Aqua Control SP Series Operating and maintenance instructions

Quick Installation Manual
Rev. A - 6 November 2008
ULTRA VIOLET LIGHT
SP Series for Marine Systems
AquaControl Marine | [phone] | Bergen op Zoom - The Netherlands | www.aquacontrolmarine.com

UV Light-SP Series Rev A
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This manual provides quick installation, operation and
maintenance instructions for the Sea Recovery Ultraviolet
Disinfection Unit-SP Series. It is intended for individuals
with working knowledge of servicing electrical and
mechanical equipments.
SAFETY ISSUES
Anyone responsible for the installation of Sea Recovery
Ultraviolet Disinfection Unit must read this manual
thoroughly and comply with the instructions, guidelines,
and safety requirements at all times.
WARNING! Remove all electrical power to the UV
unit before servicing. The electrical panel is an
electrical hazard. Death can result if precautions and
safety requirements are not followed. Before
servicing all electrical power to the equipment,
including power from signal and monitoring systems,
must be isolated.
WARNING! Never service the equipment under
pressure. The unit’s water source must be closed;
unit must be depressurized and drained.
WARNING! Never look directly at the UV lamp. The
lamp produces harmful radiation and will damage
eyes and skin. Always use protective apparels. The
UV lamp contains mercury and must be handled and
disposed of properly.
1Unit Description
The SP Series is appropriate for many low volume indoor
applications because of the compact design and easy
installation. SP Series combines electrical components
and treatment chamber in one integral unit.
The UV unit is comprised of a stainless steel cylinder and
a ballast box. The cylinder forms the treatment chamber,
houses the quartz sleeve and UV lamp. The cylinder has
two ¼” female fittings and compression nuts on each
end. The ballast box is attached to the cylinder. Inside
the ballast box are the circuit board, UV lamp connector,
and the pass-through for the quartz sleeve. Water flows
in either direction around the quartz sleeve.
Figure 1 UV Unit-SP Series
1.1 Components
The UV unit consist of the following components.
Cylinder Main body that forms the treatment
chamber with 2 ports and 2 pass-thru.
O-ring Two O-rings placed at the quartz sleeve
ends for sealing.
Compression
Nut
Two compression nuts maintain sealing
to the treatment chamber. One nut has a
viewport; the other has a pass-thru.
Fitting Two quick fit elbow fittings to connect
plumbing to the cylinder ports
UV Lamp Ultraviolet lamp emits radiation to treat
fluid inside the treatment chamber.
Quartz Sleeve The quartz sleeve protects the UV lamp
from fluid inside the treatment chamber.
Ballast Box The plastic box, attached to cylinder,
houses the circuit board that connects to
the power cable.
Table 1 SP Series Elements
CAUTION! Operating water should be between 37ºF
and 104ºF (3ºC to 40ºC).
CAUTION! Excessive vibration will damage the UV
unit electrical components and cause premature
failure of the UV lamp.
CAUTION! Ultraviolet light exposure degrades non-
metallic piping materials and may lead to material
breakdown or failure.
2Unit Operation
The SP series sterilize water by emitting UV light to
penetrate water as the water flows through the treatment
chamber.

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3Installation Requirements
The SP Series UV unit is shipped with the UV lamp,
quartz sleeve, fittings, and O-rings and need to be
assembled before the UV unit can be used.
1. Install the UV unit in a sheltered, well ventilated area.
2. Install the UV unit as close as possible to the point-of-use
to avoid potential contamination discharge from pipes,
fittings, etc.
3. The UV unit should be mounted on stable support to avoid
straining or warping. Allow sufficient clearance around
the unit for servicing.
4. Verify the location is free from vibration.
5. All UV units are rated for maximum operating pressure at
50psig (8.24 bar).
6. The UV unit must be properly grounded for safe and
proper operation. Failure to properly ground the UV unit
automatically voids all unit warranty.
7. Line voltage must be within 10.56V to 16.50V. Voltage
outside the range will compromise the performance of
the UV unit.
3.1 Plumbing Requirements
All piping, tubes and hoses leading to the UV unit
connection points must be leak-free before the UV unit
can be installed.
NOTE! The UV unit may be installed horizontally or
vertically. For vertical installation, make sure the
inlet port is positioned at the bottom.
4Installation Procedure
NOTE! Do not assemble or install damaged parts.
Quartz sleeve and UV lamp are fragile and must be
handled with care.
4.1 Install Fittings
Perform this procedure to prepare the UV unit for
installation.
1. Inspect each port and fitting to ensure threads are free of
dirt, burrs, and excessive nicks. If threads are badly
nicked, replace the fitting.
2. Wrap ¼” wide PTFE tape 2 to 3 turns counter-clockwise
around the male threads of the ¼” fitting. Do not wrap
tape around the first thread.
3. Screw the fitting into cylinder ports to finger tight position
to achieve desired alignment.
4. Do not back-off fitting. Do not over-tighten fitting. Over-
tightening could strip the fitting threads and cause leak.
4.2 Install Quartz Sleeve
Perform this procedure only when water piping for UV
unit is in place and ready for service.
1. Visually inspect quartz sleeve for cracks and damages.
2. Remove the four screws holding the ballast box cover
and remove the cover.
3. Remove the rubber boot and pull out the 4-point lamp
connector.
4. Remove the compression nuts.

