Aquafine Optimahx Manual

READ THIS MANUAL PLEASE KEEP FOR PERMANENT REFERENCE

Part No. 120, Rev. 6.0 10/04

This manual covers the installation, operation and general maintenance requirements for Aquafine Ultraviolet Water Treatment Equipment.

Disinfection

It is imperative that those responsible for the installation of this equipment, as well as operating personnel, read this manual and carefully follow all instructions and guidelines. EQUIPMENT OPERATORS AND INSTALLERS MUST COMPLY WITH OPERATIONAL SAFETY REQUIREMENTS.

SAFETY ISSUE

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1.800.423.3015 (outside California and within domestic USA) email: [email protected] web: www.aquafineuv.com

Optima HX

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TTaabbllee ooff CCoonntteennttss PURPOSE AND SCOPE ................................................................................................... 3 SYSTEM DESCRIPTION.............................................................................................. 4-12

Unit Description................................................................................................. 5-6 Standard Monitoring System ........................................................................... 7-9 Aqualogic 2000™ Monitoring System ......................................................... 10-12

INSTALLATION.......................................................................................................... 13-18 Guidelines ...................................................................................................... 13-14 HX and HX-U Unit Do's and Don'ts .............................................................. 14-15 Quartz Sleeve Installation.................................................................................. 16 UV Lamp Installation.......................................................................................... 17 Powering Up ....................................................................................................... 18

HX AND HX-U SERIES OPERATION........................................................................ 19-28 Operational Guidelines ...................................................................................... 19 Integrated Monitoring System........................................................................... 20 Setting the UV..................................................................................................... 22 Setting the SET 100% Level .............................................................................. 22 Setting the Low UV Alarm Level ....................................................................... 22 Aqualogic 2000™ Monitoring System .............................................................. 23 Setting the UV................................................................................................ 23-24 Setting the SET 100% Level .............................................................................. 25 Setting the Low UV Alarm Level ....................................................................... 25 Setting the Aqualogic 2000™ Status Display Board.................................. 26-27

PREVENTATIVE MAINTENANCE............................................................................. 28-34 Recommended Preventative Maintenance ...................................................... 28 Unit Maintenance................................................................................................ 39 Quartz Sleeve Maintenance............................................................................... 30 Checking for Leaks ............................................................................................ 31 Lamp Operation Lamp-Out Alert....................................................................... 32 Replacing UV Lamps.......................................................................................... 32 Inspecting the Lamp Socket.............................................................................. 33 Ballast Replacement .......................................................................................... 33 Cleaning the Detector Window ......................................................................... 34 Measuring Performance .................................................................................... 34 LED Display Maintenance.................................................................................. 34

TROUBLESHOOTING GUIDELINES......................................................................... 35-42 Standard......................................................................................................... 35-37 Aqualogic 2000™ .......................................................................................... 38-42

Warranty Information................................................................................................ 43-44 Replacement Parts List ............................................................................................ 45-46

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IInnssttrruuccttiioonn ffoorr OOppttiimmaa HHXX aanndd HHXX--UU sseerriieess Purpose and Scope

Purpose: To provide instructions for the installation and operation of the Optima HX and Optima HX-U series.

Scope: This instruction is intended for personnel that have a working knowledge of

servicing electrical and mechanical equipment.

Warning:

• Remove all electrical power to the unit before servicing the unit. The electrical panel is an electrical hazard. Death can result if proper precautions and safety are not obeyed. All electrical power to the equipment, including power from signal and monitoring systems, must be completely isolated.

• Never service the system under pressure. The treatment chamber must be valved off

from the water source, the pressure must be released, and then the system must be drained.

• Never look at the UV lamps. The lamps produce harmful radiation and will damage eyes and skin. Use protective apparel.

Optima HX unit with Standard Monitoring System

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The Optima HX product line is designed to offer the latest in low pressure UV technology over a wide range of application flow rates. It includes the critical quality and performance features that have made Aquafine® the standard in UV water treatment for over 50 years, while doing so in a highly cost-effective manner.

Key HX design features include:

• Reduced lamp count by utilizing high-output long life lamp technology.

• Designed with state-of-the-art Multiple Point Source Summation (MPSS) and Computational Fluid Dynamics (CFD) mathematical models.

• All wetted components made from 316L SS.

• Lamp status indication

• Running time meter

• 150 psig rated treatment chamber

The most basic differentiation within the HX product line is the designation “HX” or “HX-U”. “HX” units come with the cylinder and electrical enclosure mechanically attached together. “HX-U” units have a remote enclosure that is suitable for wall mounting. Beyond this distinction, the HX product line is offered with a variety of configurations and options to suit your particular needs. Please refer to the product literature TSG 005-04 for further information on available configurations/options or contact Aquafine® Applications Engineering.

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Unit Description:

Fig. A HX SERIES UNIT IDENTIFIED ELEMENTS Elements to identify the HX Series Unit are: See Fig. A above.

1. Treatment Chamber 2. Sample Port - optional 3. Gasket Endplate 4. Control Cabinet 5. Quartz Sleeves and Lamps – located inside the treatment chamber 6. Drain Port 7. Socket Covers

Treatment Chamber: The UV Treatment Chamber is compiled of a 316L stainless steel cylinder. O-rings, or gasket endplates are located on both ends (except A & B style units), which contain the stainless steel nipples and lamp socket retainer assemblies.

Sample Ports: Two optional sample ports are available for obtaining water samples pre and post the UV treatment chamber. Sanitary sampling valves should be installed on the ports.

Gasket Endplate: Treatment chambers greater than 4” inches in diameter are provided with 2 removal endplate assemblies. The endplates are installed with sealing gaskets/O-rings, located between the socket cover and the endplate. See Fig. B

Drain Port: Each treatment chamber is provided with Fig. B GASKET ENDPLATE a drain port to complete drainage of the treatment chamber. A drain valve should be installed on the port.

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Socket Covers: The socket covers on either end of the treatment chamber protect the lamp socket assemblies.

Quartz Sleeves And Lamps: The quartz sleeves and lamps fit inside the UV treatment chamber. The lamp sockets connect to the lamps, creating a water resistant seal and a vibration-proof grip. The socket covers on either end of the chamber protect lamp socket assemblies.

Fig. C LAMP SOCKET ASSEMBLY

Elements to identify the Lamp Socket Assembly are: See Fig. C above.

1. Stainless Steel Nipple The stainless steel nipple is a threaded fitting, which the compression nut attaches to.

2. Quartz Sleeves The quartz sleeves provide a barrier between the UV lamp and the water. Special manufactured quartz material allows the passage of the 254nm radiation that provides the energy to destroy the microorganism. Alternative sleeves should not be used.

3. O-Ring The O-ring provides the seal for the quartz sleeves. The material is specially specified to withstand UV energy, heat, ozone and other elements in contact with the unit.

4. SE Compression Nut The compression nut provides compression for the sealing of the quartz sleeves.

5. UV Lamp Source for 254nm energy

6. SE Lamp Socket The lamp socket provides electrical power to the UV lamp. This socket should never be removed during operation of the UV unit.

7. SE Lamp Cap To secure the lamp socket to the compression nut, the lamp cap is provided.

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STANDARD MONITORING SYSTEMS:

Fig. A STANDARD MONITORING SYSTEM CONTROL PANEL ON AN OPTIMA HX

Elements to identify the HX Standard Monitoring System are:

1. UV LED Operational Display 2. Main Power Switch 3. Running Time Meter 4. Integrated Monitoring System 5. Lamps Operational - optional 6. Lamp Out Alert - optional

Fig. B STANDARD CONTROL PANEL UV Operational Display: FOR NEMA RATED CABINET To verify the status of the UV lamps, the LED display gives the operator a visual indication of the lamp status. When the UV lamp is “ON”, the LED will illuminate. When “OFF”, the LED will not illuminate. Should any UV lamp fail to operate, the corresponding LED light will automatically turn “OFF”. Each UV lamp is numbered at the end of the treatment chamber and the corresponding LED light carries the same number on the display panel.

Main Power Switch: The Main Power Switch isolates all electric power to the unit.

Running Time Meter: Each of the UV units is furnished with a Running Time Meter that cannot be reset. It is used to determine the number of hours on the equipment and for maintenance. It is very important to record the running time hours and lamp maintenance.

Lamps Operational & Lamp Out Alert: For remote monitoring of the UV lamp status, the Lamp Out Alert option is available. The printed circuit board continuously monitors the lamp status. When one or more lamps are out, a SPDT contact is available for customer interfacing during Lamp Out Condition. The contact will enable interfacing into a central monitoring system (PLC, DCS, etc). During the lamp out fault condition, a visual

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indicator lamp will illuminate RED on the front panel. The Lamp Out Alert for 4 lamps and above units are equipped with a 3 minute time delay. During the first 3 minutes of operation, the circuit will ignore any lamp out condition. The delay allows time for the proper warm up of the lamps and prevents false alarm conditions. If the water system is not designed with any central monitoring system or local alarm, then the Lamp Out Alert is not necessary. There is always local display of the lamp status via the standard LED display. Depending on the system design, a lamp(s) out condition may require immediate action. This will be based upon the sizing of the equipment, and if any redundancy is built into the system. Therefore, in a Lamp Out Condition, the action of the operator will be based upon the overall design. Integrated Monitoring Station: The Aquafine® UV Integrated Monitoring System consists of 3 basic components: the Monitoring Station, the Detector and the Cable with connector.

