Hayward ProLogic User manual

ProLogic®/AquaLogic
Troubleshooting Guide Residential
TSG-PL447c Copyright 2016 Hayward Industries Inc.

Safety Precautions
!
Warning
2
High Voltage Electrocution Hazard
Hazardous 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

Table of Contents
How
ProLogic® Works & Main PCB Layout
Pg.
4-
5
How To:
Pg.
6-
15
Reset
Config. to Default & Reset Average Salt
7-
8
Adjust Chlorinator Output & Adjust ORP Set Point
9-
10
Change Cell Type
& Clear Inspect Cell Message
11
-
12
Clean 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
Reading Serial Numbers
50
3

ProLogic: How It Works
•All ProLogic systems are salt chlorination ready
and can control 4-16 high voltage relays, 3-4
valve actuators and 1-2 heaters.
•These systems can manage: Hayward Variable
Speed 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

ProLogic: Main PCB Layout
A
Remote
DSP comm (RS485 –10VDC)
B
Temp sensor terminal block (5
VDC)
C
Heater
1&2 terminal block (dry contacts)
D
Valves 1
-4 & 4Amp fuse ( 24VAC)
E
Cell
Plug for chlorination
F
High
Voltage Relays (top –Filter, Lights,
AUX1, AUX2; bottom (AUX 3
-6).
G
Flow Monitor (flow switch connector)
H
Transformer Input (120
VAC X 2)
I
System
Input Power (120VAC from breaker)
J
Rectifier input (24
VAC 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 (11
VDC)
I
G
J
Transformer
Rectifiers
Air/Water Sensor
M
H
K
L
N
F
E
D
C
B
A
P O

ProLogic®
How To:

Follow these steps ONLY if you wish to restore the system to factory default.
WARNING: Resetting the system to factory default will wipe out all configuration
changes, schedules, and settings preferences.
Once the reset has been completed, the display will report
‘Config. Reset Confirmed’. To exit Config., press the ‘Menu’
button, to continue programming press the (>) button.
How To: Reset Config. to Default
7
Step 3 Step 4
Step 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 resetting the
Configuration to Default.
Step 2
Press the (+) key to reset. The system will ask ‘Are you sure?’,
press ‘Menu’ to cancel, OR the (+) button again to confirm.
Warning: Once confirmed, all stored information will be erased.

Follow these steps ONLY if Salt Chlorination is Enabled. The Average Salt level needs to
be reset after initial start up, after a board replacement, following major pool
chemistry adjustments, and when a cell is replaced.
Press the (+) key to replace the existing average with this new
instant salt reading; this will start the average process over
again. Press the ‘Menu’ button to exit.
How To: Reset Average Salt
8
Step 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 MUST have flow to
successfully complete this process.
Step 2
Above is an example of the updated instant salt reading in PPM.
If this instant salt reading varies from the average press the (>)
one time, then go to step 4.

Note: If the chlorine levels do not increase within 24 hours, test the water chemistry to determine the
current salt, stabilizer, phosphate, and nitrate levels.
For the second body of water, use the (+) or (-) key to adjust the
desired chlorinator output. Once complete, press the ‘Menu’
button to exit.
How To: Adjust Chlorinator Output
9
Follow these steps to adjust the Chlorinator Output Percentage ONLY if Salt
Chlorination 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 display chlorinator % options.
Step 2
Use the (+) or (-) button to adjust desired chlorinator output. If
multiple bodies of water are programmed, press the (>) button
again. IF only one body of water, press the ‘Menu’ button to exit.

Once the value is set, press the (>) key until ‘-End of Wizard-’
appears on the display, then press ‘Menu’ to exit config.
How To: Adjust ORP Set Point (S&D)
10
Follow these steps to adjust the Chlorinator’s ORP Set Point, ONLY if Salt Chlorination
is Enabled AND the system is configured for ‘ORP Auto Sensing’.
Step 3 Step 4
Step 1
Press the ‘Menu’ until, ‘Configuration Menu-Locked’ appears. To
unlock, press 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, note the reported ORP reading, this
represents the value for maintaining adequate free chlorine levels.
Step 2
Use the plus (+) key to increase, or the minus (-) key to decrease
the ORP set point.

