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Hayward hydrorite uvo3, Troubleshooting Manual

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Hayward hydrorite uvo3 Troubleshooting Manual Download Page 12

12 

HydroRite: Main Board Overview 

J 

I 

A 

C 

B 

D 

E 

G 

H 

K 

A 

  Sensor Input  

B 

  Flow switch & over temp (status) 

C 

  Alarm output (reporting) 

D 

  UV lamp engage (dry contacts) 

E 

  Display control board power (120VAC) 

F 

  Fuse - Display power (1 amp) 

G 

  Not Used 

H 

  Alarm output Fuse (1 amp) 

I  

  Membrane switch (ribbon cable) 

J 

  Display PCB (ribbon cable) 

K 

  Voltage Selector (leave at 230V) 

F 

Summary of Contents for hydrorite uvo3

Page 1: ...Copyright 2017 Hayward Industries Inc Commercial HydroRite Commercial Troubleshooting Guide TSG UVO C 158b ...

Page 2: ...se serious personal injury property damage or death Improper installation and or operation will void the warranty The device must be connected only to a supply circuit that is protected by a Ground Fault Circuit Interrupter GFCI FAILURE TO CONNECT THIS DEVICE TO A GFCI SUPPLY CIRCUIT COULD RESULT IN ELECTRICAL SHOCK CAUSING SERIOUS BODILY INJURY INCLUDING DEATH WARNING Disconnect all AC power duri...

Page 3: ...ever touch the glass with bare hands Wipe any fingerprints from lamps and sleeves with alcohol CAUTION this device is for swimming pool use only Do not use this device for potable drinking water sanitization DANGER ULTRAVIOLET RADIATION Disconnect Power Before Replacing Lamp This device contains an ultraviolet lamp that can cause discomfort irritation and damage to the eyes if viewing occurs while...

Page 4: ...istry Requirements Replacement Parts 15 16 How To Pg 17 25 UV Lamp Removal Replacement Calibration 18 21 Cleaning the Quartz Sleeve Lamp Sensor 22 25 Troubleshooting Pg 26 51 1 SYS ERR Appears on Display 27 31 2 Display Not Lit 32 37 3 FLO Appears on Display 38 42 4 Vessel is Leaking 43 47 5 Circulation System is Loud 48 51 Additional Information Pg 52 55 Reading Serial Numbers 53 Frequently Asked...

Page 5: ...cteria viruses protozoa e g Cryptosporidium and Giardia algae spores and other single vessel waterborne microbes The 185 nm wavelength on the other hand is considered the ozone generating wavelength and is responsible for converting oxygen O contained in the quartz sleeve area into ozone O The ozone created is introduced into the water stream using a venturi Ozone a strong oxidizer and bactericide...

Page 6: ...lumbing diameter 2 inch Input Power 120VAC 50 60Hz Power Consumption Control Center 2 5A Booster Pump 13 8A Maximum Operating Pressure 50 psi Operating Flow Range 32 75 gpm Maximum Flow Rate 75 gpm Number of Bulbs 3 Volume of Vessel 75 gallon ...

Page 7: ...HydroRite UVO3 Overview ...

Page 8: ...E All Chlorinators include salt chlorine generators MUST be plumbed down stream of the HydroRite ALSO Heaters can be plumbed before or after the vessel however to achieve optimal results water entering the HydroRite SHOULD NOT exceed 104 F ...

Page 9: ... All Chlorinators include salt chlorine generators MUST be plumbed down stream of the HydroRite ALSO Heaters can be plumbed before or after the vessel however to achieve optimal results water entering the HydroRite SHOULD NOT exceed 104 F ...

Page 10: ...10 HydroRite Vessel Top ...

Page 11: ...wer 120VAC D Transformer Output 230VAC E Main PCB Power 120VAC F Main PCB Interface Connection G Not Used H Output to Ballast Fan 12VDC I Not Used J Output to Ballast 230 VAC K Sensor Output Jack to display PCB L Flow Interlock Sensors interchangeable M Booster Pump Dry Contact N Lamp Efficiency Vessel Sensor F E K M N ...