The corresponding labels identify the different controls. The use of each of these controls is described in the Monitoring Station Operation section. See page 20.

Fig. A FRONT VIEW OF THE MONITORING STATION The backside of the Monitoring Station is not accessible to the user after the unit is installed. During installation, the authorized technician must connect different inputs and outputs and select the proper position of some switches depending on the installation and unit requirements. See Fig. B.

NOTE: The UV Monitoring System is not a UV Lamp replacement tool, nor can it be used as a dosage meter. Degradation of the UV lamps, facility power variation, quartz sleeves, water temperature, water transmission, and general changes in water quality, will affect the readings. It is a useful maintenance tool used to determine UV lamp replacement and/or quartz sleeve cleaning requirements. However, if set-up and monitored properly, it can also give insight into potential system shortfalls or changes in water quality.


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Fig. B REAR VIEW OF THE MONITORING STATION

Elements to identify in the back area of the Monitoring Station are: See Fig. B

1. Temp alarm settings switch 2. 0-1V UV output terminal block 3. 4-20 mA output terminal block 4. UV relay terminal block 5. Power input terminal block 6. 230V / 115V voltage selector 7. Temperature relay terminal block 8. Temperature output (ºC / ºF) switch 9. Sensor input terminal block

Detector: The Detector is a combination temperature and UV probe. A state-of-the-art GaN photodiode and semiconductor temperature sensor is uniquely packaged into a hermetically sealed stainless steel housing. The assembly of the unit is done under dry nitrogen gas to eliminate the presence of oxygen and water. The semiconductor sensor signals are then processed within the sensor and sent via the cable into the Monitoring Station. Do not attempt to remove any of the screws that seal these ports. By doing so, you may damage the Detector and will void the warranty and the optional NIST-traceable calibration certification (if included). See page 12 for sample certificate. The Detector is provided with an O-ring. This O-ring is necessary to create the proper seal when the unit is installed in the Aquafine® UV treatment chamber. Be sure that the O-ring is present when installing the Detector in the UV treatment chamber.

Cable: The cable provided with the Detector interconnects the Detector with the

Monitoring Station. On one end it has an IP-65 grade connector that is connected to the Detector after it is installed in the UV chamber.

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AQUALOGIC 2000™ MONITORING SYSTEM: The Aqualogic 2000™ is a microprocessor-based system. The Aqualogic 2000™ system consists of two printed circuits boards; the Current Sensing Board (CSB) and the Status Display Board (SDB). The system monitors Lamp Status, UV Intensity, Low UV Alarm Point, Lamp Out Alert, Temperature Alarm, unit running time and unit “ON/OFF” cycles. Available through dry alarm contact-lamp status, high temperature status, low UV intensity and remote Start/Stop functions.

FIG. A AQUALOGIC 2000™ SYSTEM IN OPTIMA HX

Elements to identify the Aqualogic 2000™ System are: See Fig. A above.

1. Control Cabinet 2. Main Power Switch 3. Aqualogic 2000™ UV Monitoring System

Control Cabinet:

The control cabinet is available as a remote or fixed cabinet in carbon or stainless steel.

Main Power Switch:

The Main Power Switch isolates all electric power to the unit.

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AQUALOGIC 2000™ MONITORING STATION: The corresponding labels identify the different controls. The use of each of these controls is described in the Monitoring Station Operation section. See page 23.

FIG. B AQUALOGIC 2000™ STATUS DISPLAY BOARD – FRONT

The backside of the Monitoring Station is not accessible to the user after the unit is installed. During installation, the authorized technician must connect different inputs and outputs and select the proper position of some switches depending on the installation and unit requirements. See Fig. C below.

FIG. C AQUALOGIC 2000™ STATUS DISPLAY BOARD –BACK

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A SAMPLE OF AQUAFINE’S CERTIFICATE OFNIST-CALIBRATION FOR UV SENSOR

Elements to identify the Aqualogic 2000™ Status Display Board are: See Fig. C on previous page.

1. SW-5 Display Primary Time Cycle 2. SW-3 Set UV Alarm 3. SW-2 Reset Time/Cycle Counter 4. SW-8 DIP Switch 5. SW-7 DIP Switch 6. R25 UV Sensor Set Potentiometer - not used 7. J5 UV Coax Connector - not used 8. J3 Thermistor In - not used 9. J9 (Flow In) Temperature Signal 10. J10 (Spare In) UV Signal

Detector: The Detector is a combination temperature and UV probe. A state-of-the-art GaN photodiode and semiconductor temperature sensor is uniquely packaged into a hermetically sealed stainless steel housing. The assembly of the unit is done under dry nitrogen gas to eliminate the presence of oxygen and water. The semiconductor sensor signals are then processed within the sensor and sent via the cable into the Monitoring Station. Do not attempt to remove any of the screws that seal these ports. By doing so, you may damage the Detector and will void the warranty and the optional NIST-traceable calibration certification (if included). See below. The Detector is provided with an O-ring. This O-ring is necessary to create the proper seal when the unit is installed in the Aquafine® UV treatment chamber. Be sure that the O-ring is present when installing the Detector in the UV treatment chamber.

Cable: The cable provided with the Detector interconnects the Detector with the

Monitoring Station. On one end it has an IP-65 grade connector that is connected to the Detector and the other end is wired directly to the Status Display Board.


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IInnssttaallllaattiioonn The following are the guidelines and procedures for installing the Optima HX and HX-U series. INSTALLATION GUIDELINES: Location

A) Install the UV treatment unit in a horizontal position in a sheltered, well-ventilated area. Ambient temperatures surrounding the unit should be between 35°F (2°C) and 110°F (43°C). Operating water temperature should be between 40°F (4°C) to 80°F (27°C). Should your requirements differ, please contact your local Aquafine® representative or Aquafine® Customer Service.

B) As an ultraviolet UV treatment unit does not introduce any chemical residue within the water, it is desirable to install the unit as close as possible to the point-of-use in order to avoid potential recontamination by discharge pipes, fittings, etc. The base of the UV treatment unit should be mounted on suitable support to avoid undue strain on the unit or related pipes and fittings. Allow sufficient service access clearance.

C) Limit overhead piping load to 25 lbs (11.3kg), for 2” & 3”, 50 lbs (23kg), for 4” and 75 lbs (34kg), for 6” or above. If your piping system is subject to impulse pressure resulting in a “water hammer” condition, a surge tank or other means must be provided to remove this condition; otherwise the extreme momentary pressure may rupture and fracture the quartz sleeves.

D) All units are rated for a maximum operating pressure of 150 psig (10.3 bar).

E) Ultra pure water users have reported that over time, exposure to ultraviolet

light may phytochemically degrade nonmetallic piping materials, including most or all fluoro-polymers, resulting in a material breakdown and/or structural failure. Should your water application and piping material be so classified, we recommend that you install “UV light traps” to isolate any susceptible material from direct exposure to the ultraviolet light. Install the UV light trap to the inlet/outlet of the UV treatment chamber prior to the connection of any non-metallic piping. Should you require any additional assistance, please contact your local Aquafine® representative or call customer service.

F) Please note the clearance requirements for the replacement of UV Lamps and

quartz sleeves. See page 14 “Do’s and Don’ts”, section H.

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Electrical Power A) The power requirement for each unit depends on the number and type of lamp

used in the treatment chamber. The overall power consumption of each unit is indicated on the equipment nameplate decal on the unit. The unit’s main fuse provides primary over-current protection.

B) The units (240 VAC incoming power) require a single phase, grounded neutral

source. If the unit needs to be powered by a 120V AC or 208V AC supply, an externally mounted step up transformer can be provided.

a) If the external transformer is factory installed local to the electrical enclosure, the secondary terminations are factory wired by Aquafine®.

b) If the external transformer is required, the transformer primary connections to the customer’s incoming power shall be made in conformance to the local codes and be consistent with good electrical practice.

c) UV performance is line voltage sensitive. Line voltage should be +5% of rating shown on the electrical nameplate decal. Voltage outside these limits will affect the performance of the UV equipment.

d) All power and control wiring to be done per enclosed wiring diagram.

HX AND HX-U UNIT INSTALLATION & OPERATION DO’S AND DON’TS:

Do’s A) Install the UV treatment unit in a horizontal position. The UV treatment

chamber should be firmly mounted and secured. For units with remote enclosures (HX-U), suitably rated fasteners should be used.

B) Provide ample ventilation. Ambient temperatures surrounding the unit should be between 35°F(2°C) and 110°F (43°C).

C) Protect the equipment from the environment. Do not expose the equipment to direct water spray.

D) Verify the location is free from vibration, which could be caused by proximity to heavy equipment and erratic or improper pumps. Excessive vibration will damage internal electrical components and cause premature failure of the UV lamps.

E) Install a drain valve and pipe to drain. F) Install sample port valves, if required. G) Provide isolation valves on the inlet and outlet nozzles. Isolation valves will

allow safe maintenance of the equipment. H) Allow at least 36” of clearance for 30” units or 72” of clearance for 60” units on

the lamp-changing end of the unit. Clearance for servicing the electrical panel should be allowed.

I) Support all piping to the unit. Limit overhead piping load to 25 lbs (11.3kg), for 2” & 3”, 50 lbs (23kg), for 4” and 75 lbs (34 kg), for 6” or above.

NOTE: It is imperative that the unit be properly grounded for safe and proper operation. FAILURE TO PROPERLY GROUND THE UV TREATMENT UNIT AUTOMATICALLY VOIDS ALL EQUIPMENT WARRANTY.

