Local Display power 11VDC P Plugs for accessory equipment 11VDC I G J Transformer Rectifiers Air...

Page 6: ...ProLogic How To ...

Page 7: ...1 Press the Menu until Configuration Menu Locked appears To unlock press and hold the keys until the text on the display changes from Locked to Unlocked Press the one time Reset Config to Default should appear on the display Note pressing the repeatedly in configuration also eventually lead to this screen Note It is important to write down the system s configuration settings and timers prior to re...

Page 8: ... 3 Step 4 Step 1 The active salt readings instant salt appears in the Diagnostic Menu Press the Menu button repeatedly until the Diagnostic Menu appears Then press one time If all zeros or if Chlorinator Off Percentage Met press key IF after a short countdown delay the display does not revert to zeros refer to step 3 NOTE The main circulation pump MUST be ON and the chlorinator AND flow switch MUS...

Page 9: ...n is Enabled NOTE IF Sense Dispense ORP Auto Sensing is being used output must be adjusted under the Chemistry Config Wizard refer to next page Step 3 Step 4 Step 1 To display the settings press the MENU key until Settings Menu appears Then press the until Super Chlorinate appears Use the or button to toggle between super chlorinate On or Off depending on preference Then press the one time to disp...

Page 10: ...s and hold the until the text on the display changes from Locked to Unlocked unit will beep Press the repeatedly until Chemistry Config Wizard appears on the display Press the key to enter then until Maintain ORP level appears on the display Note ONLY increase or decrease the ORP Set Point in increments of 25 mV Once free chlorine reaches 3 0 verify and or balance the water chemistry Once balanced...

Page 11: ...Menu until Configuration Menu Locked appears To unlock press and hold the until the text on the display changes from Locked to Unlocked Press the until Chlor Config appears on the display Press the button one time to enter into the Chlorinator Configuration screen Note If the Cell Type option does not appear in the Chlor Config menu then review the system s model number to identify the type of cel...

Page 12: ...nspect and or clean the cell if necessary Once complete press the Menu button to exit How To Reset Inspect Cell Message 12 Step 3 Step 4 Step 1 Press the Menu until Default Menu appears on the display This menu is where the Inspect Cell message is stored Press the key repeatedly until Inspect Cell Hold to reset appears on the display Step 2 To clear press hold the key while message is displayed ...

Page 13: ...eaning if salt accuracy is off AND OR chlorine production has diminished Wear Protective Equipment If the cell requires cleaning please wear protective equipment It is highly recommended to use a Hayward Cell Cleaning Stand as shown on the right GLX CELLSTAND Turn Pump Off Remove Cell Step 1 Clean Cell Calcified Cell Step 2 NOTE ALWAYS WEAR PROPER EYE PROTECTION AND PROTECTIVE GLOVES MIX SOLUTION ...

Page 14: ... into the cell until it reaches the top The solution should remain in the cell for 15 minute intervals until the reaction is complete Carefully pour solution back into approved container Mix 4 Parts H2O 1 Part Muriatic Acid Step 3 Step 4 NOTE ALWAYS ADD ACID TO WATER NEVER ADD WATER TO ACID The cell cleaning solution may be reused a few times ALWAYS STORE MIXED SOLUTIONS IN A SAFE AREA OUT OF HARM...

Page 15: ...to the step 6 IF the Inspect Cell alarm appears then press the Menu button until Default Menu screen appears navigate using the until Inspect Cell press to reset appears then promptly press the key Thoroughly Rinse Cell Return Step 5 Step 6 NOTE If the cell was reading a low salt level prior to cleaning the average salt may need to be reset To reset the average salt level follow the steps outlined...

Page 16: ...ProLogic Troubleshooting ...

Page 17: ...s ProLogic AquaLogic Main Board GLX PCB PRO Main Board GLX PCB MAIN Local Display GLX PL LOC xx substitute appropriate model number xx P4 PS4 PS8 or PS16 Local Display GLX LOCAL xx substitute appropriate model number xx P 4 PS 4 PS 8 or PS 16 ...