Page 12: ...w switch over temp status C Alarm output reporting D UV lamp engage dry contacts E Display control board power 120VAC F Fuse Display power 1 amp G Not Used H Alarm output Fuse 1 amp I Membrane switch ribbon cable J Display PCB ribbon cable K Voltage Selector leave at 230V F ...

Page 13: ...detailed descriptions Initializing Upon startup this light flashes during lamp warm up 30mins Intensity Appears when the lamp is being reported Circulation Flow Is lit when flow is detected is OFF when flow is not detected or interlock alarm exists System Power OFF Red System is not powering the ballasts System Power ON Green Power is being sent to the ballasts ...

Page 14: ...ported during initial calibration TeP Stands for high temperature condition related to the internal controller temperature HydroRite Menu Reports Errors 14 Menu Description CAL Calibration only to be used after replacing all three lamps S Test Direct voltage readout dSP Test voltage readout that was obtained at calibration Aud Audible alarm for flow switch interlock sensor ON OFF run Hours of lamp...

Page 15: ...abilizer CYA 30 50 ppm 0 ppm for indoor pools Too High Partially drain dilute Too Low Add Cyanuric acid Total Alkalinity 80 to 120 ppm Too High Muriatic Acid Too Low Baking Soda Calcium Hardness 200 to 400 ppm Too High Partially drain dilute Too Low Add Calcium Iron 0 3 ppm 0 3 mg L Too High Add a chelating sequestrant Too Low No such thing Manganese 0 05 ppm 0 05 mg L Too High Add a chelating seq...

Page 16: ...ypad Assembly HYX2DVTA Venturi Ozone Tube Assembly Kit HYXSPCBA PCB Assembly for Digital Display Panel BSX1CAP2 2 Simplex PVC Port Cap 2 Commercial Only HYXSSECA Cable Assembly for UV sensor BSX1PLUG2 1 PVC Drain Plug HYXSFANA Fan Assembly ECX12S 2 PVC Pipe Connector Socket 2 Commercial Only HYXSLACA Cable and Connectors for UV Lamp Lamp Not Included ECX12T 2 PVC Pipe Connector Threaded 2 Commerci...

Page 17: ...HydroRite UVO3 How To ...

Page 18: ...lug the HydroRite from its power source and turn off the filtration pump Close off the bypass valve to isolate the HydroRite hydraulically Step 1 Step 2 Remove the vessel cover by loosening the four retaining screws Disconnect the three Ozone tubes from the Ozone manifold tubes are fixed to lamps Step 3 Step 4 ...

Page 19: ...s for both removal and installation Remove lamps rotating the base connection counter clockwise and pull lamps straight out Disconnect lamps from ballast cables and reverse steps 1 5 with the new lamps Step 6 Step 5 IMPORTANT DO NOT touch the lamps with bare hands CALIBRATE the HydroRite ONLY after replacing all three lamps ...

Page 20: ...talled plug in the controller make sure lamps are off Access the menu by holding the menu button located just above the center of the screen Toggle the display using the arrows until CAL appears then press enter The display should show YES press enter again to accept Step 1 Step 2 Step 4 Step 3 IMPORTANT Prior to Calibrating the HydrorRite the water MUST be balanced including target free chlorine ...

Page 21: ...stem is calibrating the screen will cycle between a countdown CAL Once calibration is complete a P pass or F fail will appear press enter to accept The screen should now show 100 100 the new readings are now recorded Step 5 Step 6 Step 7 IMPORTANT Prior to Calibrating the HydrorRite the water MUST be balanced including target free chlorine levels between 1 3ppm ...

Page 22: ...power source and turn off the filtration pump Verify there is no pressure in the system close the inlet outlet valves to the vessel Step 1 Step 2 Cleaning Quartz Sleeve Lamp Sensor Remove the drain plug from the vessel to drain it of water Remove the vessel cover by loosening the four retaining screws Step 4 Step 3 ...

