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Optima HX
Optima HX &
Optima HX-U Series
SAFETY
ISSUE
Installation and
Operation Manual
Table of Contents
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
Instruction for
Optima HX and HX-U series
Purpose and Scope
Purpose: To provide instructions for the installation and operation of the Optima HX and
Optima HX-U series.
Scope:
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.
System Description
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.
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
Unit Description:
2
4
3
Fig. A
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. Orings, 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.
Socket Covers:
The socket covers on either end of the treatment chamber protect the lamp socket
assemblies.
4
Fig. A
1.
2.
3.
4.
5.
6.
UV 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.
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.
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.
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.
1
1
99
2
2
3
3
4
4
88
6
5
5
77
1.
Control Cabinet
2.
3.
Control Cabinet:
The control cabinet is available as a remote or fixed cabinet in carbon or stainless
steel.
10
Main
Power
Switch
isolates
all
electric
power
to
the
unit.
10
FIG. C AQUALOGIC 2000 STATUS DISPLAY BOARD
BACK
11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
12
Installation
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, wellventilated area. Ambient temperatures surrounding the unit should be
between 35F (2C) and 110F (43C). Operating water temperature should
be between 40F (4C) to 80F (27C). Should your requirements differ, please
F) Please note the clearance requirements for the replacement of UV Lamps and
quartz sleeves. See page 14 Dos and Donts, section H.
13
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 units 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)
b)
c)
d)
All power and control wiring to be done per enclosed wiring diagram.
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.
14
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.
Donts
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 80F (27C). Units should not be operated with water
temperatures exceeding120F (49C). For applications between 80F (27C) and
120F (49C), 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 120F (49C). 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.
15
Handle
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 Orings 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 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.
16
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.
ensures that the lamp is secure within the quartz sleeve.
This
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).
17
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.
SAFETY
ISSUE
18
2.
3.
4.
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.
Operation
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 40F to 80F. For applications
outside these temperatures, contact customer service for assistance. In no
case should the water temperature be below 35F or above 120F. For heat
sanitization above 170F, stainless steel compression nuts and Viton
elastomers are recommended. With these components, sanitization up to
250F (121C) is allowed in a non-operating state.
4) Intermittent operation is allowed as long as the water temperature does not
exceed 120F; 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 24hour 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!
19
In addition, the Monitoring Station also reports the current temperature value of the water
either in degrees Celsius or Fahrenheit. See Fig. A #7.
10
9
7
6
Fig. A INTEGRATED MONITORING SYSTEM DISPLAY
20
21
2.
3.
4.
First set the SET 100% LEVEL. See below for instructions.
5.
Then set the Low UV ALARM LEVEL. See below for instructions.
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.
22
2)
3)
4)
4
5
6
2
7
3
8
9
10
FIG. A AQUALOGIC 2000 STATUS DISPLAY BOARD FRONT
23
24
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.
25
10
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.
Model #
Lamp
Quantity
Switch
Position 1
Switch
Position 2
Switch
Position 3
Switch
Position 4
HX12
HX10
12
10
OPEN
CLOSED
CLOSED
OPEN
CLOSED
CLOSED
OPEN
OPEN
HX8
OPEN
OPEN
CLOSED
OPEN
HX6
CLOSED
CLOSED
OPEN
OPEN
HX05
CLOSED
CLOSED
OPEN
OPEN
HX4
OPEN
CLOSED
OPEN
OPEN
26
POSITION
SW7-1
SW7-2
SW7-3
SW7-4
SW7-5
SW7-6
SW7-7
SW7-8
SWITCH POSITION
FUNCTION
Open
60%
Deactivated
(DEFAULT)
Deactivated
170F
9,000 hours
(DEFAULT)
Deg. C
Deactivated
(DEFAULT)
Absolute
(DEFAULT)
Closed
80%
(DEFAULT)
Active
Active
(DEFAULT)
120F
(DEFAULT)
8,000 hours
Deg. F
(DEFAULT)
Active
Relative
27
Preventative Maintenance
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 modelseven 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.
