Hayward RSR3 Series Manual

1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page i of i
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
TO PREVENT POTENTIAL INJURY, DEATH, OR DAMAGE TO PROPERTY, READ THIS MANUAL CAREFULLY AND COMPLETELY.
Installation, Operation and
Maintenance Instructions
RSR3 Series

IMPORTANT SAFETY INSTRUCTIONS
Basic safety precautions should always be followed, including the following: Failure to follow instructions
can cause severe injury and/or death.
This is the safety-alert symbol. When you see this symbol on your equipment or in this manual, look
for one of the following signal words and be alert to the potential for personal injury.
WARNING warns about hazards that could cause serious personal injury, death or major property
damage and if ignored presents a potential hazard.
CAUTION warns about hazards that will or can cause minor or moderate personal injury and/or
property damage and if ignored presents a potential hazard. It can also make consumers aware of
actions that are unpredictable and unsafe.
The NOTICE label indicates special instructions that are important but not related to hazards.
WARNING - Read and follow all instructions in this IOM manual and on the equipment. Failure to
follow instructions can cause severe injury and/or death.
WARNING – Risk of Electric Shock. All electrical wiring MUST be in conformance with applicable
local codes, regulations, and the National Electric Code (NEC). Hazardous voltage can shock, burn, and
cause death or serious property damage. To reduce the risk of electric shock, do NOT use an extension
cord to connect unit to electric supply. Provide a properly located electrical receptacle. Before working
on any electrical equipment, turn o󰀨 power supply to the equipment.
WARNING – To reduce the risk of electric shock replace damaged wiring immediately.
WARNING – Ground all electrical equipment before connecting to electrical power supply. Failure
to ground all electrical equipment can cause serious or fatal electrical shock hazard.
WARNING – Do NOT ground to a gas supply line.
WARNING – To avoid dangerous or fatal electrical shock, turn OFF power to all electrical equipment
before working on electrical connections.
WARNING – Failure to bond all electrical equipment to system structure will increase risk for
electrocution and could result in injury or death. To reduce the risk of electric shock, see installation
instructions and consult a professional electrician on how to bond all electrical equipment. Also, contact
a licensed electrician for information on local electrical codes for bonding requirements.
CAUTION – Potential pinch point. Equipment connected to or driven by this device may start
unexpectedly and may cause personal injury or entrapment in linkage systems.
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 1 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control

Table of Contents
1 ................... Product Safety Information
2 ................... Product Notifications
3 ................... Handling and Installation
4 ................... Actuator Specifications RSR3 Series
5 ................... Dimensional & Wiring Data
6 ................... Wiring Diagrams
7 ................... Optional External Auxiliary Switch Pack
8 ................... Optional Manual Override Handwheel
9 ................... Troubleshooting
Notice: The RSR Series actuators are designed to operate over a 90° range. There are NO
mechanical stops or adjustments on the actuator. On/Off models (ending in -0 or -2) can be driven
CW or CCW in incremental steps without causing a spring return cycle. Proportional control models
(ending in -P) require either a 4-20mA input or a 2-10vdc input for positioning (wire selectable).
Notice: The RSR Series are mechanical spring return actuators that can be selected to spring
return in a clock-wise (CW) or counter-clockwise (CCW) direction by selecting which SIDE of the
actuator is mounted face up. To change the direction of spring return travel, simply remove the
actuator from its mount, ip it over and re-install. Spring return direction will now be reverse of what
it was before the change was made.
Notice: Hayward RSR actuators are installed onto valve assemblies oriented to fail CLOSED in a
clockwise (CW) direction. This is the default orientation unless otherwise specied by the customer
at time of order.
WARNING: The RSR Series actuators employ a mechanical spring return mechanism that
automatically engages on loss of power to the actuator. The spring return mechanism is abrupt
and cannot be halted once released. Exercise caution when installing and operating this
equipment.
RSR3 Series
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 2 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control