Page 23: ...amps Disconnect the lamp sensor located in the center of the vessel cap counterclockwise Remove lamps rotating the base connection counter clockwise and pull lamps straight out Disconnect lamps from ballast cables followed by the interlock sensor Step 5 Step 6 Step 8 Step 7 IMPORTANT Always wear included gloves when handling lamps DO NOT touch the lamps with bare hands Cleaning Quartz Sleeve Lamp ...

Page 24: ...ose carefully slide it straight off Rinse clean the outside of the quartz sleeve ONLY then clean with rubbing alcohol or muriatic acid DO NOT use abrasives Once dry inspect the quartz sleeves for cracks IF any cracks exist immediately replace DO NOT install cracked quartz sleeves Step 9 Step 10 Step 12 Step 11 IMPORTANT DO NOT clean or get the inside of the quartz sleeves wet or dirty inside the s...

Page 25: ...opropyl alcohol rubbing alcohol The lamp sensor should be cleaned in this fashion every time the quartz sleeves are maintenance Once cleaned proceed to step 14 Once the cleaning procedure is complete AND the quartz sleeves are completely dry reverse steps 1 10 to reassemble the unit NOTE the stainless steel sleeve only goes on in one orientation DO NOT force it Step 13 Step 14 Cleaning Quartz Slee...

Page 26: ...HydroRite UVO3 Troubleshooting ...

Page 27: ...rify LEDs on ballasts 27 Are they correct YES Verify 216 264VAC present on the PCB Reseat retest YES NO Run time exceeds 9 000 hrs Are voltage readings correct Replace lamps NO Replace Interconnect PCB Problem solved Is chemistry balanced NO YES Balance retest Check lamp run hours Contact Tech Support 908 355 7995 NO Replace ballast s YES YES NO Are cables damaged Replace lamp cables YES NO Replac...

Page 28: ...aned restore system power wait 30 minutes IF after 30 minutes the efficiency is still below 70 go to 1B Inspect each ballast verify the state of the status LED These LEDs provide information pertinent to the ballast lamp IF all ballast LEDs are ON green go to step 1C IF NOT jump to step 1E Clean Quartz Sleeves Lamp Sensor Step 1A Step 1B Inspect Ballast LEDs 28 1 SYS ERR Appears on Display NOTE IF...

Page 29: ... 30 minutes IF chemistry is balanced proceed to step 1D Press hold the menu button until the CLr appears Press the down arrow repeatedly until run appears then press enter IF service hours are 9 000 900 or greater replace lamps IF not contact tech support 908 355 7995 Test Chemistry Step 1C Step 1D Verify Lamp Run Hours 29 1 SYS ERR Appears on Display cont NOTE Lamp hours will appear in standard u...

Page 30: ... the ballast LEDs IF there are NO LEDs illuminated procced to step 1F IF the LEDs are illuminated in RED proceed to step 1G Verify 216 264VAC present on the PCB IF NO LOW voltage replace the interconnect PCB HYX2CSIPCB IF correct replace ballast HYXSBCHA Inspect Ballast LEDs cont Step 1E Step 1F Verify Ballast Input Power 30 1 SYS ERR Appears on Display cont ...

Page 31: ...damaged go to 1H Power the HydroRite down replace the lamp s HYX2DLAS It is recommended to replace lamps in threes Verify Lamp Connection Cable Step 1G Step 1H Replace lamp s 31 NOTE It is recommended to replace lamps in sets of three IF all three lamps are replaced then it is prudent to calibrate the HydroRite IF only 1 or 2 of the lamps are replaced DO NOT calibrate the unit 1 SYS ERR Appears on...

Page 32: ...puts show 108 132VAC YES Replace Transforme r Test interconnect board fuses Is power correct Verify source power is 108 132VAC present NO Resolve source power issue YES Replace fuse retest Is the fuse blown YES NO Replace main PCB YES Replace interconnect board NO NO Are fuse s blown NO YES Replace interconnect board Verify voltage selectors are correct Verify voltage selectors are correct Did the...

