HydroRite UVO 3 Troubleshooting Guide Residential TSG-UVO158a Copyright 2015 Hayward Industries Inc.
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. Improper installation and/or operation could cause 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 during installation. 2
Safety Precautions (cont.) CAUTION - To prevent possible fire or electrical shock, use only replacement lamp specified by the manufacturer. 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. Replace damaged cords immediately. Lamps and quartz sleeves are made of glass and are extremely delicate. Care should be taken when handling or replacing these components. Wear cotton gloves when handling lamps or sleeves. Hold bulbs by the ends only. Never 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 device is in operation. Prolonged exposure to the eyes can cause serious injury to the eyes, including blindness. DO T VIEW UV LAMP WHILE THE DEVICE IS IN OPERATION. 3
Table of Contents How HydroRite Works & Specifications Pg. 5-6 Installation: Pg. 7-15 Installation Overview & Parts Description 8-9 Venturi & Lamp Installation 10-11 Vessel top & Connecting Control Box to Vessel 12-13 PCB Overview & LED Indicators 14-15 Maintenance: Pg. 16-24 UV Lamp Removal & Replacement 17-19 Cleaning the Quartz Sleeve 20-24 Troubleshooting: Pg. 25-33 1. UV Lamp Not Lit 26-27 2. Power LED Not Lit 28-29 3. Lamp/Ballast LED is Red 30 4. Flow/Over Temp/Interlock LED 31-32 5. Vessel Makes Noise or Leaking 33 Flow Charts Pg. 34-38 Frequently Asked Questions (FAQ) Pg. 39-41 4
HydroRite: How It Works The Hayward HydroRite contains a high intensity electrically operated Ultraviolet (UV) lamps which is located inside the unit s wet chamber. The UV lamp emit light at two separate wavelengths within the UV spectrum; 254 nm and 185 nm. The 254 nm wavelength is called the germicidal wavelength. This wavelength is capable of inactivating a wide array of microorganisms such as bacteria, viruses, protozoa (e.g. Cryptosporidium and Giardia), algae spores and other single vesseled waterborne microbes. The 254 nm UV light alters the DNA and RNA of the microorganisms rendering them incapable of infection. The 185 nm wavelength, on the other hand, is called the ozone generating wavelength and is responsible for converting oxygen, contained in the quartz sleeve area, into ozone. The ozone created is introduced into the water stream using a venturi. Ozone, a strong oxidizer and bactericide in its own right, works together with the UV to oxidize bather waste and inactivate microorganisms utilizing a process known as advanced-oxidation. 5
Specifications & Head Loss HYD-UVO: Plumbing diameter: 2 inch Input Power: 120VAC, 60Hz Power Consumption: 0.8A Maximum Operating Pressure: 50 psi Operating Flow Range: 10-75 gpm Maximum Flow Rate: 75 gpm Number of Bulbs: 1 Volume of Vessel:.75 gallon 6
HydroRite UVO 3 Installation and Overview
8 HydroRite: Installation Overview
HydroRite: Part Description 1 2 1 Transformer 2 Fan 8 3 Ballast: Green LED = Ok Red LED = Error 7 4 3 4 PCB 5 Vessel 5 6 Inlet Union 7 Outlet Union 8 Vessel lock nut 6 Fig. 1 Fig. 2 9
HydroRite: Venturi Ozone that accumulates in the UV lamp sleeve is introduced into the water stream using the venturi. 10
Vessel: Lamp Installation 11 Fig. 3
HydroRite: Vessel Top Fig. 4 12
HydroRite: Connecting Control Box to Vessel 1. Lamp and corresponding socket connector has a unique design (Fig.5). 2. Lower lamp into vessel (Fig. 6). 3. Socket fitting twists into place. 4. Connect UV sensor. Note: 7a represents the interlock cable AND 7b shows the interlock switch. 7a 7b Fig. 5 Fig. 6 Fig. 7 13
HydroRite: PCB Overview A B C D A Transformer Input (120VAC) E F G H B C D E F G H I 2X (1.25A) PCB Fuses PCB Input Power (120VAC) Transformer Output (240VAC) Input from Ballast (Operation Status) Output to Ballast Fan (12VDC) Output to LED Display (12VDC) Output to Ballast (240 VAC) Flow & Interlock Sensors (interchangeable) 14 I
HydroRite: LED Indicators Power On LED This green LED will be on under normal operation. Even when the pool pump is not running and HydroRite shuts off its lamp, the Power On LED will be lit. Lamp/Ballast LED This red LED indicator implies an issue with the lamp or ballast, or a problem with the connection from the ballast cable to the lamp. Note that the lamp has a defined life and will eventually need to be replaced. 15 Flow/Over Temperature/Interlock LED The HydroRite will shut down due to the following conditions: Flow - the LED indicates a no or low flow condition. Over Temperature - The HyroRite has a temperature sensor that will shut down operation to protect itself if high temperatures are sensed. This can be caused by high ambient temps & direct sunshine. Interlock - The LED indicates the vessel cap has not been installed properly OR the interlock connection is not properly made.