1. This actuator is shipped in the FULL spring return position. When mounting to valve assemblies, the valve must also
be in its full spring return position.
2. NOTICE: THIS ACTUATOR MUST HAVE WATER TIGHT EMT FITTINGS, WITH CONDUIT DRAINAGE INSTALLED
AND POWER SUPPLIED TO UNIT TO KEEP THE HEATER WARM AT THE TIME OF INSTALLATION.
3. Storage: This unit should NOT be stored outside unless it is powered up and has proper conduit terminations.
When NOT powered up, it should be stored in a clean, dry environment at all times.
4. NOTICE: The actuator CANNOT operate with a rotation greater than 95°.
5. There are no mechanical stops on this series. Use caution when operating the manual override.
6. These actuators are designed to operate on power supplies ranging from 24V to 230V AC/DC.
7. These actuators are designed to be used in any position. Take precautions to prevent valve and/or piping
condensate from depositing directly onto the actuator.
8. When installing conduit, use proper techniques for entry into the actuator. Use drip loops to prevent conduit
condensate from entering the actuator.
9. The internal low power heater cannot be disconnected.
10. Do NOT install the actuator outdoors or in humid environments unless it is powered up and the heater is
functioning.
11. Use proper wire size to prevent actuator failure (see chart on page 5 for proper wire sizing).
12. The RSR Series can have multiple on/o󰀨 actuators wired in parallel and connected to the same control points.
13. When installing the RSR Series actuators in environments where ambient temperatures are less than +50
deg F (+10 deg C), it is important to immediately connect the actuator to power to enable the heater and
prevent internal condensate build-up.
14. The actuator will NOT activate until the internal temperature reaches at least -8 deg F (-20 deg C). All
functions are disabled until after this heating-up period.
15. The actuator must be operated with a load requirement of AT LEAST 27”lbs/3Nm.
16. The initial inrush upon power-up of the actuator, regardless of voltage, is roughly 2.0A for 1 second.
17. The power consumption for the internal heater is 16 watts.
18. If the actuator encounters torque requirements greater than the actuator capability, it will stall in position and the current
consumption will be Max 20 watts.
19. To protect against unstable control schemes and signals, internal electronics monitor the incoming control signals. Receiving
more than 20 pulses with a duration of less than 1.0 sec each suspend the actuator. Should this occur, a RESET is mandatory
and is accomplished by removing the supply power for 2-3 seconds.
20. For outdoor installations, place a hood over the actuator to protect it from direct UV and solar heating, rain and snow. Protect the
actuator from high solar or environmental heating above 150°F as this may cause the internal thermal fuse to trip. Should this
occur, the actuator is permanently disabled and cannot be revived.
WARNING – DO NOT operate the manual override when power is present. Do not use powered tools
to turn the manual override. Geartrain damage and/or personal injury may occur.
WARNING – To avoid dangerous or fatal electrical shock, turn OFF power to all electrical equipment before
working on electrical connections.
RSR3 Series
Installation Notes
RSR3 Series
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 3 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control 1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 3 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control

RSR3-0 RSR3-2 RSR3-P
Torque (motor) Minimum 133”lb/15Nm
Torque (spring) Minimum 133”lb/15Nm
Minimum Required Torque 27”lb/3Nm
Supply Voltage/Frequency 24...230vac/dc, +15% / -20% AC:50/60Hz
Current Draw 4.7A @ 3 sec Mode MAX
Wiring Class Class 1 (grounded)
Angle of Rotation 95 deg including 5 deg pre-load
Runtime (Power) 30 seconds @ 90 deg
Motor Type Brushless DC
Runtime (Spring) 10 seconds @ 90 deg
Life Cycles at 10 sec Spring Minimum 10,000 Cycles at 10 sec Spring
Response Time (Spring) Up to 1 second after power failure
Control Mode On/O󰀨/Jog On/O󰀨/Jog 4-20mA or 2-10vdc IN
Feedback None None 4-20mA or 2-10vdc OUT
Auxiliary Switch Rating
(2) - xed @ 5° and 85° None 0.1A @ 250vac / 3A @ 24vac None
Drive Conguration 12mm Double Square, 100% Overload-Proof
Self-Locking up to 133”lbs/15Nm
Electrical Connections 1m Cable, Exits through 1/2” EMT Connector
Environmental Rating NEMA 4X / IP66
Manual Override Supplied Hex Key (Opt Handwheel)
Integral Heater Thermostatically controlled
Housing Material Aluminum die casting
Physical Dimensions 8.3”L x 3.7”W x 3.2”D / 210mm x 95mm x 80mm
Weight 7.8 lbs / 3.5Kg (no options installed)
Ambient Operating Range Storage Temp: -40F/+158F (-40C/+70C)
Working Temp: -40F/+122F (-40C/+50C)
Duty Cycle (>14 sec Mode) 50% 50% 50%
Maintenance Maintenance Free
Default Mode: Power:
Spring:
133”lb/15Nm - 30 sec @ 90 deg
133”lb/15Nm - 10 sec @ 90 deg
Actuator Specications
RSR3 Series
WARNING – the manual override allen key will NOT remain in position... once you let go of the key,
the spring WILL drive the actuator back to its unwound position.
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 4 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control 1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 4 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
The RSR has a manual override built into the geartrain. Inserting the supplied allen key into
the port (black arrow above), you can manually turn the spring mechanism to WIND the spring
system. However you CANNOT UNWIND the spring system if power is present. As shown
above, the RSR has a spring CW and a spring CCW side, identied by the “L” and “R” on
their respective sides of the actuator label. Notice that the override key rotates in OPPOSITE
directions depending on which side of the actuator you are accessing.
Note label identier “R” (blue arrow). The
manual override key winds the spring in a
CCW direction, and the spring unloads in
a CW direction (default for Hayward valve
assemblies).
Note label identier “L” (blue arrow). The
manual override key winds the spring in
a CW direction, and the spring unloads
in a CCW direction. (non-standard for
Hayward assemblies).

