Hayward LifeStar VS User manual

LifeStar®VS
Owner’s Manual
Hayward LifeStar® VS is the Aquatic Industry’s most energy efficient variable speed pump. The totally
enclosed, permanent magnet motor combined with its advanced hydraulic design provides unparalleled energy
savings. LifeStar® VS is easily installed either as a programmable stand-alone pump or with a Hayward or
third party controller and features an easy-to-use digital control interface that can be mounted in four different
positions on the pump or removed and mounted on the wall for total user convenience.
NOTE - To prevent potential injury and to avoid unnecessary service calls, read this manual carefully and
completely.
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Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS …………………………………………………………. 3
2. General Information ………………………………………………………………………………….. 6
2.1. Introduction 6
2.2. Primary Features 6
2.3. Product Dimensions 6
3. Energy Efficiency Overview ………………………………………………………………………... 7
4. Installation and Wiring ……………………………………………………………………………… 7
4.1. Pump Location 7
4.2. Pump Mounting 8
4.3. Pipe Sizing Chart 8
4.4. Plumbing 8
4.5. Electrical 9
4.6. Electrical Specs 9
4.7. Voltage 9
4.8. Grounding and Bonding 9
4.9. Wiring 10
4.10. Remote Control Wiring / Operation 10
4.11. Digital Control Interface Orientation 11
4.12. Interface Wall Mounting 11
5. Wiring Diagrams …………………………………………………………………………………… 14
5.1. Input Power/Motor Wiring (Required) 14
5.2. Wall Mounted Digital Control Interface Wiring (Optional) 14
5.3. Hayward Control Wiring (For remote control of pump speed) 15
5.4. External Relay Speed Control Wiring (For remote selection of pump speed) 16
5.5. Remote Stop Switch Wiring (Optional) 17
6. Startup & Operation ………………………………………………………………………………… 17
6.1. Prior to Start-Up 17
6.2. Starting/Priming the Pump 17
6.3. User Interface Summary 19
6.4. Menu Outline 20
LifeStar® VS Password Protection 21
6.5. Initial Startup 22
6.6. Configuration Menu 22
6.7. Timer Menu 24
6.8. Preset Speed Setup Menu 25
6.9. Diagnostic Menu 26
6.10. Stop/Resume 27
6.11. Quick Clean 27
6.12. Remote Stop 28
7. Maintenance …………………………………………………………………………………………. 28
8. Storage ………………………………………………………………………………………………. 28
8.1. Storing Pump for Winterization 29
9. Shaft Seal Change Instructions ……………………………………………………………………… 29
9.1. Removing the Motor Assembly 29
9.2. Removing the Impeller 29
9.3. Removing the Ceramic Seat 30
9.4. Seal Installation 30
9.5. Replacing the Impeller and Diffuser 30
9.6. Replacing the Motor Assembly 30
10. Replacement Parts ………………………………………………………………………………….. 31
10.1. Parts Diagram 32
10.2. Parts Listing 32
11. Troubleshooting ……………………………………………………………………………………. 33
11.1. General Problems 34
11.2. Check System Messages 35
12. Warranty …………………………………………………………………………………………… 36
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Basic safety precautions should always be followed, including the following: Failure to follow instructions
may result in injury.
This is the safety-alert symbol. When you see this symbol on your pump or in this manual, look for
one of the following signal words, and be alert to the potential for personal injury.
WARNING warns about hazards that could cause serious personal injury, death or major property
damage and if ignored presents a potential hazard.
CAUTION warns about hazards that will or can cause minor or moderate personal injury and/or
property damage and if ignored presents a potential hazard. It can also make consumers aware of actions
that are unpredictable and unsafe.
The NOTICE label indicates special instructions that are important but not related to hazards.
1. IMPORTANT SAFETY INSTRUCTIONS
Before installing or servicing this electrical equipment, turn the power supply OFF.
WARNING – Read and follow all instructions in this owner’s manual and on the equipment.