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5. Insert the close-end of the quartz sleeve into the cylinder
through the ballast box pass-thru.
6. Allowing ½” of the quartz sleeve to expose on the
viewport pass-thru.
7. Lubricate the tips of the quartz sleeve with clean water
and insert new O-ring. Ensure the O-ring has all-round
contact with the cylinder pass-thru.
8. Tighten the compression nut while making sure the nut
does not contact the quartz sleeve. Adjust O-ring position
as necessary. The compression nut should be snug and
tight, not over-torque.
9. Repeat Step 7 & 8 on the ballast box compression nut.
4.3 Connect Plumbing
Tube or hose ends must be cut squared and clean; must
have no rough edges. The quick fit elbow fitting has a C-
clamp that will lock the tube in place once inserted.
1. Insert the supply pipe into one cylinder port and label the
port “Inlet”.
2. Insert the temporary pipe into the other cylinder port to
direct water into a container.

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3. Slowly fill the cylinder with water and flush cylinder for 1
minute.
4. Remove temporary pipe and insert the return pipe into
the cylinder port and label the port “Outlet”.
5. Slowly pressurize the UV unit by filling the cylinder with
water while checking for leaks.
6. If leaks are found on the compression nuts, depressurize
the unit and slightly tighten the leaking compression nut.
7. Retest until a leak-free installation is verified.
8. Once UV unit is leak-free, the quartz sleeve installation is
complete and the UV lamp can be installed.
NOTE! To remove tube from fitting, first remove the C-clamp
then push fitting sleeve down. Once the fitting sleeve is down,
pull the tube out of the fitting.
4.4 Install Ultraviolet Lamp
Perform this procedure only after the quartz sleeve
installation and leak-tests are completed successfully
1. Connect the UV lamp to the 4-point receptacle. If the lamp
is not installed properly, lamp breakage will occur.
2. Insert lamp into quartz sleeve through compression nut
pass-thu.
3. Install rubber boot over compression nut.
4. Connect unit power cable to power source.
5. Tighten the 4 screws to secure ballast box cover.
6. Turn ON the power to the unit.
7. Verify UV lamp operation from the viewport.
8. Allow one minute for the UV lamp to warm up prior to
flowing water through the UV unit.
CAUTION! Use the viewport to verify the proper
operation of the UV lamp.
CAUTION! Rapid successive cycling of the power to
the ballast can cause premature failure of the unit.
CAUTION! Prior to energizing the lamp, make sure
there is no water leaking from the quartz sleeve
compression nuts.
4.5 Mounting the Unit
Once the UV unit is assembled and tested successfully, it
can be mounted onto its permanent operational location.
The unit must be mounted in a manner that will prevent