Page 18: ...ansformer output Verify transformer input Replace fuse GLX F20A 10PK NO Is wiring correct Replace main board see pg 17 YES NO Correct wiring Is 120VAC available on both transformer inputs NO YES Replace Transformer GLX XFMR 120VAC present on input power terminal block Test Main PCB input power NO Resolve source power issue Replace main board see pg 17 YES ...

Page 19: ...C is present between the two yellow wires this represents the transformer output IF no low volts proceed to step 1B IF voltage is correct jump ahead to step 1D Disconnect the transformer input wires On the PCB verify 120VAC between blue white posts 120VAC between violet grey IF no low voltage go to 1C IF voltage is correct replace transformer GLX XFMR Test transformer output Step 1A Step 1B Test t...

Page 20: ... 17 Visually inspect test the 20Amp fuse IF fuse is blown replace it GLX F20A 10PK IF fuse is OK inspect the rectifier wiring IF rectifier wiring is correct replace the main board see pg 17 PCB Input Power Step 1C Step 1D NOTE Verify the main board s input power comes from positions 3 4 on the terminal block which is labeled Control Power The two bottom left terminal blocks are factory installed f...

Page 21: ...al Problem is in terminal block or comm equipment Isolate equipment to find root cause YES NO YES System has a 2amp integrated fuse Fuse has continuity Test 3amp violet fuse Fuse has continuity YES NO Replace main board see pg 17 Replace fuse GLX F3A 10PK Test incoming power Is 120VAC present NO NO YES NO Resolve source power issue YES Local display power is 11VDC NO Replace Main Board see pg 17 R...

Page 22: ...t cable 908 355 7995 IF okay go to 2B With power OFF remove the terminal blocks on the left side of the PCB including comm equipment Restore power IF display appears problem resides in the terminal blocks IF display is still OFF go to 2C Verify display connections Step 2A Step 2B Disconnect terminal blocks 2 Blank Display No LEDs NOTE If the blank display or No LEDs symptom is being caused by the ...

Page 23: ...grated into the board IF this fuse is not present go to step 2D IF fuse has continuity proceed to step 2E IF the fuse is damaged replace the main board see pg 17 With power OFF test the 3amp fuse located near the local display IF the fuse is bad replace it GLX F3A 10PK IF the fuse has continuity go to step 2E NOTE this style of fuse is only found on AquaLogic systems Test fuse Step 2C Step 2D Test...

Page 24: ...o step 2F With power OFF disconnect display and restore power Verify across pins 1 3 left to right for 5 11VDC IF no low voltage replace main board IF correct replace display see pg 17 Test incoming power Step 2E Step 2F Test local display power 2 Blank Display No LEDs cont NOTE Verify the main board s input power comes from positions 3 4 on the terminal block which is labeled Control Power The tw...

Page 25: ...mm port power 3 CSM Comm Error Is a chemistry sensing module installed Verify connections inspect CSM wire for damage Replace CSM Module GLX SD ELEC MOD 5 10VDC between pins 1 3 Replace main board see pg 17 YES NO Problem solved YES NO NO Replace CSM Module GLX SD ELEC MOD ...

Page 26: ...IF not installed go to step 3B to disable this feature IF a sensing module is installed proceed to step 3C Press Menu button until Configuration Menu appears Press hold the buttons until config Is unlocked Press until Chemistry Wizard appears press to enter Finally press again to disable Verify HL CHEM is installed Step 3A Step 3B Disable sensing system 3 CSM Comm Error 1 2 3 HL CHEM CSM Chemical ...

Page 27: ... is damaged replace GLX SD ELEC MOD IF free of damage go to step 3D While powered test for 5 10VDC between pins 2 4 left to right IF no low voltage replace the main board see pg 17 IF voltage is correct replace the chemistry sensing module GLX SD ELEC MOD Verify wires connection Step 3C Step 3D Test comm port 3 CSM Comm Error cont NOTE If the cable that runs from the HL CHEM to the ProLogic board ...

Page 28: ...ct TCELL type in configuration 4 Chlorinator OFF High Salt Amps Test salt level Dilute salt level and reset average salt Replace main board see pg 17 NO Does cell model match programming Change programming to match installed cell model Reset average salt is error still present Contact tech support 908 355 7995 YES NO Problem solved YES NO ...