Failure to follow instructions can cause severe injury and/or death.
WARNING – This product should be installed and serviced only by a qualified professional.
CAUTION – All electrical wiring MUST be in conformance with all applicable local codes,
regulations, and the National Electric Code (NEC).
USE OF NON-HAYWARD REPLACEMENT PARTS VOIDS WARRANTY.
ATTENTION INSTALLER - THIS MANUAL CONTAINS IMPORTANT INFORMATION
ABOUT THE INSTALLATION, OPERATION, AND SAFE USE OF THIS VARIABLE SPEED
PUMP THAT MUST BE FURNISHED TO THE END USER OF THIS PRODUCT. FAILURE
TO READ AND FOLLOW ALL INSTRUCTIONS COULD RESULT IN SERIOUS INJURY.
WARNING – To reduce risk of injury, do not permit children to use or climb on this product.
CAUTION – This product is designed for indoor and outdoor use. If used outdoors, it is strongly
advised to protect the electrical components from the weather. Select a well-drained area, one that will
not flood when it rains. It requires free circulation of air for cooling. Do not install in a damp or non-
ventilated location. If installed within an outer enclosure or beneath, adequate ventilation and free
circulation of air must be provided to prevent overheating of the motor.
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WARNING – Components (seals, gaskets, etc.) have a finite life. All components should be
inspected frequently and replaced at least every ten years, or if found to be damaged, broken, cracked,
missing, or not securely attached.
WARNING – Risk of Electric Shock. All electrical wiring MUST be in conformance with
applicable local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can
shock, burn, and cause death or serious property damage. To reduce the risk of electric shock, do NOT
use an extension cord to connect unit to electric supply. Provide a properly located electrical receptacle.
Before working on pump or motor, turn off power supply to the pump.
WARNING – To reduce the risk of electric shock replace damaged wiring immediately.
WARNING – Risk of Electric Shock. In accordance with the National Electric Code (NEC),
connect only to a branch circuit protected by a ground-fault circuit-interrupter (GFCI). Contact a
qualified electrician if you cannot verify that the circuit is protected by a GFCI. The unit must be
connected only to a supply circuit that is protected by a ground-fault circuit-interrupter (GFCI). Such a
GFCI should be provided by the installer and should be tested on a routine basis. To test the GFCI, push
the test circuit button. The GFCI should interrupt power. Push the reset button. Power should be
restored. If the GFCI fails to operate in this manner, the GFCI is defective. If the GFCI interrupts
power to the pump without the test button being pushed, a ground current is flowing, indicating the
possibility of an electric shock. Do not use this pump. Disconnect the pump and have the problem
corrected by a qualified service representative before using.
WARNING – Failure to bond pump to the structure will increase risk for electrocution and could
result in injury or death. To reduce the risk of electric shock, see installation instructions and consult a
professional electrician on how to bond pump. Also, contact a licensed electrician for information on
local electrical codes for bonding requirements.
Notes to electrician: Use a solid copper conductor, size 8 or larger. Run a continuous wire from
external bonding lug to reinforcing rod or mesh. Connect a No. 8 AWG (8.4 mm2) [No. 6 AWG (13.3
mm2) for Canada] solid copper bonding wire to the pressure wire connector provided on the pump
housing and to all metal parts of the structure, and to all electrical equipment, metal piping (except gas
piping), and conduit within 5 ft. (1.5 m) of inside walls of the structure(s). IMPORTANT - Reference
NEC codes for all wiring standards including, but not limited to, grounding, bonding and other general
wiring procedures.
WARNING – Suction Entrapment Hazard. Suction in suction outlets and/or suction outlet
covers, which are damaged, broken, cracked, missing, or unsecured cause severe injury and/or death due
to the following entrapment hazards.