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excessive vibration and warping which will damage the
quartz sleeve.
5Operational Guidelines
a) Release the pressure in the UV treatment chamber
before breaking the compression nut seals.
b) Disconnect all power to the UV unit before servicing.
c) Do not allow the inlet water temperature to drop
below 35ºF (2ºC).
d) Do not allow the flow rate to exceed 2 GPM.
e) Do not cycle the UV unit more than 3 “ON/OFF”
cycles in a 24-hour period.
f) Ensure all plumbing connections are tightly sealed
before applying pressure.
g) Before connecting the return tube, flush the unit to
rinse out any debris left from the installation process.
WARNING! UV LIGHT EXPOSURE CAN SEVERELY
BURN AND DAMAGE EYES AND SKIN.
WARNING! DO NOT look at the blue UV light. DO
NOT operate the UV lamp outside of the UV treatment
chamber.
CAUTION! The unit operates on high voltage and
must be serviced by qualified personnel only.
CAUTION! Standard flow rate are based on water
temperature 35ºF to 100ºF. If the inlet water
temperature exceeds 100ºF (38ºC), please contact
your local CSR.
CAUTION! Cycling more than 3 cycles will reduce
the end-of-life (EOL) output and/or cause premature
lamp failure.
6Preventative Maintenance
Follow the preventative maintenance procedures to
maximize the efficiency, reliable, and longevity of the UV
unit.
Refer to Table 2 Periodic Maintenance Table for
recommended maintenance schedule.
WARNING! The most important consideration is
operator safety. The following directly relates to
operator safety. All personnel must review and
comply with the following.
CAUTION! Operators must observe Safety
Requirements at all times
6.1 Safety Requirements
The following safety requirements are mandatory. Failure
to comply can cause injuries and/or damages to the UV
unit.
1. Never look directly at the blue ultraviolet lamp when it’s
“ON”. Never operate the ultraviolet lamp outside the
stainless steel cabinet. UV light exposure can severely
burn and damage eyes and skin.
2. Properly ground the UV unit. Failure to properly ground the
UN unit can cause severe electrical shock hazard.
3. Provide watertight piping and compression nut seals.
Failure to provide watertight seals can cause damage to
electrical components or cause electrical shock hazard.
4. Disconnect power before servicing the UV unit. The UV
lamp and electrical components operate with high voltage
electrical power. Do not attempt to service the UV unit
without first disconnecting the power source. Shut off the
source of power at the main panel breaker and use
appropriate tag-out or lock-out procedures to prevent
accidental power-up.
5. Only qualified service personnel should perform services
to the UV unit.
6. Remove pressure before servicing the UV unit.
7. Never operate the UV unit for more than 30 minutes
without water flow. Elevated water temperature can
damage the UV unit.
8. Do not exceed 3 “Start/Stop” cycles per 24-hour period.
Exceeding 3 cycles will subjected the lamp filament to
excessive thermal stress leading to premature failure of
the UV lamp.
6.2 Unit Maintenance
The exterior surfaces of the UV unit should be kept clean
and dry. In most cases it may be necessary to clean the
exterior of the unit once a month. Use soft cloth and
soapy water, or any commercial stainless steel cleaner.
Interior of the ballast box should be inspected for debris.
Any debris should be removed using vacuum.
6.2.1 Quartz Sleeve
Debris and other matter in the water will settle onto the
quartz sleeve and eventually block the ultraviolet rays
from penetrating into the water. It is necessary to
determine a cleaning schedule for the quartz sleeve. The
frequency will depend on the specific type of water being
processed and the duty cycle of the unit.
Inspect the quartz sleeve 30 days after initial installation
to assess the amount of contamination collected over the

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30-day period. Use the finding to determine a reasonable
schedule and frequency for periodic cleaning.
Clean-In-Place (CIP) cleaning is sometimes effective in
removing debris from the quartz sleeve. Conduct a CIP
cleaning test to determine its effectiveness. If CIP
cleaning is not effective, then a manual cleaning or
replacement is required.
When the quartz sleeve is due for cleaning, use the
following procedures.
1. Turn off the water source to the UV unit.
2. Disconnect the power source to the UV unit.
3. Drain the UV treatment chamber.
4. Remove the ballast box cover.
5. Remove rubber boot and carefully pull out the UV lamp
through the compression nut pass-thru.
6. Use a channel lock to remove the compression nuts.
7. Remove the Quartz Sleeve carefully.
8. Wash the Quartz Sleeve with mild soapy water and rinse
in clean hot water.
If dirt remains after rinsing, the quartz sleeve should be
replaced. Contact your local CSR to order a replacement.
NOTE! Failure to perform quartz sleeve maintenance
may reduce the efficiency of the UV light to
adequately treat water in the treatment chamber.
6.2.2 Checking for Leaks
Visual inspect the UV unit exterior for signs of leakage.
The cause of any leakage must be located and repaired.
If a leakage is detected, perform the following.
1. Shut off all electrical power. Shut off the source of power
at the main panel breaker and use appropriate tag-out
procedures to prevent accidental power-up.
2. Depressurize the UV unit.
3. Remove ballast box cover and remove the rubber boot.
4. Locate which end of the quartz sleeve is leaking.
6.2.3 Repairing Leaks
If both ends of the quartz sleeve are leaking, perform the
following on both ends.
1. Use a channel lock to loosen and remove the compression
nut.
2. Remove the quartz sleeve O-ring without pulling the
quartz sleeve out.

