Hayward OmniLogic HLEXPAND Bedienungsanleitung

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Hayward Pool Products

620 Division Street, Elizabeth NJ 07207

Phone: (908) 355-7995

www.hayward.com

OmniLogic

Owner’s Manual

HLEXPAND

Contents

Before You Begin.........................1

Overview....................................1

Mounting Equipment..................3

Plumbing...................................5

Wiring.......................................6

System Startup.........................15

Expansion Panel for OmniLogic

092504 RevA

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IMPORTANT SAFETY INSTRUCTIONS

When using this electrical equipment, basic safety precautions should always be fol-

lowed, including the following:

• READ AND FOLLOW ALL INSTRUCTIONS

• WARNING: Disconnect all AC power during installation.

• WARNING: Water in excess of 100 degrees Fahrenheit may be hazardous to

your health.

• WARNING: To reduce the risk of injury, do not permit children to use this product

unless they are closely supervised at all times.

• WARNING:DonotusetheOmniLogictocontrolrepitsorrelatedreequip-

ment.

• A green colored terminal marked “Grounding” is located inside the wiring compart-

ment. To reduce the risk of electric shock, this terminal must be connected to the

grounding means provided in the electric supply service panel with a continuous

copper wire equivalent in size to the circuit conductors supplying the equipment.

• One bonding lug for US models is provided on the external surface. To reduce

the risk of electric shock, connect the local common bonding grid in the area of

the swimming pool, spa, or hot tub to these terminals with an insulated or bare

copper conductor not smaller than 8 AWG US / 6 AWG Canada.

• Alleldinstalledmetalcomponentssuchasrails,ladders,drains,orothersimilar

hardware within 3 meters of the pool, spa or hot tub shall be bonded to the equip-

ment grounding bus with copper conductors not smaller than 8 AWG US / 6 AWG

Canada.

• SAVE THESE INSTRUCTIONS

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FCC Statement

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause

harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Changes or modiﬁcations not expressly approved by Hayward could void the user’s authority to operate this equipment.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC

Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment

generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harm-

ful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this

equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on,

the user is encouraged to try to correct the interference by one or more of the following measures:

-- Reorient or relocate the receiving antenna.

-- Increase the separation between the equipment and receiver.

-- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

-- Consult the dealer or an experienced radio / TV technician for help.

Industry Canada Statement

This Class B digital apparatus complies with Canadian ICES-003.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

The term “IC” before the certiﬁcation / registration number only signiﬁes that the Industry Canada technical speciﬁcations were met.

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Table of Contents

Before you Begin Before you Begin...............................................................1

Preparing

Mounting OmniLogic Enclosure........................................................3

Equipment Temperature Sensors........................................................4

Optional Chlorination........................................................4

Optional HL-CHEM Sensing Kit........................................4

Optional AQL-CHEM2 pH Dispensing................................4

Optional Web Connected Devices......................................4

Optional HLWLAN.............................................................4

Optional Valve Actuators.................................................5

Plumbing TurboCell..........................................................................5

Flow Switch......................................................................5

Electrical MainService.....................................................................7

Wiring Grounding and Bonding.....................................................7

Circuit Breaker Installation and Wiring................................7

General Purpose Outlet.....................................................7

HLEXPAND Power..............................................................7

Pool Equipment Connection Table......................................8

High Voltage Pool Equipment.............................................9

Low Voltage Wiring..........................................................10

System Startup System Startup...............................................................15

Warranty OmniLogic Limited Warranty............................................19

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Before you Begin

The HLEXPAND is an expansion panel accessory for the Hayward OmniLogic HLBASE pool control. The HLEXPAND increases the number of sensor/external

inputs, high voltage outputs (for pumps, water features, outdoor lights, etc.), low voltage outputs (for heaters, variable speed pumps, valve actuators, etc.) and

adds an additional chlorinator output to your existing OmniLogic, expanding the functionality of the HLBASE. A circuit breaker panel is included in the HLEX-

PAND for easy wiring to the additional equipment. For remote access through the internet, the HLEXPAND connects to the OmniLogic as well as the home’s

router using a standard Cat5/6 Ethernet cable which can be run up to 200 ft. away. If a hard wired connection to the router is difﬁcult, a Hayward HLWLAN

wireless transceiver may be used instead.

Although the HLEXPAND looks similar to the OmniLogic, there is no touchscreen and all connected equipment is controlled through the OmniLogic’s touch-

screen, remote terminals, and web connected devices.