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J) If your piping system is subject to impulse pressure resulting in a “water hammer” condition, a surge tank or other means must be provided to remove this condition; otherwise the extreme momentary pressure may rupture and fracture the quartz sleeves.

K) Provide an electrical disconnect switch to the unit if it is not supplied with the unit. During service and maintenance, the electrical power must be removed.

L) Operate the equipment within +/- 5% of 240vac. M) Interface the Low UV, High Temperature, or Lamp Out Alert Alarm relays to

any system monitoring station. N) After installation of the quartz sleeves, always pressure test the system prior to

installation of the UV lamps and applying electrical power. All leaks should be repaired. During pressure testing, do not stand in a direct line with the quartz sleeves.

O) Before start-up, flush the UV unit and discharge piping to rinse out any debris left from installation.

P) The UV treatment chamber should be filled with water. The flow of water during the initial filling should not exceed 50 GPM. Failure to comply may result in quartz sleeve breakage.

Q) While the equipment is in normal operating mode, check to see that there is airflow at the cooling fan intake and exhaust ports. Depending upon the model, there are generally one or more exhausted fans that should be cleaned and maintained. Some units have mesh filter, which should be cleaned frequently, depending upon the operating environment.

Don’ts

A) Do not exceed maximum operating pressure of unit. B) Do not exceed the maximum flow rate of the model. C) To maintain standard rated performance, do not allow the inlet water

temperature to exceed 80°F (27°C). Units should not be operated with water temperatures exceeding120°F (49°C). For applications between 80°F (27°C) and 120°F (49°C), contact Aquafine® Customer Service.

D) For heat sanitization it is recommended that stainless steel compression nuts be used in place of CPVC compression nuts. The selection of the Elastomer should be considered.

E) Never allow operating water temperature to exceed 120°F (49°C). Permanent damage can be caused to the UV lamp(s), electronic ballast and related components above this temperature. Operating the ultraviolet unit above the defined temperature through the chamber automatically voids the warranty. Elevated temperatures cause the UV lamp(s) to lose effectiveness. The heat can permanently damage the ultraviolet lamp(s). The heat can also damage the lamp ballast and related instrumentation.

F) Do not exceed 3 “ON/OFF” cycles per 24-hour operation. Excessive cycling of the unit will prematurely age the UV lamps.

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QUARTZ SLEEVE INSTALLATION: The quartz sleeves designed for this series are open on both ends. The following are the guidelines and procedure for quartz sleeve installation.

1. Turn off all power to the unit. 2. Wear clean cotton gloves to prevent contamination of the quartz sleeves. 3. Carefully remove each quartz sleeve from the factory packaging. Handle

these with care, as they are fragile. 4. Visually inspect all quartz sleeves for cracks or other damage. DO NOT install

damaged quartz sleeves. 5. Remove the socket cover on the end of the treatment chamber. Put the O-

rings and compression nut tool in a safe location. 6. Remove all compression nuts. 7. A PVC pipe is provided for installing the quartz sleeves. Slide the PVC pipe

through the threaded nipple and push through the second endplate nipple. Repeat for all quartz sleeves.

8. Place the end of the quartz sleeve over the PVC pipe, into the threaded nipple and slowly push the sleeve into the chamber through to the second endplate. Repeat for all quartz sleeves. For HX and HX-U units with operating flow above 1,000GPM, some resistance may be felt from the support Teflon bushing.

9. Install the compression nut and O-ring by placing the O-ring into the internal relief of the compression nut, below the threaded area.

10. Place the compression nut and O-ring onto the end of the quartz sleeve until the end of the quartz sleeve touches the end of the compression nut. Some pushing and twisting may be required. Deionized water may be used as a lubricant.

11. Tighten the compression nut approximately ½ turn after the threaded nipple and O-ring make contact. DO NOT OVER TIGHTEN.

12. Repeat this procedure for the second endplate. 13. Slowly pressurize the system and fill the chamber with water to check for

leaks. 14. If there are leaks in any compression nut assembly, depressurize the system

and use the compression nut tool to slightly tighten the leaking compression nut assembly.

15. Retest until a leak-free installation is verified. 16. You are now ready to install the UV lamps.

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ULTRAVIOLET (UV) LAMP INSTALLATION: Once it has been verified that there are no leaks in the system, the unit is ready for UV lamp installation.

1. Remove all the power to the UV unit.

2. Depressurize the system.

3. Wear clean cotton gloves to prevent contamination of the UV lamps.

4. Carefully remove each UV lamp from the factory packaging. Handle these with care, as they are fragile.

5. Visually inspect all lamps for cracks or damage. Do not install damaged lamps.

6. Using both hands, slowly insert the lamp into the quartz sleeve by pushing one end of the lamp with one hand, while continuing to support the lamp in a level horizontal position with the other. This is very important; if not installed properly, lamp or quartz sleeve breakage will occur.

7. Twist the lamp into the locking mechanism of the compression nut. This ensures that the lamp is secure within the quartz sleeve.

8. Each lamp socket is identified with a number that corresponds to each lamp position marked on the endplate. Match the lamp socket and connect to the appropriate lamp.

9. The two pins in the lamp must be pushed down to fit securely into the pins with the connector.

10. Rotate and screw the lamp socket cap into place. Only hand tightening is required. DO NOT OVERTIGHTEN!

11. Install the compression nut caps and the compression nuts on the second endplate and tighten by hand.

NOTE: If the unit is supplied with a monitoring system, recalibration must be performed after the first 100 hours of operation on new UV lamps, both at the time of installation and each time the UV lamps are replaced. Failure to correct may result in incorrect readings of relative UV irradiance (percentage).

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POWERING UP:

Prior to turning on the UV unit, the following must be verified: 1. The UV chamber should be filled with water. The flow of water for the

initial filling should not exceed 50 GPM. Failure to comply may result in quartz sleeves breakage.

• Ensure there are no system leaks and no piping connection leaks.

• All earth ground connections are properly made.

• All lamp connections are properly made.

• The socket cover is secured to the end of the UV treatment unit.

• Verify that all incoming power conductors, including the ground conductor, are properly terminated.

2. Turn on the electrical power to the UV unit.

3. Observe the UV LED Operational Display. For non-Aqualogic 2000®

units, the LED should illuminate yellow when the lamp is on. For the Aqualogic 2000® units, the Lamp Status LED should change from RED to GREEN. GREEN indicates the lamp is “ON”, RED indicates the lamp is “OFF”.

4. Connect the Monitoring Detector Cable, if equipped.

CAUTION! PRIOR TO ENERGIZING THE BALLASTS AND LAMPS, ENSURE THERE IS NO WATER LEAKING INTO THE QUARTZ SLEEVES AND COMPRESSION NUT CAVITIES BY PROPERLY INSTALLING THESE COMPONENTS. EVEN A SMALL LEAK CAN FLOOD A QUARTZ SLEEVE AND COMPRESSION NUT CAVITY. DURING OPERATION, HIGH VOLTAGE IS PRESENT AT THE LAMP PINS AND RECEPTACLES OF THE LAMP CONNECTORS. PROLONGED FLOODING OF THE QUARTZ SLEEVE AND COMPRESSION NUT CAVITY CAN CAUSE PREMATURE FAILURE OF THE LAMP CONNECTOR CABLE AND MAY RESULT IN A MELTDOWN OF THE CABLE INSULATION.

SAFETY ISSUE


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OPERATIONAL GUIDELINES:

1) Release the pressure in the UV treatment chamber before attempting to remove the protective covers and sealing items.

2) Disconnect all power to the UV unit before servicing. The unit operates on high voltage and should only be serviced by qualified personnel.

3) Do not allow the unit to overheat by operating without water flow. Standard flow rates are based on water temperatures of 40°F to 80°F. For applications outside these temperatures, contact customer service for assistance. In no case should the water temperature be below 35°F or above 120°F. For heat sanitization above 170°F, stainless steel compression nuts and Viton elastomers are recommended. With these components, sanitization up to 250°F (121°C) is allowed in a non-operating state.

4) Intermittent operation is allowed as long as the water temperature does not exceed 120°F; optional devices (T-120 or monitoring stations) are available to prevent this problem. Should the unit be used for batch flow operations, it can be turned “ON” and “OFF” manually. Make sure the unit is allowed to warm up for at least 3 minutes before use, and make sure the unit is turned “OFF” after each session.

5) Do not allow the flow rate to exceed the maximum rated capacity. 6) DO NOT electrically cycle the UV unit more than 3 “ON/OFF” cycles in a 24-

hour period. Cycling more than this will reduce End-Of-Life (EOL) output and/or cause premature lamp failure.

NOTE: DO NOT look at the lighted blue UV lamps. DO NOT operate the UV lamps outside of the UV treatment chamber. EXPOSURE CAN SEVERELY BURN AND DAMAGE EYES AND SKIN!

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INTEGRATED MONITORING SYSTEM for HX or HX-U series: The Monitoring Station has the capability to display continuously the level of irradiance detected by the sensor in irradiance units (µW/cm2) or in percentage value (%). See Fig. A # 8. In addition, the Monitoring Station also reports the current temperature value of the water either in degrees Celsius or Fahrenheit. See Fig. A #7.

Fig. A INTEGRATED MONITORING SYSTEM DISPLAY

1. Liquid Crystal Display (LCD) Displays irradiance values in µW/cm2 (from 0 to 5,000 with 1 µW/cm2 resolution) or in percentage (000.0 to 100.0 with 0.1% resolution) and temperature values in °F or °C (32.0 to 212.0 °F or 000.0 to 100.0 °F – with 0.1 ° resolution).