Follow these steps ONLY if Salt Chlorination is Enabled. It is important to verify which
cell type is being used AND to verify the system is configured for the correct model. If
incorrectly set, salt readings and chlorinator operations will be unreliable.
If the cell type shown does not match the model plumbed-in,
press the (+) or (-) until it matches. Then press the ‘Menu’ to exit.
How To: Change Cell Type
11
Step 3 Step 4
Step 1
Press the ‘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 cell that should be used with the system. Some earlier board
revisions could not be configured for different cell types.
Step 2
The display should show ‘Chlorinator Enabled’ if not, press the
(+) button to Enable it. Then press the (>) two times.

Follow these steps ONLY if Salt Chlorination is Enabled AND the system shows a Check
System LED, with an ‘Inspect Cell’ message. Every 500 operational hours this message
will appear. Before resetting, inspect 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.

How To: Clean the TurboCell
13
Cell cleaning frequency is dependent on several factors; pH & calcium levels have the
greatest effect on how often cells requires cleaning. In pH environments between (7.2 -
7.8) cells typically require cleaning 3-4 times a year (with moderate calcium levels).
Holding the cell up to a light source, inspect for calcium
deposits. Even if a TurboCell appears clean, it may still
require cleaning 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 CellCalcified Cell
Step 2
NOTE: ALWAYS WEAR PROPER EYE PROTECTION AND PROTECTIVE GLOVES.
MIX SOLUTION AND CLEAN CELL ONLY IN A WELL VENTILATED AREA.
MURIATIC AND OTHER ACIDS CAN CAUSE SEVERE INJURY, BURNS AND RESPIRATORY PROBLEMS IF
NOT HANDLED PROPERLY. REFER TO THE MANUFACTURER’S DIRECTIONS FOR SAFE HANDLING.

14
The TurboCell draws amperage when power is applied, during chlorination. The
amperage draw will be impaired when calcium and other debris exist within the cell’s
electrolytic grid; this in turn effects the salt reading and chlorination efficiency.
Mix a solution comprised of 4 parts water to 1 part
Muriatic Acid. Always Add Acid to Water. Once mixed
turn the turbo up vertically either in a bucket or using
the recommended cell cleaning stand.
Carefully pour the solution 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 HARMS WAY.
When the solution is depleted, follow the manufacturer’s instructions for proper disposal.
1 Part:
Muriatic Acid
4 Parts:
Water
Carefully Pour Solution into Cell
Cleaning Tip:
For best results,
stand the cell
vertically with
cord-side down
How To: Clean the TurboCell (cont.)

15
The check system > ‘Inspect Cell’ message indicates that the system is recommending
the TurboCell should be inspected and cleaned (if necessary). This message will appear
every 500 operational hours as a reminder to inspect and/or clean the TurboCell.
After the solution has been safely removed, thoroughly
rinse the TurboCell before returning it to its place in the
plumbing. Once returned turn the pump back ON and
proceed 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 on pg.8 or wait 24 hours for the
system to acclimate to the recent changes. For detailed instructions on resetting the ‘Inspect Cell’
message, refer to pg. 12.
Reset: ‘Inspect Cell’ message
How To: Clean the TurboCell (cont.)
1
2
3

ProLogic®
Troubleshooting

SKUs: ProLogic vs. AquaLogic
17
Product SKUs
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)

18
No Cell Pwr.
/Low Volts
Is 24VAC
present?
YES
NO
Check 20A
fuse
Is fuse
damaged?
YES
Check Rectifier
wiring
1. No Cell Power/Low Volts
Verify 24VAC on
the transformer
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

19
‘No Cell Power’ & Low Volts implies the chlorinator cycle has been interrupted due to
no/low voltage detected when the cell power relay was turned on. If the system
reports ‘CELL POWER ERROR’, replace the main board (see pg. 17).
Verify that 20-24VAC 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 transformer input
1. No Cell Power/Low Volts

20
‘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 the ProLogic is receiving 120VAC between the
black & white wires on the “Control Power” side of the
terminal block. IF no/low volts, correct at the breaker.
IF correct replace the main PCB board (see pg. 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 for SENSE &
DISPENSE OUTPUT POWER ONLY, AND SHOULD NOT BE USED TO POWER THE MAIN SYSTEM
BOARD.
Inspect Fuse & Rectifier wiring
1. No Cell Power/Low Volts (cont.)
*