Hayward TriStar VS SP3200VSP, TriStar VS SP3200VSPND Owner's Manual

IS3200VSP Rev-C
TriStar® VS
Owner’s Manual
Models SP3200VSP, SP3200VSPND
TriStar VS Variable Speed Pump
Hayward’s TriStar VS variable speed pump delivers incredible energy savings via its advanced hydraulic design combined with a totally enclosed, permanent magnet motor. TriStar VS is easily installed either as a programmable stand-alone pump or with a Hayward or third party controller and features an easy­to-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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Hayward Pool Products
620 Division St, Elizabeth, NJ 07201
Phone: (908) 351-5400
www.haywardpool.com
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS .............................................................................................................. 4
2. General Information ..................................................................................................................................... 7
2.1. Introduction 7
2.2. Primary Features 7
2.3. Product Dimensions 7
3. Energy Efficiency Overview .......................................................................................................................... 8
4. Installation and Wiring ................................................................................................................................ 8
4.1. Pump Location 8
4.2. Pump Mounting 9
4.3. Pipe Sizing Chart 9
4.4. Plumbing 9
4.5. Electrical 10
4.6. Electrical Specs 10
4.7. Voltage 10
4.8. Grounding and Bonding 10
4.9. Wiring 10
4.10. Remote Control Wiring/Operation 11
4.11. Digital Control Interface Orientation 11
4.12. Interface Wall Mounting 12
4.13. Installation Procedure 14
5. Wiring Diagrams......................................................................................................................................... 15
5.1. Input Power Wiring (Required) 15
5.2. Wall Mounted Digital Control Interface Wiring (Optional) 15
5.3. External Relay Speed Control Wiring (For remote selection of pump speed) 16
5.4. Hayward Pro Logic Control Wiring (For remote control of pump speed) 17
5.5. Remote Stop Switch Wiring (Optional) 18
6. Startup & Operation ................................................................................................................................... 18
6.1. Prior to Start-Up 18
6.2. Starting/Priming the Pump 19
6.3. User Interface Summary 20
6.4. Menu Outline 21
6.5. Initial startup 21
6.6. Configuration Menu 22
6.7. Timer Menu 23
6.8. Preset Speed Setup Menu 24
6.9. Diagnostic Menu 24
6.10. Stop/Resume 25
6.11. Quick Clean 25
6.12. Remote Stop 26
7. Maintenance............................................................................................................................................. 26
8. Storage / Winterization ............................................................................................................................. 26
8.1. Storing Pump For Winterization 26
9. Shaft Seal Change Instructions ................................................................................................................... 27
9.1. Removing the Motor Assembly 27
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Page 2 of 36 TriStar VS Pump IS3200VSP Rev-C
9.2. Removing the Impeller 27
9.3. Removing the Ceramic Seat 27
9.4. Seal Installation 27
9.5. Replacing the Impeller and Diffuser 28
9.6. Replacing the Motor Assembly 28
10. Replacement Parts .................................................................................................................................... 28
10.1. Parts Diagram 28
10.2. Parts Listing 29
11. Troubleshooting .........................................................................................................................................30
11.1. General Problems 30
11.2. Error Messages 32
12. Warranty .................................................................................................................................................... 33
13. Product Registration ................................................................................................................................... 33
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Page 3 of 36 TriStar VS Pump IS3200VSP Rev-C
Basic safety precautions should always be followed, including the following: Failure to follow instructions may result in
1. IMPORTANT SAFETY INSTRUCTIONS
Before installing or servicing this electrical equipment, turn power supply OFF.
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.
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. Closely
supervise children at all times. Components such as the filtration system, pumps, and heaters must be positioned to prevent children from using them as a means of access to the pool.
CAUTION – This pump is intended for use on permanently installed swimming pools and may also be used
with hot tubs and spas if so marked. Do NOT use with storable pools. A permanently installed pool is constructed in or on the ground or in a building such that it cannot be readily disassembled for storage. A storable pool is constructed so that it is capable of being readily disassembled for storage and reassembled to its original integrity. Though this product is designed for outdoor use, 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 the skirt of a hot tub or spa, adequate ventilation and free circulation of air must be provided to prevent overheating of the motor.
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Page 4 of 36 TriStar VS Pump IS3200VSP Rev-C
WARNING – Pool and spa 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.
WARNINGRisk 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. Locate conduit to
prevent abuse from lawn mowers, hedge trimmers and other equipment.
WARNINGRisk 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 pool 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 swimming pool, spa, or hot tub, and to all electrical equipment, metal piping (except gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming pool, spa, or hot tub. 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 (symbols complements of APSP):
Hair Entrapment - Hair can become entangled in suction outlet cover. Limb Entrapment - A limb inserted into an opening of a suction outlet sump or suction outlet cover that is damaged,
broken, cracked, missing, or not securely attached can result in a mechanical bind or swelling of the limb. Body Suction Entrapment - A differential pressure applied to a large portion of the body or limbs can result in an
entrapment. Evisceration/ Disembowelment - A negative pressure applied directly to the intestines through an unprotected
suction outlet sump or suction outlet cover which is damaged, broken, cracked, missing, or unsecured can result in evisceration/disembowelment.