RSR3 Series
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 5 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control 1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 5 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
Push Button
12mm Double-Square Drive
Optional Switch Pack mounting holes
3mm Key Manual Override
Standard Mounting Holes
using (4) M4x100mm screws.
Spring CW Side
80mm
3.15"
210mm 8.28"
1m 39"
119mm 4.69"
30mm
1.18"
95mm
3.74"
74mm
2.92"
14mm
0.55"
Ø6.6 THRU
(6) HOLES TOTAL
M4 THREAD (Existing)
(6) HOLES TOTAL
DOUBLE SQUARED
12 x 12 mm
30mm
1.18"
cast aluminum
upper housing
sealed electronics
enclosure
steel geartrain
assembly
memory action
recoil spring
cast aluminum
lower housing
Spring CCW Side
Spring CW Side
wind
spring
Spring CW Side
"Stick" port
Wire sizing data is provided in the table below to assist in the selection
of the proper wire size for Hayward RSR3 actuators using various wire
sizes over distance. Please make sure to reference the correct voltage
and do not exceed the indicated length of the wire run for each model.
RSR3 Dimensional Data
Wire Sizing Data
16
18
22
24
Wire
Gage
MAX distance between Actuator and Supply (feet)
RSR3
24VAC/DC
111
70
29
RSR3
120VAC
3463
2204
903
18 566
RSR3 Key Points
RSR3
230VAC
9957
6336
2597
1627
All electrical connections to the actuator are via the
included 1M single cable. It is the option of the installer
to utilize the attached conduit port or not, depending
on local code requirements. The capped access port
MUST remain tightened. The capped port, as well as
the RED push button, have no function in Hayward
valve assemblies.

