Hayward HydroRite UVO3 Troubleshooting Manual
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Hayward HydroRite UVO3 Troubleshooting Manual

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Commercial HydroRite
Commercial Troubleshooting Guide
TSG-UVO(C)158b
Copyright 2017 Hayward Industries Inc.

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February 10, 2025

filter cavitation detected message

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Summary of Contents for Hayward HydroRite UVO3

  • Page 1 Commercial HydroRite Commercial Troubleshooting Guide TSG-UVO(C)158b Copyright 2017 Hayward Industries Inc.
  • Page 2 Safety Precautions Warning • When installing and using this electrical equipment, basic safety precautions should always be followed, including the following: – READ AND FOLLOW ALL INSTRUCTIONS • This product should be installed by a professional service technician or similar person who is qualified in electrical equipment installation.
  • Page 3 Safety Precautions (cont.) • A bonding lug is provided on the external surface. To reduce the risk of electric shock, connect the local common bonding grid in the area of the swimming pool, spa, or hot tub to these terminals with an insulated or bare copper conductor not smaller than 8 AWG US / 6 AWG Canada.

  • Page 4: Table Of Contents

    Table of Contents How HydroRite Works & Specifications Pg. 5-6 Overview: Pg. 7-16 Installation Location, Booster pump, & Vessel Assembly 8-10 Interconnect & Main PCB Overview 11-12 LED indicators & Menu/Reporting/Errors 13-14 Chemistry Requirements & Replacement Parts 15-16 How To: Pg.

  • Page 5: How Hydrorite Works & Specifications

    HydroRite: How It Works The Hayward HydroRite contains 3 high intensity electrically operated Ultraviolet (UV) lamps. The UV lamps emit light at two separate wavelengths within the UV spectrum; 254 nm and 185 nm. • The 254 nm wavelength is considered the “germicidal”...
  • Page 6 Specifications & Head Loss HYR2CSC-UVO: Plumbing 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: Overview

    HydroRite UVO Overview:...

  • Page 8: Installation Location, Booster Pump, & Vessel Assembly

    HydroRite: Installation Location NOTE: 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 HydroRite: Booster Pump & Vessel NOTE: 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 HydroRite: Vessel Top...

  • Page 11: Interconnect & Main Pcb Overview

    HydroRite: Interconnect PCB Overview Transformer Input (120VAC) 2X (3.15A) PCB Fuses PCB Input Power (120VAC) Transformer Output (230VAC) Main PCB Power (120VAC) Main PCB Interface Connection Not Used Output to Ballast Fan (12VDC) Not Used Output to Ballast (230 VAC) Sensor Output Jack (to display PCB) Flow &...
  • Page 12 HydroRite: Main Board Overview Sensor Input Flow switch & over temp (status) Alarm output (reporting) UV lamp engage (dry contacts) Display control board power (120VAC) Fuse - Display power (1 amp) Not Used Alarm output Fuse (1 amp) Membrane switch (ribbon cable) Display PCB (ribbon cable) Voltage Selector (leave at 230V)

  • Page 13: Led Indicators & Menu/Reporting/Errors

    HydroRite: LED Indicators Indicator Description Lamps ON Lamps are being sent power. A problem has been detected: Check System compare display to message key for detailed descriptions. Upon startup, this light flashes Initializing during lamp warm-up (30mins). Appears when the lamp % is Intensity % being reported.
  • Page 14 HydroRite: Menu & Reports/Errors Menu Button Enter Button / Silence Alarms Lamp Operation (Auto or OFF) Report Description Menu Description Indicates that the lamp is in an OFF cycle (Manual) Calibration (only to be used after replacing all three lamps) Appears if the HydroRite passed calibration Test = Direct voltage readout Appears if the HydroRite failed calibration...