Page 29: ...rrect go to 4B With the pump running press the Menu button until Diagnostic Menu appears Press the one time Then press the to reset the chlorinator and go to 4C Test salt level Step 4A Step 4B Reset chlorinator in diagnostics 4 Chlorinator OFF High Salt Amps NOTE If the main circulation pump was recently turned on the chlorinator may show up to a 60 second Filter delay Once the countdown expires v...

Page 30: ...ace the main board see pg 17 IF voltage is under 35V proceed to step 4D Verify model number of installed cell To verify press the Menu until Configuration Menu appears Press one time followed by Press two times to display Cell Type IF programmed cell does not match model use to change IF correct contact tech support 908 355 7995 Verify chlorinator readings Step 4C Step 4D Verify cell programming 4...

Page 31: ...ent test Part 2 Subtract the Ave Pool Depth by the answer from part 1 This will give you the total number of inches to drain and replenish with fresh water to achieve a salt level of 3200 Part II Ave Pool Depth Answer from Part 1 Amount of Water to Drain Example a pool has an ave depth of 54 and the salt level is 4500ppm 54 X 3200 172800 4500 38 4 Example Part I 54 38 4 15 6 Example Part II Step 4...

Page 32: ...for at least 2 minutes NO YES Test local display wiring harness Harness has continuity Replace local display see pg 17 Problem solved Did Comm Error clear Problem is in terminal block or comm equipment Isolate equipment to find root cause NO Contact tech support for replacement 908 355 7995 Did Comm Error clear YES NO Replace main board see pg 17 ...

Page 33: ...p 5B 5 Comm Error 1 OR 2 With power OFF remove the terminal blocks on the left side of the PCB including comm equipment Restore power IF Comm Error clears the problem resides in the terminal blocks IF still present go to 5C Disconnect terminal blocks NOTE With ProLogic revision 4 10 a heater terminal block was added moving the heaters off the main sensor block which was common in older revisions V...

Page 34: ...continuity matching wire colors IF continuity is found on each wire go to step 5D IF not contact tech support for a replacement 908 355 7995 Test the local display harness Step 5C Step 5D 5 Comm Error 1 OR 2 cont Replace the local display matching the model number inside control door with the replacement part number on pg 17 IF replacing the display does not solve the problem replace the main boar...

Page 35: ... Pump Is pump ON YES Did the heater fire YES Exit service mode Inspect Check System LED NO Is it ON Clear all errors first YES NO Raise heater set points to 104F Did heater fire YES Problem solved Contact tech support 908 355 7995 NO Both term have 24VAC YES NO Do neither have 24VAC YES NO Replace main board see pg 17 The problem resides on the heater it either has an error message it is not in by...

Page 36: ...ed by an illuminated Filter LED Also verify the main circulation pump is running IF the pump is off and cannot be turned on through the controller go to section 7 IF pump is running proceed to step 6B Check main circulation pump Step 6A Step 6B 6 Heater Not Firing On the local display with the main circulation pump running verify the Heater LED is illuminated IF the heater LED is not illuminated g...

Page 37: ...ater button to force it on If the heater LED illuminates AND the heater fires then take the system out of service and go to step 6F IF the heater LED illuminates but the heater does not fire go to step 6D Service mode test Step 6C Step 6D 6 Heater Not Firing cont With the heater LED illuminated test the top heater terminal for 24VAC against ground then do the same for the bottom terminal against g...

Page 38: ... in bypass or may be experiencing a failure IF voltage is present on only one wire then bypass wires are likely damaged Troubleshoot heater Step 6E Step 6F 6 Heater Not Firing cont First verify the status of the Check System LED IF ON go to the Default Menu to identify if error relates to heating i e water temperature sensor failure IF Check System LED is OFF access the heater set points under the...

Page 39: ...n is preventing manual turn on Is the equipment running YES Section B Go To Section B NO Is voltage present NO Is AUX plugged into correct relay socket YES Replace main board see pg 17 Inspect for interlocks call tech support 908 355 7995 YES Relay line power present 120 240VAC YES Load power present 120 240VAC NO Correct source power issue YES Problem resides in the wiring or equipment NO Replace...

