CalMag CALULTRA 12 User manual

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Calming troubled waters

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CongratulationsonpurchasingthisCALMAGYORKSHIRELTDultravioletdisinfectionsystem.
BypurchasingaCALMAGYORKSHIRELIMITEDUVDisinfectionsystemyouarereceivingnotonlyahigh
qualityproductbutalsopeaceofmind.
ProtectingyourwatersupplywithaUVsystemgivesyoureassurancethatyourfamilywillhaveaccess
tosafedrinkingwaterthroughoutyourentirehomewithnochanceofmicrobiologicalcontamination.
This is chemical free process which is simple in its concept and effective in its abilities to inactivate
microorganismspresentinthewatersupply.
Simple maintenance, continuous disinfection and ultimately safe water, CALMAG YORKSHIRE LIMITED
makesitthateasy.
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TABLEOFCONTENTS
SafetyConsiderations............................................................................................................................Page4
BeforeYouBegin...................................................................................................................................Page4
WaterQualityParameters.....................................................................................................................Page4
Assembly................................................................................................................................................Page5
SystemSizing.........................................................................................................................................Page6
Location.................................................................................................................................................Page6
Installation.............................................................................................................................................Page7
SystemDisinfection...............................................................................................................................Page10
Cleaningthequartzsleeve.....................................................................................................................Page11
CleaningtheUVsensor..........................................................................................................................Page12
OperationControllerOverview...........................................................................................................Page12
OperationPowerupSequence............................................................................................................Page13
Operation–RemoteAlarmModuleCheck............................................................................................Page14
Operation–OperationalScreens..........................................................................................................Page14
OperationUVIntensity........................................................................................................................Page15
OperationLampCountdownSequence...............................................................................................Page15
OperationLampCountdownResetSequence.....................................................................................Page16
OperationFailureModes.....................................................................................................................Page16
OperationQRCodes............................................................................................................................Page18
ExpansionModules................................................................................................................................Page18
WarrantyRegistration...........................................................................................................................Page19
CalUltraSpecifications...........................................................................................................................Page20
LimitedWarrantyStatement.................................................................................................................Page21
ToObtainWarrantyService...................................................................................................................Page22
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SafetyConsideration
AlthoughyourUVsystemhasbeenmanufacturedtothehighestsafetystandards,extremecaremustbefollowed
whenoperatingand/ormaintainingyoursystem.
1. Wheneveryouareservicingthisequipment,alwaysdisconnectthepowercordfromtheelectricaloutlet.
2. AstheenergygivenoffbytheUVlampcanbeharmfultoyoureyesandskin,NEVERlookdirectlyatan
illuminatedUVlampwithoutadequateeyeprotectionandalwaysprotectyourskinfromdirectexposure
totheUVlight.
3. Toensurethesystemprovidesadequatedisinfection,ALWAYSreplaceanycomponent(lampandsleeve)
withagenuineCalmagYorkshireLimitedreplacementpart.
4. Donotoperatetheunitifithasanydamagedormissingcomponents.
5. Toavoidpossibleelectricalshock,useonlywithaproperlygroundedelectricaloutlet.
6. Neverperformany maintenancetothesystemunlessyouarecomfortablein doingso.Contact Calmag
YorkshireLimitedforserviceinstructionsifrequired.
7. Donotusethissystemforanypurposeotherthanwhatitwasintendedfor.Misuseofthissystemcould
potentiallycauseharmtotheuser.
8. Yoursystemisintendedtobeinstalledindoorsandawayfromleakingplumbing.DONOTplugtheunitin
ifthesystemoranyofthecomponentsarewet.
9. Thedisinfectionsystemshouldbedirectlyinstalledintoagroundfaultcircuitinterrupter(GFCI).Iftheuse
ofanextensioncordisrequired,thecordmustbemanufacturedwithaminimumof16gaugewireand
careshouldbetakentoavoidpotentialtrippinghazards.
10. WerecommendthatacompetentplumberorcertifiedUVtechnicianperformtheinstallation.
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BeforeYouBegin
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Beforeyoubegin,youwillneedthefollowing:
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Tools
•Pipecutter,hacksaworotherspecializedtoolsrequiredtocutintoyourexistingplumbing(e.g.ifyouhave
PEXpiping)
•Solderingtools(torch,flux,emeryclothandsolder)
•Wrench(fortighteningfittings)
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OtherMaterials
•Variousfittings
•PTFEtape
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WaterQualityParameters
UVdisinfectionisextremelyeffectiveagainstmicroorganismsbutonlyiftheUVlightcanpassthroughthewaterit
needs to treat. This means that the quality of your water is very important in order to ensure complete
disinfection.
Itisimperativethatyouhaveyourwatertestedforattheleasttheparameterslistedbelow.Ifthewaterexceeds
the listed parameters CALMAG YORKSHIRE LIMITEDstrongly recommends that appropriate pretreatment
equipmentbeinstalled(pretreatmentwilldependonparametersbeingtreated):