2. TEMPERATURE DISPLAY button Hold down this button to display the water temperature, otherwise the LCD shows the irradiance value.

3. UV DISPLAY UNITS button With two fixed positions; this allows the user to toggle between absolute irradiance values (µW/cm2) or in percentage (%).

4. SET 100% LEVEL potentiometer By turning this control, the percentage value reported is modified. This control is normally set each time UV lamps are replaced. The user then may set the irradiance value detected to 100%. To properly operate this control, the UV Display UNITS button (3) must be set to show irradiance value in % units.

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5. UV ALARM SET button Displays the user-set alarm level in % value under which the system will trigger the low level UV alarm protocol. The alarm level % is displayed only while this button is pressed.

6. SET ALARM LEVEL potentiometer By turning this control, the user-set alarm level in % value under which the system will trigger the low level UV alarm protocol is modified.

7. Temperature °F or °C LEDs These LED indicators are “OFF” during unattended operation. When the TEMPERATURE DISPLAY button (2) is pressed, one of these two LEDs will turn “ON”, indicating the units of the temperature value displayed in the LCD. The temperature units (°F or °C) are selected by a small switch located on the electronic board. The installer selects the switch during system installation.

8. UV IRRADIANCE % or µW/cm2 LEDs Only one of these two LEDs is “ON” during unattended operation, indicating the value selected to report UV radiation status by the sensor (% or µW/cm2). By pressing the UV DISPLAY UNITS button (3) and toggling between the two positions (one of the LEDs will be “ON” while the other will be “OFF”), the user can select to display UV irradiance level between absolute irradiance values (µW/cm2) or in percentage (%). In addition, when pressing the UV ALARM SET button (5) to set the alarm level, the % LED is “ON” and the µW/cm2 is “OFF”, indicating that the alarm level is set only in percentage value.

9. UV IRRADIANCE LOW LED When the UV radiation levels fall under the alarm pre-set level, the low level UV alarm protocol is activated. This will cause the LED to blink intermittently along with activation of a 2kHz sound for 30 seconds. In addition, the DPDT relay contact will be triggered.

10. HIGH TEMPERATURE LED Ultraviolet lamps produce heat. The heat within the treatment chamber must be dissipated to prevent damage to the UV unit and water system. Sealing materials, gaskets, O-rings, compression nuts, lamp sockets, UV lamps and the UV sensor can be damaged due to excessive heat. Under normal operating conditions, the water flow is sufficient to remove the heat generated by the lamp.

The Detector has a built-in temperature monitoring circuit. When the temperature of the treatment chamber exceeds 120°F, the UV lamps will automatically switch “OFF”, preventing overheating conditions. When the water temperature drops below 100°F, the UV lamps will re-energize. A SPDT contact is available for customer interfacing during a High Temperature Condition. The contact will enable interfacing into a central monitoring system (PLC, DCS, etc). During the high temperature fault condition, the High Temperature LED will illuminate.


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UV PROCEDURE FOR SETTING THE MONITORING STATION

1. Gradually start the normal flow rate. 2. Bring the unit up to normal operating pressure and temperature. 3. Turn on the UV lamps – wait a minimum of 15 minutes. 4. First set the “SET 100% LEVEL”. See below for instructions. 5. Then set the “Low UV ALARM LEVEL”. See below for instructions.

Setting the SET 100% LEVEL

The SET 100% LEVEL potentiometer (4) is protected with a plastic screw and O-ring set.

1) First, set the UV DISPLAY UNITS button (3) to show the irradiance value

in % units. 2) Unscrew and remove the plastic screw and O-ring set. 3) Use a 2 mm (5/64”) flat blade jewelers’ screwdriver adjusting the SET

100% LEVEL potentiometer to 100%. This control is to be readjusted each time the UV lamps are replaced and after first 100 hours of operation.

4) Replace and tighten the plastic screw and O-ring set into place after setting the SET 100% LEVEL. Failure to do so may cause damage to the monitoring system.

Setting Low UV ALARM LEVEL:

The SET ALARM LEVEL potentiometer (6) is protected with a plastic screw and O-ring set.

1) First, set 100% level as described above. 2) Unscrew and remove the plastic screw and O-ring set. 3) Press and hold UV ALARM SET button (5) and use a 2mm (5/64”) flat

blade jewelers’ screwdriver to adjust the SET ALARM LEVEL potentiometer in %. Set the alarm level at 80%.

4) Replace and tighten the plastic screw and O-ring set into place after setting the SET ALARM LEVEL. Failure to do so may cause damage to the monitoring system.

NOTE: The temperature and transmission play a major role when monitoring UV intensity output in a reactor. Therefore the set-up procedure should be carried out when the equipment is operating in a worse case condition. The set-up of the SET 100% LEVEL and SET ALARM LEVEL should be completed at the lowest possible water transmission and/or temperature scenario. This will prevent you from experiencing premature alarm status if and when the feed water parameters change.

If the alarm level needs to be set at a certain absolute irradiance value, calculate this value as a percentage with respect to the 100% level selected. As long as the SET 100% LEVEL potentiometer (4) and the SET ALARM LEVEL potentiometer (6) are not set, the alarm value will not be modified.

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AQUALOGIC 2000™ MONITORING SYSTEM: The Aqualogic 2000™ has the capability to display continuously the level of irradiance detected by the sensor in irradiance units (µW/cm2) or in percentage value (%). Reading can be measured and displaced in either Absolute (0-5000µW/cm2 ) or Relative (0-100%) by the DIPswitch SW7-8. In addition, the Aqualogic 2000™ also reports the current temperature value of the water either in degrees Celsius or Fahrenheit by the DIPswitch SW7-6

PROCEDURE FOR SETTING THE AQUALOGIC 2000™

1) Gradually start the normal flow rate. 2) Bring the unit up to normal operating pressure and temperature. 3) Turn on the UV lamps – wait a minimum of 15 minutes. 4) Set the “SET100% LEVEL” See page 25.

FIG. A AQUALOGIC 2000™ STATUS DISPLAY BOARD –FRONT

Elements to identify the Status Display Board are: See Fig. A above.

1. Running Time LED Indicator 2. Cycle and Hour Display 3. Cycle Mode LED Indicator 4. Lamp Status Indicator-Red Lamp “not operating” 5. Lamp Status Indicator-Green Lamp “operating” 6. Lamp Operation Indicator 7. Low UV Intensity Indicator 8. UV Intensity and Temperature Display 9. High Temperature Indicator 10. Lamp Out Alert Indicator

1

2

3

5

6

7

8

9

4

10

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1. Running Time Indicator The running time Indicator will illuminate when the elapsed time of the unit is displayed on the Cycle/Hour display. Aqualogic controls are equipped with a re-settable running time meter and are used to determine the number of hours on the equipment and for maintenance. It is very important to record the running time hours and lamp maintenance.

2. Cycle and Hour Display The digital display alternates between the number of times the lamps have been cycled “ON” and “OFF” and the elapsed running time of the unit.

3. Cycle Mode Indicator The Cycle Mode Indicator will illuminate when the number of cycles is displayed on the Cycle/Hour display. The cycle counter displays the number of times that the lamps have been turned “OFF” and “ON”. This counter aids in the lamp maintenance. The cycle counter is reset to zero when the running time counter is set to zero.

4. – 5. UV Lamp Operational Display To verify the status of the UV lamps, the LED display gives the operator a visual indication of the lamp status. When the UV lamp is “ON”, the LED will illuminate GREEN, and when “OFF”, the indication will be RED.

6. Lamp Operational Indicator When all lamps are operating properly, the individual lamp LED’s will be green and the Lamp Operational Indicator will be illuminated. During any fault conditions, this indicator lamp will not illuminate.

7. Low UV Intensity LED The Detector is a sensing probe place in the treatment chamber that monitors the relative change in lamp output through the fluid as detected by the UV sensor at the endplate of the UV treatment chamber. As time passes, the sensor reading will decline as the lamps age, quartz sleeves foul, temperature changes in the fluid, or if there are changes in the fluid quality. The Low UV Intensity LED display will illuminate when 80% of the set value has been reached.

8. UV Intensity and Temperature Display The digital display will indicate the UV intensity in relative (0-100%) or absolute (0-5000µW/cm²) mode and fluid temperature. To display temperature, the temperature switch must be activated.

9. High Temperature/Low Temperature Shutdown Indicator Ultraviolet lamps produce heat. The heat within the chamber must be dissipated to prevent damage to the UV unit and water system. Sealing materials, gaskets, O-rings, compression nuts, lamp sockets, UV lamps and the UV sensor can be damaged due to excessive heat. Under normal operating conditions, the water flow is sufficient to remove the heat generated by the lamp.

Aqualogic units have a temperature circuit mounted on the endplate or on the inlet nozzle of the treatment chamber. When the temperature of the treatment chamber exceeds 120°F, the UV lamps will automatically switch “OFF”,

25

preventing overheating conditions. When the water temperature drops below 100°F, the UV lamps will re-energize.

A SPDT contact is available for customer interfacing during a High Temperature Condition. The contact will enable interfacing into a central monitoring system (PLC, DCS, etc). During the high temperature fault condition, the High Temperature LED will illuminate.

10. Lamp Out Alert Indicator For remote monitoring of the UV lamp status, the Lamp Out Alert feature is available. When one or more lamps are out, a SPDT contact is available for customer interfacing during Lamp Out condition. The contact will enable interfacing into a central monitoring system (PLC, DCS, etc).