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WARNING – Hazardous Pressure. Water circulation systems operate under hazardous pressure
during start-up, normal operation, and after pump shut-off. Stand clear of circulation system equipment
during pump start-up. Failure to follow safety and operation instructions could result in violent
separation of the pump housing and cover due to pressure in the system, which could cause property
damage, severe personal injury, or death. Before servicing the water circulation system, all system and
pump controls must be in off position and filter manual air relief valve must be in open position. Before
starting pump, all system valves must be set in a position to allow system water to return back to the
water source. Do not change filter control valve position while pump is running. Before starting pump,
fully open filter manual air relief valve. Do not close filter manual air relief valve until a steady stream
of water (not air or air and water mix) is discharged from the valve. All suction and discharge valves
MUST be OPEN when starting the circulation system. Failure to do so could result in severe personal
injury and/or property damage.
WARNING – Separation Hazard. Failure to follow safety and operation instructions could result in
violent separation of pump components. Strainer cover must be properly secured to pump housing with
strainer cover lock ring. Before servicing the circulation system, all system and pump controls must be
in off position and filter manual air relief valve must be in open position. Do not operate the circulation
system if a system component is not assembled properly, damaged, or missing. Do not operate the
circulation system unless filter manual air relief valve body is in locked position in filter upper body.
All suction and discharge valves MUST be OPEN when starting the circulation system. Failure to do so
could result in severe personal injury and/or property damage.
WARNING – Never operate the circulation system at more than 50 PSI maximum.
WARNING – Fire and burn hazard. Motors operate at high temperatures and if they are not
properly isolated from any flammable structures or foreign debris they can cause fires, which may cause
severe personal injury or death. It is also necessary to allow the motor to cool for at least 20 minutes
prior to maintenance to minimize the risk for burns.
WARNING – Failure to install according to defined instructions may result in severe personal
injury or death.
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2. General Information
2.1. Introduction
This manual contains information for the proper installation and operation of the Hayward LifeStar®
Variable Speed Pump. The instructions in this manual MUST be followed precisely.
2.2. Primary Features
Totally enclosed, permanent magnet motor
Advanced hydraulic design
Fully programmable with a self-contained 24-hour clock and up to 8 custom speed and timer
functions
For enhanced management, the LifeStar® VS can be controlled by Hayward or third party control
platforms without the need for additional accessories
Digital control interface that can be mounted in four different positions on the pump or removed and
mounted on the wall
No-rib, extra-large basket design ensures easy debris removal and extends time between cleanings
Motor drive includes built-in protection for high temperatures and voltage fluctuations. Drive is also
designed to withstand temperatures below freezing without issue
2.3. Product Dimensions
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3. Energy Efficiency Overview
The energy consumed by a pump is measured in terms of Watts (W) or Kilowatts (kW). The LifeStar®
Variable Speed Pump displays power consumption in Watts. Given this information, you can determine the
cost of operating the pump:
Power consumption of pump X Cost of electricity = Cost of Pump Operation per Hour
Example: LifeStar® Variable Speed Pump operating at 300 W. Cost of electricity = $0.10 per kWh
Convert Watts to Kilowatts: 300 W = 0.3 kW
0.3 kW X $0.10/kWh = $0.03 per hour
Note the power consumption is greatly affected by the speed of the pump. Lowering the speed of the pump
can drastically reduce the power that is consumed. Below are some of the major benefits of running the
pump at lower speeds.
Benefits of running at low speeds
Save electricity and money
Improved filtration – the filter can often remove smaller particles when the water moves slower
Quiet operation
Reduced Total Dynamic Head – less stress on equipment (e.g. filter) which can lengthen equipment life
When determining the speed(s) to operate your pump, you must also take into account the minimum
requirements for proper sanitation and equipment/water feature functionality.
It is recommended you filter (“turnover”) all the water according to the schedule set by the Life Support
Manager. Running the pump at a lower speed may require running the pump for a longer period of time in
order to meet the turnover requirements for proper sanitation.
After setting the pump speed(s), it is recommended you check that all other equipment/water features are
functioning as intended. For example, when running at a low speed for daily filtration, verify water is
adequately flowing. Operate the pump at higher speeds for the shorter periods of time needed to operate a
heater, water feature, etc.
