HAYWARD GL-235 Operation Manual

5-Year Limited Solar Warranty

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.

Hayward warrants its Hayward solar products to be free from defects in material or workmanship, 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 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, contractor, 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

Years 1-3: no charge Years 4-5 60% of current list price plus $5.00 shipping and handling

Aqua Solar

GL-235

Electronic Solar Control

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 nominal fee to cover inspection, test, and return freight for all controls where no faults or problems are detected. All charges will be COD (COD charge will be included) unless you 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 Hayward product. Products that exhibit evidence of abuse, misuse, field damage (water/fire damage, line voltage applied to low voltage terminals, missing parts, etc.) or installed for more than the warranty period are not eligible for warranty repair replacement.

620 Division St. Elizabeth, NJ 07207

092007G RevH

Operation and Installation

Manual

GL-235

www.haywardnet.com

Description

26,100 3.61809,29

2.41

120

1.37160

1,688

0.72

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, calibrated 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.

Input power can be either 115 or 240 VAC. The output controls a 24VAC 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.

195-250VAC, .3A 50/60Hz

Output: Selectable low voltage

24VAC, 20VA, .85A or 12VAC, 20VA, 1.7A

SPST-NO isolated contact 115VAC 1HP 240VAC 2HP

Sensors: 2 required (thermistor, 10Kohm @ 25C/77ºF).

Differential: on at 4ºF, off at 1.5ºF

Desired Pool Temp.: 70-104ºF calibrated scale

or Solar Off, 75 (24ºC) 104ºF (40ºC) on some models

Recirculate freeze: On at <40ºF (4.5ºC), off at

> 42ºF (5.5ºC), Enabled via jumper

Nocturnal cooling: On when collector 8ºF

less than pool and pool hotter than limit, off when collector 3ºF less than pool or pool cooler than high limit. Enabled via jumper

Installation

Mounting

The GL-235 is designed for outdoor use. Mount the box vertically with the knockouts facing downward. For safety, the GL-235 must be a minimum of 5 feet (horizontally) from the pool or spa.

Power input

Turn off power at circuit breaker before wiring. Remove the internal panel to expose the wiring connections. Either 115VAC or 240VAC can be used. Refer to the input wiring diagram (Figure 1) on next page. WARNING: Applying 240VAC to the 120VAC input

terminals will cause permanent damage to the 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.

With the sensor disconnected from the unit, measure the resistance of the sensor using an ohmmeter. At room temperature (25ºC/77ºF) the sensor should measure approximately 10K ohms (10,000 ohms ± 1%). For other resistance 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 SENSOR”. If the “CHECK SENSOR” indicator remains on, the unit is defective and needs to be replaced.

If FREEZE PROTECTION is enabled:

When a sensor is disconnected from the unit 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 25ºC/77ºF. 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 ±0.5ºF. 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.

°F Ohm sVolts °F OhmsVolts °F OhmsVolts °F OhmsVolts

1 82,719 4.46 41 25,391 3.59 81 9,076 2.38 121 3,679 1.34 2 80,142 4.45 42 24,704 3.56 82 8,861 2.35 122 3,602 1.32 3 77,656 4.43 43 24,037 3.53 83 8,651 2.32 123 3,527 1.30 4 75,255 4.41 44 23,391 3.50 84 8,447 2.29 124 3,454 1.28 5 72,937 4.40 45 22,764 3.47 85 8,249 2.26 125 3,382 1.26 6 70,698 4.38 46 22,156 3.45 86 8,056 2.23 126 3,312 1.24 7 68,535 4.36 47 21,566 3.42 87 7,867 2.20 127 3,244 1.22 8 66,447 4.35 48 20,993 3.39 88 7,684 2.17 128 3,177 1.21

9 64,428 4.33 49 20,438 3.36 89 7,506 2.14 129 3,112 1.19 10 62,479 4.31 50 19,900 3.33 90 7,333 2.12 130 3,049 1.17 11 60,595 4.29 51 19,377 3.30 91 7,164 2.09 131 2,987 1.15 12 58,774 4.27 52 18,870 3.27 92 6,999 2.06 132 2,926 1.13 13 57,014 4.25 53 18,377 3.24 93 6,839 2.03 133 2,867 1.11 14 55,313 4.23 54 17,899 3.21 94 6,683 2.00 134 2,809 1.10 15 53,669 4.21 55 17,435 3.18 95 6,530 1.98 135 2,752 1.08 16 52,078 4.19 56 16,985 3.15 96 6,382 1.95 136 2,697 1.06 17 50,541 4.17 57 16,548 3.12 97 6,238 1.92 137 2,643 1.05 18 49,054 4.15 58 16,123 3.09 98 6,097 1.89 138 2,591 1.03 19 47,616 4.13 59 15,711 3.06 99 5,960 1.87 139 2,539 1.01 20 46,225 4.11 60 15,310 3.02 100 5,827 1.84 140 2,489 1.00 21 44,879 4.09 61 14,921 2.99 101 5,697 1.81 141 2,440 0.98 22 43,577 4.07 62 14,543 2.96 102 5,570 1.79 142 2,392 0.97 23 42,318 4.04 63 14,176 2.93 103 5,446 1.76 143 2,345 0.95 24 41,099 4.02 64 13,820 2.90 104 5,326 1.74 144 2,299 0.93 25 39,919 4.00 65 13,473 2.87 105 5,208 1.71 145 2,254 0.92 26 38,777 3.97 66 13,136 2.84 106 5,094 1.69 146 2,210 0.90 27 37,671 3.95 67 12,809 2.81 107 4,982 1.66 147 2,167 0.89 28 36,601 3.93 68 12,491 2.78 108 4,873 1.64 148 2,125 0.88 29 35,565 3.90 69 12,182 2.75 109 4,767 1.61 149 2,084 0.86 30 34,561 3.88 70 11,882 2.72 110 4,664 1.59 150 2,044 0.85 31 33,590 3.85 71 11,589 2.68 111 4,563 1.57 151 2,005 0.84 32 32,648 3.83 72 11,305 2.65 112 4,464 1.54 152 1,966 0.82 33 31,737 3.80 73 11,029 2.62 113 4,368 1.52 153 1,929 0.81 34 30,853 3.78 74 10,761 2.59 114 4,274 1.50 154 1,892 0.80 35 29,998 3.75 75 10,500 2.56 115 4,183 1.47 155 1,856 0.78 36 29,169 3.72 76 10,246 2.53 116 4,094 1.45 156 1,821 0.77 37 28,365 3.70 77 9,999 2.50 117 4,007 1.43 157 1,787 0. 76 38 27,587 3.67 78 9,758 2.47 118 3,922 1.41 158 1,753 0. 75 39 26,832 3.64 79 9,525 2.44 119 3,839 1.39 159 1,720 0. 73

,758

All controls are shipped with the output voltage set to the industry standard 24VAC. To use the GL-235 with older 12VAC valves, move jumper J4, located on the right side of the circuit board.

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