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HAYWARD GL-235 Operation Installation Manual

1. da o VAC e e FILTER FILTER TIMER PUMP GL 235 high voltage output used for Timer Override Figure 3
2. Measuring Voltage of Pool Sensor Use the same method to measure the Solar Sensor Figure 5 NOCTURNAL COOL ENABLE RECIRCULATE FREEZE PROTECTION POOL OR SPA T 7 OONN SOLAR SENSOR A FUSE VALVE MOTOR mp oe SELECT VALVE ACTUATOR CONNECTOR LS A BOOSTER EE PUMP 240 e VAC FILTER FILTER TIMER PUMP 115 240 VAC FROM SEPARATE CIRCUIT GL 235 high voltage output used for Booster Pump Figure 4 Operation For normal operation place the switch in the AUTO position and adjust the desired pool spa temperature setting The Power LED indicator should always be on NOTE During initial powerup the POWER indicator will blink for approximately 10 seconds while it stabilizes temperature readings The Heating LED indicator will show when the system is collecting solar heat If the nocturnal cooling function is enabled inside the GL 235 the Cooling LED indicator will show when the system is dissipating excess heat Inthe AUTO position the GL 235 will heat the pool or spa rotate valve to solar loop when the collector solar sensor temperature is higher than the pool spa sensor temperature by 4 F or more AND the pool spa temperature is less than the Desired Temperature setting The GL 235 will stop heating return valve to pool lo
3. when the GL 235 senses a freeze condition at the collector sensor it will allow circulation of relatively warm water from the pool to the collector panels The GL 235 willallow recirculation when the collector temperature falls below 40 F and will stop circulation when the collector temperature rises above 42 F While this type of freeze protection has proven to be adequate in relatively mild climates it is extremely important that the sensors be properly placed and that the homeowner realize that the system is unprotected in the event ofa power failure Recirculate freeze protection is NOT recommended in climates where freezing temperatures are common or last for extended periods Hayward strongly recommends the use of GC 3 freeze snap switches if freeze protection is being utilized Snap switches should be wired in series with the collector sensor Placement of the snap switches at the coldest point of the collector array and exposed plumbing will help assure that freeze protection starts early enough to protect the system The GL 235 is shipped from the factory with recirculate freeze protection disabled the jumper is present but installed on one pin only To activate recirculate freeze protection install the jumper across both pins marked RECIRC located near the top right of the main circuit board Ifrecirculate freeze protection is to be used on a GL 235 either e The filter pump must be set for continuous operation or e The
4. GL235 High Voltage Output must be wired for Timer Override function Nocturnal Cooling The GL 235 has nocturnal cooling logic which can be enabled disabled via a jumper on the main circuit board During nighttime hours when enabled the GL 235 will circulate relatively warmer water from the pool to the collector panels thus cooling the pool over time The GL 235 will circulate water when the collector temperature AND the pool temperature is hotter than the high limit setting Circulation will stop when the collector temperature is 3 F less than the pool temperature OR the pool temperature is cooler than the high limit setting The GL 235 is shipped from the factory with nocturnal cooling disabled the jumper is present but installed on one pin only To activate nocturnal cooling install the jumper provided onto the two pins marked COOLING located near the top right of the main circuit board Ifnocturnal cooling is to be used either e The filter pump must be set for continuous operation or e The GL235 High Voltage Output must be wired for Timer Override function NOCTURNAL COOL ENABLE RECIRCULATE FREEZE PROTECTION POOL OR SPA N SENSOR SOLAR SENSOR 2 AMP ATO 2 ee VALVE MOTOR a tT T VOLTAGE SELECT VALVE ACTUATOR CONNECTOR i A fos VAC FILTER FILTER TIMER PEME