Page 40: ...liary button that corresponds with the relay in question IF the relay LED fails to turn ON go to step 7B IF ON jump to step 7D Inspect relay LED Step 7A Step 7B Activate service mode press the relay button IF the LED illuminates a control related feature is overriding the relay preventing normal operation from occurring example interlock etc go to step 7C IF LED does not turn ON replace the local ...

Page 41: ...button the system should explain any interlocks or preventions contact service for additional assistance 908 355 7995 Equipment running on in service Step 7C With the Auxilary LED illuminated remove the relay bracket providing access the low voltage side of the relay Test suspect relay for 20 25VDC between the red black wires IF no low voltage is present proceed to step 7E IF correct jump to step ...

Page 42: ...he correct socket on the board IF incorrect power down move wiring harness retest IF correct replace main board see pg 17 Inspect Relay wiring harness Step 7E Step 7F To verify the relay is receiving power test the first terminal against ground to verify 120VAC is present IF wired for 240VAC also test the third terminal against ground IF terminal 1 120V OR 1 3 240V do not have power correct at the...

Page 43: ...r 120VAC For 240V equipment also test the fourth terminal to ground for 120VAC IF no voltage is present on either 2 OR 2 AND 4 then replace the relay GLX RELAY IF power is correct the problem resides in the equipment wiring or equipment itself Test relay high voltage load side Step 7G 7 Auxiliary Equipment Inactive cont ...

Page 44: ...ProLogic Additional Information ...

Page 45: ...or residential pools up to 15 000 gallons X 4 10 or later 4 10 or later T CELL 5 For residential pools up to 18 000 gallons All revisions All revisions All revisions T CELL 9 For residential pools up to 25 000 gallons X 4 10 or later 4 10 or later T CELL 15 For residential pools up to 40 000 gallons All revisions All revisions All revisions ...

Page 46: ...0 19 900 3 33 70 11 882 2 72 90 7 333 2 12 110 4 664 1 59 130 3 049 1 17 150 2 044 0 85 11 60 595 4 29 31 33 590 3 85 51 19 377 3 30 71 11 589 2 68 91 7 164 2 09 111 4 563 1 57 131 2 987 1 15 151 2 005 0 84 12 58 774 4 27 32 32 648 3 83 52 18 870 3 27 72 11 305 2 65 92 6 999 2 06 112 4 464 1 54 132 2 926 1 13 152 1 966 0 82 13 57 014 4 25 33 31 737 3 80 53 18 377 3 24 73 11 029 2 62 93 6 839 2 03 ...

Page 47: ... 67 80 93 107 120 133 147 160 173 187 200 213 227 240 253 267 2600 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 2800 27 33 40 47 53 60 67 73 80 87 93 100 107 113 120 127 133 3000 13 17 20 23 27 30 33 37 40 43 47 50 53 57 60 63 67 3200 Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal Ideal 3400 OK OK OK OK OK OK OK OK OK OK OK OK OK OK...

Page 48: ...orine for 50 1 5 hrs of each 3 hr cycle for a total of 4 5 hrs 2 Super chlorinate is an additional option to use in order to catch up in chlorine production when making adjustments to the desired output level To activate press the menu button until the Settings Menu appears Press the right arrow until Super Chlorinate Off appears press the to change it from Off to On This will cause the system to ...

Page 49: ...evel of free chlorine in the pool is appropriate NEVER add additional salt in this circumstance 4 If the free chlorine is not appropriate and the steps in item 2 have been followed and addressed as needed then the Desired Output needs to be increased in a 25 increment for example from 50 to 75 to allow for the TurboCell to operate for a longer period of total operating time in order to produce a s...

Page 50: ...L0112 Year of Manufacture 3L0112 Month of Manufacture 123456 Manufacturing ID 3L0112 123456 3L11284 123456 Beginning 08 05 2011 Beginning 11 01 2001 3L11284 Standard Warranty Term 3L11284 Product Family 3L11284 Year of Manufacture 3L11284 Day of Manufacture 123456 Manufacturing ID ...

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