CalMag CALULTRA 132 User manual

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CALULTRADISINFECTIONUNITS
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OWNERSMANUAL
Operation&InstallationInstructions
CALULTRA132
CALULTRA220
CALULTRA322
CALULTRA416
CALULTRA530
CALULTRA662
CALULTRA1500
CALULTRA2400
R
Reemmeemmbbeerr ddoonn’’tt gguueessss……....AASSKK
Calming troubled waters

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CongratulationsonpurchasingthisCALMAGYORKSHITELIMITED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 the water being
treated by this UV system is microbiologically safe without the addition of any potentially
harmfulchemicals.
This process is simple, effective and carries the lowest O&M costs of all the disinfection
processes.
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5
Assembly................................................................................................................................................Page6
SystemSizing.........................................................................................................................................Page7
Location.................................................................................................................................................Page7
Installation.............................................................................................................................................Page9
SystemDisinfection…………………………………………………………………………………………………………………………Page12
Cleaningquartzsleeve…………………………………………………………………………………………………………………….Page12
CleaningUVsensor………………………………………………………………………………………………………………………….Page13
Operation………………………………………………………………………………………………………………………………………..Page14
LampCountdown&Reset……………………………………………………………………………………………………………….Page16
FailureModes………………………………………………………………………………………………………………………………….Page16
CalUltraOptions………………………………………………………………………………………………………………………………Page17
WarrantyRegistration……………………………………………………………………………………………………………………..Page18
LimitedWarrantyStatement……………………………………………………………………………………………………………Page18
CALULTRASpecifications………………………………………………………………………………………………………………….Page20
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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.
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manufacturer’s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
themanufacturer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).
Please note that as the CALMAG commercial units are available in 230 volt only, special High
current GFCI’s (GFI’s) are required. These special GFCI’s can easily be obtained through an
electricalsupplyhouse,orarereadilyavailableformalocalspa/hottubsupplystoreastheyare
commonlyusedintheseapplications.
10. WerecommendthatacompetentplumberorcertifiedUVtechniciancarryouttheinstallation.
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BeforeYouBegin:
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Beforeyoubegin,you’ll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dependentonapplication/installation
•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 LTD strongly recommends that appropriate
pretreatmentequipmentbeinstalled(pretreatmentwilldependonparameterstargeted):
Hardness: <7GPG(120mg/L)–ifhardnesslevelis7GPG(grainspergallon)
orslightlybelowthequartzsleevemustbecleanedperiodicallyinordertoensureefficientUV
penetration;ifabovethewatermustbesoftened
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LTDifwaterhasaUVT
thatislessthan80%forpretreatmentrecommendations)
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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cansupplyprefiltersonallCommercialunitsrangingfromtheCALULTRA132totheCALULTRA
2400.
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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 outlined parameters are met. PLEASE NOTEthat unless a flow restrictor is part of the
installation,thesystemmaypassmorewaterthroughthesystemthanwhatthesystemisratedat.Ifthis
happens,thesystemmaybedeliveringaUVdoselevelthatisbelowwhatmaybeexpected.Asaresult,
themaximumflowasspecifiedintheequipmentspecificationsshouldbestrictlyadheredto(alowerflow
isnotaconcernasthedosewillincreaseduetoalongercontacttime).
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fromafaucetandtimehowlongittakestofill
up.Thiswillbethemaximumflowrateforthatparticularwatersystem.TheappropriateCalmagUVunit
shouldthenbechosen.
PLEASE NOTE:It is always better to oversize your UV system than to undersize. For example, if your
pumpdelivers190litresperminuteitisrecommendedtoinstalltheCALULTRA220UVunit.Therewillbe
occasionswhereyourhomeisusingwateratthepump’smaximumcapacity.
Location:
Step 1:Find a suitable location to mount the UV chamberand the accompanying control panel. In
choosingyourlocationensurethatthepanel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.The panelcan be upto 8 feetaway from thechamberoramaximumof5metersif
custom lamp cables are ordered (for an additional cost).  If you have any other water treatment
equipment,suchasasoftenerorwaterfilter,ensurethattheUVisthelastpieceoftreatmentequipment.