What’s Included

Before attempting to install the HLEXPAND, check that the following components have been included in the package:

• OmniLogic Expansion Panel

• (3) Temperature sensors with 15 ft. (5m) cable, hose clamp

• 15 ft. Ethernet cable with Ferrite bead

• Spare Main Board fuses

What’s NOT Included

Some of the additional items that you may need to complete the installation include:

Circuit breakers

None are included with HLEXPAND—see page 7 and inside door label for suitable breakers

Wire

Wire/conduit for 100A service from main panel to HLEXPAND

Wire/conduit for ﬁlter pump and other high voltage loads

Wire for remote heater control and other low voltage devices

Wire for bonding

Miscellaneous

Optional utility electrical outlet and weatherproof cover (for mounting on lower right side of HLEXPAND)

Mounting hardware (screws, bolts, etc.) for mounting HLEXPAND

Valve Actuators (to automate valve functions)

Accessory Products - Order Separately

HLRELAYBANK Additional relay pack adds 4 high voltage relays

HLRELAY Single high voltage relay kit

HLIOEXPAND Input/Output Expander Board adds 4 additional sensor/external inputs, 4 heater/low voltage outputs, and 4 actuator outputs

HLWLAN Wireless home network connectivity - eliminates the need to hard wire the HLEXPAND to the home’s router/access point

HL-CHEM ORP & pH Sensing Kit for monitoring and controlling pool chemistry

GVA-24 Valve Actuator

V&A-xx Valve & Actuator (xx=1P (1.5” pos. seal), -2P (2” pos. seal)

T-CELL-3 Chlorinator Cell - generates chlorine for pools up to 15k gallons

T-CELL-9 Chlorinator Cell - generates chlorine for pools up to 25k gallons

T-CELL-15 Chlorinator Cell - generates chlorine for pools up to 40k gallons

P-KIT Chlorination plumbing kit containing ﬂow switch and cell unions

AQL-CHEM2 CO2dispensing kit for pH control

HL-CHEM4-ACID Liquid acid feeder for pH control

HL-CHEM4-CHLOR Liquid chlorine feeder

CL200 Chlorine tablet feeder

NOTE: Before installing this product as part of a saline water puriﬁcation system in a pool or spa using natural stone for coping or for immediately adjacent

patios/decking, a qualiﬁed stone installation specialist should be consulted regarding the appropriate type, installation, sealant (if any) and maintenance of stone

used around a saline pool with an electronic chlorine generator in your particular location and circumstances.

NOTE: The use of dry acid (sodium bisulfate) to adjust pool pH is discouraged especially in arid regions where pool water is subject to excessive evaporation and

is not commonly diluted with fresh water. Dry acid can cause a buildup of by-products that can damage your chlorinator cell.

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Overview

It is important to completely read through this manual before attempting to install, conﬁgure or operate this unit. Many of the installation steps are the same as

the OmniLogic. If installing both units at the same time, it’s recommended to install the OmniLogic ﬁrst but do not start the conﬁguration process until after the

HLEXPAND has been installed and wired. Also, skip the OmniLogic’s Ethernet connection and refer to instructions in this manual.

Features

The HLEXPAND adds the following features to your OmniLogic:

• control up to 4 (expandable to 8 using HLRELAYBANK) high voltage (120/240V) relays to control pumps, pool lights, yard lights, water features, chemical

dispensers and more. Two more relays (HLRELAY) can be added to the HLEXPAND for a total of 10

• control up to 4 (expandable to 8 with HLIOEXPAND) automatic valve actuators including pool and spa valves, water feature valves, cleaner valves and more

• control up to 4 (expandable to 8 with HLIOEXPAND) heaters or low voltage equipment including gas heaters, electric heat pumps, and solar heaters as well

as various low voltage devices

• controls up to 16 EcoStar variable speed pumps without the use of a relay

• inputs for up to 4 temperature sensors or external input devices (expandable to 8 with HLIOEXPAND)

• Ethernet ports for connection to OmniLogic and to the home’s router/access point

• 100A electrical subpanel that can accommodate up to 12 circuit breakers

• connection for Hayward TurboCell used to generate chlorine for an additional body of water

• connection for ﬂow switch used to detect water ﬂow

• input for HL-CHEM ORP and pH sensing kit for an additional body of water

Optional pH and ORP

up to 10 120/240V Relays (using HLRELAYBANK)

up to 8 24V Actuators (using HLIOEXPAND adds 4)

up to 8 Heaters and Low

Voltage devices (using HLIOEXPAND)

Optional HLIOEXPAND adds

4 Temperature Sensors and

4 External Input devices

Optional Wireless

Remote Terminals

Optional Wired

Remote Terminals

Flow Switch

Computers Android and IOS

Mobile devices

optional Chlorinator Cell

up to 8 heaters and low voltage devices

up to 16 EcoStar variable speed pumps

Chlorinator Cell

Circuit Breaker

Subpanel

Circuit Breaker

Subpanel

240 VAC

Power

240 VAC

Power

up to 16 EcoStar variable speed pumps

up to 10 120/240V Relays

up to 8 24V Actuators

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Installation Steps

DANGER of Death, Injury or Property Damage if procedure not followed. Dead front removal is required for this installation. Power to the HLEXPAND MUST

be shut off whenever the dead front is removed. This means a complete shutdown of power to the entire Expansion Panel.