  • Page 15: Chemistry Requirements & Replacement Parts

    HydroRite: Chemistry Requirements Chemical Ideal Levels Recommendations Too High: Chlorine reducer Free Chlorine 1.0 to 3.0 ppm Too Low: Superchlorinate/ Add Chlorine Too High: Muriatic Acid or CO2 7.2 to 7.8 Too Low: Soda Ash 30-50 ppm Too High: Partially drain/dilute Stabilizer (CYA) (0 ppm for indoor pools) Too Low: Add Cyanuric acid...
  • Page 16 HydroRite: Replacement Part Numbers Part # Description Part # Description HYX2CCPS 2" Commercial Controller UVO - Controller Only HYX2DLAS-3PK 2" Commercial Lamp - UV/03 - Dual Wavelength - Pack of 3 HYX2C-XFMR 2" Commercial Power Transformer - 250 VAC HYX2DVEN-CK Complete Venturi Kit for 2"...

  • Page 17: How To

    HydroRite UVO How To:...

  • Page 18: Uv Lamp Removal/Replacement & Calibration

    UV Lamp Removal & Replacement Follow the steps provided below to remove and/or replace the UV lamps. Step 1 Step 2 First unplug the HydroRite from its power Close off the bypass valve to isolate the source and turn off the filtration pump. HydroRite hydraulically.
  • Page 19 UV Lamp Removal & Replacement (cont.) Pro Tip: Disconnecting the vessel sensor provides more room to access the lamp connections for both removal and installation. Step 5 Step 6 Remove lamps, rotating the base connection Disconnect lamps from ballast cables and counter-clockwise and pull lamps straight out.
  • Page 20 Calibrating the HydroRite NOTE: Calibration of the UV lamps SHOULD ONLY be conducted when all three lamps have been replaced. DO NOT calibrate if servicing the vessel or quartz sleeves only. Step 1 Step 2 Once new lamps have been installed, plug in Access the menu by holding the menu button the controller &...
  • Page 21 Calibrating the HydroRite (cont.) NOTE: Calibration takes 30 minutes, once calibration is complete the system will report either a ‘P’ (pass) or an ‘F’ (fail). Step 5 Step 6 While the system is calibrating, the screen will Once calibration is complete a ‘P’ (pass) or ‘F’ cycle between a countdown &...

  • Page 22: Cleaning The Quartz Sleeve & Lamp Sensor

    Cleaning Quartz Sleeve & Lamp Sensor Follow the steps provided below when attempting to clean the Quartz Sleeve Step 1 Step 2 First unplug the HydroRite from its power Verify there is no pressure in the system & source and turn off the filtration pump. close the inlet &...
  • Page 23 Cleaning Quartz Sleeve & Lamp Sensor (cont.) Pro Tip: Disconnecting the vessel sensor cable before the lamps will provide more room to access the lamp connections for removal. Step 5 Step 6 Disconnect the three Ozone tubes from the Disconnect the lamp sensor located in the Ozone manifold (tubes are fixed to lamps).
  • Page 24 Cleaning Quartz Sleeve & Lamp Sensor (cont.) IF calcium deposits are encountered, rinse quartz sleeves with tap water, then clean with Lime-A-Way®, Muriatic Acid (4 parts water – 1 part acid), or isopropyl alcohol. Step 9 Step 10 Loosen the vessel lock nut, rotating counter Pinch the sleeve near the clips to spring it loose clockwise &...
  • Page 25 Cleaning Quartz Sleeve & Lamp Sensor (cont.) DO NOT remove the lamp sensor from the vessel body. Pro Tip: When reattaching the stainless steel sleeve, first align the quartz sleeves with the concave returns (looking through the clear plastic bottom piece), then flip the whole unit over to verify the sleeves are lined up with the bezels before securing.

  • Page 26: Troubleshooting

    HydroRite UVO Troubleshooting...