PLEASENOTE:AllCALMAGYORKSHIRELTDUVdisinfectionsystemsareintendedforindooruseonlyas
theyshouldnotbeexposedtotheelements.
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Step2:TherearetwodifferentCALULTRAcontrolpanels,dependingonwhichsystemispurchased.The
threesinglelampsystems(“35”,“55”and“85”series)useacontrolpanelthatis30.0x20.0x16.0cm
(11.8x7.9x6.3")insize(seeFigure2),whilethethreetwolampsystemsuseacontrolpanelthatis40.0
x30.0x16.0cm(15.8x11.8x6.3")insize(seeFigure3).
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Figure2.OneLampSystemsFigure3.TwoLampSystems
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Step3:Your UV systemincludes mounting hardwarefor the UV chamberand the control panel. If the
suppliedfastenersarenot compatiblewith thestructurein whichyou are mountingthe device,please
ensureyouusethecorrectfasteners.
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Step4:Tofacilitatelampremoval,ensurethereisenoughspaceatoneendtosafelyremovetheUVlamp
and/orquartzsleeve(aspaceequaltothelengthoftheunitwillsuffice)(seeFigure4).
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Figure4.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anyhotorcoldwaterlines.
Step2:CALMAGYORKSHIRELTDstronglyrecommendsthata5micronfilterbeinstalledbeforetheUV
systemforafinalpolishingstepbeforethewaterisdisinfected.
Step3:Thechambercanbeinstalledeitherhorizontallyorverticallyusingtheclampsprovided.
Step4:Ifyoudonotknowtheflowrateofthewatersupplyintheapplication,itisrecommendedthat
youuseaflowrestrictorsothattheratedflowofyourparticularCALULTRAsystemisnotexceededand
the UV dose is not compromised. The flow restrictor should be installed on the outlet port of the
chamber.
Step 5:It is strongly recommended to have a licensed plumber connect the UVchamberto the water
supply and may be a requirement depending on where you are located. 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 LTD
recommendstheuseofunions,abypassassemblyandshutoffvalvesasthiswillallowyoutoisolateand
remove the UV chamberif necessary (this is a recommended method only however it allows for the
maximumconveniencebutitrequiresextracomponentsandmoretimeforinstallation).
Step 7: Before you cut into the cold water line, measure and cut all piping as per the recommended
layout.Onceallthecomponentsareready,startbyinstallingthefemaleadaptersontotheportsofthe
chamber.Toensureaproperseal,theuseofPTFE™tapeisrecommendedonallthreadedconnections.
Step8:Nextsolderalltheassemblytogether,includingballvalvesandunionsandfinallyconnectedthe
bypassassemblytothecoldwaterfeedline(waterinandwaterout).
Step9:YoucannowgentlyremovethequartzsleevefromitspackagingbeingVERYcarefulnottotouch
thelengthwithyourhands.Theuseofcottongloves(notincluded)isrecommendedforthisprocedureas
oilsfromourhandscanleaveresidueonthesleeveandlampwhichcanultimatelyblocktheUVlightfrom
gettingtothewater.Inthepackage,youwillfindtwolubricatedOrings.
Step 10:Carefully slide the sleeve into the chamberuntil you can feel it hit the opposite end of the
chamber.Maneuverthesleevegentlyuntilitslidesthroughtheoppositeendofthechamber.Witha¼”
ofthesleevestickingouteachendofthechamberslideoneOringontoeachend.EnsurethateachO
ring is butted up against the chamber(see Figure 5). Assemble the bottom gland nut (the black nut
without the through hole) onto the threaded end of the chamberand tighten. The gland nuts have a
positivestoptoavoidovertightening,handtightenONLY.Next,assemblethetopglandnut(theblacknut
withthe throughhole) ontothethreaded endof the chamberandtighten.Slidetheprovidedstainless
steel compression spring inside the quartz sleeve. This spring simply sits in the bottom of the quartz
sleeveandworkswiththelampandconnectortocreatetheproperlampalignment.
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UV Sensor port
UV Chamber
UV Controller
UV Sensor
UV Sensor port
chamber
PTFE
chamber
chamber
chamber
chamberrin
chamber
leaks.
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