IntelliFlo3 Relay Board + IC30 + poolController = What am I doing wrong?

[pmturso-star]

I can control my IC30 via the relay board on the IF3 with the Pentair app, no problem.
But when I switch to Nixie (is that the same as poolController?) (I'm a newb). The relay won't activate. Is there a setting that I have to do within Nixie or...?

Some say it works, but I don't know how. Some say it doesn't. And other say I have to use another set of wires to the relay board from the Pi?

Sorry for all the questions. poolController is amazing. I'm a HUGE fan. :)

Pete

[mguinness]

I believe that @rstrouse has the IF3, but not sure if they also have the relay control board. It's possible that when automation control is established through RS-485 the functionality from the Pentair app would no longer work.

What would be nice workaround is if Pentair could adapt the pump firmware to activate auxiliary relays based on RPM (like Jandy ePump) then that would provide a means to achieve relay control via automation based on speeds.

[pmturso-star]

Ok... apparently this:
https://a.co/d/0h1IamI3

Will allow me to turn on the relay via the Nixie... at least that is what my AI ability tells me... I dunno... I'll play with it - unless someone tells me a I'm an idiot... If nothing else, I wonder if I can use it to run a small peristaltic pump for acid?...

[mguinness]

If you have a RS-485 USB adapter connected to your RPi then it'll allow direct control of IF3 and IC30. @ufoDziner used the Sequent Microsystems HAT to achieve this.

[pmturso-star]

I can get it to work with the 485... but I've got a new problem:

Now that I have the 5a relay wired instead of having the pump wired hot all the time... here's my latest issue:

I'm on 24 hours of this... I'm beat.
Tell me something. Make it make sense.

If Nixie is powered up.
IC30 powered from relay board on IF3
IC30 refuses to power up. I bought the WaveShare board for the pi... I have it clicking with Nixie...
But NOTHING powers up the IC30.
I moved to SP2... set P2 to 40GPM, relay on for IC30, it works great under pentair app, but the minute I power on the pi... the IC30 will NOT power up.

Talk to me! I'm at the point where drink is on me.Please and thanks!! :)

[mguinness]

Ideally your IF3 should be wired hot all the time and not through the relay. A relay would only be needed for the IC30 as an additional safety. Nixie would control the pump and chlorinator via RS-485, setting output to 0% when pump is off. Regarding the relay, test with a clamp ammeter or multimeter to see what the amp draw is when relay activates.

[mguinness]

I'm not aware of that requirement regarding the PC100 transformer, If you can cite the section in NEC Article 680 that would be insightful.

The answer to your question is yes, it's no different to how it works with automation like IntelliConnect that can control the IC30 via RS-485, relay or both.

[pmturso-star]

Then there has to be something "on" that is conflicting with running the program. I think the next step is to have nothing running on the nixie and go from there.

[pmturso-star]

Got the final verdict.

NO! you can NOT run the IC30 from the 5a IF3 relay via Nixie. Period. The ONLY way to make it happen is if you put the IC30 on a relay and let the nixie waveshare trigger the relay to supply 240ac to the ic30. But I can 100% assure you that the VOUT / SP1 (or 2 3 4) will NOT trigger the IC30 and the IC30 will not power up if there is automation beyond the Pentair app.

Two and half days of my lift. But now you know.

[pmturso-star]

Hi.

Correct. The IF3 is always hot.
The IC30 is on the relay.
This works perfectly when Nixie is NOT in the picture.
When Nixie is in the picture (active), the IC30 will not run any SP (1,2,3,4).

Jumping VOUT and SP1 will allow SP1 to run properly, however there is NO provision to initiate the 5a (or any) relay via SP in the Pentair app.

Again - if Nixie is active, the IC30 will not power on. That's the problem I've been battling with.
The answer seems to be that it can not be done unless you either:

1. Return IC30 to constant power (then nixie is happy)
2. Place the IC30 on a relay that allows Nixie to turn on that 240vac relay (which forces the IC30 to power on as if it was always hot).

If you are saying that Nixie CAN work with IC30 and IF3 AND the 5a Relay (so that the IC30 is powered via the IF3 relay)... I'll buy a beer... or two... or donate to the cause... or... you name it. :)

[mguinness]

It would be helpful if you can share photos of how everything is wired, I don't think I'm following especially regarding speeds 1,2,3,4 (if that what SP refers to). However, in general you can either use Nixie or the Pentair app for automation. If you use Nixie then you will lose functionality of the relays in the IF3 - which is confirmed by your experience.

[pmturso-star]

On the relay board of the IF3 there are automation terminals. VOUT, GND, S1, S2, S3, S4.
When you "jump" (or create continuity) between VOUT and, for example S1, that will tell the pump to run S1 programming. (This is found on the Pentair app). But it only allows for control of the pump speed, NOT any relays.

How it's wired?

We have the two comm wires running to the 485. (two wires to if3 and two wires to the ic30 box). This all gets combined to the 485.
If you aren't using the IF3 relay board, this all works fine.

Then, on the IF3 relay board, we have the proper wiring going to the Waveshare relay piggy-back board on the pi, so I am able to trigger the relay from Nixie (or REM).

The problem is that trigging the relay on the IF3 only allows you to control an SP... which, again, will not allow 240v power to go to the IC30.

The sticking point is that something, somewhere is preventing Nixie from turning on the IC30 when 240v is coming from the IF3 relay board.

[mguinness]

OK, those are the digital inputs. Presumably using those would prevent the use of the IF3 relay board through the Pentair app - the onboard NO relay will never close. I think it's clear now that you can only use the onboard relays when Pentair app is controlling the pump, i.e. not through DI or RS-485.

Either use the Pentair app and onboard relay for IC30, or use Nixie and Waveshare relay for IC30. For the latter the Pentair app will be unnecessary as the IF3/IC30 would be controlled directly from Nixie (as documented) via RS-485. Using a Waveshare relay as an additional safety for IC30 is optional.