Pro Logic Version Rev. 4.45 Diagnostics Manual Turbo Cell & Control Electronics Copyright 2014 Hayward Industries Inc.
Table of Contents Important safety instructions Pg. 1 Adjusting Chlorinator Output Pg. 17 Pro Logic Board Layout Diagram Pg. 2 Configuring Cell Type Pg. 18 ‘No Cell Power 1’ & ‘No Cell Power 2’ Pg. 3 ‘High Salt/Amps’ error message Pg. 19 ‘No Cell Power’ & ‘Low Volts’ error message diagnostics Pg. 4-8 Cell cleaning instructions Pg. 20-22 ‘Cell Power Error’ message diagnostics Pg. 9 ‘Comm Error 1’ and ‘Comm Error 2’ Pg. 23-24 ‘Chlorinator Off-Test Salt Level’ error message Pg.
Pro Logic Version 4.45 Diagnostics Warning ! High Voltage Electrocution Hazard Hazardous voltage can shock, burn, cause serious injury and or death.
Pro Logic Board Layout Diagram Plugs for S&D control module, base antenna and CL module. Plug for the local display. Dispense power circuit; output 120VAC. Remote display communication terminal block. Three amp fuse, protects S+D circuit. (Red & Black) Chlorinator circuit, 18-33 VDC output from rectifiers. 20 amp fuse; protects chlorinator circuit. Temperature sensor / external input terminal block. (Yel) Chlorinator circuit 24 VAC from the transformer.
Check System Light On: 1. No Cell Power 1 or No Cell Power 2 ‘No Cell Power’ means the current chlorinator cycle has been interrupted due to no voltage being detected when the cell power relay was turned on. No Cell Power 1 Go to Step 1A, page 4.
1. Check System Light On: No Cell Power & Low Volts Message Diagnostics ‘No Cell Power’ means the current chlorinator cycle has been interrupted due to no voltage being detected when the cell power relay was turned on. Verify that 20-24 Volts AC is present between the two yellow wires. Step 1A Turn off power to the controller.
1. Check System Light On No Cell Power & Low Volts Message Diagnostics Verify the chlorinator is not in an ‘off’ cycle. If it is, reverse polarity and proceed, with the filter pump on. Step 1C Verify that 20-24 Volts AC is present between the two orange wire connections. Step 1D Press the ‘MENU’ key until ‘Diagnostic Menu’ is displayed. Then press right arrow key. All zeros, except temperature means the chlorinator is off. Press the plus (+) or minus (–) key.
1. Check System Light On No Cell Power & Low Volts Message Diagnostics Test the 20 amp (yellow) fuse, using an Ohm reading and not just a visual test. Step 1E Verify that 18-33 Volts DC is present between the black and red wire connections. Step 1F Note: The red & black wires cannot be reversed, this will also cause a ‘No Cell Power’ message. Replace the fuse if blown. If the fuse is OK, replace the Main Circuit Board (PCB). If no/low voltage is present, replace the rectifiers, go to step 1G .
1. Check System Light On No Cell Power & Low Volts Message Diagnostics The rectifiers are both located beneath the transformer. It is important, when replacing the rectifiers to connect the wires in accordance with the instructions. Step 1G Note: The bottom right corner of each rectifier should be cutoff. If this is not correct, loosen them and rotate each block until they appear like the diagram below.
1. Check System Light On: No Cell Power & Low Volts Message Diagnostics Remove the cell and clean per Hayward’s cleaning instructions (pages 18-20). Reinstall the cell and check (see note below). If the ‘No Cell Power’ message remains, replace the cell. Step 1H Note: If the controller is still powered when unplugging the cell and then the cell is subsequently plugged back in, it may display a ‘Low Temp’ fault message and the ‘Check System’ light may still illuminate. Turn the filter pump on.
2. Check System Light On: Cell Power Error Message ‘Cell Power Error’ means the current chlorinator cycle has been interrupted and cell voltage was detected when cell power relay was turned off. Main board PCB is the only cause, replace with GLX-PCB-PRO.