INITIAL
START
UP
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
Quartz Cleaning/
Replacement
Set Detector 100%
Operating Conditions
Cleaning of Unit
Inspection for Leaks
Inspection for Lamp
Operation-Lamp Out Alert
Alarm
Low UV Intensity Alarm
High Temp Alarm
Replacement of UV Lamps
Inspection of Cooling Fans
Lamp Socket Inspection
DAILY/MONTHLY
ANNUALLY
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
SAFETY REQUIREMENTS
TO BE OBSERVED AT ALL TIMES
28
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.
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.
29
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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.
30
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.
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
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
1.800.423.3015 (outside California and within domestic USA)
email: sales@aquafineuv.com
web: www.aquafineuv.com
31
254 N.M.:
For Validated Disinfection
Standard
Lamp
GOLD
BURGUNDY
S Type
GOLD-S
BURG-S
L Type
GOLD-L
BURG-L
LAMP
TYPE
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.
32
Ballast Replacement:
Ballast replacement is not part of the UV units 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.
33
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.
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.
34
Troubleshooting guidelines
STANDARD:
SYMPTOM
UV SYSTEM NONPERFORMANCE BACTERIA
PROBABLE CAUSE
REMEDY
UV Lamp Maintenance
SYSTEM NOT
OPERATING
UV & Temperature
Monitoring System
optional
Blown Fuse
HOA Switch
optional
GFI
optional
Power to the Unit
35
SYMPTOM
LAMP IS NOT
OPERATING ON LED
DISPLAY, IS NOT
YELLOW
PROBABLE CAUSE
REMEDY
Lamp Failure
Lamp Connection
Ballast Overheating
LED Board
UV SENSOR
DECLINING, OR IF
EQUIPPED WITH
MONITORING
STATION LOW UV
INDICATOR LAMP IS
ON.
Defective Component
UV Lamps
Water Quality
Temperature
PREMATURE (LESS
THAN 9,000 HOURS)
LAMP FAILURE
Leaking/Water in Quartz
Sleeve
Ballast Power
36
SYMPTOM
PREMATURE (LESS
THAN 9,000 HOURS)
LAMP FAILURE
PROBABLE CAUSE
Lamp Cycling
Electrical Power
Electrical Connection
Heat
Mechanical Vibration
Compression Nut
Over Pressure
LEAKING
Gasket Failure
O-Rings
Sealing Material
Water Hammer
REMEDY
Systems in which the UV is turned ON
and OFF frequently (more than 3X) will
cause lamp filament damages.
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.
Vibration can cause the electrical
connections to become loose. The
connections should be inspected and
repaired if damaged.
Excessive heat from no flow conditions
can damage the lamps.
Vibration from water hammer, pumps
and unsupported piping can cause excess
stress to the lamp filament and
equipment.
Inspect the compression nut and O-ring to
insure that they are installed properly.
System pressure greater than the design
pressure will cause the sealing material to
fail.
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, which are not compressed
properly, will cause the quartz sleeves to
leak. Reinstall and replace the O-ring.
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 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.
The ends of the sleeves should be
inspected for cracks and chips. Any
broken sleeves should be replaced.
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.
37
AQUALOGIC 2000:
SYMPTOM
UV SYSTEM NONPERFORMANCE
PROBABLE CAUSE
Water Flow Too High
Water Quality
Defective Component
UV Lamp Maintenance
Quartz Sleeve
Maintenance-Dirty
Sampling Procedures
Concentration Spikes
Piping Contamination
Leaking
OP IS DISPLAYED
Water temperature is
greater than 250F
SH IS DISPLAYED
Wire connections from
temperature probe to the
SDB are OPEN.
HIGH
TEMPERATURE LED
IS ILLUMINATED
HOUR DISPLAY IS
FLASHING
65555 IS DISPLAYED
TEMPERATURE
INDICATES WRONG
TEMPERATURE
COUNTER RESET TO
0 AFTER
ELECTRICAL
POWER IS
REMOVED
NO 4-20MA SIGNAL
LAMP OUT ALERT
INDICATOR LAMP IS
ILLUMINATED
38
REMEDY
If the capacity of the equipment exceeds
the design capacity, then performance will
be compromised.
If the water has debris, chemicals or
materials that absorb the UV energy, the
performance will be compromised.
See factory representative.
The lamps may require maintenance.
The
quartz
sleeves
may
need
maintenance.
Sampling procedures can contribute to
measuring errors. For recommended
procedures, see page 42.
Contamination or concentration spikes
can result in temporary negative
performance.