4. Installation and Wiring
WARNING– This product should be installed and serviced only by a qualified professional.
4.1. Pump Location
Locate pump as close to the water source as practical and run suction lines as
direct as possible to reduce friction loss. Suction lines should have continuous
slope upward from lowest point in line. Joints must be tight (but not over-
tightened). Suction line diameter must equal or be larger than the discharge line
diameter. Though the pump is designed for indoor or outdoor use, it is advised
to place pump in an outdoor application in the shade to shield them from
continuous direct heat. Select a well-drained area that will not flood when it rains. Do NOT install
pump and filter in a damp or non-ventilated location. Keep motor clean. Pump motors require free
circulation of air for cooling.
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4.2. Pump Mounting
Install pump on a level concrete slab or other rigid base to meet all local and national codes. Secure
pump to base with screws or bolts to further reduce vibration and stress on pipe or hose joints. The base
must be level, rigid, and vibration free.
Pump mount must:
Allow pump inlet height to be as close to water level as possible.
Allow use of short, direct suction pipe (to reduce friction losses).
Allow for valves in suction and discharge piping.
Be protected from excess moisture and flooding.
Allow adequate access for servicing pump and piping.
4.3. Pipe Sizing Chart
MAXIMUM RECOMMENDED SYSTEM FLOW RATE BY
PIPE SIZE
Pipe Size
in. [mm] Maximum Flow Rate GPM [LPM]
Minimum Straight
Pipe Length “L” in.
[mm] *
1 ½” [50] 45 [170] 7 ½” [190]
2” [63] 80 [300] 10” [254]
2 ½” [75] 110 [415] 12 ½” [317]
3” [90] 160 [600] 15” [381]
* Note: It is recommended that a minimum length of straight piping (shown as “L” in above diagram),
equivalent to 5 pipe size diameters, be used between the pump suction inlet and any plumbing fittings
(elbows, valves, etc.).
When installing the LifeStar® VS, care should be taken to ensure proper pipe and equipment
sizing to handle the maximum flow required. It is recommended to set the maximum speed in
order to not exceed the maximum flow rate. See section 6.6 item #7.
4.4. Plumbing
1. Use PTFE tape to seal threaded connections on molded plastic components. All plastic fittings must
be new or thoroughly cleaned before use. NOTE - Do NOT use Plumber’s Pipe Dope as it may
cause cracking of the plastic components. When applying PTFE tape to plastic threads, wrap the
entire threaded portion of the male fitting with one to two layers of tape. Wind the tape clockwise as
you face the open end of the fitting, beginning at the end of the fitting. The pump suction and outlet
ports have molded-in thread stops. Do NOT attempt to force hose connector fitting past this stop. It
is only necessary to tighten fittings enough to prevent leakage. Tighten fitting by hand and then use
a tool to engage fitting an additional 1 ½ turns. Use care when using PTFE tape as friction is
reduced considerably; do NOT over-tighten fitting or you may cause damage. If leaks occur,
remove connector, clean off old PTFE tape, re-wrap with one to two additional layers of PTFE tape,
and re-install connector.
2. Fittings (elbows, tees, valves, etc.) restrict flow. For better efficiency, use the fewest possible
fittings. Avoid fittings that could cause an air trap.
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4.5. Electrical
WARNING – All electrical wiring MUST conform to local codes, regulations, and the National
Electric Code (NEC).
WARNING – Ground and bond pump before connecting to electrical power supply. Failure to
ground and bond pump can cause serious or fatal electrical shock hazard. Do NOT ground to a gas
supply line. To avoid dangerous or fatal electrical shock, turn OFF power to pump before working on
electrical connections. Fire Hazard - match supply voltage to pump nameplate voltage. Insure that the
electrical supply available agrees with the pump’s voltage, phase, and cycle, and that the wire size is
adequate for the amps rating and distance from the power source. Use copper conductors only.