3. Chlorinator Off: Test Salt Level Message Verify the system is configured for correct model cell. (Page 18). If the incorrect cell is chosen, the system will inaccurately interpret the salt level in the pool and the system may turn the chlorinator off. Maximum Current (Amps) before shutdown T-CELL-3 5.50 T-CELL-9 10.00 T-CELL-5 6.75 T-CELL-15 10.
4. Local Display: Blank/No Lights If the local display shows a blank display or no lights are illuminated an abrupt power outage may have been the cause, resetting the unit may correct this problem. Step I If no information appears on the display start by turning off the breaker responsible for sending power to the main circuit board. Step II When the power is off, disconnect the local display from the main circuit board.
4. Local Display: Blank/No Lights Remove the black and white wires (from the incoming power). Verify that 115-120 Volts AC is present across these leads. Step 4B Step 4A Step 4C If no/low voltage is measured, check connections at the terminal block. Confirm breaker, within the system’s sub-panel and main power source, are both turned on. If no voltage is still present, go to Step 4B. If proper voltage is present, go to Step 4C. Measure 110-120 Volts AC at the terminal block coming from the breaker.
4. Local Display: Blank/No Lights Turn off power and test the 2 amp non-replaceable fuse. An Ohm measurement should be taken and not just a visual test. Step 4D If blown, replace the board, if this fuse is OK, turn the power back on and go to step 4E. Measure for 9-10 Volts DC across pins 1 and 3 (red and yellow wires). Step 4E If no/low voltage is present, replace PCB, if the voltage is OK, replace the local display. Unplug harness. Check across pins 1 (red) & 3 (yellow) for 5-10VDC.
Check System Light On: Low Temperature Error Message ‘Chlorinator Off Low Temperature’ means the current chlorinator cycle has been interrupted due to a cell temperature reading of less than 50°F. 1. Check the water temperature. If the temperature is below 50°F the system will shut the cell down under normal circumstances. 2.
Check System Light On: Low Salt Error Message A low salt error means the average salt level is less than or equal to 2600 PPM. Cell is still operating. 1. Test the salt level in the pool using a suitable tester. Be sure the tester has been calibrated and is clean. Add salt as needed to bring up to the 3200 PPM level. 2. Remove and clean cell per the Hayward’s cleaning instructions. Be sure to ‘reset’ the average salt by following the instructions on page 16.
Resetting (Average) Salt Reading The salt reading displayed in the ‘Default – Menu’ is actually an average salt reading. This average is calculated by using previous instant salt readings over a period of time. When diagnosing and repairing faults relating to high or low salt readings, it will be necessary to ‘reset’ the average salt by replacing it with the instant value in order to prevent the same fault from appearing at startup.
Adjusting Chlorinator Output If using Sense and Dispense™ chlorinator output will be adjusted by ‘Chemistry Config. Wizard’ under the ‘Configuration Menu’. Please refer to the Sense & Dispense™ manual for details. Step III Step I To display the ‘Settings Menu’, press the ‘MENU’ key until ‘Settings Menu’ appears. Then press the right arrow key. Step II Use the plus (+) or minus (-) key to adjust the desired chlorinator output for spa. Then press the right arrow key.
Configuring Cell Type It is important to verify which cell type is being used and to make sure the system is configured for the correct model cell. Step I Step III Press the ‘MENU’ key until the ‘Configuration MenuLocked’ appears on the screen. To unlock the ‘Configuration Menu’ press and hold the left and right arrow keys for five to ten seconds. Step II Once the ‘Configuration Menu’ is unlocked press the right arrow key once. ‘Chlor. Config. + to view/change’ should appear on the display.
Check System Light On: High Salt/Amps Error Message 1. Test the salt level in the pool using a suitable tester. Be sure the tester has been calibrated and is clean. If it is determined that the salt level in the pool exceeds 3400ppm, slowly drain and replenish with fresh water until salt levels are between 2700ppm – 3400ppm. 2. Check to make sure the system is configured for correct model cell (page 18). 3.
Cell Cleaning Instructions: Cell cleaning frequency is dependent on several factors; pH and calcium levels in the water are the two that have the greatest effect on how often the cell requires cleaning. Maintaining pH at the levels recommended in the operating instructions (7.2 - 7.8) should result in the cell being cleaned 3-4 times a year in areas with hard water. Cells may be cleaned less frequently in soft water areas.