System sanitation is critical. If the pipe
system
is
contaminated,
then
performance may be flawed.
Leaking can result in system
contamination.
Let water cool to less than 250F.
Check sensor probe and connector
connection. Check connection on J9 of
SDB.
Inspect wire connections from the
temperature probe to board.
Check water temperature is less than
100 F and greater then 40 F.
If connections are open, the temperature
will drift to above and below the 100F
and 40F set points.
Replace lamps or reset counter.
Reinitialize system.
If
connections
are
OPEN,
the
temperature will drift to above and below
the 100F and 40F set points.
Reinitialize. If defective, replace board.
Replace lamps.
SYMPTOM
LAMP OUT ALERT
INDICATOR LAMP IS
ILLUMINATED
LAMP OUT DOES
NOT INDICATE
WHEN ONE OR
MORE LAMP LEDS
ARE ILLUMINATED
RED
LAMP LED IS RED
AND
LAMP
OUT
ALERT
LED
IS
ILLUMINATED
PROBABLE CAUSE
Lamp Failure
Lamp Connection
Ballast
Ballast Overheating
Wiring
CSB/SDB Components
UV LAMPS WILL
NOT TURN ON
REMEDY
High Temperature UV
Shutdown
Low Temperature UV
Shutdown
SH is displayed on the UV
Intensity and Temperature
Display.
OP is displayed on the UV
Intensity and Temperature
Display.
39
SYMPTOM
UV LAMPS WILL
NOT TURN ON.
PROBABLE CAUSE
Temperature Signal
floating or the UV
Temperature probe is not
connected.
ON /OFF Switch
System in Auto Switch
Power to the Unit
GFI
optional
Blown Fuse
UV Lamps
LOW UV INTENSITY
IS ILLUMINATED.
Water Quality
Temperature
Connections
Heat
Lamp Cycling
40
REMEDY
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.
Switch to ON position.
Units wired with remote operation should
determine if signal is connected.
Main power to the unit should be checked.
Some UV units are equipped with a GFI.
Resetting the GFI will restore power to the
unit.
Check main fuse. A complete inspection
to determine the cause of failure should
be completed.
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.
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.
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 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.
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.
The Detector must be removed in
applications exceeding 250F (121 C).
Systems in which the UV is turned ON
and OFF frequently (more that 3X) will
cause the lamp filament damage.
SYMPTOM
PROBABLE CAUSE
LOW UV INTENSITY
IS ILLUMINATED.
Leaking/Water in Quartz
Sleeve
Ballast Power
PREMATURE (LESS
THAN 9000 HOURS)
LAMP FAILURE.
Electrical Power
Electrical Connection
Heat
Mechanical Vibration
Compression Nut
Over Pressure
Gasket Failure
LEAKING
O-Rings
Sealing Material
Water Hammer
REMEDY
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.
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.
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.
Vibration can cause the electrical
connects to become loose.
The
connection should be inspected and
repaired if damaged.
Excessive heat from no flow conditions
can damage the lamps.
Vibration from water hammer, pumps
and unsupported piping can cause excess
stress to the lamp filament and
equipment.
Inspect the compression nut and O-ring to
insure that they are installed properly.
System pressure greater than the design
pressure will cause the sealing material to
fail.
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 that are not compressed properly
will cause the quartz sleeves to leak.
Reinstall and replace the O-ring.
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 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.
The ends of the sleeves should be
inspected for cracks and chips. Any
broken sleeves should be replaced.
41
SYMPTOM
PROBABLE CAUSE
REMEDY
LEAKING
42
Warranty Information
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 120F.
NOTE: To maintain your UV units warranty, please complete and return the Warranty
registration Card located in the back pocket of this manual.
43
44
Part No.
4253
40413
40432
15601
40428
16063
40429
16790
40427
40328
41634-1
41174
41174-4
Monitoring Station
41114-1
41174-2
41174-3
Cable, 20ft
41116
41128
2 Fan 240V
4206
4 Fan 240V
3903
3118
16673
3244
16674
GOLD-S
L Type
GOLD-L
45
Part
Part No.
BURG-S
L Type
BURG-L
3184
3198
40569-3
40569-8
40569-16
17489
19685
40357
17489-1
18517
41115
41177-12
19385-12
46
19737