During the lamp out fault condition, the Lamp Out Alert indicator lamp will illuminate RED. The Lamp Out Alert is equipped with a 30 second time delay. During the first 30 seconds of operation, the circuit will ignore any lamp out condition. The delay allows time for the proper warm up of the lamps and prevents false alarm conditions.

Depending upon the system design, a lamp(s) out condition may require an immediate action. In single or multiple lamp units, if one or more lamps are out, the water may not get treated properly. This will be based upon sizing of the equipment and if any redundancy is built into the system. Therefore, in a Lamp Out condition, the action of the operator will be based upon the overall design.

Setting the SET 100% LEVEL 1) To set the SET 100% LEVEL, the initial value (100%) should be set.

2) The unit should be operating under normal operating conditions (flow, temperature) with new lamps and clean quartz sleeves.

3) The Aqualogic 2000™ should be set to read the “RELATIVE” mode by switching DIPswitch SW7-8 to the “CLOSED” position.

4) The SW3 button then should be pressed. A beep should be heard which indicates that the 100% intensity has been set into the memory. Switching the DIPswitch SW7-8 into the “OPEN” position will register the 100% intensity value in µW/cm2.

Setting Low UV Alarm Level: 1) DIPswitch SW7-1 sets the low UV ALARM SET point.

2) For HX units, DIP switch SW-7 should be set to the “CLOSED” position (80%).

3) When the relative UV level indicates 80% (or when 80% of the 100% level of the absolute intensity), the LOW-level alarm lamp will illuminate RED and the audio alarm will sound for 30 seconds.

The UV ALARM SET point must be set with all UV lamps operating.

NOTE: Resetting the 100% value must be performed after the first 100 hours of operation on new UV lamps, both at the time of installation and each time the UV lamps are replaced.


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Setting the Aqualogic 2000™ Status Display Board: Adjust the dipswitches, per system requirements.

1) SW-5 Display Primary Time/Cycle There are two elapsed clock memories in the system. One is the elapsed time that can be reset with SW-2 and the total accumulated time. The SW-5 switch allows the user to display the total accumulated operational hours and cycles on the unit. Reinitializing the system erases the total accumulated operational and cycle memory.

2) SW-3 Set UV Sensor 0 & 100%

The SW-3 sets the UV intensity 100% set point. When pressed, the relative intensity is set into the memory; this is the 100% set point. When 80% of the value is reached, the low UV intensity indicator is activated.

3) SW-2 Reset Time/Cycle Counter

The SW-2 switch resets the total elapsed time and cycle counter to zero. This switch is used when the lamps are replaced.

4) SW-8 Status Display Board Lamp Assignments

Model # Lamp Quantity

Switch Position 1

Switch Position 2

Switch Position 3

Switch Position 4

HX12 12 OPEN CLOSED CLOSED OPEN HX10 10 CLOSED OPEN CLOSED OPEN HX8 8 OPEN OPEN CLOSED OPEN HX6 6 CLOSED CLOSED OPEN OPEN

HX05 5 CLOSED CLOSED OPEN OPEN HX4 4 OPEN CLOSED OPEN OPEN

NOTE: Down is “OPEN”, Up is “CLOSED”.

1

2

3

4

5

6

7

8

9

10

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5) SW-7 DIP Switch The Aqualogic 2000™ DIP switch 7 allows the user to set different

parameters related to the operation. See table below.

SWITCH POSITION POSITION FUNCTION Open Closed SW7-1 Sets the Low UV Alarm Set Point 60% 80%

(DEFAULT)

SW7-2

TT/CC reset Allows user to reset the indicated elapsed time and cycle counter when SW-2 is pressed.

Deactivated (DEFAULT) Active

SW7-3 Allows the user to display the Average UV Intensity. Deactivated Active

(DEFAULT)

SW7-4 Allows the user to select the High Temperature set point. 170°F 120°F

(DEFAULT)

SW7-5

Allows the user to set the warning point for the lamp replacement based on elapsed time. At the set level, the running time display will flash. The elapsed time and cycle counted must be reset to ZERO when the lamps are changed.

9,000 hours (DEFAULT) 8,000 hours

SW7-6 Allows the user to set the temperature display in °F or °C. Deg. °C Deg. °F

(DEFAULT)

SW7-7 Allow the user to reinitialize the Aqualogic 2000™ system.

Deactivated (DEFAULT) Active

SW7-8 For setting the UV display in Absolute (0-5000µW/cm²) or Relative (0-100%)

Absolute (DEFAULT) Relative

6) R26 UV Sensor Set Potentiometer R2 Not used - No UV adjustment is required.

7) UV Coax Connector Not used.

8) J10 UV Signal Input

The signal from the UV Sensor is input into this position. 9) J9 Temperature Signal Input The signal from the temperature probe is input into this position.

10) J3 Thermistor In

Not used.

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The following provides users of Aquafine UV treatment equipment with recommendations and procedures that will maximize the efficiency, consistency, reliability, and longevity of the equipment. Once the equipment is properly installed and fully operational, this will provide time-oriented guidelines for:

1) Performance monitoring, 2) Recognizing the need for time based preventive measures, 3) Organized analysis of performance, based on your particular operational

environment. 4) Establishing optimum parameters for periodic replacement of vital

components.

Keep in mind that operating conditions can differ substantially for identical UV models-even within the same building-due to such variables as:

• Water quality (tap water, DI water, pH level, chemical content, solids, etc.) • Entering water temperature • Flow rate (high, low or constant) • Process status (continuous, intermittent)

Because of these variables, each UV unit may have to be serviced differently. For instance, those with continuous high flow, or with lower quality water require more frequent cleaning of the quartz tubes than those exposed to cleaner water, lower flow rates and/or intermittent usage.

Regarding UV lamp replacement, the rule is to replace the lamps every 9,000 hours or every 24 months, whichever comes first. This means that the units, which are continuously used for 24 hours a day, will reach 9,000 hour limit within 375 days, or slightly over 1 year. The following table represents the recommended PM for the equipment.

DESCRIPTION INITIAL START

UP DAILY/MONTHLY ANNUALLY

1 Quartz Cleaning/ Replacement X

2 Set Detector 100% X X 3 Operating Conditions X X 4 Cleaning of Unit X X 5 Inspection for Leaks X X X 6 Inspection for Lamp

Operation-Lamp Out Alert Alarm

X X X

7 Low UV Intensity Alarm X X X 8 High Temp Alarm X X X 9 Replacement of UV Lamps X

10 Inspection of Cooling Fans X X X 11 Lamp Socket Inspection X

SAFETY REQUIREMENTS TO BE OBSERVED AT ALL TIMES

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CAUTION! The most important consideration for proper installation, operation and maintenance of any piece of equipment is operator safety. The following caution statements directly relate to operator safety. Please review with all applicable personnel to ensure continuous compliance.

The following safety requirements are mandatory. Failure to carefully follow them can cause injury to the operator and damage to the UV unit.

A) Never look at lighted blue ultraviolet lamps. Never operate the ultraviolet

lamps outside the UV Disinfection Chamber. UV lamp exposure can severely burn and damage eyes and skin.

B) Properly ground the UV Disinfection unit. Failure to properly ground the unit can result in severe electric shock hazard.

C) Provide watertight piping and compression nut seals. Failure to do so can cause damage to electrical components, as well as create an electrical hazard to operating personnel.

D) Disconnect power before servicing unit. The UV lamps and electrical components are operated with high voltage electrical power. Do not attempt to service the UV treatment unit without first disconnecting power to the unit. Shut off the source power at the equipment’s main panel breaker and use appropriate tag-out or lockout procedures to prevent accidental power-up by other personnel. Only properly qualified service personnel should perform service.

E) Remove pressure before servicing units. The UV unit has components under pressure. Before completing any service, the pressure should be removed.

Operating Conditions: Never operate the unit for more than 30 minutes without flow of water. Elevated water temperatures can be dangerous and damaging to the unit. Do not exceed three (3) “START/STOP” cycles per 24-hour period; otherwise lamp filaments will be subjected to excessive thermal stress, which could cause premature failure.

Unit Maintenance:

1) Depending on the environment of the installation, clean the exterior surfaces of the UV treatment chamber, and electrical enclosure. The frequency of cleaning will be dependent upon the environmental condition. In some cases, it may be necessary to clean the unit from once a month to yearly.

2) Use a soft cloth with soap and water, or any commercial stainless steel cleaner.

3) Avoid scratching the Lexan windows.

4) Interior of the electrical cabinet should be inspected for debris. Any dirt, dust or external material should be removed with a vacuum. The electrical terminal should be cleaned with a commercial electrical contact cleaner.

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Quartz Sleeves Maintenance: As water passes through the UV treatment unit, minerals, debris and other matter in the water will settle and deposit onto the quartz sleeves. This will impair the ability of the ultraviolet rays to penetrate into the water. Therefore, it is imperative to determine a cleaning schedule for the quartz sleeves. The frequency will depend on the specific type of water being processed, i.e. its turbidity, its flow rate, and on the duty cycle, i.e. 24 hour continuous or intermittent at planned or random intervals. Replacement of the quartz sleeves should be completed every 2 years of operation. For replacing, follow the installation procedure on page 16.

Inspect the quartz sleeves one month after the first installation for a good indication of the degree of contamination you can expect over subsequent longer periods. Then you will be able to determine a reasonable time schedule for periodic cleaning.