  • Page 27: Sys Err' Appears On Display

    1. ‘SYS ERR’ Appears on Display After 30 mins. Are ballast Clean Quartz ‘SYS ERR’ on does ‘SYS ERR’ LEDs ON in Sleeve & Lamp Display still appear? Green? Sensor Verify LEDs Is chemistry Problem on ballasts balanced? solved Inspect the Are LEDs ON lamp cable Check lamp...
  • Page 28 1. ‘SYS ERR’ Appears on Display When the HydroRite experiences a ‘SYS ERR’ (system error), the lamp efficiency has fallen to 70% or lower. Start by cleaning the quartz sleeves. IF the lamp efficiency has dropped to 0, please contact technical support (908) 355-7995. Clean Quartz Sleeves &...
  • Page 29 1. ‘SYS ERR’ Appears on Display (cont.) High chlorine residuals may cause the UV efficiency reading to be lower than expected. An imbalance in water chemistry should be corrected before replacing hardware. Test Chemistry Verify Lamp Run Hours Step 1C Step 1D Test the water chemistry, following the table on page Press &...
  • Page 30 1. ‘SYS ERR’ Appears on Display (cont.) NOTE: Ballasts should be plugged into the interconnect board via terminals 1, 3, & 5. Verify the ballasts are plugged into these positions before proceeding. Inspect Ballast LEDs (cont.) Verify Ballast Input Power Step 1E Step 1F Inspect the ballast LEDs.
  • Page 31 1. ‘SYS ERR’ Appears on Display (cont.) Damage to the lamp cable may have a detrimental effect on lamp output. Verify the lamp cables are free of any significant damage. Verify Lamp Connection/Cable Replace lamp(s) Step 1G Step 1H Inspect lamp connections & cable for damage. IF Power the HydroRite down &...

  • Page 32: Display Not Lit

    2. Display Not Lit Test main board Test power to input power for 192- Is power Display Not Lit display, is power 288VAC off correct? less than 5VDC? interconnect board Test the 1A Replace Transformer Replace display interconnect output shows the display power fuse board...
  • Page 33 2. Display Not Lit The display board requires 5VDC from the main board (green) in order to function properly. IF 5VDC is present but the display is not illuminated then the display will need to be replaced. Verify Display Power Display Output (interconnect) Step 2A Step 2B...
  • Page 34 2. Display Not Lit (cont.) 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. Test the 1A Fuse (Main Board) Verify Voltage Selectors (main) Step 2C...
  • Page 35 2. Display Not Lit (cont.) CAUTION: Transformer output is 240VAC! Test Transformer Output Test Transformer Input Step 2E Step 2F Verify transformer output is 192-288VAC. IF the voltage Verify transformer input is 108-132VAC between pins 1- is correct, replace the interconnect board (HYX2CSIPCB). 3 &...
  • Page 36 2. Display Not Lit (cont.) 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. Test Interconnect Fuses Verify Voltage Selectors (intercon.) Step 2G...
  • Page 37 2. Display Not Lit (cont.) Verify the GFCI receptacle, supplying power to the HydroRite control panel, is not tripped. Test Incoming Power Step 2I Verify source power is 108-132VAC. IF NO/LOW, resolve incoming power issue. IF voltage is correct, replace the interconnect board (HYX2CSIPCB).

  • Page 38: Flo' Appears On Display

    3. ‘FLO’ Appears on Display ‘FLO’ Flow is a min. Pump is Is filter of 15GPM*? running? clean? Appears Turn on Increase Plug a new flow Clean filter Problem pump, after 3 pump speed switch into the & retest solved mins did ‘FLO’...
  • Page 39 3. ‘FLO’ Appears on Display The ‘FLO’ error message appears when either: flow is not detected by the flow switch OR the interlock sensor is reporting that the vessel cover is open, make sure the pump is on and the cover is secure before proceeding. Verify Main Pump is On Check the Flow Rate Step 3A...
  • Page 40 3. ‘FLO’ Appears on Display (cont.) PRO TIP: It is always helpful to keep an extra flow switch available for testing purposes. All Hayward sanitization systems utilize the same flow switch (GLX-FLO-RP). Check the Filter Plug-in a Test Flow Switch...
  • Page 41 3. ‘FLO’ Appears on Display (cont.) IF the ‘FLO’ error persists despite running the pump and isolating out the interlock switch, then the inline flow sensor is likely the cause of the error. IF isolating the interlock switch clears the error, then the problem is related to the interlock circuit. Replace Flow Switch &...
  • Page 42 3. ‘FLO’ Appears on Display (cont.) PRO TIP: Often times the interlock sensor is disconnected while servicing the top vessel compartment, make sure the interlock sensor connection is secure before proceeding. Inspect the Interlock Switch Cable Verify Interlock Switch Connection Step 3G Step 3H Locate &...