5. of manual If the sensor is not returning the correct value it is defective and will need to be replaced If the sensor is returning approximately the correct value reconnect it to the terminals marked POOL SENSOR If the CHECK SENSOR indicator remains on the unit is defective and needs to be replaced CHECK SENSOR indicator blinking If the CHECK SENSOR indicator is blinking there may be a possible open circuit or short circuit with the solar sensor Using a voltmeter measure the voltage across the terminals of the solar sensor If the voltage is close to zero volts the sensor has a short to ground Remove the sensor from the terminal block and measure the voltage across the solar terminals again If the voltage is still close to zero volts there is an internal short and the unit must be returned for repair If the voltage is close to five volts the solar sensor itself may be at fault 10 The GL 235 provides two different types of connections to the pool spa actuators For older actuators withno wire end connector a3 position terminal block is used Connect the wires to the proper terminal block according to the color code shown in Figure 4 If the valve operates opposite to the way it is supposed to reverse the red and white wires Becareful notto short the valve output wiring The GL 235 is fused and shorting the output will require replacing the fuse For newer Hayward Compool and Jandy actuators with wire
6. 2 18 870 3 27 92 6 999 2 06 132 2 926 1 13 57 014 4 25 53 18 377 3 24 93 6 839 2 03 133 2 867 1 11 55 313 4 23 54 17 899 3 21 94 6 683 2 00 134 2 809 1 10 53 669 4 21 55 17 435 3 18 95 6 530 1 98 135 2 752 1 08 52 078 4 19 56 16 985 3 15 96 6 382 1 95 136 2 697 1 06 50 541 4 17 57 16 548 3 12 97 6 238 1 92 137 2 643 1 05 49 054 415 58 16 123 3 09 98 6 097 1 89 138 2 591 1 03 47 616 413 59 15 711 3 06 99 5 960 1 87 139 2 539 1 01 46 225 4 11 60 15 310 3 02 100 5 827 1 84 140 2 489 1 00 44 879 4 09 61 14 921 2 99 101 5 697 1 81 141 2 440 0 98 43 577 4 07 62 14 543 2 96 102 5 570 1 79 142 2 392 0 97 42 318 4 04 63 14 176 2 93 103 5 446 1 76 143 2 345 0 95 41 099 4 02 64 13 820 2 90 104 5 326 1 74 144 2 299 0 93 39 919 4 00 65 13 473 2 87 105 5 208 1 71 145 2 254 0 92 38 777 3 97 66 13 136 2 84 106 5 094 1 69 146 2 210 0 90 37 671 3 95 67 12 809 2 81 107 4 982 1 66 147 2 167 0 89 36 601 3 93 68 12 491 2 78 108 4 873 1 64 148 2 125 0 88 35 565 3 90 69 12 182 2 75 109 4 767 1 61 149 2 084 0 86 34 561 3 88 70 11 882 2 72 110 4 664 1 59 150 2 044 0 85 33 590 3 85 71 11 589 2 68 111 4 563 1 57 151 2 005 0 84 32 648 3 83 72 11 305 2 65 112 4 464 1 54 152 1 966 0 82 31 737 3 80 73 11 029 2 62 113 4 368 1 52 153 1 929 0 81 30 853 3 78 74 10 761 2 59 114 4 274 1 50 154 1 892 0 80 29 998 3 75 75 10 500 2 56 115 4 183 1 47 155 1 856 0 78 29 169 3 72 76 10 246 2 53 116 4 0
7. 5 Year Limited Solar Warranty Aq ua S O la r This Five Year Limited Warranty statement is only applicable to Solar controls and accessories sold and installed within the USA and Canada and supersedes any warranty statements dated prior to November 1 2010 2 Ll Hayward warrants its Hayward solar products to be free from defects in material or workmanship 4 under normal use and service for 5 years from date of manufacture providing it is installed according to the installation instructions and specifications The datecode stamped on the outside of the product and also coded on the printed circuit board will be the sole determination of manufacturing date To obtain warranty service or repair please contact the place of purchase or the nearest Hayward O HAYWARD kes authorized warranty service center For more information please contact the Hayward Technical Service Support Center or visit us on the web at www haywardnet com Hayward will not assume any of the cost incurred in removal or reinstallation of the product One year outside the USA and Canada The express warranty above constitutes the entire warranty of Hayward Pool Products with respect to its solar products and IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING A WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL HAYWARD BE RESPONSIBLE OR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER No wholesaler agent dealer contrac