This manual assumes that you have already installed the OmniLogic that will control this Expansion Panel. Follow the similar installation steps on the following

pages.

Mounting the Equipment

HLEXPAND Enclosure

The HLEXPAND is contained in a raintight enclosure that is suitable for outdoor mounting. The control must be mounted a minimum of 6 ft. (2 meters) horizontal

distance from the pool/spa (or more, if local codes require). The HLEXPAND is designed to mount vertically on a ﬂat surface with the knockouts facing downward.

Because the enclosure also acts as a heat sink (disperses heat from inside the box), it is important not to block the four sides of the control. Do not mount the

HLEXPAND inside a panel or tightly enclosed area.

When selecting a location, note that the standard cables supplied with the included temperature sensors, as well as optional accessories like a Hayward Turbo-

Cell and actuators are all 15 ft. (5m) long. Also, a 15 ft. Ethernet cable is included for connection to the OmniLogic so if mounting further away, you will need

to supply your own cable. An additional Ethernet connection must be made to the home’s router or a HLWLAN if remote web connected devices are to be used.

The HLEXPAND weighs close to 60lbs and will require two people to position and install. Select the proper location and mounting hardware given the size and

weight of the unit. The mounting brackets require a total of 6 mounting bolts to fasten the enclosure to the mounting surface.

Note that there is a heat sink on the back of the enclosure. In all cases the heat sink on the back of the enclosure should not contact the wall behind the panel.

This restricts air ﬂow and makes the heat sink less efﬁcient. A minimum separation of 1/8” (except for vinyl siding) should be maintained between any heat

sink pin and the siding on the wall behind the enclosure. In the case of a

ﬂat wall the mounting ﬂanges on the enclosure ensure that the minimum

clearance is maintained. For shingles, clapboards or other siding with a

non-ﬂat proﬁle, the installer must ensure the minimum separation. Refer

to the adjacent diagram.

Special Installation Instructions for Vinyl Siding

IMPORTANT: The heat sink on the back of the HLEXPAND enclosure can-

not be allowed to contact vinyl siding; during normal chlorinator operation

the heat sink pins get warm enough to deform vinyl siding on contact. An

increased minimum separation of 3/8” should be maintained between any

heat sink pin and the vinyl siding behind the enclosure.

Minimum Clearance between heat sink and mounting surface - 1/8”

For Vinyl Siding - 3/8”

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Temperature Sensors

Three sensors are included with the HLEXPAND. Depending on your application, these sensors may or may not be used. If more than 2 bodies of water will

be managed by the HLBASE you will need to use the Pool and/or Spa water temperature sensors on the HLEXPAND. The air temperature sensor is optional

and the solar sensor is required only if a second solar heating function is enabled.

Water Sensor

This sensor is used to measure the pool/spa temperature and is installed in the ﬁltration plumbing after the ﬁlter but before either the solar or conventionally

fueled heaters—refer to the plumbing overview diagram.

1. Drill a 3/8” (10mm) diameter hole in the PVC piping and remove all chips and burrs.

2. Insert sensor until O-ring collar sits ﬂush on the hole.

3. Position hose clamp over the sensor and gently tighten until O-ring makes an adequate seal. Do not overtighten.

Air Sensor

The HLEXPAND’s air sensor is not used in any of the pool’s functions and is provided as a convenient way of monitoring an additional airspace. This sensor

can be mounted indoors or outside but not in direct sunlight. IMPORTANT: The Freeze Protection function will only reference the OmniLogic air sensor, not

the HLEXPAND’s air sensor.

Solar Sensor

For solar applications, mount the sensor near the solar collector array so that it is exposed to the same sunlight as the collectors. Use additional cable (20

AWG) if necessary.

Optional Chlorination Function

The HLBASE offers optional chlorination for the primary body/bodies of water. The HLEXPAND can provide chlorination for an additional body of water if

needed. This function requires a chlorinator cell and P-KIT (ﬂow switch and cell unions) purchased separately at your Hayward dealer. Choose a chlorinator

cell model based on the size of your additional pool/spa. The following models are available:

T-CELL-15 for pools up to 40,000 gallons

T-CELL-9 for pools up to 25,000 gallons

T-CELL-3 for pools up to 15,000 gallons

Refer to pages 5 and 16 for plumbing and wiring instructions.