Page 33: ...eplaced Verify that 5VDC is present between bottom right most pins IF NO LOW voltage is present proceed to step 2B IF correct replace the display HYXSDIAS On the interconnect board unplug J16 test for 192 288VAC between 1 2 top to bottom IF voltage is correct go to 2C IF NO LOW proceed to 2E Verify Display Power Step 2A Step 2B Display Output interconnect 33 2 Display Not Lit ...

Page 34: ... is blown proceed to step 2D IF the fuse passes a continuity test then replace the main board HYXSPCBA On the main board verify the voltage selector is set to 230V Once confirmed replace the blown fuse CAX 20101 retest IF fuse immediately fails again replace the main board HYXSPCBA Test the 1A Fuse Main Board Step 2C Step 2D Verify Voltage Selectors main 34 2 Display Not Lit cont NOTE IF the volta...

Page 35: ...ltage is correct replace the interconnect board HYX2CSIPCB IF NO LOW go to 2F Verify transformer input is 108 132VAC between pins 1 3 2 4 IF OK replace transformer HYX2C XFMR IF NO LOW go to step 2G Test Transformer Output Step 2E Step 2F Test Transformer Input 35 2 Display Not Lit cont ...

Page 36: ...mmediately fails again replace the board HYX2CSIPCB Test Interconnect Fuses Step 2G Step 2H 36 2 Display Not Lit cont Verify Voltage Selectors intercon There are two voltage selector plugs the one located on the main green board should be set to 230V and the one on the interconnect blue board should be set to 115V If either of these are incorrect fuses on the corresponding board may blow NOTE IF t...

Page 37: ...wer to the HydroRite control panel is not tripped Verify source power is 108 132VAC IF NO LOW resolve incoming power issue IF voltage is correct replace the interconnect board HYX2CSIPCB Step 2I 37 2 Display Not Lit cont Test Incoming Power ...

Page 38: ... 38GPM minimum Plug a new flow switch into the interlock port Turn pump on close new flow switch does the error clear NO NO Plug interlock switch back in replace the existing flow switch turn on pump did the error clear YES NO Check interlock cable is it damaged YES Problem solved Contact tech support 908 355 7995 NO YES Is interlock connection secure Secure connection retest NO YES Replace interl...

Page 39: ...and wait 3 minutes before checking again After 3 minutes IF the error still appears proceed to step 3B Verify that the flow rate is at least 15 gallons per minute IF lower than 15GPM increase the flow rate retest after 3 minutes IF the flow rate is greater than 15GPM go to step 3C Verify Main Pump is On Step 3A Step 3B Check the Flow Rate 39 3 FLO Appears on Display 15GPM MIN NOTE 15GPM is enough ...

Page 40: ...sing through the Hydrorite vessel IF cleaning is required clean the filter recheck IF the filter pump basket are both clean continue to step 3D On the panel locate the interlock connector replace it with a new flow switch Leaving the inline switch installed turn the pump on Manually close the new flow switch IF the error persists go to 3E IF the error clears go to 3F Check the Filter Step 3C Step ...

Page 41: ...w switch Then restore the interlock switch connection on the main panel Turn the pump back on wait 3 minutes IF the error still appears jump to step 3G to troubleshoot the interlock switch Unplug the new flow switch used in step 3D plug the interlock switch back into the main panel The inline flow switch has been confirmed Proceed to step 3G to troubleshoot the interlock switch its cable connectio...

Page 42: ... the cover has been removed IF the cable is damaged please contact tech support 908 355 7995 IF the cable is free of damage go to step 3H Under the vessel cap disconnect the switch reestablish its connection Secure the cover retest After 3 minutes of circulation IF the error does not clear then the interlock switch assembly should be replaced HYX MAN2 Inspect the Interlock Switch Cable Step 3G Ste...

Page 43: ...O YES NO YES IMPORTANT Unplug unit from power until resolved Remove the vessel cover remove disconnect the lamps disconnect remove the sensor cable with the cover removed run the circulation pump With the cover removed run the circulation pump to determine the source of the leak path Is the leak path evident Replace damaged components AND OR secure loose fittings YES NO Contact Tech Support 908 35...

