Spear,
When I run my SPA/PUMP/HEATER-ON functions, my Filter Pump RPM is running at 2950.. My maximum rpm is 3450, so 2950/3450= 85.5%. I have an "ecostar", but I'm pretty sure your tristar needs to be running 80-85% RPM too.
Here is what I would do:
-Write down every serial #/Model # and Software level and Rev Level of everything you have
-(this might be painful) But call Hayward Tech Support and get them to verify that everything you have WILL INDEED work when properly configured.
-REAL IMPORTANT - ask them if there have been any technical service bulletins or product updates on any and all of the pump, prologic, etc ? You can have what you call the latest tech service manual, but it may have left out a very important update that is the "missing link" to your problem(s).
To conclude, the main thing is you want to make sure that everything you have will indeed function together. If so, that you have the very latest in all product updates, then you should be good to go.
Another option is to post your general service area location and see if anyone in the TFP forum might know a good tech/company that can solve this for you.
Finally, it's the very basic step, but if you have 2 wires the same color and they are in conduit from point A to B, just make sure you are working w the same "green" wire on both ends. It can be something that simple of a correction to make a game changer. We are all pulling for you and best of luck up there.
tstex