HydroRite UVO 3 Maintenance
UV Lamp Removal & Replacement 1. Unplug the device from the power outlet (Fig 8 & 9). 2. Shut off the circulation pump and make sure there is no pressure in the system. Then close the inlet and outlet valves on either side of HydroRite. 3. Drain the unit by unscrewing the threaded plug from the base of the vessel (Fig. 9 & 10). TE: If the Acid Wash system is plumbed, remove the hose to the shut-off valve from the base of the vessel. You can then open the valve to release the pool water. 4. Removing the Electrical Enclosure Cover by unscrewing the four screws (Fig. 12 & 13). 5. Remove the power clips from the Pressure switch and set cover aside. Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 17
UV Lamp Removal & Replacement (cont.) 6. Remove the lamp by grasping the lamp connector and rotating counterclockwise to unlock the lamp from the nut (Fig. 14). 7. Once unlocked, slowly pull the lamp straight up and away from the quartz sleeve until it clears the vessel (Fig. 15). Carefully place the lamp(s) in a safe location while cleaning the quartz sleeve. Fig. 14 CAUTION: The UV lamp is sensitive to handling and should be allowed to fully cool before being moved. Wait at least 30 minutes after disconnecting power to begin the removal process. Fig. 15 18
UV Lamp Removal & Replacement (cont.) 8. Slowly lower the new lamp(s) down into the quartz sleeve (Fig.16). Once you have verified that the lamp(s) are secured, reconnect the 4- Pin Connector (Fig. 17 & 18) to the pins on top of the lamp(s). TE: The ceramic 4-Pin Connector is designed to fit onto the end of the lamp in ONLY ONE ORIENTATION. Clean and re-lubricate the O-ring before reinstalling the enclosure cover. Fig. 16 Fig. 17 Fig. 18 9. Place the plastic electrical cover on the top of the HydroRite unit and tighten the screws using a Phillips screwdriver (Fig. 19 & 20). Plug in the power cord. Turn on the circulation pump, making sure to open any valves (if applicable) that were closed. Verify that the lamp is lit. Fig. 19 Fig. 20 19
Cleaning The Quartz Sleeve: Automatic When using an automatic cleaner, the HydroRite s quartz sleeve can be cleaned with no need to disassemble the Cell Vessel. When the user initiates a cleaning, an acid bath will clean the quartz sleeve. The cleaner will be permanently plumbed into the system; connected to the inlet and outlet ports located on the top and bottom sides of the vessel. Muriatic Acid: Use a diluted mixture of 4 parts water to 1 part Muriatic acid (20º Baume hydrochloric acid 31.45% by weight). ALWAYS ADD ACID TO WATER, and do so slowly. Cleaning Procedure: 1. Shut off pool filter pump. 2. Close the two 3-way valves (page 5) to isolate the vessel from the pool system. 3. Open inlet and outlet port valves, if used. 4. Start the automatic cleaner and run the acid wash pump for no less than 30 minutes to fully clean the system. 20
Cleaning The Quartz Sleeve: Manually Cleaning Procedure: 1. Unplug the device from the power outlet (Fig. 21 & 22). 2. Shut off the circulation pump and make sure there is no pressure in the system. Then close the inlet and outlet valves on either side of HydroRite. 3. Drain the unit by unscrewing the threaded plug from the base of the vessel (Fig. 23 & 24). TE: If the Acid Wash system is plumbed, remove the hose to the shut-off valve from the base of the vessel. You can then open the valve to release the pool water. 4. Removing the Electrical Enclosure Cover by unscrewing the four screws (Fig. 25 & 26). 5. Remove the power clips from the Pressure switch and set cover aside. Fig. 21 Fig. 22 Fig. 23 Fig. 24 Fig. 25 Fig. 26 21
Cleaning The Quartz Sleeve: Manually (cont.) 6. Use a soft clean cotton cloth (or cotton gloves) to remove the lamp(s) by grasping the lamp connector and rotating counter-clockwise to unlock the lamp from the nut (Fig. 27). 7. Once unlocked, slowly pull the lamp straight up and away from the quartz sleeve until it clears the vessel (Fig. 28). Carefully place the lamp(s) in a safe location while cleaning the quartz sleeve. CAUTION: The UV lamp is sensitive to handling and should be allowed to fully cool before being moved. Wait at least 30 minutes after disconnecting power to begin the removal process. TE: If you should touch the lamp with your bare hands, it can be cleaned with a soft cotton cloth and rubbing alcohol Fig. 27 Fig. 28 22
