IS3200XE REV B 8d8c
IS3200XE REV B 8d8c
XE Pump Series
Owner’s Manual
Contents
Pump Warnings...............2
Overview.........................5
Installation.....................6
Operation.......................9
Troubleshooting............14
Maintenance.................15
Winterization.................16
Shaft Seal Change.........17
Replacement Parts........20
TriStar® XE
MaxFlo® XE
Super Pump® XE
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).
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 SERI-
OUS 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 con-
structed 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.
WARNING – Risk 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.
WARNING – Risk 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 in-
terrupts power to the pump without the test button being pushed, a ground current is flowing, indicating the possibil-
ity 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 electri-
cian 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 includ-
ing, 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 entrap-
ment hazards (symbols complements of APSP):
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.
• 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 posi-
tion 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 iso-
lated 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.
Product Dimensions
TriStar XE
CL CL
MaxFlo XE
MOUNTING CL CL
Super Pump XE
MOUNTING CL CL
NAME DATE
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.
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.
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 XE pump, 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.
WARNING – Hazardous Pressure. Pumps, filters, and other equipment/ components of a swimming pool filtration system operate under pres-
sure. Incorrectly installed and/or improperly tested filtration equipment and/or components may fail resulting in severe personal injury or death.
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.
Electrical Specs
Refer to motor nameplate for voltage and current ratings. Use copper conductors only. For indoor & outdoor use. Connect pump to an appropriately
sized/rated branch circuit protector 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.
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% or more than 110% of rated voltage when pump is running at full load, consult the power
company.
Input Power
WARNING – All electrical wiring MUST conform to local codes, regulations, and National Electric Code (NEC).
Pump MUST be permanently connected to circuit. Connect pump to an appropriately sized/rated branch circuit protector in accordance with local
codes, regulations, and the National Electric Code (NEC). Use the circuit breaker as the master On-Off switch.
L1
L2
Ground
230 VAC
ATTENTION: ROUTE WIRING DIRECTLY FROM FIELD
CONDUIT TO TERMINAL BLOCK AS SHOWN. DO NOT
BUNDLE EXCESS WIRING INSIDE DRIVE ENCLOSURE.
L1
Ground
115 VAC
4. Connect the pump to the pool bonding system as described on page 7. A lug for bonding is provided on the top of the motor.
5. After all electrical connections have been made, replace the wiring compartment cover, taking care to make sure it is properly aligned with the motor
drive. Tighten the four screws to secure. Note: The wiring compartment cover must be installed properly to provide environmental protection for the wiring
compartment.
WARNING – If circulation equipment must remain in the plumbing system during water pressure test, do not apply more than 10 psi pressure to
the system. Be sure water pressure has been released, using the filter manual air relief valve, before removing pump strainer cover.
WARNING– All suction and discharge valves MUST be OPEN, as well as filter air relief valve (if available) on filter, when starting the circulating
pump system. Failure to do so could result in severe personal injury.
WARNING – Return to filter to close filter manual air relief valve when a steady stream of water (not air or air and water) is discharged from valve.
Failure to do so could result in severe personal injury.
ATTENTION – NEVER OPERATE THE PUMP WITHOUT WATER. Water acts as a coolant and lubricant for the mechanical shaft seal. NEVER run
pump dry. Running pump dry may damage seals, causing leakage, flooding, and voids warranty. Fill strainer housing with water before starting motor.
ATTENTION – Do NOT add chemicals to pool/spa system directly in front of pump suction. Adding undiluted chemicals may damage pump
and voids warranty.
ATTENTION – Before removing strainer cover:
1. STOP PUMP before proceeding.
2. CLOSE VALVES in suction and outlet pipes.
3. RELEASE ALL PRESSURE from pump and piping system using filter manual air relief valve. See filter owner’s manual for more details.
4. Remove strainer cover and fill strainer housing with water.
5. Clean and lubricate strainer cover O-ring with “Jack’s 327” if necessary.
6. Replace strainer cover on strainer housing.
7. OPEN VALVES in suction and outlet pipes.
Note: Tighten strainer cover (lock ring or hand knobs) by hand only. Do not use tools or wrenches.
Turn on power and wait for pump to prime, which can take up to ten (10) minutes. Priming time will depend on vertical length of suction lift and horizontal length
of suction pipe. If pump does NOT prime within 10 minutes, stop motor and determine cause. Be sure all suction and discharge valves are open when pump
is running. See Troubleshooting Guide.
Operating Speeds
There are six speeds available on the XE pumps. When programming the Daily Schedule (page 11), refer to this information.
1
12 hours
24 hour
V
AL
ur
2
s
To prime the system, the pump will run for 8 minutes at maximum speed whenever power is first applied.
The daily schedule starts as soon as power is applied to the pump. After priming, the pump will run at the speed programmed in Interval 1 for four hours, and
then it will change to the speed programmed in Interval 2 for eight hours, and finally the speed of Interval 3 for twelve hours. After the end of Interval 3, the
pump will return to the start of Interval 1. This daily schedule will run continuously until power is removed from the pump.