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Hardness: <120ppm(120mg/L)–ifhardnesslevelis120ppmorslightlybelowthe
quartzsleevemustbecleanedperiodicallyinordertoensureefficientUV
penetration;ifabovethewatermustbesoftenedwithaCalmagwater
softener
Iron(Fe):<0.3ppm(0.3mg/L)
Manganese(Mn):<0.05ppm(0.05mg/L)
Turbidity:<1NTU
Tannins(organics):<0.1ppm(0.1mg/L)
UVT(transmittance):>85%(PleasecontactCALMAGYORKSHIRELIMITEDifthewaterhasaUVT
thatislessthan80%forpretreatmentrecommendations)
Youcanhaveyourwatertestedataprivateanalyticallaboratoryorcontactyourlocalcouncilforadviceinregards
toyourlocalenvironmentalhealthofficer.Itisalwaysrecommendedtoinstallprefiltrationofatleast5microns
priortoaCALMAGYORKSHIRELIMITEDUVdisinfectionsystem.CALMAGYORKSHIRELIMITEDprovidesprefilters
housingsandcartridgesasstandardontheCALULTRA12andCALULTRA22unitsanddorecommendprefilterson
allunits.Pleasecalltodiscusstheappropriatefilterfortheunit.
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Assembly
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Step1:Unpackthesystemandensureallthecomponentsareincludedwiththesystem.Yoursystemisshipped
withthefollowingcomponents:
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SystemSizing
All CALMAG YORKSHIRE LIMITEDUV systems are rated for a specific flow rate under specific water quality
parameters.Theequipmenthasbeendesignedtoensurethattheappropriatedosewillbedeliveredprovidedall
parametersarefollowed.PLEASENOTEthattheflowrateforeachsystemcan behigherorlowerthanwhat the
system is rated for
howeverthiswillchangethedoselevelthatthesystemwilldeliver.Alowerflowisnota
concernasthedosewillincreasehoweverahigherflowratewilldecreasethedoseandthereforecompromisethe
microorganisminactivation.
It is important to know the maximum flow rate that your water system delivers.  If you do not have this
informationyoucansimplyfilla1gallonbucketwithwaterandtimehowlongittakestofillup.Thiswillbethe
maximumflowrateforthehome.TheappropriateCalmagUVunitshouldthenbechosen.
PLEASENOTE:Itisalwaysbettertooversizeyoursystemthentoundersize.Forexample,ifyourpumpdelivers60
litresperminuteitisrecommendedtoinstalltheCALULTRA79UVunit.Therewillbeoccasionswhereyourhome
isusingwateratthepump’smaximumcapacity.
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Location
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Step1:FindasuitablelocationtomounttheUV
unit. In choosing your location ensure the
controller is located within 5 feet of a ground
fault circuit interrupter (GFCI) and that there is
easyaccesstothemaincoldwaterlinepriorto
any branch lines and before the hot water
heater. If you have any other water treatment
equipment, such as a water softener or water
filter, ensure that the UV is the last piece of
treatment equipment. PLEASE NOTE: All
CALMAG YORKSHIRE LIMITEDUV disinfection
systemsareintendedforindooruseonlyasthey
shouldnotbeexposedtotheelements.
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Step 2:Your system includes mounting
hardware for both the UV unitand the
controller. If the supplied fittingsare not
compatiblewith thestructure inwhichyou are
mountingthedevice,pleaseensureyouusethe
correctfittings.
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Step3:Tofacilitatelampremoval,ensurethere
is enough space at the lamp connector end to
safelyremovetheUVlampand/orquartzsleeve
(a space equal to the length of the unit will
suffice)(seeFigure1.).
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Figure1.LampRemovalSpacing
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Installation
Step1:TheUVdisinfectionsystemshouldalwaysbethelastpieceoftreatmentbeforethewaterbranchesoffto
thehotandcoldwaterlinesiftheintentisforPointofEntry(POE)(seefigure2).IftheintentfortheUVsystemis
forPointofUse(POU)thesystemshouldbethefinalstepbeforethedrinkingtap.
Step2:CALMAG YORKSHIRELIMITEDstronglyrecommendsthat the5 micron filter includedbe installed before
theUVsystemforafinalpolishingstepbeforethewaterisdisinfected.TheCalUltra12andCalUltra22willbepre
mountedonabackingboard.
Step3:Theunitcanbeinstalledeitherhorizontallyorverticallyusingtheclampsprovided.
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Figure2.Exampleofaninstallation
Step4:Ifyoudonotknowtheflowrateofthewatersupplyinyourhomeitisrecommendedthatyouuseaflow
restrictorsothattheratedflowofyourparticularCALMAGYORKSHIRELIMITEDsystemisnotexceededandtheUV
doseisnotcompromised.Theflowrestrictorshouldbeinstalledontheoutletportoftheunit.
Step5:ItisstronglyrecommendedtohaveacompetentplumberconnecttheUVunittothewatersupplyandmay
have other requirements depending on any specific Water Regulations in your area.Ifyouare attempting this
yourself,ensureyouhaveallthenecessarytoolsandfittingstoaccomplishthistask.
Step6:Althoughtherearemanymethodsofinstallation,thismanualwillprovidearecommendedprocedureusing
copperplumbingandstandardsolderingmethods.CALMAGYORKSHIRELIMITEDrecommendstheuseofunions,a
bypass assembly and shutoff valves as this will allow you to isolate and remove the UV unitif necessary (this
method is a recommended method only however it allows for the maximum conveniencebut it requires extra
componentsandmoretimeforinstallation.PleaserefertoFigure3fortherecommendedinstallation.