Cleaning The Quartz Sleeve: Manually (cont.) 8. Remove the stainless steel sleeve from the top seal plate before moving on (Fig. 29 & 30). 9. Remove quartz sleeve by turning the locknut counter clockwise and removing (Fig. 31 & 32). Carefully clean both the inside and the outside of the quartz sleeve using N-ABRASIVE CLEANERS, as they can scratch the high quality glass. If lime or hard water calcium deposits are encountered, rinse the quartz sleeve with tap water, then clean with lime removal products such as Lime-A-Way using lint-free cloth. After using the lime removal products, rinse and wipe with alcohol. Completely dry the sleeve both inside and out before placing the UV lamp inside the quartz sleeve. 10. Carefully inspect the cleaned quartz sleeve for cracks. If any cracks in the quartz sleeve are found, the sleeve should be replaced. Broken quartz sleeve will allow water to enter the dry electrical chamber and attack the electrical components of the unit, which will cause them to fail. 23 Fig. 29 Fig. 30 Fig. 31 Fig. 32
Cleaning The Quartz Sleeve: Manually (cont.) 11. Slowly lower the lamp down into the quartz sleeve (Fig. 33). Once sleeve is secured (Fig. 34), reconnect the 4-Pin Connector to the pins on top of the lamp. TE: DO T touch the lamp with bare hands (Use included gloves). The ceramic 4- Pin Connector is designed to fit onto the end of the lamp in ONLY ONE ORIENTATION. Clean and re-lubricate the O-ring before reinstalling the enclosure cover. 12. Gently clean the UV Sensor using a non-abrasive cleaning solution and a soft cloth. 13. Place the plastic electrical cover on the top of the HydroRite unit and tighten the screws using a Phillips head screwdriver (Fig. 35). 14. Plug in the power cord. Turn on the circulation pump, making sure to open any valves (if applicable). Verify that the lamp is lit. 15. HydroRite should now be operational! 24 Fig. 33 Fig. 34 Fig. 35
HydroRite UVO 3 Troubleshooting
Step 1A 1. UV Lamp Not Lit Power LED status Verify ballast LED Step 1B If the power LED is lit proceed to 1B. If T, go to Step 2A, Power LED Not Lit. If LEDs are lit on the ballast proceed to 1C. If lit, jump to step 1D. Step 1C Check ballast input power Step 1D Green ballast LED lit 26 Verify 216-264 VAC present on the PCB. If /LOW voltage replace PCB (GLX-HYDPCB). If correct, replace ballast (GLX-HYDBALLAST). If green ballast LED is lit, Replace lamp (GLX-HYD- LAMPUV). If not, proceed to step 1E.
Step 1E 1. UV Lamp Not Lit (cont.) Verify lamp connection Replace lamp Step 1F Inspect lamp connections & cable for damage, if damaged, replace cable (HYXSLACA). If not damaged, go to 1F. Power off, inspect quartz sleeve & replace lamp (GLX-HYD-LAMPUV). If this did not correct the problem go to 1G. Step 1G Replace ballast 27 Replace the ballast (GLX-HYDBALLAST).
Step 2A 2. Power LED Not Lit Verify source power Verify LED power Step 2B Verify source power (108-132 VAC). If /LOW resolve incoming power. If correct go to 2B. Test for 10-12 VDC on LED input. If /LOW go to step 2C, if OK contact support: 908.355.7995. Step 2C Check PCB fuses 28 Remove fuses and verify continuity. If open, replace fuse(s), if closed go to step 2D.
2. Power LED Not Lit (cont.) CAUTION: Transformer output is 240VAC! Step 2D Transformer output Step 2E Transformer input Verify Transformer output is 192-288 VAC. If OK replace PCB (GLX-HYDPCB). If /LOW go to 2E. Verify Transformer input is 108-132 VAC between pins 1-3 & 2-4. If OK replace transformer (GLX- HYDXFMR), if /LOW replace PCB (GLX-HYDPCB). 29
Step 3A 3. Lamp/Ballast LED is Red Verify lamp connection Verify lamp cable Step 3B Remove & reconnect lamp cable. If problem not solved go to step 3B. Inspect lamp cable for damage. If damaged replace cable (HYXSLACA). If not go to step 3C. Step 3C Replace lamp Step 3D Replace ballast 30 Power off, inspect quartz sleeve & replace lamp (GLX-HYD-LAMPUV). If LED is still ON go to 3D. Power off, replace the ballast (GLX-HYDBALLAST). Then reapply power.
Step 4A 4. Flow/Over Temp/Interlock LED Verify pump is on Inspect HydroRite vessel Step 4B 15GPM (MIN) Verify the pump is running. If it is not, turn the pump on and recheck. If ON go to step 4B. Verify water is passing through the vessel (15GPM MIN). If OK go to 4C. If not, resolve flow issue. Step 4C Check the filter Step 4D Unplug & inspect switches 31 Check filter, if cleaning is required, clean filter and recheck. If clean, go to step 4D. Unplug flow & interlock switches. If damaged replace (GLX-HYDMAN/GLX-FLO-RP), if not go to 4E.