In order to ensure the pump operates throughout the day at the desired speed, apply power to the pump at a time suitable for the application.
If it is desired that the pump run at 50% at all times, apply power to the pump and use the default schedule. If different speeds are desired, program the daily
schedule as shown on page 11.
Important: Any time power is removed and re-applied to the pump, such as turning off a switch or breaker, the pump will restart the daily schedule at the
beginning of Interval 1. The start of the daily schedule will always be the time at which power is applied to the pump. Note that when power is removed from the
pump, the LED will blink for a short period and you must wait for the LED to fully turn off before reapplying power. This may take up to 30 seconds. If power is
applied while the LED is still blinking, the motor will not start for 6 minutes. This delay can be overridden if the button is pressed.
10
• Speed 1 (fastest)
• Speed 2
• Speed 3
• Speed 4
• Speed 5
• Speed 6 (slowest)
• STOP
Programming the pump follows a simple process of pressing the button to cycle through available speeds (from fastest to slowest), and pressing and holding
the button to save the speed to a given interval. An overview is shown below.
INTERVAL 1 INTERVAL 2 INTERVAL 3
To ENTER
PROGRAM MODE 4 hours 1 8 hours 2 12 hours 3
4 second hold 4 second hold 4 second hold 4 second hold
3x
3x 3x 3x
Solid
Back to
Press & Hold Choose Save & Choose Save & Choose Save & Daily
until the light pump speed Continue pump speed Continue pump speed Continue Schedule
blinks
START PROGRAMMING
2. Once in programming mode, the LED ring will communicate which interval is being programmed. The first interval is Interval 1, and the LED ring will repeat-
edly flash one time, followed by a pause.
3. To save a speed to Interval 1:
a. Adjust the speed of the pump to the desired speed by pressing the button. The first press always brings you to maximum speed (Speed 1=100%)
and each press after will decrease the speed until it reaches STOP and then the cycle will repeat. Refer to the diagram below.
11
Example Program
Desired schedule starting at 8:00AM every day (apply power at 8:00AM to start program) - 80% for 4 hours, 40% for 8 hours and OFF for 12 hours
80 4 hours 1 2 3 4 5 6 7
4 second hold 4 second hold 4 second hold 4 second hold
INTERVAL 2
3x 3x 3x 3x
40 8 hours
INTERVAL 3
0 12 hours Press & Hold Press two times Press & Hold Press six times Press & Hold Press seven times Press & Hold
Important: If power is lost/removed from the pump during programming, any changes made to the schedule will not be saved. While in programming mode, if
no commands are entered by using the button within 2 minutes, then the pump will default to normal operation. In this case, any change made to the schedule
WILL be saved.
For the schedule to start at 8:00AM, remove and reapply power at 8:00AM.
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Note: Initiating override mode will not change the start time for the daily schedule. While in override mode, the pump will operate at a single speed for 3 hours
and then will revert back to normal operation according to the daily schedule. This does not apply to the STOP function and the pump will remain stopped until
manual override is cancelled or a manual override speed is selected.
The manual override mode can also be canceled by pressing and holding the button for 4 seconds while override mode is active. This will cause the pump to
resume the daily schedule in the same manner as if the manual override expired.
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The pump will prime when either of the following conditions are met:
• Power is first applied to the pump
OR
• An interval with a programmed speed follows an interval which was set to (STOP)
OR
• When completing programming or exiting override mode
Example:
24 HOUR DAILY SCHEDULE
The pump will prime at the start of Interval 3 for 8 minutes, since Interval 2 was set to STOP.
If the desire is to prevent the pump from entering the 8 minute self-prime sequence, then this feature may be disabled by pressing and holding the button for
10 seconds during normal operation. To enable, press and hold again for 10 seconds.
The most common application may be to run the pump at a single speed by setting all Interval speeds the same and have the pool control power it on and off
each day. If various speeds are desired, combine Interval programming with the pool control’s schedule to gain more control over the pump’s operation. For
example, you can control the exact amount of run time and end the operation in the middle of any Interval. Restarting the pump will always restart the daily
schedule at Interval 1 so running two or more schedules in one day will allow you to repeat Interval(s) within a 24 hour period. This type of control is not available
if the pump is connected to constant power.
When using a pool automation control, input wiring to the XE pump shown on page 8 will come directly from the relay output of the control. Refer to your specific
pool control’s manual for these wiring instructions.
14
Noisy Pump
1. Air leak in suction piping, cavitations caused by restricted or undersized suction line or leak at any joint, low water level in pool, and unrestricted discharge
return lines. Correct the suction condition or throttle return lines, if practical. Holding your hand over the return fitting will sometimes prove this, or by put-
ting in a smaller eyeball fitting.