  • Page 43: Vessel Is Leaking

    4. Vessel is Leaking IMPORTANT: Is water leaking Vessel is Unplug unit from out of the vessel Leaking power until cover? resolved Remove the Drain plug or Top vessel vessel cover, Replace o-ring o-ring intact? remove & drain plug damaged? disconnect the lamps, disconnect Replace...
  • Page 44 4. Vessel is Leaking IF the vessel is leaking it is important to first determine whether the leak is occurring: under the vessel cap or from an exterior source. Inspect the Vessel for Leaks IMPORTANT: POWER DOWN Step 4A Step 4B It is important to identify where the water is coming Power down the HydroRite immediately by unplugging from.
  • Page 45 4. Vessel is Leaking (cont.) When quartz sleeves are cracked, water generally works its way up (flooding the quartz sleeves first). When a quartz sleeve is only partially flooded, this may indicate that water entered from the top down. Remove Cables, Sensors, & Lamps Inspect Vessel’s Top Compartment Step 4C Step 4D...
  • Page 46 4. Vessel is Leaking (cont.) Both the main seal & drain plug have o-rings that act to seal the vessel from leaking. IF either of these parts are damaged this may provide a leak path. Inspect O-Ring (Vessel’s Main Seal) Inspect Drain Plug &...
  • Page 47 4. Vessel is Leaking (cont.) The HydroRite’s Vessel is attached to the plumbing via unions and o-rings. IF o-rings or unions are damaged OR not properly secured, this may provide a leak path. Inspect Vessel Unions & O-Ring Step 4G Inspect the unions &...

  • Page 48: Circulation System Is Loud

    5. Circulation System is Loud Booster Vessel Needle valve System is pump is secured to closed/barely Loud secured to pad? open? pad? Adjust needle valve until Secure Secure noise vessel to pad vessel to pad reduces Verify the pump is not STOP: Shut the Vessel is being experiencing cavitation...
  • Page 49 5. Circulation System is Loud IF either the Vessel or Booster Pump are not secured to the equipment pad, vibration may cause normal operation to be loud. Vessel is Secured to Pad Booster Pump is Secured to Pad Step 5A Step 5B Verify that the HydroRite vessel is secured to the Verify the booster pump is secured to the equipment...
  • Page 50 5. Circulation System is Loud (cont.) The Needle Valve regulates the amount of vacuum caused by the Venturi. If the restriction is too great, this can cause the booster pump to sound labored. When a bypass is engaged, the booster pump should not receive power. Venturi Needle Valve Inspect Bypass Valves Step 5C...
  • Page 51 5. Circulation System is Loud (cont.) IF the pump is not wired correctly this may cause excessive noise. Also cavitation (resulting from a flow restriction on the suction-side) OR a restriction on the pressure- side, can increase noise and may put unnecessary strain pump. Verify Booster Pump Wiring Inspect Suction &...

  • Page 52: Additional Information

    HydroRite UVO Additional Information...

  • Page 53: Reading Serial Numbers

    Reading Serial Numbers 3U16200 Standard Warranty Term 3U16200 Product Family 3U16200- 115601 3U16200 Year of Manufacture 3U16200 Day of Manufacture 115601 = Manufacturing ID...

  • Page 54: Frequently Asked Questions (Faqs)

    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.
  • Page 55 A. YES, you can add any number of HydroRite units to a manifold system to allow for larger outputs and flow rates beyond the capacity of a single HydroRite unit. Contact Hayward to obtain a drawing showing the proper method of plumbing multiple HydroRites for larger applications.

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