8. 94 1 45 156 1 821 0 77 28 365 3 70 77 9 999 2 50 117 4 007 1 43 157 1 787 0 76 27 587 3 67 78 9 758 2 47 118 3 922 1 41 158 1 753 0 75 26 832 364 79 9 525 2 44 119 3 839 1 39 159 1 720 0 73 26 100 3 61 80 9 297 2 41 120 3 758 1 37 160 1 688 0 72 BROWWOWHAWHWWWONNNNNNNNNNSSS2S2aaaaaan R SO BDVNATRONADOHINAGRONSSCOBVNATEONSZOOPVNAARON AH 11 Troubleshooting No Power Indicator e Check main power circuit breakers e Check fuse Fuse Replacement The GL 235 is protected by a fuse located on the left side of the main circuit board Replace the fuse with a 2A type ATO 2 fuse readily available in most automotive or electronics stores If Heating is always on Disable recirculate freeze protection if enabled Check that the switch is inthe AUTO position Next verify that the control circuitry is operating properly by disconnecting the solar sensor from the terminal block The Heating LED should go off and the CHECK SENSOR LED should begin to blink If Heating remains on there is an internal circuit failure and the GL 235 will have to be returned for repair If Heating never comes on Verify that the switch is in the AUTO position the desired pool temperature dial is set higher hotter that the actual pool temperature and the solar sensor is warmer than the pool water Also check that the switch on the valve actuator is NOT in the OFF position Disconnect the poo
9. ed water temperature high limit Automatic nocturnal cooling for pools that overheat in hot climates and recirculate freeze protection functions can be enabled disabled via internal jumpers Inputpower can be either 115 or240 VAC Theoutputcontrolsa24V AC automatic valve actuator For older systems with 12VAC valves an internal jumper can be moved to select 12VAC output operation The GL 235 also has a high voltage output for controlling a filter pump or booster pump Specifications Power 105 130VAC 5A 50 60Hz se or 00 195 250VAC 3A 50 60Hz Temp 70 104 F calibrated scale or Solar Off 75 24 C Output Selectable low voltage 104 F 40 C on some 24VAC 20VA 85A models or 12VAC 20VA 1 7A Recirculate freeze Onat lt 40 F 4 5 C offat SPST NO isolated contact 242 F 5 5 C 115VAC 1HP Enabled viajumper 240VAC2HP Nocturnal cooling On when collector 8 F less than pool and pool hotterthan limit off when collector 3 F less than Sensors 2 required thermistor 10Kohm 25C 77 F pool or pool cooler than Differential on at 4 F offat 1 5 F high limit Enabled via jumper Installation Mounting The GL 235 is designed for outdoor use Mount the box vertically with the knockouts facing downward Forsafety the GL 235 must be aminimum of5 feet horizontally from the pool or spa Power input Turn off power at circuit breaker before wiring Remove the internal panel to expose the wiringconnections Eithe
10. end connectors two 3 pin connectors are supplied Plug the actuator into one of the two 3 pin connectors as shown in figures 2 or 3 Ifthe valve operates opposite to the way it is supposed to disconnect and plug into the other connector High Voltage HV output Booster Pump The GL 235 can control a high voltage booster pump in addition to the normal low voltage solar valve Note the high voltage relay contacts are isolated so thatthe booster pump can be run on a separate circuit as required by many local codes The GL 235 ae on the valve output will operate first and then the HV relay will operate 30 seconds ater High Voltage HV output Timeclock Override The GL 235 can also be used to override the filter pump timer This is very important ifrecirculate freeze protection or nocturnal cooling functions are being used Also this function can be used on systems where the system should operate whenever solar heat is available regardless of the timer settings The HV relay will operate approximately 30 seconds after the LV relay Sensor Mounting and Wiring Most installations use a PC sensor to measure the pool temperature and another PC sensor to measure the solar temperature Alternatively an SC 4 sensor can be screwed into the pump strainer basket to measure the pool temperature Pool Sensor Drilla3 8 or 5 16 hole in the PVC pipe Remove burrs around the hole Check that the O ring is seated on the PC sensor and then in