4. Flow/Over Temp/Interlock LED (cont.) Flow switch Interlock switch Step 4E Step 4F If flow switch was not already swapped, replace flow switch (GLX-FLO-RP). If LED still ON go to 4F. If interlock switch was not already changed, replace (GLX-HYDMAN). If LED still ON go to 4G. Step 4G Contact support 32 The LED is still on due to a temperature related situation. Contact tech support (908) 355.7995.
Step 5A 5. Vessel Makes Noise or Leaking Verify vessel mounting Inspect top vessel o-ring Step 5B Step 5C Verify whether vessel is secured to pad. If not, secure vessel to pad. If secured, go to step 5B. Inspect quartz sleeve Step 5D Turn off pump, and inspect top vessel o-ring. If damaged, replace (SB2KIT). If Ok go to step 5C. Inspect drain plug 33 Inspect the quartz sleeve for damage. If damaged, replace (HYX2DQSA). If not, go to 5D. With pump off, inspect drain plug & o-ring. If damaged, replace (BSX1PLUG2).
1. UV Lamp Not Lit UV Lamp Not Lit Power LED ON? Are any LEDs lit on ballast Green ballast LED On? Replace lamp Jump to: Power LED Not Lit pg. 35 Check ballast input power. Verify lamp Connection Jump to Section B Replace PCB 192-288 VAC present? Replace ballast Section B Connection correct? Lamp cable damaged? Replace lamp cable Fix lamp connection Replace lamp & inspect quartz sleeve Lamp lit? Problem solved Replace ballast 34
2. Power LED Not Lit Power LED Not Lit Verify source power. 108-132 VAC present? 10-12VDC present at LED connection? Contact Tech Support: (908) 355.7995 Resolve source power issue Check Fuses, Are fuses OK? Transformer output shows 192-288 VAC? Replace bad Fuse(s) Jump to Section B Replace PCB Section B Both transformer inputs show 108-132 VAC? Replace Transformer Replace PCB 35
3. Lamp/Ballast LED is Red Lamp/Ballast LED is Red Connection correct? Lamp cable damaged? Replace lamp cable Fix lamp connection Replace lamp & restart Lamp lit? Problem solved Replace ballast 36
4. Flow/Over Temp/Interlock LED Flow, Over Temp, Interlock LED Pump running? Water passing through vessel? (min 15gpm) Filter clean? Turn pump ON Resolve flow issue Clean filter Section B Unplug & inspect sensors Jump to Section B Damaged? Replace damaged switch(s) 37 Contact Tech Support: (908) 355.7995 Replace flow switch, did LEDs go out? Replace interlock switch, did LEDs go out? Problem solved
5. Vessel Makes Noise or Leaking Vessel Makes Noise or Leaking Vessel secured to pad? Top vessel o-ring intact? Quartz sleeve intact? Secure vessel to pad Replace o-ring Replace quartz sleeve Jump to Section B Section B Inspect drain plug Drain plug or o-ring damaged? Replace drain plug 38
HydroRite UVO 3 Frequently Asked Questions (FAQs)
FAQs Q. Is HydroRite compatible with ALL pool chemicals? A., except for a biguanide sanitizer. The strong oxidizing power of the HydroRite device will destroy the biguanide chemical, rendering the water a milky white color. Q. Is there any residual effect from UV? A., UV light is applied only to the water while it passes through the HydroRite vessel. For this reason, a chemical sanitizer such as bromine or chlorine is still required; however, the levels of these sanitizers can be reduced by as much as 75% over typical levels. Q. Is the HydroRite system designed for salt water use? A., all plastic components are compatible with pools equipped with Hayward Salt Chlorine Generator Systems. The stainless steel insert sleeve (if used) 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 of the lamp life can be expected when the HydroRite unit is turned off and back on frequently. However, a daily on/off cycle will not create a major lamp life issue. Frequent on/off cycles should be avoided, however. For best lamp efficiency, the lamp should be replaced on yearly basis. 40
FAQs Q. Can the HydroRite unit be mounted horizontally? A., vertical mounting is required to maintain the proper flow dynamics inside the vessel for maximum exposure to the UV light. Also, the unit has been designed for maximum weather integrity of the electronics when mounted vertically. Q. Can multiple units be used together for larger systems? A., 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. 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 the water returns to the pool. Q. Do I need to turn HyroRite off when cleaning my filter? A. No, the flow sensing pressure switch that is part of your HydroRite unit will automatically shut the UV lamp off until proper flow inside the HydroRite vessel is re-established. Should you need to turn the HydroRite off, simply unplug the power cord from the power outlet. 41