Mechanical Entrapment - There is potential for jewelry, swimsuits, hair decorations, fingers, toes, or knuckles to be caught in an opening of a suction outlet cover resulting in mechanical entrapment.
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Page 5 of 36 TriStar VS Pump IS3200VSP Rev-C
WARNING – To Reduce the risk of Entrapment Hazards:
When outlets are small enough to be blocked by a person, a minimum of two functioning suction outlets per
pump must be installed. Suction outlets in the same plane (i.e. floor or wall), must be installed a minimum of three feet (3’) [0.91 meter] apart, as measured from near point to near point.
Dual suction fittings shall be placed in such locations and distances to avoid “dual blockage” by a user. Dual suction fittings shall not be located on seating areas or on the backrest for such seating areas. The maximum system flow rate shall not exceed the values shown in the “Pipe Sizing Chart” found in section
4.3 below.
Never use pool or spa if any suction outlet component is damaged, broken, cracked, missing, or not securely
attached.
Replace damaged, broken, cracked, missing, or not securely attached suction outlet components
immediately.
In addition to two or more suction outlets per pump installed in accordance with latest APSP standards and
CPSC guidelines, follow all national, state, and local codes applicable.
Installation of a vacuum release or vent system, which relieves entrapping suction, is recommended.
WARNING – Hazardous Pressure. Pool and spa 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 pool and spa 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 pool. 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 pool and spa 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 pool and spa circulation system if a system component is not assembled properly, damaged, or missing. Do not operate pool and spa 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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Page 6 of 36 TriStar VS Pump IS3200VSP Rev-C
2. General Information
2.1. Introduction
This manual contains information for the proper installation and operation of the Hayward TriStar VS 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
(SP3200VSP only)
For enhanced pool management, can be controlled by Hayward (SP3200VSPND only) or third party (SP3200VSP
only) pool and spa 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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Page 7 of 36 TriStar VS Pump IS3200VSP Rev-C
3. Energy Efficiency Overview
The energy consumed by a pool pump is measured in terms of Watts (W) or Kilowatts (kW). The TriStar VS 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: TriStar VS 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 in the pool at least once every 24 hours. Check with local requirements for the minimum turnover rate. 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.
Equipment such as heaters, skimmers, and chlorinators require minimum flows to operate correctly. Refer to individual equipment manuals for specific flow requirements.
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 over the skimmer weirs. 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 pool 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 outdoor use, it is advised to place pump and filter 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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Page 8 of 36 TriStar VS Pump IS3200VSP Rev-C
Pipe Size
Maximum Flow Rate
Minimum Straight
Pipe
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]
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
in. [mm]
* 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 TriStar 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.
WARNING – Hazardous Pressure. Pumps, filters, and other equipment/ components of a swimming pool
filtration system operate under pressure. Incorrectly installed and/or improperly tested filtration equipment and/or components may fail resulting in severe personal injury or death.
GPM [LPM]
Length “L” in. [mm] *
4.4. Plumbing
1. Use Teflon 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 Teflon 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 Teflon tape as friction is reduced considerably; do NOT over-tighten fitting or you may cause damage. If leaks occur, remove connector, clean off old Teflon tape, re-wrap with one to two additional layers of Teflon 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. Pool and spa fittings MUST conform to the International Association of Plumbing and Mechanical Officials (IAPMO) standards.
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Page 9 of 36 TriStar VS Pump IS3200VSP Rev-C
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: 0.4 - 11.0
3. Speed Range: 600-3450 rpm Use copper conductors only. For indoor & outdoor use. Connect 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 pool, spa, or hot tub 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 (230VAC) 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 pool structure. Bonding will connect all metal parts within and around the pool 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 swimming pool, spa, or hot tub, and to all electrical equipment, metal piping (except gas piping), and conduit within 5 ft. (1.5 m) of inside walls of swimming pool, spa, or hot tub.
4.9. Wiring
WARNING – All electrical wiring MUST conform to local codes, regulations, and 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 TriStar VS pump is being used to replace an existing pump that was controlled by a separate mechanical
time clock, the TriStar 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 (such as a heater, heat pump, or booster pump) that requires the filter pump to be operating when used. If the time clock is used in this manner, it should be set to
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Page 10 of 36 TriStar VS Pump IS3200VSP Rev-C
power the equipment during a time cycle when the TriStar 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
TriStar VS can be controlled in a wide variety of ways as described below:
1. TriStar VS (SP3200VSP) can operate by itself in Stand-Alone Mode using its built-in programmable timers.
2. TriStar VS (SP3200VSP) can also be controlled from third party controls (i.e. another manufacturer’s control) and
Hayward controls that are not software compatible using relay contacts. See section 5.3 for more information regarding connecting TriStar VS and third party/non-software compatible Hayward controls.
3. TriStar VS (SP3200VSPND) can communicate with and be controlled by Hayward Pro Logic. See section 5.4 for
more information regarding connecting TriStar VS and Hayward Pro Logic.
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 4.11-1)
Figure 4.11-1
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Page 11 of 36 TriStar VS Pump IS3200VSP Rev-C
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