If the water has been conditioned through deionization, reverse osmosis or distillation, the cleaning frequency can be set at once per year. If clear, fresh water is used, the cleaning frequency should be anywhere from once every thirty days to once every six months. With super clean water, this can even be extended further. Determine cleaning frequency by visually inspecting any one quartz sleeve to see how much debris or film has settled on the outside of it.

Clean In Place (CIP) cleaning is sometimes effective in the removal of debris from the sleeves. A test should be completed to determine the effectiveness of a CIP cleaning. After a chemical CIP has been completed, the quartz sleeves should be visually inspected for the removal of material. If CIP cleaning is not effective, then a manual cleaning or replacement of the sleeves will be required

Cleaning the Quartz Sleeves: Visually inspect a quartz sleeve thirty days after use to see if any debris or film has settled on the outside. If dirty, use the following procedures. Should this be insufficient, they should be replaced. To place an order, please contact your local Aquafine® representative or call customer service.

1. Turn off the water to the unit. 2. Disconnect the electrical circuit. 3. Drain the UV Treatment Chamber. 4. Remove the socket cover. 5. Wear clean gloves to prevent contamination of the quartz sleeves and

UV lamps. 6. Remove the retainer caps and lamp sockets. 7. Remove the UV lamps from inside the quartz sleeves. 8. Using the appropriate compression nut tool, loosen the compression

nuts and carefully remove the quartz sleeves. 9. Wash the quartz sleeves with mild soap and water. Rinse in clean, hot

water. 10. The Detector window should be cleaned during quartz sleeve

cleaning and maintenance. See page 35.

NOTE: Failure to perform quartz sleeve cleaning maintenance may cause inadequate UV treatment and low sensor values. The quartz sleeves maintenance is very important to the overall operation of the equipment. If the quartz sleeves are not properly maintained, the UV efficiency will be reduced.

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Checking for Leaks: To ensure there are no leaks, a visual inspection of the treatment chamber should be made. The source of any leaking should be found and repaired. Follow the installation procedures of the quartz sleeves and UV lamps for replacing the O-ring. See pages 16 thru 17.

Visually check the bottom pans at both ends of the cylinder for dripping water. If a leak is detected, follow this procedure:

1) Shut off all electrical power. Shut off source power at the facilities main

panel and use appropriate tag-out safety procedures to prevent accidental power-up by other personnel.

2) Remove the socket cover from the leaking end.

3) Determine whether the leak comes from one or more of the lamp socket nipples (leaking quartz tube), or from the main end plate gasket. IF A QUARTZ TUBE IS LEAKING: 4. Release the pressure. Open the drain valve connected to the bottom

fitting of the cylinder and drain fluid from the cylinder until the water level is below the leaking tube.

5. Unscrew the lamp socket and lamp from the leaking nut.

6. Unscrew the compression nut counterclockwise (CCW) and remove it and its O-ring from the end of the quartz tube. Be sure not to pull the quartz tube out of the opposite compression nut, or you may have to reassemble all items on that side as well.

7. Place a new O-ring into the leaking compression nut and reassemble all parts mentioned above in the reverse order. Refill the tank to test all seals before restoring power.

IF THE ENDPLATE SEAL IS LEAKING: Do not use any gasket compounds and make sure the gasket and all seal surfaces are clean before reassembling.

4. Torque the perimeter bolts evenly approximately 5-10 ft./lbs. above their present torque, using a cross-symmetrical tightening progression. See the torque label on the end plate.

5. If that does not stop the leaking, the gasket/O-ring may require replacement.

6. Remove all UV lamps

HX MODEL TORQUE SPECIFICATIONS

HX-C, D 25ft./lbs. or 34 N.M.

HX-E, F, G 50ft./lbs. or 68 N.M.

HX-A, B NONE


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7. Remove all quartz sleeves

8. Remove end plate seal.

9. Replace end seal and then reassemble all components in reverse order.

Inspection for Lamp Operation Lamp-Out Alert: A visual check of the LED display should be made. The LED will be GREEN when the lamp is “ON”.

Action: If one or more lamps are not operating, the Lamp Out Alert LED will illuminate RED and audio alarm will sound for 30 seconds and then will stop.

Replacing the Ultraviolet Lamps: The Colorguard™ UV lamps are rated for 9,000 hours or every 24 months, whichever comes first. This means that the units, if continuously used for 24 hours a day, will reach 9,000-hour limit within 375 days, or slightly over 1 year. After this time, the lamp glass will photo chemically change and no longer allow sufficient 254-N.M. short-wave UV, the germicidal ray of the lamp, through the glass to effectively kill bacteria.

Color Coded Ceramic Lamp Bases

BASE COLOR

LAMP TYPE

254 N.M.: For Disinfection

254 N.M.: For Validated Disinfection

Standard Lamp

GOLD

BURGUNDY

“S” Type GOLD-S BURG-S

“L” Type GOLD-L BURG-L

COLORGUARD™ UV LAMP CERAMIC BASES ARE EXCLUSIVE TO AQUAFINE AND MAKE MIXING OF DIFFERENT LAMP TYPES VIRTUALLY IMPOSSIBLE DURING LAMP CHANGE OUT.

NOTE: The Lamp Out Alert alarm and function will not activate for the first 30 seconds of operation after the lamps have been turned “ON”. NOTE: Failure to replace the ultraviolet lamps on a timely basis of at least once every 9,000 hours may cause the equipment to fail. With intermittent use, in no case should the ultraviolet lamp be used for more than 24 months without replacement, regardless of the number of hours of operation, due to normal operational degradation of the UV lamp.

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Inspecting the Lamp Socket: When replacing lamps, inspect the lamp socket contacts and related hardware. They should be inspected for corrosion of the metal contact, deterioration of the material or burning.

1) Be sure all power to the equipment is disconnected.

2) Inspect the condition of the socket retainer caps. If they show signs of cracking or any chemical degradation, they should be replaced.

3) Inspect the condition of the lamp socket (resilient boot) and the metal lamp contact imbedded in the end with the lip seal.

4) Metal contacts must be clean, free of corrosion and straight.

5) Resilient boots must be clean, free of cracks and free of any chemical degradation.

6) Lip seals must be pliable, unbroken and fit snugly over the ceramic lamp sockets.

7) The wires must be clean, with all insulation intact and no signs of brittleness.

In case any of these descriptions are not prevalent, replace the entire lamp socket assembly.

Ballast Replacement: Ballast replacement is not part of the UV unit’s routine maintenance. However, in the event that the ballast needs to be replaced, the following procedure should be followed:

1) Power down the UV unit by returning the unit isolator switch, if installed, to the “OFF” position. If not, ensure that the power to the unit is removed by opening the switch or breaker upstream of the UV unit.

2) Locate the old ballast to be replaced. Refer to the electrical diagram, if necessary.

3) Isolate the old ballast from the rest of the system by disconnecting the ballast connector.

4) Remove and discard the old or defective ballast.

5) Install the new ballast.

6) Reconnect the ballast connector(s).

7) Restore the power to the UV unit by turning the unit isolator switch to the “ON” position or by closing the upstream switch or breaker.

8) Turn the power “ON” and resume operation. Whenever new lamps have been installed, follow all resetting instructions.

34

Cleaning the Detector Window: 1) Shut off the flow and release the pressure. 2) Shut off all power to the UV unit. 3) Remove the cable by twisting the connector terminal counterclockwise.

The connector will slide off. 4) Unscrew the Detector. 5) Use a lint-free cloth with alcohol and very carefully wipe the lens face on

the front of the Detector. 6) Replace the Detector and the cable. 7) Turn the power “ON” and resume operation.

Measuring Performance: Every UV treatment unit should be tested periodically to verify actual efficiency. Regardless of the intended application or any optional equipment that may have been provided with your UV unit, the most accurate and dependable procedure is to conduct post-UV sample analysis in accordance with standard testing methods. For obtaining proper water samples, see page 28.

LED Display Maintenance: If an LED bulb does not light after you replace a UV lamp, you need to verify the electrical output of the ballast connected to that specific UV lamp. Testing the ballast open circuit voltage does this. This should be done by an electrician or qualified facilities personnel. Follow these recommended procedures:

1) Turn the power to the UV unit “OFF”.

2) Remove the socket cover.

3) Identify the faulty UV lamp, which corresponds to the number on the LED display.

4) Remove the lamp socket(s) from the faulty UV lamp base.

5) Use a voltmeter and set an operating range at >700 VAC.

6) Measure the open circuit voltage. Connect the voltmeter across the receptacles of the lamp socket.

7) Turn the power to the UV unit “ON”.

8) Record the reading.

9) Turn the power to the UV unit “OFF”.

10) The open circuit voltage for the ballasts is 800V AC max.

NOTE: If the voltage reading is zero, or a number above or below the acceptable range, this indicates a ballast fault and the ballast connected to the faulty UV lamp must now be replaced. NOTE: If the voltage reading is within the acceptable range, but the LED does not light, the LED board has failed and needs to be replaced.

35

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STANDARD:

SYMPTOM PROBABLE CAUSE REMEDY UV Lamp Maintenance Lamps may require maintenance.

Water Flow Too High If the capacity of the equipment exceeds the design capacity, then performance will be compromised.

Water Quality If the water has debris, chemicals or materials that absorb the UV energy, the performance will be compromised.

UV Lamp Maintenance The lamps may require maintenance. Quartz Sleeve

Maintenance-Dirty The quartz sleeves may need maintenance.