1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 6 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control 1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 6 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
Wiring Diagrams for RSR3 -
On/O󰀨/Jog Control
Proportional Control
Control Modes
(select by wiring method):
On/O󰀨
Jog
0-10vdc
4-20mA
Input impedance:
20k ohms (0-10vdc)
250 ohms (4-20mA)
Feedback Signal Output: 4-20mA
Referenced to the common terminal.
Max Load: 500 ohms
2 Wire - Drive OPEN (CLOSED),
Spring CLOSED (OPEN).
4 Wire - Drive OPEN or CLOSED,
Spring CLOSED or OPEN.
...Shown with the optional
INTERNAL aux switches...xed at
5 and 85 degrees rotation. (Replace
-0 with -2 at end of actuator part
number).
See Application
Notes Pg 3 Item
13 concerning
low temperature
applications.
Note: -2 Option (internal
aux switches) NOT
available on proportional
control models.
GND
1 2 3 4
- +
heater
24 to 240 VAC/DC
~~ If mounted CW side UP:
... close “a” = drive CCW
! ATTENTION !
If you use this type of wiring,
the heater does NOT work
when “a” is open.
a
GND
1 2 3 4
- +
heater
24 to 240 VAC/DC
~~ If mounted CCW side UP:
... close “a” = drive CW
! ATTENTION !
If you use this type of wiring,
the heater does NOT work
when “a” is open.
a
1 2 3 4
- +
heater
24 to 240 VAC/DC
5 6 7 8
< 5° > 85°
~~
GND
1 2 3 4
- +
heater
24 to 240 VAC/DC
~~
GND
If mounted CCW side UP:
... close “a” = drive CW
... close “b” = drive CCW
If mounted CW side UP:
... close “a” = drive CCW
... close “b” = drive CW
(Optional)
Internal aux. switches are
dry contact Form A type. Max
24v/3A, 230v/0.25A. Switch
points are FIXED at 5° and
85° rotation. Either CW or
CCW side up does not a󰀨ect
the switch points.
abc
Loss of Main Power “c”
causes spring return,
regardless of “a” or “b”
condition.
Loss of Main Power
causes spring
return, regardless of
“Y”condition.
6
VDC/mA
24 to 240 VAC/DC
4-20mA 4-20mA
5
heater
~
GND
7
ref
~2-10v 2-10VDC
32
+
1
-
4

RSR3 Series
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 7 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
1m / 39" 40mm / 1.58"
120mm / 4.73"
Product Options
The RSR-EXT-X is an add-on dual switch pack
with two independently adjustable SPDT 3A rated
switches. This unit mounts directly to either side of
the RSR series and utilizes the 16mm square drive
to mechanically link the actuator to the switch drive
mechanism. Two 3C cables exit the switch enclosure
through sealed glands. This unit can be mounted to
all -0, -2 or -P RSR Series products. Installation can
be performed at the factory or in the eld, and has the
same environmental rating as the actator.
External Switch Option
HS1
90
0
90
90
CAMS SHOWN @ 0° ON CCW MOUNT
CAMS SHOWN @ 90° ON CCW MOUNT
RL
RL
BLK
< 5°
> 85°
HS2
GRY BLU BLK GRY BLU
HS1
BLK
< 5°
> 85°
HS2
GRY
BRN
BLK
GRY
BRN
Function 2 potential free Form C Mech switches
Max Current (AC/DC) 3A @ 24V - 0.25A @ 250V
min current 4mA @ 5V
Mechanical Life 2x10^6 switch cycles
Cable Connection (1) 3C20 cable for each sw, 1M long
Ambient Termp (°F/°C) -58°F ~ 140°F / -50°C ~ 60°C
Accuracy < 5°
Switch Hysteresis approx 5%
Switch Material Au plated Ag Contacts
Technical Data
cam tool
HS1
90
0
90
90
CAMS SHOWN @ 0° ON CCW MOUNT
CAMS SHOWN @ 90° ON CCW MOUNT
RL
RL
BLK
< 5°
> 85°
HS2
GRY BLU BLK GRY BLU
Mounting and Adjustment
1. Insert the 12mm square switch drive into the actuator drive
shaft.
2. Align the slotted shaft of the switch into the slot in the 16mm
drive insert.
3. Mount the switch box to the actuator using the (4) supplied
self-threading screws.
4. Drive actuator to its full spring return position.
5. Remove the switch box cover and adjust the cam position
using the provided tool. Check the cam setting before tightening
the cam set screw.
6. Drive the actuator to its full spring wind position.
7. Adjust the second cam, check and tighten the cam setting
screw.
8. Replace the cover.
cams shown @ 0° on
CCW mounting side.
cams shown @ 90°
on CCW mounting
side.