Cell Cleaning Instructions: Cleaning instructions using a container. Mix 1 part acid to 4 parts water. Stand the cell vertically in the solution. The level of the solution should be slightly over the product label. Let the cell stand in the solution for 15 minutes (Fig. 6A to the right), then flip the cell over and let stand on the other end (Fig. 6B to the right) for an additional 15 minutes. Although the cord can be submerged, be sure that the connector does not come in contact with the solution.
Cell Cleaning Instructions: Using the Hayward T-Cell Cleaning Stand Follow the same safety and mixing instructions as described when using a container (pages 20 and 21). Mix enough solution to fill the inside of the cell ( Approximately 1.5 qts). Fasten the cell to the T-Cell Cleaning Stand with the cord side down (Fig. 6C below). Before filling cell with muriatic acid solution, put a container underneath to avoid any spills damaging the surrounding area.
5. Comm Error 1 and Comm Error 2 ‘Comm Error 1’ is usually a false error caused by an abrupt power outage. ‘Comm Error 2’ is usually a misplaced wire in the sensor terminal block, a failing wired remote, a failing local display or a failing main circuit board. Turn the system’s main power breaker off, leave off for 2 minutes, then turn back on and check the display. Step 5A If the communication error is gone then the problem should be resolved.
5. Comm Error 1 and Comm Error 2 Unplug green terminal block that contains all the sensors then turn the breaker back on (with the block still removed). Step 5C If the communication error disappears then check everything wired into the sensor terminal block. If the problem still exists proceed to step 5D. Check the local display wiring harness for continuity. Step 5D If the wiring harness does not show continuity through any of the four terminals, replace the wiring harness.
“Check System” Troubleshooting Charts 20-24 VAC between yellow wires on PCB MAIN No Cell Power & Low Volts Chlorinator in “OFF” cycle YES Reset chlorinator (Page 5) (Page 4) YES NO Ohm out transformer leads, blue & white: 2.0-2.9 gray & violet: 2.0-2.
“Check System” Troubleshooting Charts Replace PCB-PRO Cell Power Error (Page 9) Unplug wired remotes & wireless Base RF. Reboot system Blank Local Display Reattach wired remotes and wireless base RF until message reappears.
“Check System” Troubleshooting Charts Low Temperature Error Water temp. YES Normal below 50o F operation (Page 14) (Page 14) High Temperature Error NO (Page 14) (Page 14) NO Reset system NO (Page 14) Replace cell Replace cell Salt level is YES 2700-3400ppm Low Salt Error (2400-2600ppm) (Page 15) YES Very Low Salt Error (<2400ppm) Water temp.
“Check System” Troubleshooting Charts High Salt/Amps Error (>8.0 amps) Configured for correct cell? (Page 18) NO Configure for correct cell (Page 18) YES Salt level is 2700-3400ppm Problem only occurs when switching from pool to spa mode.
“Check System” Troubleshooting Charts ‘Comm Error 1’ & ‘Comm Error 2’ Turn breaker off for 2 mins. Then back on. NO (Page 23) Turn breaker off YES Problem solved Unplug temperature sensor terminal block then turn breaker back on. (Page 24) NO Identify failing wire/equipment in block and replace. NO Identify failing wire/equipment in block and YES replace. Turn breaker off NO Turn breaker off (Page 23) YES B Unplug ‘Remote’ terminal block then turn breaker back on. Replace terminal block.
Additional “Check System” Errors Note: If Variable Speed Pump is not being used, change Filter Pump type in the ‘Configuration Menu’ to remove these error codes Below is a list of additional “Check System” error codes which relate to the Pro Logic’s operation with Hayward’s TriStar Energy Solution™ Variable Speed Pump & Control.
Additional “Check System” Errors Note: If Sense & Dispense is not being used, disable the ‘Sensing System’ under the ‘Chemistry Config.