Sampling Procedures Sampling procedures can contribute to measuring errors.

Concentration Spikes Contamination or concentration spikes can result in temporary negative performance.

Piping Contamination System sanitation is critical. If the pipe system is contaminated, then performance may be flawed.

UV SYSTEM NON- PERFORMANCE -BACTERIA

Leaking Leaking can result in system contamination.

UV & Temperature Monitoring System

optional

UV and Temperature monitoring system option: The unit will automatically shut “OFF” when the temperature exceeds 120oF. When the water temperature cools down to below less than 100oF, the unit will turn back “ON”.

Blown Fuse Check main fuse. A complete inspection to determine the cause of failure should be completed.

“HOA” Switch optional

The HOA switch in units wired with remote START/STOP capabilities insure that the switch is in “AUTO” and the proper signal is supplied.

GFI optional

Some UV units maybe equipped with a GFI. Resetting the GFI will restore power to the unit.

SYSTEM NOT OPERATING

Power to the Unit Main power to the unit should be checked.

36

SYMPTOM PROBABLE CAUSE REMEDY

Lamp Failure The UV lamp should be inspected for damage. Replace UV Lamp.

Lamp Connection The socket should be inspected to insure that the lamp connection is tight and no damage is present. Replace if defective.

Ballast Overheating

Each of the ballasts have an overheat circuit. When the ballast temperature reaches the preset temperature, the ballast automatically shuts “OFF”. When the ballast cools down, the ballast will reenergize. Excessive continuous heat will destroy the ballast.

LAMP IS NOT OPERATING ON LED DISPLAY, IS NOT YELLOW

LED Board The LED board may be defective, indicating false lamp-out.

Defective Component See factory representative

UV Lamps

As the UV lamps age, the lamps solarize. After a normal operation of 9,000 hours, the lamps should be replaced. Please note that the lamps will remain lit for many hours after 9,000 hours, but the UV output will decline.

Quartz Sleeves Fouling

In raw water applications (non RO/DI), minerals or debris will attach to the quartz sleeves. The material will block the transmission of the UV energy into the water. The quartz sleeves must be replaced or cleaned. CIP does not always properly clean the quartz sleeves.

Water Quality

Any changes in the water transmission or quality, will cause the sensor reading to change. In some applications where the water is blended, the transmission properties can change.

UV SENSOR DECLINING, OR IF EQUIPPED WITH MONITORING STATION – LOW UV INDICATOR LAMP IS ON.

Temperature

UV output of the lamps is sensitive to temperature. If the UV sensor is set with a water temperature of 70o F and the operational temperature is 50o F, the sensor reading will be less. The relative output of the UV sensor should be set to the “worst case” operating temperature.

Leaking/Water in Quartz Sleeve

If water is present in the quartz sleeve, the leak should be repaired immediately. Water can cause the lamp socket to arc, corrosion on the lamp pins, burning of the lamp sockets and damage to the ballast and LED components.

PREMATURE (LESS THAN 9,000 HOURS) LAMP FAILURE

Ballast Power

The ballast controls the current to the lamps. The lamps current should be measured to determine if the current is within specification. The ballast should produce 0.8 Amps to each lamp.

37


Lamp Cycling Systems in which the UV is turned “ON“ and “OFF” frequently (more than 3X) will cause lamp filament damages.

Electrical Power

Low equipment power will cause damage to the electrical equipment. The electrical power should be within 5% of the nameplate voltage. Small transformers may be required to boost low voltages.

Electrical Connection

Vibration can cause the electrical connections to become loose. The connections should be inspected and repaired if damaged.

Heat Excessive heat from “no flow conditions“ can damage the lamps.

Mechanical Vibration

Vibration from “water hammer”, pumps and unsupported piping can cause excess stress to the lamp filament and equipment.

Compression Nut Inspect the compression nut and O-ring to insure that they are installed properly.

PREMATURE (LESS THAN 9,000 HOURS) LAMP FAILURE

Over Pressure System pressure greater than the design pressure will cause the sealing material to fail.

Gasket Failure

The gasket and O-rings should be inspected for deterioration. These materials can be subjected to UV, ozone and heat, which is damaging to the material.

O-Rings O-rings, which are not compressed properly, will cause the quartz sleeves to leak. Reinstall and replace the O-ring.

Sealing Material

O-ring and gasket material that are damaged due to UV, ozone and physical damage, will result in leaking. The material should be changed.

“Water Hammer”

“Water hammer” pressure can be 5 -10X higher than the static pressure of a water system. “Water hammer” can cause leaking and breakage to the quartz sleeves.

Broken Quartz Sleeves The ends of the sleeves should be inspected for cracks and chips. Any broken sleeves should be replaced.

LEAKING

Heat Damaged Part

If the unit is operating with compression nuts manufactured with CPVC (gray plastic) and has been exposed to elevated temperatures, the compression nut may be damaged. Excessive heat can distort the plastic material, resulting in a loss in compression of the O-ring seal. Change compression nuts to stainless steel.

38

AQUALOGIC 2000™:


Water Flow Too High If the capacity of the equipment exceeds the design capacity, then performance will be compromised.

Water Quality If the water has debris, chemicals or materials that absorb the UV energy, the performance will be compromised.

Defective Component See factory representative. UV Lamp Maintenance The lamps may require maintenance.

Quartz Sleeve Maintenance-Dirty

The quartz sleeves may need maintenance.

Sampling Procedures Sampling procedures can contribute to measuring errors. For recommended procedures, see page 42.

Concentration Spikes Contamination or concentration spikes can result in temporary negative performance.

Piping Contamination System sanitation is critical. If the pipe system is contaminated, then performance may be flawed.

UV SYSTEM NON- PERFORMANCE

Leaking Leaking can result in system contamination.

OP IS DISPLAYED Water temperature is greater than 250°F Let water cool to less than 250°F.

Check sensor probe and connector connection. Check connection on J9 of SDB.

SH IS DISPLAYED Wire connections from temperature probe to the SDB are “OPEN”. Inspect wire connections from the

temperature probe to board. Fluid in treatment chamber exceeds set points.

Check water temperature is less than 100° F and greater then 40° F.

HIGH TEMPERATURE LED IS ILLUMINATED

Temperature Connections If connections are open, the temperature will drift to above and below the 100°F and 40°F set points.

HOUR DISPLAY IS FLASHING

System warning indicating lamp replacement due to elapsed time.

Replace lamps or reset counter.

65555 IS DISPLAYED Electrical Surges Reinitialize system.

“OPEN” Connections If connections are “OPEN’, the temperature will drift to above and below the 100°F and 40°F set points.

TEMPERATURE INDICATES WRONG TEMPERATURE

Defective SDB Reinitialize. If defective, replace board. COUNTER RESET TO “0” AFTER ELECTRICAL POWER IS REMOVED

SW-7-7 is set in CLOSED position. Set SW-7-7 in “OPEN” position.

NO 4-20MA SIGNAL 24 V DC power not applied System requires 24V DC for activation. LAMP OUT ALERT INDICATOR LAMP IS ILLUMINATED

One or more UV lamp is not operating. Replace lamps.

39

SYMPTOM PROBABLE CAUSE REMEDY LAMP OUT ALERT INDICATOR LAMP IS ILLUMINATED

SDB board is set for the wrong number of lamp inputs.

Check SW-8 DIP switch settings in relation to equipment model number.

LAMP OUT DOES NOT INDICATE WHEN ONE OR MORE LAMP LEDS ARE ILLUMINATED RED

Time delay in system program.

Wait 30 seconds after power has been applied.

Lamp Failure The UV lamp should be inspected for damage. Replace UV lamp.

Lamp Connection The socket should be inspected to insure that the lamp connection is tight and no damage is present. Replace if defective.

Ballast

In a situation where two consecutive lamps are out, the ballast may be defective. Each ballasts controls two lamps. Ballast A –lamps l-2, Ballast B –lamps 3-4 Ballast C –lamps 5-6 Ballast D –lamps 7-8 Ballast E –lamps 9-10 Ballast F –lamps 11-12 Single channel ballast failures can occur. Each of the ballasts have an overheat circuit. When the ballast temperature reaches the preset temperature, the ballast automatically shuts “OFF”. When the ballast cools down, the ballast will reenergize. Excessive continuous heat will destroy the ballasts. Cooling fan not operating

Ballast Overheating

Fan filter blockage Wiring Inspect wire connections

LAMP LED IS RED AND LAMP OUT ALERT LED IS ILLUMINATED

CSB/SDB Components Replace defective boards

High Temperature UV Shutdown

If the High temperature LED is “ON” and the water temperature is above 120°F, then the unit is in over heat condition. The fluid temperature must be reduced.

Low Temperature UV Shutdown

If the High temperature LED is “ON” and the water temperature is below 40° F, the unit will automatically shut “OFF”. When the water temperature has risen to 44 °F, the unit will reactivate.

UV LAMPS WILL NOT TURN ON

SH is displayed on the UV Intensity and Temperature

Display.

Temperature indicates SH. A SH indicates that the signal to J9 of the SDB is not connected, probe is not connected to the connector, power to the probe is not connected or a defective component.

OP is displayed on the UV Intensity and Temperature Display.

Temperature indicates OP. When OP is displayed, the temperature is greater then 250°F.

40


Temperature Signal floating or the UV Temperature probe is not connected.

If the High temperature LED is “ON” and the temperature displayed is not correct or drifting, the UV unit will shut “OFF”. Check the controller connection on J9 of the SDB, probe connector, and power to the probe.