4.6. Electrical Specs
1. Voltage: 230VAC, 60Hz, Single Phase
2. Amps: 10.9
3. Speed Range: 600-3450 rpm
Use copper conductors only. For indoor & outdoor use, connect the pump to a 15 amp branch circuit in
accordance with local codes, regulations, and the National Electric Code (NEC). A disconnecting
means located at least 5 ft. from the inside wall of the water vessel must be provided.
4.7. Voltage
Voltage at pump MUST NOT be more than 10% above or below nameplate rated voltage, or
components may overheat, causing overload tripping and reduced component life. If voltage is less than
90% (207 VAC) or more than 110% (253 VAC) of rated voltage (203) when pump is running at full
load, consult the power company.
4.8. Grounding and Bonding
1. Install, ground, bond, and wire pump in accordance with local or national electrical code
requirements.
2. Permanently ground pump. Use green ground terminal provided under access plate; use size and
type wire required by code. Connect ground terminal to electrical service ground.
3. Bond pump to water structure. Bonding will connect all metal parts within and around the water
structure with a continuous wire. Bonding reduces the risk of a current passing between bonded
metal objects, which could potentially cause electrical shock if grounded or shorted. Reference NEC
codes for all wiring standards including, but not limited to, grounding, bonding and general wiring
procedures.
4. Use a solid copper conductor, size 8 or larger. Run wire from external bonding lug to reinforcing
rod or mesh. Connect a No. 8 AWG (8.4 mm2) [No. 6 AWG (13.3 mm2) for Canada] solid copper
bonding wire to the pressure wire connector provided on the motor housing and to all metal parts of
the water structure and to all electrical equipment, metal piping (except gas piping), and conduit
within 5 ft. (1.5 m) of inside walls of the water structure.
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4.9. Wiring
WARNING – All electrical wiring MUST conform to local codes, regulations, and the National
Electric Code (NEC).
1. Pump MUST be permanently connected to circuit. If other lights or appliances are also on the same
circuit, be sure to add their amp loads before calculating wire and circuit breaker sizes. Use the
circuit breaker as the master On-Off switch.
2. If the LifeStar® VS pump is being used to replace an existing pump that was controlled by a
separate mechanical time clock, the LifeStar® VS pump should be connected directly to the line
power supply, bypassing the time clock. The time clock can then be used to power other equipment
that requires the filter pump to be operating when used. If the time clock is used in this manner, it
should be set to power the equipment during a time cycle when the LifeStar® VS pump is operating
at an appropriate flow rate to operate the other equipment, as defined by the timers set in the Timer
Menu. See section 6.7
4.10. Remote Control Wiring/Operation
The LifeStar® VS pump can be controlled in a wide variety of ways as described below:
1. LifeStar® VS pumps can operate by itself in Stand-Alone Mode using its built-in programmable
timers.
2. LifeStar® VS pumps can communicate and be controlled by a variety of Hayward controls. See
Section 5.3 for more information regarding connecting the LifeStar® VS pump and Hayward
controls.
3. LifeStar® VS pumps can also be controlled from third party controls (i.e. another manufacturer's
control) using relay contacts. See Section 5.4 for more information regarding connections with the
LifeStar® VS pump and third party controls.
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4.11. Digital Control Interface Orientation
The Digital Control Interface can be rotated to any of four desired positions after installation by
removing the two screws securing the interface to the motor drive, lifting the interface and rotating it to
the desired position, and replacing the two screws in the new position. (Figure )
Figure 4.11.-1
4.12. Interface Wall Mounting
The interface can also be wall mounted using the parts supplied in the wall mount kit using the
following procedure.