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3. Lubricate the quartz sleeve tip with clean water and place
new O-ring. Ensure the O-ring has all-round contact with
the cylinder pass-thru.
4. Replace and tighten the compression nut.
5. Refill the treatment chamber and verify a leak-free
condition.
6.2.4 Measuring Performance
Every UV unit must be tested periodically to verify its
efficiency. Regardless of the intended application or any
optional equipment provided with the UV unit, the most
accurate procedure is the Post-UV Analysis. The Post-UV
Test must be performed in accordance with standard
testing methods, see Section 6.2.7 below.
6.2.5 Verifying Lamp Operation
The UV lamp is “ON” when the blue light is emitting thru
the viewport.
6.2.6 Obtaining Water Samples
Vast majority of unsatisfactory Post-UV Test results are
directly related to the improper sample-taking techniques.
Although several commercial sample collection
apparatuses are available, the proper manufacturer’s
sample procedures must be followed.
NOTE! Sea Recovery recommends a valve with a
discharge orifice not to exceed ¼” (6mm).
6.2.7 Sampling Procedure
Use sterile sample bottles obtained from reliable
laboratory that has been autoclaved and kept in plastic
bag for this procedure.
1. Use temporary tube to direct water from UV unit to
container or drainage.
2. Pressurize the UV unit and flush unit with sample valve
fully opened for 3.5 minutes. After flushing for 3.5
minutes, reduce valve opening to 50% and flush for 3
minutes.
3. Open the sample bottle and keep the inside of the cap
facing down.
4. Fill the sample bottle and avoid breathing directly into the
bottle or touching the inside of the bottle, cap, or neck.
5. Immediately cover and secure the cap after filling the
sample bottle.
6. Label the sample bottle and place in a clean plastic bag.
7. Take sample bottle to the laboratory for plating as soon
as possible.
NOTE! Sample processing must begin within 3 hours
after sample collection and must comply with
accepted standard methods.

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7Periodic Maintenance Table
The table below represents the recommended Periodic
Maintenance (PM) for the SP Series UV Unit.
Description Init. Daily Mn Ann. Other
Quartz Sleeve
Cleaning
x
Quartz Sleeve
Replacement*
x
Operating
Condition
x
Unit Cleaning x x
Leak Inspection x x x
UV Lamp
Inspection
x x x
UV Lamp
Replacement-SP-
1
x 4,400
hrs
UV Lamp
Replacement-SP-
2
x 8,000
hrs
Table 2 Periodic Maintenance Table
* Quartz Sleeve replacement will occur more frequently for
systems operating with continuous high flow rate or low water
quality water, and less frequently for systems operating with
low flow rate or high water quality.
8Replacement Parts List
Part Part No.
Stainless Steel Cylinder 40000300CV
UV Lamp 40000100CV
Quartz Sleeve 40000400CV
Compression Nut 40001400CV
O-ring 40001300CV
Table 3 Replacement Parts List
9UV Unit Specifications
Type 12 VDC Operating UV Sterilizer for 2 gallon per
minute of water flow
Ballast Type Solid State
Bulb Type 16 Watts Single Ended
Bulb Life 8000 Hours minimum
Materials Body: SS304; Ballast Box: PVC
Power Cord 4 meters 2 conductors
Weight 500g Body
Table 4 General Specifications
Temperature Range Operating: +3ºC to +40ºC; Dry
Storage: -25ºC to +85ºC
Table 5 Environmental Specifications
Operating Voltage
Range 10.56V minimum; 16.50V maximum
Current 1.45A maximum @ Standard Test
Voltage
UV Dosage 22mJ/cm2 @ 254nm
Table 6 Electrical Specifications
Operating Pressure 50psi
Inlet/Outlet Ports ¼” NPT Female
Flow Rate 2 gpm
Disinfection Rate 99%
Table 7 Mechanical Specifications