2. Vibration due to improper mounting, etc. Mount the pump on a level surface and secure the pump to the equipment pad.
3. Foreign matter in the pump housing. Loose stones/debris hitting the impeller could be the cause. Clean the pump housing.
4. Motor bearings noisy from normal wear, rust, overheating, or concentration of chemicals causing seal damage, which will allow chlorinated water to seep
into bearings wiping out the grease causing bearing to whine. All seal leaks should be replaced at once.
15
Note: All errors can be manually reset by pressing the button when the error is shown, or by cycling power applied to the pump after the error has occurred. If
the troubleshooting steps listed above do not help to resolve the error condition, then the problem may be internal to the motor/drive. Contact Hayward Technical
Service at (908) 355-7995 for additional assistance.
Maintenance
• Clean strainer basket regularly. Do NOT strike basket. Inspect cover gasket regularly and replace as necessary.
• Hayward pumps have self-lubricating motor bearings and shaft seals. No lubrication is necessary.
• Keep motor clean. Keep motor air vents free of obstructions to avoid damage. Do NOT use water to hose off motor.
• Occasionally, shaft seals must be replaced, due to wear or damage. Replace with genuine Hayward seal assembly kit. See “Shaft Seal Change Instructions”
in this manual.
Storage / Winterization
WARNING – Separation Hazard. Do not purge the system with compressed air. Purging the system with compressed air can cause
components to explode, with risk of severe injury or death to anyone nearby. Use only a low pressure (below 5 PSI), high volume blower when air
purging the pump, filter, or piping.
ATTENTION – Allowing the pump to freeze with water in it will void the warranty.
ATTENTION – Use ONLY propylene glycol as antifreeze in your pool/spa system. Propylene glycol is non-toxic and will not damage
plastic system components; other anti-freezes are highly toxic and may damage plastic components in the system. Drain all water from pump and
piping when expecting freezing temperatures or when storing pump for a long time (see instructions below). Gravity drain system as far as possible.
Keep motor dry and covered during storage. To avoid condensation/corrosion problems, do NOT cover or wrap pump with plastic film or bags.
16
Exercise extreme care in handling both the rotating and the stationary sections of the two-part replacement seal. Foreign matter or improper handling will easily
scratch the graphite and ceramic sealing surfaces.
Seal Installation
7. Clean and lightly lubricate the motor shaft and seal recesses in the seal plate with a dilute solution of non-granulated liquid-type soap. Gently wipe the
polished face of the ceramic seal with a soft cotton cloth. Lubricate the rubber cup on the ceramic seat and press it firmly into the recess of the seal plate,
with the polished ceramic surface facing out.
8. Reassemble the motor to the seal plate using the four (4) 3/8” x 1” bolts, and re-attach the motor support to the seal plate. Ensure that the upper two
housing bolts are installed in the seal plate prior to mounting the motor to the seal plate.
9. Gently wipe the black, polished surface of the spring seal assembly with a soft cotton cloth.
10. Press the spring seal assembly onto the motor shaft, with the black polished surface facing the ceramic seat.
17
Exercise extreme care in handling both the rotating and the stationary sections of the two-part replacement seal. Foreign matter or improper handling will easily
scratch the graphite and ceramic sealing surfaces.
Seal Installation
7. Clean and lightly lubricate the motor shaft and seal recesses in the seal plate with a dilute solution of non-granulated liquid-type soap. Gently wipe the
polished face of the ceramic seal with a soft cotton cloth. Lubricate the rubber cup on the ceramic seat and press it firmly into the recess of the seal plate,
with the polished ceramic surface facing out.
8. Reassemble the motor to the seal plate using the four (4) 3/8” x 1” bolts. Torque the bolts to 100 in-lbs.
9. Gently wipe the black, polished surface of the spring seal assembly with a soft cotton cloth.
10. Press the spring seal assembly onto the motor shaft, with the black polished surface facing the ceramic seat.
18
Exercise extreme care in handling both the rotating and the stationary sections of the two-part replacement seal. Foreign matter or improper handling will easily
scratch the graphite and ceramic sealing surfaces.
Seal Installation
6. Clean and lightly lubricate the motor shaft and seal recesses in the seal plate with a dilute solution of non-granulated liquid-type soap. Gently wipe the
polished face of the ceramic seal with a soft cotton cloth. Lubricate the rubber cup on the ceramic seat and press it firmly into the recess of the seal plate,
with the polished ceramic surface facing out.
7. Reassemble the motor to the seal plate.
8. Gently wipe the black polished surface of the spring seal assembly with a soft cotton cloth.
9. Press the spring seal assembly onto the impeller shaft, with the black polished surface facing the ceramic seat.
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TriStar XE
17
23
2
2
17
21
2
5
14
8
1
22
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 harmful 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:
-- Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
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All other trademarks not owned by Hayward are the property of their respective owners. Hayward is not in any way
affiliated with or endorsed by those third parties. For patent information, refer to www.hayward.com/patents.