Hayward DE7220 integration with Hayward ECOSTAR SP3400VSP; minimum RPM requirements

[rogue]

Mark: Thanks for the perspective on cold water ops

Dave: I understand re ECOSTAR timers not working in relay mode. I plan on using the existing intermatic timer to turn the ECOSTAR pump on/off with speed 1 set at 1000 rpm per Mark. This morning I confirmed the HV output terminals of the GL-235 solar controller (ie last two to the right of the power connection block) are simply controlled by an open/close switch that closes when solar is engaged. I will connect these terminals to the ECOSTAR pump 24V AC terminals and input 1 with associated speed 2 set at an RPM to drive 55 GPM for solar.

Good point on the flow meter before the filter. It is a pitot static setup so the dirt would be an issue. Guess I'll need to get non-solar flow from determining total dynamic head at the pump (ie see INYO POOLS http://www.inyopools.com/HowToPage/h...th_gauges.aspx ) then go into the ECOSTAR performance graph with 1000 rpm and determine Hayward's predicted GPM flow rate.

While going through the install process I'll take a few pictures of the setup and post in case others pass this way.

Thanks for all the advice! I'll print and put in my pool maintenance log.

[mas985]

I can also calculate head loss with just filter pressure and a description of the suction side plumbing. Those were the questions I had asked in the second post. You can also do this yourself with one of my spreadsheets:

Pool Spreadsheets Link

The EcoStar spreadsheet can calculate flow rate from just RPM and wattage. The Pool Pump Tools spreadsheet is more generic and a bit more accurate and can calculate flow rate for many different pumps in several different ways.

But again, knowing the exact flow rate of the pump really doesn't help you any. It just doesn't matter.

For reference, your current flow rate is around 82 GPM and on solar it is about 69 GPM. To match the same solar rate, the EcoStar would need to be set at about 3000 RPM.

[rogue]

Hi,

In an earlier post I asked for help in configuring my new Hayward ECOSTAR SP3400 VSP variable speed pump with a GoldLine GL-235 Solar Controller. The previous pool filter pump was an 8 year old 1.0 HP Hayward Super II pump (model SP3010EEAZ) connected at 220 V with the GL-235 solar controller, GoldLine AquaRite chlorine generator, and an auto-fill system on the same timer to support my 25,000 gal salt water pool. The Hayward DE7220 DE filter pre-coat pressure with the Super II pump and without solar was 14 PSI and with solar 20 PSI. The solar is on a 2nd story roof. Water travels approx. 46 feet in 2 inch pipe over a 26 ft high ridge to the far side of the roof where the first of eleven (11) Heliocol HC-50 panels are located.

When reading this post it will be helpful to have the ECPOSTAR SP3400VSP Owner’s Manual handy for reference. For installation I also found the Hayward ECOSTAR Variable Speed Pump and Drive Technical Guide to be very helpful…nice pictures. Both can be found online.

As seen in the attached picture (unable to attach or upload at this time) the connection is straight forward. After turning power and circuit breakers off:

1. Disconnect the power and ground wires from the Super II pump and connect them to the ECOSTAR as shown.
2. On the ECOSTAR used 12 gauge wire to connect the Input terminal #2 to the closest 12 VAC terminal (note from owner’s manual pg 14 section 4.4 “connection wire must be rated for a minimum of 300 V.” see following picture.
3. Connect the far right GL-235 switch terminal #6 to ECOSTAR Input terminal #1
4. Connect the GL-235 switch terminal #5 to the remaining open ECOSTAR 12 VAC terminal
5. Observe the GL-235 note not to run the sensor wires in the same conduit with power carrying wires.

Though the ECOSTAR and Super II pump dimensions were similar, I had to re-plumb to get the 10 inch minimum suction pipe length called for on page 8 Section 3.3 of the ECOSTAR Owner’s manual as well as to accommodate the ECOSTAR Union joints.