Optional HL-CHEM Sensing Kit

Like the OmniLogic, the HLEXPAND supports the HL-CHEM ORP and pH sensing kit for additional bodies of water. The HL-CHEM functions in the same

manner as described in the OmniLogic manual and can be used to control chlorine generation/dispensing and pH dispensing. Wiring and plumbing require-

ments for the HL-CHEM should be considered before installing the HLEXPAND. Refer to the HL-CHEM manual for speciﬁc installation information. NOTE:

OmniLogic and HLEXPAND are not compatible with AQL-CHEM.

Optional AQL-CHEM2 CO2Dispensing Kit

The AQL-CHEM2 is a CO2dispensing device that connects directly to the HLEXPAND. When used with an HL-CHEM, the HLEXPAND will sense the pH level

and automatically dispense the correct amount of CO2to control the water’s pH to the desired level. Wiring and plumbing requirements for the AQL-CHEM2

should be considered before installing the HLEXPAND. Refer to the AQL-CHEM2 manual for speciﬁc installation information.

Optional AQL-CHEM4-ACID, AQL-CHEM4-CHLOR Dispensing Systems

The OmniLogic and HLEXPAND can be used to control Hayward chemical dispensing systems. These units are large capacity, with 15 gallon pump and

tank and are capable of automatically dispensing acid for pH control (AQL-CHEM4-ACID) or liquid chlorine for sanitization (AQL-CHEM4-CHLOR).

Ethernet and Web Connected Devices

The OmniLogic offers Ethernet connectivity to the web through the home’s network. Once connected, web enabled devices such as a PC, laptop, tablet or

phone can be used to control and monitor the OmniLogic. For this functionality, two Ethernet connections must be made to the HLEXPAND. First, a con-

nection from the HLEXPAND to the OmniLogic using the provided 15 ft. cable allows communication between the two units. Second, an Ethernet cable

must be run from the HLEXPAND to the home’s router/access point or to a Hayward HLWLAN.

HLWLAN

If running Ethernet cable from the home’s router/access point to the HLEXPAND is impractical, an optional HLWLAN can be used (see page 14). The

HLWLAN is a 802.11b/g/n transceiver kit that can make a wireless connection up to 250 ft. to the home’s router/access point preventing the need to run

cable for web access. Refer to the HLWLAN Owner’s Manual for wiring and conﬁguration information.

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Optional Valve Actuators

Like the OmniLogic, optional actuators can be used with the HLEXPAND. Note that the internal cams in the actuator may also have to be adjusted depending on

the way the actuator is mounted on the valve and the desired valve action.

Plumbing

Optional TurboCell

The TurboCell must be plumbed AFTER the ﬁlter and heater. If installed on a pool/spa combination system, the cell must be plumbed BEFORE the pool/spa return

valve in order to allow proper chlorination of both the pool and the spa. Refer to plumbing diagram below:

The cell may be mounted vertically or horizontally, and water can move in either direction through the cell. Install using the 2” unions provided. Tighten unions

BY HAND for a watertight seal. For systems with 1½” plumbing use adapters (provided by installer).

Flow Switch (supplied with P-KIT)

A Hayward ﬂow switch is required if using the optional TurboCell for chlorination, a liquid chlorine dispenser, chlorine tablet feeder or an AQL-CHEM2 for pH dis-

pensing. The ﬂow switch is a safety device that ensures that water is ﬂowing before the OmniLogic/HLEXPAND starts to generate/dispense chlorine or dispenses

acid. It must be plumbed in the same section of piping as the TurboCell or dispenser. Failure to properly install the ﬂow switch can result in explosive gases or

harsh chemicals accumulating in the pool plumbing system.

IMPORTANT: There must be at least a 12” (30cm) straight pipe run before (upstream) the ﬂow switch. If the switch is plumbed after the cell, the cell can be

counted as the 12” (30cm) of straight pipe.

IMPORTANT: To ensure proper operation, verify that the arrow on the ﬂow switch points in the direction of water ﬂow.

RETURN SUCTION

OUT

(Common)

OUT IN

FLOW

SWITCH

VALVE

POOL

12”

FLOW

SWITCH

VALVE

TurboCell TurboCell

POOL SPA

12”

min

Flow Switch

before Cell

Flow Switch

after Cell

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Electrical Wiring

The Expansion Panel requires both high and low voltage connections. Low voltage connections will be made to actuators, sensors, etc. High voltage connections