11. it and freeze protection has been enabled the GL 235 will recognize this as a freeze condition and activate freeze protection Temperature Resistance Voltage All Hayward controls use 10K thermistor sensors When disconnected from the control the sensor will read 10K ohms at 25 C 77 F Refer to the chart below for the resistance at other temperatures For a given temperature the resistance reading should be accurate to 1 For a given resistance reading the temperature reading should be accurate to 0 5 F Voltage measurements should be accurate to 2 Ohm measurements made with sensor disconnected from unit Voltage measurements made with sensor connected to unit and power applied Sensor voltages are DC volts Ohms Volts F Ohms Volts F Ohms Volts F Ohms Volts 82 719 446 41 25 391 3 59 81 9 076 2 38 121 3 679 1 34 80 142 4 45 42 24 704 3 56 82 8 861 2 35 122 3 602 1 32 77 656 443 43 24 037 3 53 83 8 651 2 32 123 3 527 1 30 75 255 4 41 44 23 391 3 50 84 8 447 2 29 124 3 454 1 28 72 937 440 45 22 764 3 47 85 8 249 2 26 125 3 382 1 26 70 698 4 38 46 22 156 3 45 86 8 056 2 23 126 3 312 1 24 68 535 4 36 47 21 566 3 42 87 7 867 2 20 127 3 244 1 22 66 447 4 35 48 20 993 3 39 88 7 684 2 17 128 3 177 1 21 64 428 4 33 49 20 438 3 36 89 7 506 2 14 129 3 112 1 19 62 479 4 31 50 19 900 3 33 90 7 333 2 12 130 3 049 1 17 60 595 4 29 51 19 377 3 30 91 7 164 2 09 131 2 987 1 15 58 774 4 27 5
12. l sensor from the terminal block and verify that the CHECK SENSOR LED turns on Ifthe CHECK SENSOR LED does notturn on there is an internal failure and the GL 235 will have to be returned for repair Reconnect the pool sensor and verify that the Check Sensor LED turns off Next disconnect the solar sensor from the terminal block and verify that the CHECK SENSOR LED begins to blink Ifthe CHECK SENSOR LED does not begin to blink thereis an internal failure and the GL 235 will have to be returned for repair CHECK SENSOR indicator on Ifthe CHECK SENSOR indicator is onand NOT blinking there may bea possible open circuit or short circuit with the pool sensor Using a voltmeter measure the DC voltage across the terminals of the pool sensor as indicated in figure 5 If the voltage is close to zero volts the sensor has a short to ground Remove the sensor from the terminal block and measure the voltage across the pool terminals again Ifthe voltage is still close to zero volts there is an internal short and the unit must be returned for repair Ifthe voltage is close to five volts the pool sensor itself may be at fault With the sensor disconnected from the unit measure the resistance of the sensor using an ohmmeter At room temperature 25 C 77 F the sensor should measure approxi mately 10K ohms 10 000 ohms 1 For other resistance measurements at different temperatures consult the table at back
13. op when the two sensor temperatures get to within 1 5 F OR the pool spa sensor is above the Desired Temperature setting To test the system move the switch to MANUAL TEST and verify that both the Heating and Cooling indicators light and that the valve s are in the solar loop position Move the switch to MANUAL OFF and verify that all indicators except Power are off The valve s should be in the normal recirculating loop position If the valve s positions are working inreverse follow the instructions in section marked Low Voltage LV Solar Valve to correct WARNING If recirculate freeze protection is being used do NOT leave the switch in the MANUAL OFF position during cold weather Also note that the switch does NOT turn power off to the GL 235 NOCTURNAL COOL ENABLE RECIRCULATE FREEZE PROTECTION POOL OR SPA L SENSOR fe n OONN c SOLAR SENSOR 2 AMP FUSE VALVE MOTOR e VOLTAGE SELECT VALVE ACTUATOR CONNECTOR J 240 e E VAC FILTER FILTER TIMER PUMP Basic Installation ofGL 235 Figure 2 NOCTURNAL COOL ENABLE RECIRCULATE FREEZE PROTECTION POOL OR SPA SENSOR 2 e SOLAR SENSOR 2 AMP FUSE VALVE MOTOR iol a VOLTAGE SELECT VALVE ACTUATOR E CONNECTOR