Programming setup was fairly straight forward. I was initially concerned the pump didn’t turn on right away, but there is a delay as it goes through an internal diagnostic first. Two points here before I discuss the setup described in the owner’s manual. See page 10 Section 3.10 Remote Control Wiring/Operation.
• When there is no input from the GL-235 with solar off the Timer speed one is active. When the GL-235 senses temperatures appropriate to engage the solar system and powers up the 3 Way valve signal, a signal is also sent to close the GL-235 switch connected to the ECOSTAR. When the switch closes the 12 V signal is recognized by the ECOSTAR and Timer Speed 2 is initiated
• In Relay Mode, which you will select during configuration, “Preset speeds 1-4 and Quick Clean are disabled when the pump is remotely controlled” such as by the GL-235. (Note: Not sure why the Quick Clean is disabled…would have been nice to have this available for vacuuming the pool without having to reprogram timer speeds.) However, the Stop/Resume button is functional in Relay Mode.

OK, Section 5.5 has some initial startup data entry items before section 5.6 the full configuration menu. To access the configuration menu the comment states that you “press and hold < and > for several seconds to unlock Configuration Menu. Steps 1 through 9 apply to all pump modes, but in step 10 you will select Relay Mode to integrate the ECOSTAR and the GL-235. Steps 11 through 16 will likely not apply to you and 18 is informational. I also selected Auto Sense prime in step #9. Once you are done you will press + to accept changes.
To get to the section 5.7 timer mode press the menu button after seeing the configuration menu title. You will not have to unlock the Timer Mode function. Once you enter the timer mode program Timer 1 for non-solar, low speed setting and timer 2 for higher speed solar setting. I set the times at 23 hours since the time is controlled by the Intermatic on/off timers

Pre-set speed startup menu will not apply to you in Relay mode.

Once you have completed this program turn the pump on by activating the remote Intermatic timer thus supplying power to all pool components. Assuming GL-235 solar is off, set the GL-235 manual switch to Test. When the solar valve opens the 12 VAC signal is sent to the ECOSTAR Input #1 and the Timer 2 is activated with its higher RPM.
To help determine proper flow rates I installed pitot static flow meters on the vertical solar feed pipe and on a GLX-Cell-Pipe blank to replace the Aqua Rite Solar salt cell. I verified the flow rates by installing pressure and vacuum gauges at the pump ports and using the “how to determine total head” video at InyoPools.com

For the non-solar condition I learned from the Hayward tech reps that as long as the pump kept the filter tank full as noted by solid stream of water exiting the vent port at the top of the tank then the minimum flow rate could be determined. I settled on 1400 RPM/187 watts /37 GPM/ filter pressure 4 psi for Timer #1. There are no air bubbles shown in the ECOSTAR pump basket area at high speeds, but at low speeds (ie 1499 RPM) air bubbles do gather.
I was also concerned regarding chlorine generation at low flow rates. The Hayward technical folks stated that chlorine generation by the Aquarite system is independent of flow rate.

For the solar condition, Heliocol stated the recommended flow rate per HC-50 (i.e. 50 sq ft) panel is 5 GPM. Because I have a split series configuration with a 6 panels section first followed by a 5 panel section the Heliociol rep said that my recommended flow rate would be 30 GPM with a maximum of 10 GPM per panel or 60 GPM. Several data points are:

30 GPM at 1850 RPM/342 watts/filter 10 psi. 25,000 gal pool turnover is approx. 14 hrs
40 GPM at 2250 RPM/580 watts/ filter 14 psi. Pool turnover approx. 10.5 hrs
50 GPM at 2850 RPM/1138 watts/filter 20 psi. Pool turnover approx. 8.5 hrs
60 GPM at 3200 RPM/1600 watts/filter 24 psi.at Pool turnover approx. 7 hrs
I settled on 40 GPM for my Timer #2 solar speed

One final data point I wanted was to determine how heat exchange performance in the HC-50 panels varied with flow rate relative to the recommended 5 GPM flow rate per panel. No response yet from the Heliocol folks.

Hope this helps those who want to integrate an ECOSTAR pump with a solar controller.

Good luck!

Rogue

==============================================