1. TURN OFF THE ELECTRICAL POWER AT THE CIRCUIT BREAKER.
2. Loosen the two screws securing the user interface to the motor drive. (Figure 4.12-1)
3. Disconnect the short cable that extends out from the motor drive. (Figure 4.12-1)
4. Install the blank cover on the motor drive in the desired orientation. This cover is important to
protect internal electronics. (Figure 4. 13-2)
5. Mount the wall mount plate in the desired location. (Figure 4.12-3)
6. Connect the interface cable as shown in the Wall Mounted Digital Control Interface Wiring Diagram
shown in section 5.2 to the motor drive and user interface PCB. Use the multi-conductor, jacketed
cable suitable for the installation location. The cable must be routed through the “DATA” conduit
opening on the motor drive and through the slot provided on the backside of the wall mount plate,
SP3200DR10. Use a liquid tight cord grip that is appropriately sized for the cable being used to seal
the conduit opening. The cable being used may be up to 500 feet in length.
7. Mount the user interface to the wall mount plate using the two screws. (Figure 4.12-3)
8. Apply power to the system and resume normal operation.
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The following diagrams help illustrate the interface wall mounting procedure.
Figure 4.12-1: Removing the Digital Control Interface for Wall Mounting
Figure 4.12-2: Adding the Blank Cover
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Figure 4.12-3: Wall Mounting the Interface
1. TURN OFF THE ELECTRICAL POWER AT THE CIRCUIT BREAKER.
2. Remove the wiring access cover on the motor drive.
3. Connect 230VAC line power supply wiring to the terminal block and ground screw as shown in the Input
Power/Motor Wiring diagram. Wiring must be routed through the conduit opening labeled “POWER”. See section
5.1 for diagram.
4. If the pump will be controlled using a Hayward pool control, connect a two-conductor cable as shown in the
Error! Reference source not found. diagram. See section 5.3.
5. If the pump will be controlled using relay contacts from an external control, connect the INP1-INP3 and
12VAC power out terminals to the external relays as shown in the External Relay Speed Control Wiring
diagram. See section 5.4 and 6.6.Error! Reference source not found..
6. If the installation will use the remote stop feature of the drive, connect INP4 and 12VAC power out terminals
to the remote stop switch as shown in the Remote Stop Wiring diagram. See section 5.5.
7. Wiring for remote control and/or remote stop functions must be routed through the conduit opening labeled
“DATA”. Use a multi-conductor, jacketed cable suitable for the installation location. Use a liquid tight cord grip,
appropriately sized for the cable being used, to seal the conduit opening.
8. Connect the pump to the pool bonding system using 8AWG (6AWG for Canada) wire. A lug for bonding is
provided on the outside of the drive enclosure.
9. After all electrical connections have been made, replace the wiring access cover on the motor drive ensuring
that the motor lead wires are routed such that the wiring access cover can be installed and seated fully
without interference. Tighten the
supplied screw on the access cover.
Note: The wiring access cover must be installed properly to provide environmental protection for the wiring
compartment.
10. Apply power to the system, and proceed to “Configuration Menu”, section 6.6.
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5. Wiring Diagrams
5.1. Input Power/Motor Wiring (Required)
Figure 5.1-1
5.2. Wall Mounted Digital Control Interface Wiring (Optional)
Figure 5.2.-1
Connection wire must be rated for a minimum of 300V, and may be up to 500 feet in length. Use
removable 6-position terminal block connectors for wiring connection to display and motor drive board
taking care to note the wire colors and corresponding numbers next to the connectors. Do not connect to
the upper input terminals shown as light gray above.
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5.3. Hayward Control Wiring (For remote control of pump speed)
Note: For software compatible Hayward Controls Only
Figure 5.3-1
The LifeStar® VS pump can communicate with and be controlled by Hayward controls such as
OmniLogic™, ProLogic®, E-Command® 4, and OnCommand®. Minimum software revision
requirements: OmniLogic R1.0.0, ProLogic 3.00, OnCommand 1.00, E-Command 2.65, E-Command 4
2.80, AquaLogic 2.65, and AquaPlus 2.65. To determine Hayward control software revision, consult the
appropriate Hayward control installation manual or visit our website at www.haywardflowcontrol.com.