Page 44: ...the vessel jump to step 4E Power down the HydroRite immediately by unplugging it from the power source IF excessive water is present turn power off at the main breaker before entering the area then proceed to step 4C Inspect the Vessel for Leaks Step 4A Step 4B IMPORTANT POWER DOWN 44 4 Vessel is Leaking WARNING Water that has entered the top compartment of the vessel can cause electrical shorting...

Page 45: ... pump Then procced to step 4D With the pump running inspect the top compartment to determine the leak path IF leak path is evident replace damaged components or secure loose fittings Otherwise contact tech support 908 355 7995 Remove Cables Sensors Lamps Step 4C Step 4D Inspect Vessel s Top Compartment 45 4 Vessel is Leaking cont WARNING Water that has entered the top compartment of the vessel can...

Page 46: ... to reveal to vessel s main seal IF the o ring is damaged replace it SB2KIT IF the o ring is intact proceed to step 4F With the pump off remove the drain plug and inspect its o ring IF the o ring or plug are damaged replace the o ring SB2KIT or plug BSX1PLUG2 IF fully intact proceed to step 4G Inspect O Ring Vessel s Main Seal Step 4E Step 4F Inspect Drain Plug O Ring 46 4 Vessel is Leaking cont ...

Page 47: ...secured this may provide a leak path Inspect the unions the o rings that attach it to the plumbing IF the o rings are damaged replace them SB2KIT IF the o rings are free of damage AND OR the unions have been compromised please contact tech support 908 355 7995 Inspect Vessel Unions O Ring Step 4G 47 4 Vessel is Leaking cont ...

Page 48: ...r is running NO Adjust needle valve until noise reduces YES NO STOP Shut the system down contact tech support 908 355 7995 Verify the booster pump is correctly wired YES Fix wiring and retest Is pump correctly wired NO Verify the pump is not experiencing cavitation caused by a suction side restriction OR deadheading due to a pressure side restriction Is system still loud YES NO Contact Tech Suppor...

Page 49: ...F the vessel is not secured securing it should reduce any noise caused by vibration IF secured continue to step 5B Verify the booster pump is secured to the equipment pad IF the booster pump is not secured securing it should reduce any noise caused by vibration IF secured go to step 5C Vessel is Secured to Pad Step 5A Step 5B Booster Pump is Secured to Pad 49 5 Circulation System is Loud ...

Page 50: ...the needle valve slowly open it until the booster pump no longer sounds labored This action will also improve Ozone siphoning IF correct proceed to step 5D Verify the vessel is not being bypassed IF the vessel is being bypassed AND the booster pump is still running shut the system down immediately contact tech support 908 355 7995 IF correct go to 5E Venturi Needle Valve Step 5C Step 5D Inspect By...

Page 51: ... not wired correctly shut down the system correct IF wiring is correct proceed to step 5F Inspect valves on both the suction pressure sides IF valves are restricting flow correcting this may improve the booster pump s operation IF OK problem persists contact tech support 908 355 7995 Verify Booster Pump Wiring Step 5E Step 5F Inspect Suction Pressure side 51 NOTE Restricting flow on either the suc...

Page 52: ...HydroRite UVO3 Additional Information ...

Page 53: ...Reading Serial Numbers 3U16200 115601 3U16200 Standard Warranty Term 3U16200 Product Family 3U16200 Year of Manufacture 3U16200 Day of Manufacture 115601 Manufacturing ID 53 ...

Page 54: ... much as 75 over typical levels Q Is the HydroRite system designed for salt water use A YES all plastic components are compatible with pools equipped with Hayward Salt Chlorine Generator Systems The stainless steel insert sleeve will slowly deteriorate in salt water The sleeve can be replaced easily as it slides into the vessel Q Will use of a time clock shorten lamp life A MAYBE Some shortening o...

Page 55: ...umbing multiple HydroRites for larger applications Q Is there any residual effect from Ozone A No the Ozone create by the HydroRite is injected into the plumbing in front of the vessel After entering the HydroRite vessel the UV light converts the Ozone to Hydroxyl radicals in a process called Advanced Oxidation The Hydroxyl radicals are very short lived sanitizers oxidizers that are used up before...

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