Pag e
Installaon example
unit
connect
ASSEMBLED.
:
ring
installaon
:unit
unit ring unit
unit

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Step11:(AppliesonlyifyouhaveaUVsensor).TheUVsensorforthesystemispackagedinaseparateplastic
bag.Carefullyremove thesensor fromitspackaging andinsert thesensor intothe UVsensor port(remove the
protective cap on the UV unitfirst). The sensor canonly go in one way. Ensure that the flat portion of the UV
sensormatchesupwiththehalfmetalliponthesensorport(flatportionshouldfacethelampconnectionend)
(seeFigure5.).Ensurethatthesensorisfullyseatedinthesensorportandthentighten(turningclockwise)the
sensornut.PLEASENOTE:DONOTovertightenthenutasthiscoulddamagethePTFEsensorbody.Plugthemale
connectorintotheIEPportlocatedontherightsideofthecontroller,Figure 6,(makesurethecontrollerisnot
pluggedinasthesensorMUSTbeattachedbeforepowerisappliedtothecontroller.)
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Figure5.UVSensorInstallationFigure6.IEPConnection
Step12:Theunitisnowreadyforwaterflow.Whenallplumbingconnectionshavebeencompletedyoushould
checkforanypossibleleaks.Slowlyturnonthewatersupplyandcheckforleaks.Makesurethebypassvalvesare
functioningproperlyandthatthewaterisflowingthroughtheunit.ThemostcommonleakisfromtheOringnot
makingapropersealontheunit.Ifthisisthecaseturnthewateroff,draintheunit,removetheOring,dryitand
reapplysilicongrease.ReplaceOringensuringthatitisproperlysealedagainsttheunitandcheckagainforleaks.
Step13:Thecontrollercannowbemountedonthewall.Onboardmountedunitsthecontrollerisalreadyinthe
correctposition.Thecontrollershouldalwaysbeaboveorbesidetheunittoensurethatnomoisturecandeposit
onanyoftheconnections(seeFigure2.).Alwaysmountthecontrollervertically.Forsafetypurposesthecontroller
shouldbeconnectedtoagroundfaultcircuitinterrupter(GFCI)(alsoknownasagroundfaultinterrupter(GFI)).
ONBOARDMOUNTEDUNITSSTEPS14,15AND16HAVEBEENPREASSEMBLED.
Step14:YoucannowremovetheUVlampfromitspackagingbeingcarefulnottotouchthelampquartzwithyour
hands.Again,theuseofcottonglovesisrecommendedtoavoiddepositedoilsonthelampglass.Alwaysholdthe
lampbytheceramicends.Withthelampoutsideoftheunit,affixtheUVlamptothelampconnectorasshownin
Figure7.
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Figure7.UVLampConnection
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Step15:CarefullyinserttheUVlampintotheunitslidingitinsidethequartzsleevelocatedinsidetheunit(donot
dropthelampintotheunit).Affixtheconnectorintotheglandnutbyinsertingtheconnectorintothenutand
turningtheconnectorapproximately¼turntolocktheconnectortotheglandnut.
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Figure8.Connector
Step16:AffixthecaptivegroundscrewtothegroundlugontheUVunittoensurepropergroundingcontinuity.
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Figure9.GroundScrewConnection
Step17:YoursystemisnowreadytobepluggedintotheappropriateGFCIprotectedoutlet.Plugtheunitinand
refertothe“SystemDisinfection”sectionbeforeanywaterisallowedtoflowthroughthesystem.
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SystemDisinfection
Now that the system is installed you will need to disinfect the lines throughout the entire home or facility. To
accomplishthis,pleasefollowthesesimplesteps:
Step1:Beforeperformingthistask,checktomakesurethatthereareno“deadlegs”inthelinesthroughoutthe
homeasthesecanharbourbacteria.AlsoensurethattheUVsystemispoweredupandreadyforoperationbefore
youstartthisdisinfectionprocess.