Connection wire must be rated for a minimum of 300V, and may be up to 500 feet in length. Use
removable 2-position terminal block connector for wiring connection to motor drive board taking care to
note the wire colors and corresponding numbers next to the connectors. Do not connect to the upper
input terminals shown as light gray above.
Once installed, Remote Control Mode must be set to Standalone/Hayward in the pump Configuration
Menu (see section 6.6), and for all controls other than OmniLogic, Comm Bus Address must be set
according to instructions provided in the Hayward control installation manual (see section 6.6.11). It is
best to leave the max/min allowed speeds in the pump configuration menu set to their factory defaults to
prevent conflict with these settings in the Hayward control configuration menu. Preset Speeds 1-4 and
Quick Clean are disabled when the pump is remotely controlled. Max-speed Prime Period is disabled
only when the pump is communicating with a Hayward control.
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5.4. External Relay Speed Control Wiring (For remote selection of pump speed)
Note: For third party controls and Hayward controls that are NOT software compatible.
Figure 5.4-1
Connection wire must be rated for a minimum of 300V. See section 6.6.Error! Reference source not
found. for more details. Do not connect to the lower “COMBUS” or wall mount “DISPLAY” data
terminals.
The LifeStar® VS pump can also be controlled from third party control using relay contacts to select the
speeds set in the Timer Menu (see section 6.7). In addition to this section you may also consult the third
party control installation manual for electrical connection details. Once installed, Remote Control Mode
must be set to Relay Control in the pump Configuration Menu (see section 6.6). Preset Speeds 1-4 and
Quick Clean are disabled when the pump is remotely controlled. When Inputs 1-3 are activated via the
control relays, timer speeds 1-8 are selected according to the following table:
Timer
Speed
INP1
Status
INP2
Status
INP3
Status
1
OFF
OFF
OFF
2
ON
OFF
OFF
3
OFF
ON
OFF
4
ON
ON
OFF
5
OFF
OFF
ON
6
ON
OFF
ON
7
OFF
ON
ON
8
ON
ON
ON
The number of speeds available depends on the number of auxiliary relays used as noted below:
1. Filter pump relay plus 1 auxiliary relays allows control of 2 speeds
2. Filter pump relay plus 2 auxiliary relays allows control of 4 speeds
3. Filter pump relay plus 3 auxiliary relays allows control of 8 speeds
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5.5. Remote Stop Switch Wiring (Optional)
Figure 5.5-1
Connection wire must be rated for a minimum of 300V. Switch must be latching type; pump is stopped
when circuit is closed.
6. Startup & Operation
6.1. Prior to Start-Up
If it is necessary to perform a water pressure test prior to initial use to ensure plumbing system is
functioning properly, then the following criteria should be maintained for this test:
1. Have a professional perform this test.
2. Ensure all Hayward pump and system components are removed from system prior to performing
test.
WARNING – If circulation equipment must remain in the plumbing system during water pressure
test, do not apply more than 10 psi pressure to the system. Be sure water pressure has been released,
using the filter manual air relief valve, before removing pump strainer cover.
WARNING – All suction and discharge valves MUST be OPEN, as well as filter air relief valve (if
available) on filter, when starting the circulating pump system. Failure to do so could result in severe
personal injury.
6.2. Starting/Priming the Pump
Refer to item #9 in section 6.6 for priming mode selection.
Fill strainer housing with water to suction pipe level. If water leakage occurs from anywhere on the
pump or filter, DO NOT start the pump. If no leakage occurs, stand at least 10 feet from pump and/or
filter and proceed with starting the pump.
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WARNING – Return to filter to close filter manual air relief valve when a steady stream of water
(not air or air and water) is discharged from valve. Failure to do so could result in severe personal
injury.
ATTENTION – NEVER OPERATE THE PUMP WITHOUT WATER. Water acts as a
coolant and lubricant for the mechanical shaft seal. NEVER run pump dry. Running pump dry may
damage seals, causing leakage, flooding, and voids warranty. Fill strainer housing with water before
starting motor.