RSR3 Series
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 8 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
Product Options
The RSR-M23-SHORT and RSR-M23-LONG are
add-on manual override handwheels that mount
onto either side of the RSR3 Series actuator. The
handwheel drive shaft connects directly into the 3mm
manual key socket. There is a locking screw that can
be tightened which will hold the handwheel in position
until released. The handwheel option does not a󰀨ect
the dual auxiliary switch option, installation can be
performed at the factory or in the eld, and has the
same environmental rating as the actator.
Manual Override Option
Mounting and Use
1. Actuator is unpowered and in the full spring return position.
2. Be sure the actuator has the correct side up after mounting to the valve.
3. The lower end of the handwheel hex drive shaft ts directly into the override socket
near the middle of the actuator.
4. Mount the override bracket using the (2) supplied self-threading screws. RSR-M23-
Short is used without RSR-EXT-X and RSR-M23-Long must be used when RSR-EXT-X
is attached to the actuator.
5. Slide the 3mm hex key out of its holster when using the handwheel override.
6. With NO POWER APPLIED, rotate the handwheel in the direction shown on the
actuator label to drive the actuator to its full wind position.
7. Use the 3mm hex key to lock the screw securing the handwheel shaft from rotating
(see red circle at right).
8. To release, hold the handle and loosen the lock screw, then release the handle.
9. Do NOT rotate the handwheel against a locked spring or beyond fully unloaded
position.
RSR-M23-SHORT
RSR-M23-LONG
Side R
80mm
3.15"
210mm 8.28"
1m 39"
Side L
120mm
4.72
77mm 3.05"
167mm
6.57"
80mm 3.15"

RSR3 Series
1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 9 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control 1-888-HAY-INDL (1-888-429-4635)
RSR3IOM Rev B ECR 043V
Page 9 of 9
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
www.haywardowcontrol.com
Hayward Flow Control
Reason
No power supply attached
The actuator has been operated in excessively high
ambient temperatures, causing the internal thermal
safety to permanently shut down.
The actuator has been operated in an excessively
high ambient environment and the internal
temperature sensor shut down the actuator.
The 3 position / Jog control wiring is activating both
drive directions at the same time.
Required torque is greater than actuator capabilities.
Control signals are not connected to the proper
actuator wiring.
Actuator is binding due to an incorrect mechanical
mount.
Actuator receives more than 20 pulses (less than
0.5 sec duration) and goes into suspended mode to
protect internal electronics from damage.
Incorrectly wired (polarity)
Actuator has been mounted in ambient temperatures
less than -20 deg C and has not reached its internal
minimum operating temperature (>-20 deg C)
At start-up, an autocalibration routine was NOT
performed.
Actuator is not receiving su󰀩cient supply voltage.
Improper wire size / length based on wire sizing
tables.
Bridge 2--5 is in place (see wiring diagram)
Bridge 2--5 is NOT in place (see wiring diagram)
The Maximum permissable duty cycle was exceeded
and the actuator is in a safety disconnect mode.
Error / Symptom
Actuator does not work
LED indicator does not light
Actuator does not work
LED indicator shows steady RED
Actuator does not work
LED indicator shows steady
GREEN
Actuator does not work
LED indicator shows blinking RED
A Modulating actuator reaches its
electrical end of travel (0v/4mA
and/or 10v/20mA) before reaching
damper or valve mechanical end
of travel (90 degrees or less of
mechanical travel).
Actuator does not work
LED indicator ashes irregularly
Spring return function is 3 sec / 90
degrees. Should be 10 sec / 90
degrees.
Spring return function is 10 sec /
90 degrees. Should be 3 sec / 90
degrees.
Actuator does not start after more
than 2 cycles in the 3 sec powered
mode.
Solution
Connect power supply and turn on
Operation in conditions outside that which is specied
has caused irreversible damage inside the actuator
which now must be exchanged.
Remove power from actuator and let temperature
decrease. Reduce ambient temperatures by providing
increased airow over actuator, provide cooling from
ductwork, or reposition the actuator away from high
temperature equipment.
Correct wiring error
Increase actuator size to a higher torque output.
Review wiring diagrams and correct control wiring
faults
Remove the actuator from the driven device. Check
actuator operation without load for full rotation angle
operation
Remove power for at least 2 seconds, resetting the
internal protection device. Correct controller pulse
generator error.
Wire #1 MUST be (-,N) and wire #2 MUST be (+,H)
Ensure that the actuator is powered up at all times.
Wait for the actuator internal heater to heat up the
actuator, thereby starting normal operation.
Perform an autocalibration of the actuator (see step 6
on page 2 of this manual).
Increase power supply voltage.
Increase wire gage between actuator and supply.
Disconnect 2--5 Bridge
Connect 2--5 Bridge
Wait approx. 1 minute until internal electronics cool
down for future use.
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
Troubleshooting-