Additional “Check System” Errors Below is a list of additional “Check System” error codes which relate to open or shorted sensors: •Cell Sensor Open •Spa Sensor Open •Solar Sensor Open •Cell Sensor Short •Spa Sensor Short •Solar Sensor Short •Wtr Sensor Open •Air Sensor Open •Ambient Sensor Open •Wtr Sensor Short •Air Sensor Short •Ambient Sensor Short •Pool Sensor Open •No Flow – Filter Pump •Cell Missing •Pool Sensor Short •Chk Flow Switch ‘Open sensor’, ‘Cell Missing’, and ‘Check Flow Sw
Temperature vs. Resistance Chart F° Ohms Volts F° Ohms Volts F° Ohms Volts F° Ohms Volts F° Ohms Volts F° Ohms Volts F° Ohms Volts F° Ohms Volts 1 82,719 4.46 21 44,879 4.09 41 25,391 3.59 61 14,921 2.99 81 9,076 2.38 101 5,697 1.81 121 3,679 1.34 141 2,440 0.98 2 80,142 4.45 22 43,577 4.07 42 24,704 3.56 62 14,543 2.96 82 8,861 2.35 102 5,570 1.79 122 3,602 1.32 142 2,392 0.97 3 77,656 4.43 23 42,318 4.04 43 24,037 3.
Compatibility Chart: Cell vs. Software Revision If you have an Aqua Plus model # starting with AQL, refer to the Aqua Logic Column.
Firmware Changes Note: Firmware is software programmed into chips Pages 35 – 39 outline the important firmware changes made to the Aqua Logic/Pro Logic. Additions made prior to 4.10 Added support for Chemistry Sense and Dispense. Added displaying if the Chlorinator is off because either the percentage or ORP set point has been met to the Chlorinator Diagnostic display. Added ability to change the ORP level to the Settings Menu.
Firmware Changes – Cont’d Rev. 4.10 (Requires new PC Board (G1-066061)) (10-27-2008) Color Logic 4.0 Added support for ColorLogic 4.0 lights. Miscellaneous Added forcing the Average Salt level to 2800 ppm when resetting to the default Configuration values. Added ability to select Priority for Heater2 as a Heat Pump. Added the ability to check all Check System errors, not just the highest priority one. Added support for on-board pH dispense relays (freeing up an Aux).
Firmware Changes – Cont’d Rev. 4.20 (Requires PC Board (G1-066061)) (10-22-2009) Aqua Connect Home Network Added support for Aqua Connect Home Network. Color Logic 4.0 Added resetting any ColorLogic Aux brightness level to 100% when ColorLogic is reset to default values. Added ability to move forwards and backwards thru the ColorLogic Light Number assignment display. Added ability to have different minimum and maximum speeds for each ColorLogic program.
Firmware Changes – Cont’d Rev. 4.30 (Requires PC Board (G1-066061)) (mm-dd-2010) EcoStar VSP Added support for up to 8 EcoStar VSPs (Filter, Dual Equipment Spa Filter and up to 6 Lights/Auxes). Added VSP as a fourth possible Relay Type for each Light/Aux (up to 6, maximum). Added the ability to select the desired Filter and Spa Filter Speed when manually switching the filter from Off to On with the +/- keys (similar to setting the Dimmer On brightness).
Firmware Changes – Cont’d Rev. 4.40 (Requires PC Board (G1-066061)) (8-29-2012) Universal Color Logic Added support for the Universal Color Logic (UCL) Light. Miscellaneous Restricted an Aux Relay Type, other than Standard, to a function of Manual On/Off, Countdown or Time clock. Rev. 4.45 (Requires PC Board (G1-066061)) (9-5-2013) Aqua Connect Added support for direct temperature input via app. Miscellaneous Allowed an Aux set as function Solar to have a relay type of VSP.
IMPORTANT !!! More on Chlorine Output & Salt Levels 1. The ‘Pool Chlorinator %’ and ‘Spa Chlorinator %’ options under the Setting Menu, control the level of salt cell operation as a percent of the total operating time of the filter pump. A simple example is that if the pump/filter is programmed to operate a total of 8 hours in a given day and the ‘Pool Chlorinator %’ is set to 50% the salt cell will operate (and produce chlorine) approximately half the time, or 4 hours. 2.