ATTENTION – Do NOT add chemicals to the system directly in front of pump suction. Adding
undiluted chemicals may damage pump and voids warranty.
ATTENTION – Before removing strainer cover:
1. STOP PUMP before proceeding.
2. CLOSE VALVES in suction and outlet pipes.
3. RELEASE ALL PRESSURE from pump and piping system using filter manual air relief valve. See
filter owner’s manual for more details.
4. If water source is higher than the pump, pump will prime itself when suction and outlet valves are
opened. If water source is lower than the pump, unscrew and remove strainer cover; fill strainer
housing with water.
5. Clean and lubricate strainer cover O-ring with Krytox GPL203 grease if necessary.
6. Replace strainer cover on strainer housing; turn clockwise to tighten cover.
NOTE - Tighten strainer cover lock ring by hand only (no wrenches).
Turn on power and wait for pump to prime, which can take up to fifteen (15) minutes. Priming time will
depend on vertical length of suction lift and horizontal length of suction pipe. If pump does NOT prime
within 15 minutes, stop motor and determine cause. Be sure all suction and discharge valves are open
when pump is running. See Troubleshooting Guide.
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6.3. User Interface Summary
Figure 6.3-1
1. Preset Speeds: Buttons labeled SPEED 1 thru SPEED 4 can be used to run the pump at a
predetermined speed for a certain length of time. Preset Speed settings can be quickly updated using
the + and - arrow buttons to change the speed and then pressing the > button to save the new speed
setting. When a speed is selected, the LED beside the button will illuminate to indicate operation.
a. Default Speeds:
Speed 1: 1000 rpm
Speed 2: 1750 rpm
Speed 3: 2500 rpm
Speed 4: 3250 rpm
2. Menu/navigation buttons: The MENU button will scroll through the setup menus when pressed.
The < and > arrow buttons are used to move between displays and to select parameters to edit, and
the + and - arrow buttons are used to change parameters.
3. Status LEDs: The CHECK SYSTEM LED will illuminate when the pump is experiencing an
error
condition. The TIMERS ACTIVE LED will illuminate once timers have been programmed to run
the pump, even if the pump is not presently running.
4. Stop/Resume: This button is used to stop the pump to allow strainer basket cleaning, etc. When
this button is pressed, the pump will remain stopped until the button is pressed a second time to
resume normal operation. When the pump is stopped, the red LED beside the button will illuminate
to indicate that the pump has been stopped.
5. Quick Clean: QUICK CLEAN is a mode intended for use when the water vessel will be cleaned
with a suction side vacuum.
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6.4. Menu Outline
1. Configuration Menu (see section 6.6 for basic product configuration)
a. Set Day and Time
b. Speed Selection
c. MAX Allowed Speed
d. MIN Allowed Speed
e. Prime Duration
f. Remote Control Mode
g. Set Comm Bus Address
h. SVRS Restart
i. Low Temp Operation
j. Low Temp Speed
k. Drive Temp Setting
2. Timer Menu (see section 6.7 to program the 8 speeds with timer functions)
a. Rename Timer “X” (where “X” equals 1 through 8)
b. Pump Speed for Timer “X” (where “X” equals 1 through 8)
c. Start/Stop Time for Timer “X” (where “X” equals 1 through 8)
d. Choose Days for Timer “X” (where “X” equals 1 through 8)
3. Preset Speed Setup Menu (see section 6.8 to program the 4 preset speeds)
a. Speed “X” Name (where “X” equals 1 through 4)
b. Speed “X” Duration (where “X” equals 1 through 4)
c. Speed “X” Speed (where “X” equals 1 through 4)
4. Diagnostics Menu (see section 6.9 to view product diagnostic information)
a. Drive Serial Number
b. Motor Display/Drive Firmware Revisions
c. Input Voltage Status
d. Motor Current
e. Power Usage
f. Drive/Heat sink Temperatures
g. Comm Bus Status
h. Event Log (if applicable)
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