14. r 115VAC or240VAC canbeused Referto the input wiring diagram Figure onnextpage WARNING Applying 240VAC tothe 120VAC input terminals will cause permanent damage tothe control Grounding Refer to NEC and local codes for specific grounding requirements In general a separate ground conductor must be run to the ground terminal on the pool service panel Low Voltage LV output Solar Valve The GL 235 controls a single valve In most applications this is the solar valve which diverts water through the collector panels or through the normal pool loop depending on conditions All controls are shipped with the output voltage set to the industry standard 24VAC Touse the GL 235 with older 12 VAC valves move jumper J4 located on the right side of the circuit board 2 With the sensor disconnected from the unit measure the resistance of the sensor using an ohmmeter At room temperature 25 C 77 F the sensor should measure approxi mately 10K ohms 10 000 ohms 1 For otherresistance measurements at different temperatures consult the table at back of manual If the sensor is not returning the correct value it is defective and will need to be replaced If the sensor is returning approximately the correct value reconnect it to the terminals marked SOLAR SEN SOR Ifthe CHECK SENSOR indicator remains on the unit is defective and needs to be replaced IfFREEZE PROTECTION is enabled When a sensor is disconnected from the un
15. sert sensor into pipe Tighten hose clamp over the sensor to make a seal DO NOT OVERTIGHTEN Solar Sensor Use a screw or silicon adhesive to attach the sensor near the solar collector array The sensor does not have to be attached to the collectors It is only important that the sensor be exposed to the same sunlight as the collectors Addition ally the underside ofthe sensing element may be covered with silicon to minimize wind cooling Other 10K ohm Hayward sensors may be substituted Wire should be twisted pair 20AWG Sensor wiring run outdoors must be rated for outdoor use and ensure that the wire connections are protected from the weather Do NOT run sensor wires in the same conduit or multiconductor cable as the valve actuator wires or any 120 240V circuit For long runs or runs near other electrical wiring use shielded cable Belden 8428 for outdoor use Ground the shields to the GL 35 LV ground screw 7 2 2 2 2 2 a olala EARTH o high EARTH o high GROUND voltage GROUND voltage output output 240 VAC 115 VAC input power input power Figure 1 Freeze Protection If you are relying on the collectors naturally draining to provide freeze protection it is very important that you use a non positive seal valve or drill a hole 1 8 1 4 in the diverter of a positive seal valve to allow the collectors to drain Alternatively the GL 235 control can provide recirculate freeze protection If enabled
16. tor or other person is authorized to give any warranty on behalf of Hayward This warranty is void if the product has been altered in any way after leaving the factory Charges Electronic Solar Control Years 1 3 no charge Years 4 5 60 of current list price plus 5 00 shipping and handling Unless a copy of the original purchase invoice is enclosed the manufacturing datecode on the product will be used to determine the repair charges Hayward reserves the right to charge a z s nominal fee to cover inspection test and return freight for all controls where no faults or O p t d l t l t problems are detected All charges will be COD COD charge will be included unless you e ra l O n a n n S a a l O n already have an open account in good standing with Hayward If the product returned can not be repaired Hayward will offer and equivalent credit towards the purchase of any new M a n u a l Hayward product Products that exhibit evidence ofabuse misuse field damage water fire damage line voltage applied to low voltage terminals missing parts etc or installed for GL 235 more than the warranty period are not eligible for warranty repair replacement OHAYWARD 620 Division St j ivision St Eno aie Q HAYWARD www haywardnet com Elizabeth NJ 07207 Description The GL 235 is a differential temperature control for solar heating of pools spas and hot tubs It provides differential temperature control with an adjustable calibrat

HAYWARD GL-235 Operation Installation Manual

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