“ON /OFF” Switch Switch to “ON” position.

System in Auto Switch Units wired with remote operation should determine if signal is connected.

Power to the Unit Main power to the unit should be checked.

GFI optional

Some UV units are equipped with a GFI. Resetting the GFI will restore power to the unit.

Blown Fuse Check main fuse. A complete inspection to determine the cause of failure should be completed.

UV Lamps

As the UV lamps age, the lamps solarize. After a normal operation of 9,000 hours, the lamps should be replaced. Please note that the lamps will remain lit for many hours after 9,000 hours, but the UV output will decline.

UV LAMPS WILL NOT TURN ON.

Quartz Sleeves Fouling

In raw water applications (non RO/DI), minerals or debris will attach to the quartz sleeves. The material will block the transmission of the UV energy into the water. The quartz sleeves must be replaced or cleaned. CIP does not always properly clean the quartz sleeves.

Water Quality

Any changes in the water transmission or quality will cause the sensor reading to change. In some applications where the water is blended, the transmission properties can change.

Temperature

UV lamp Intensity is sensitive to temperature. For example: If the UV sensor is set (100%) with a water temperature of 70° F and the operational temperature is 50° F, the UV intensity will be different due to the differences in water temperature. The relative output of the UV sensor reading should be set at the “worst case” operating temperature and transmission.

Connections

Check the UV signal connection J3 on the Status Display Board, check if the detector cable is not connected to the connector, or cable power to the probe is not connected.

Heat The Detector must be removed in applications exceeding 250°F (121° C).

LOW UV INTENSITY IS ILLUMINATED.

Lamp Cycling Systems in which the UV is turned “ON” and “OFF” frequently (more that 3X) will cause the lamp filament damage.

41


Leaking/Water in Quartz Sleeve

If water is present in the quartz sleeve, the leak should be repaired immediately. Water can cause the lamp socket to arc, corrosion on the lamp pins, burning of the lamp sockets and damage to the ballast and LED components.

LOW UV INTENSITY IS ILLUMINATED.

Ballast Power

The ballast controls the current to the lamps. The UV lamps current should be measured to determine if within specification. HX ballasts should produce 0.8 Amps to each lamp.

Electrical Power

Low equipment power will cause damage to the electrical equipment. The electrical power should be within 5% of the nameplate voltage. Small transformers may be required to boost low voltages.

Electrical Connection

Vibration can cause the electrical connects to become loose. The connection should be inspected and repaired if damaged.

Heat Excessive heat from “no flow” conditions can damage the lamps.

Mechanical Vibration

Vibration from “water hammer”, pumps and unsupported piping can cause excess stress to the lamp filament and equipment.

Compression Nut Inspect the compression nut and O-ring to insure that they are installed properly.

Over Pressure System pressure greater than the design pressure will cause the sealing material to fail.

PREMATURE (LESS THAN 9000 HOURS) LAMP FAILURE.

Gasket Failure

The gasket and O-rings should be inspected for deterioration. These materials can be subjected to UV, ozone and heat, which is damaging to the material.

O-Rings O-rings that are not compressed properly will cause the quartz sleeves to leak. Reinstall and replace the O-ring.

Sealing Material

O-ring and gasket material that are damaged due to UV, ozone and physical damage will result in leaking. The material should be changed.

“Water Hammer”

“Water hammer” pressure can be 5-10X higher than the static pressure of a water system. Water hammer can cause leaking and breakage to the quartz sleeves.

LEAKING

Broken Quartz Sleeves The ends of the sleeves should be inspected for cracks and chips. Any broken sleeves should be replaced.


42

SYMPTOM PROBABLE CAUSE REMEDY LEAKING

Heat Damaged Part

If the unit is operating with compression nuts manufactured with CPVC (gray plastic) and has been exposed to elevated temperatures, the material may be damaged. Excessive heat can distort the plastic material, resulting in a loss in compression of the O-ring seal. Change nuts to stainless steel.

Obtaining Proper Water Samples: Our experience has shown that the vast majority of unsatisfactory post-UV bacteriological samples are directly related to improper sample-taking techniques.

There are a variety of commercial sample collection apparatuses available. Should you choose one, be sure to follow the manufacturer’s recommended procedures.

Optional sample unit fittings on both the intake and discharge UV chamber flange risers can be provided. We recommend you use these fittings to collect “before and after UV” water samples to eliminate the possibility of contamination by nearby piping, fittings, etc.

We recommend you select a valve with a discharge orifice no larger than ¼” (6mm).

Sampling Procedures:

1) Prior to taking the water sample, have on hand an adequate supply of sterile bottles. These should be obtained from a source laboratory and should have been autoclaved and contained within a plastic outer wrapping.

2) The inside diameter of a sample valve must not exceed ¼” (6mm) to ensure proper velocity. Prior to taking the sample, it is imperative that the test sample valve be fully opened under full pressure for a full three and a half minutes. Temporary tubing or some other material may be used to direct the water to a container or drain to avoid unnecessary spillage.

3) After the valve has been left fully open for three and a half minutes, reduce the flow to a reasonable stream of water (not less than 50% of full flow). Continue flowing to drain 3 additional minutes.

4) Remove any temporary tubing used for flow diversion.

5) Open the sterile bottle. Holding the cap in a down position, the operator should then hold his breath while taking the sample so as to avoid atmospheric contamination of the sample. The operator must also not allow any fingers to touch the inside of the cap or neck of the bottle.

6) After the water sample has been taken, the cap should be immediately secured on the sample container.

7) The sample container should be labeled and placed in a plastic wrapping and must be taken to the laboratory for plating as soon as possible. Processing should begin within 3 hours of sample collection and should comply with accepted standard methods.

43

WWaarrrraannttyy IInnffoorrmmaattiioonn The following installation and operating conditions are considered hazardous or damaging to the equipment and can compromise the ability of the Aquafine® unit to perform as intended.

Any of the following conditions will void the equipment warranty:

1. Failure to connect proper electrical service to unit. 2. Failure to properly ground the unit. 3. Failure to eliminate excessive vibration, piping, movement, or “water

hammer”. 4. Failure to exercise caution in the handling of the sensitive and delicate

components (such as lamps, quartz sleeves, electronic boards, etc.) during installation and/or maintenance procedures.

5. Failure to avoid excessive stops and starts. Not more than three (3) “ON/OFF” cycles per 24 hours of operation.

6. Operation of visibly damaged equipment. 7. Failure to avoid undue overhead piping stress, which can result in

structural damage to the UV unit. Limit the load to 25 lbs, for 2” & 3”, 50 lbs, for 4” and 75 lbs, for 6” or above. Torsion loads or side loading of the risers should be eliminated.

8. Use of components other than those provided or authorized by Aquafine®. 9. Failure to correct overhead piping connection leaks or compression nut

seal leaks which result in damage to the electrical components. 10. Allowing operating water temperature to exceed 120°F.

NOTE: To maintain your UV unit’s warranty, please complete and return the Warranty registration Card located in the back pocket of this manual.

44

45

RReeppllaacceemmeenntt PPaarrttss LLiisstt

Part Part No. O-rings – for quartz sleeves EPDM 4253

O-rings – for quartz sleeves Viton 40413

Detector O-ring – Viton 40432

Cylinder O-ring – for Optima “F” series EPDM 15601

Cylinder O-ring – for Optima “F” series Viton 40428

Cylinder O-ring – for Optima “G” series EPDM 16063

Cylinder O-ring – for Optima “G” series Viton 40429

Cylinder O-ring – for Optima “E” series EPDM 16790

Cylinder O-ring – for Optima “E” series Viton 40427

Ballast Assembly 240V 40328

Ballast Assembly 120V-240V 41634-1

Monitoring System (Station, Detector & Cable) 41174

Monitoring System (Station, Detector & Cable) NIST 41174-4

Monitoring Station 41114-1

Detector & Cable 41174-2

Detector & Cable NIST 41174-3

Cable, 20ft 41116

Aqualogic 2000™ SDB connector for Detector Cable 41128

2” Fan 240V 4206

4” Fan 240V 3903

Cylinder Gasket for Optima HX & HX-U “C” series EPDM 3118

Cylinder Gasket for Optima HX & HX-U “C” series Viton 16673

Cylinder Gasket for Optima HX & HX-U “D” series EPDM 3244

Cylinder Gasket for Optima HX & HX-U “D” series Viton 16674

UV Lamps SE 254 NM – GOLD for disinfection

“S” Type GOLD-S

“L” Type GOLD-L

46

Part Part No. UV Lamps SE 254 NM – BURGUNDY for validated disinfections

“S” Type BURG-S

“L” Type BURG-L

Quartz Sleeve “S” Type 25mm 3184

Quartz Sleeve “L” Type 25mm 3198

Lamp Socket – 30” Lead Wires 40569-3

Lamp Socket – 90” Lead Wires 40569-8

Lamp Socket – 16’ Lead Wires 40569-16

Lamp Socket Cap -for lamp socket 17489

Compression Nut – CPVC, 25mm 19685

Compression Nut – 316L Stainless Steel, 25mm 40357

Compression Nut Cap, fixed 17489-1

Compression Nut Tool 18517

UV & Temperature Detector 41115

Aqualogic 2000™ Status Display Board (SDB) 12 Lamp 41177-12

Aqualogic 2000™ Current Sensing Board (CSB) 12 Lamp 19385-12

Bushing Quartz, 25mm 19737

Documents

Aquafine Optimahx Manual