CalUltra UV-CalUltra 12 User manual

Operaon & Installaon Instrucons
CalUltra UV - Standard Systems
Model Rated Flow
UV-CalUltra 12 12 lpm
UV-CalUltra 22 22 lpm
UV-CalUltra 41 41 lpm
UV-CalUltra 79 79 lpm
Remember don’t guess....ASK

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Congratulaons on purchasing this ultraviolet disinfecon system. By purchasing a CalUltra
UV Disinfecon system you are receiving not only a high quality product but also peace of
mind. Protecng your water supply with a UV system gives you reassurance that your family
will have access to safe drinking water throughout your enre home with no chance of
microbiological contaminaon. This is a chemical free process which is simple in its concept
and eecve in its abilies to inacvate microorganisms present in the water supply. Simple
maintenance, connuous disinfecon and ulmately safe water, CalUltra makes it that easy.

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TABLE OF CONTENTS
Safety Consideraons ......................................................................................................... 4
Before You Begin ................................................................................................................ 4
Water Quality Parameters .................................................................................................. 4
Parts List ............................................................................................................................. 6
System Sizing ...................................................................................................................... 7
Locaon .............................................................................................................................. 7
Installaon ......................................................................................................................... 8
System Disinfecon .......................................................................................................... 11
Cleaning the Quartz Sleeve .............................................................................................. 11
Cleaning the UV Sensor .................................................................................................... 12
Operaon ......................................................................................................................... 12
CalUltra Controllers ................................................................................................ 13
Power-up Sequence ............................................................................................... 13
Operaonal Screens (un-monitored version) ........................................................ 14
Lamp Countdown Sequence .................................................................................. 15
Lamp Replacement ................................................................................................ 15
QR Codes ............................................................................................................... 16
System Troubleshoong......................................................................................... 17
Temperature Management Devices ................................................................................. 19
Expansion Modules .......................................................................................................... 19
CalUltra UV Standard Output System Specicaons ........................................................ 21
Limited Warranty Statement: ........................................................................................... 22
Warranty Registraon ...................................................................................................... 23

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Safety Consideraons
Although your UV system has been manufactured to the highest safety standards, care must be
followed when operang and/or maintaining your system.
1. Before servicing this equipment, disconnect the power cord from the electrical outlet.
2. Energy given o by the UV lamp is harmful to your eyes and skin. NEVER look directly
at an illuminated UV lamp without adequate eye protecon and always protect your skin
from direct exposure to the UV light.
3. For complete disinfecon, use ONLY Calmag genuine replacement parts.
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 for service instrucons if required.
7. Do not use this system for any purpose other than what it was intended for. Misuse of this
system could potenally cause harm to the user or others.
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 disinfecon 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 potenal tripping hazards.
10. We recommend that a competant plumbing installer install the system.
Before You Begin
The following will be needed for installing the UV system:
Tools
• Pipe cuer, hacksaw or other specialized tools required to cut into your exisng
plumbing (e.g. if you have PEX piping)
• Soldering tools (torch, ux, emery cloth and solder)
• Correct sized spanners (for ghtening ngs)

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Other Materials
• Various pipe ngs
• PTFE tape
Water Quality parameters
UV disinfecon is extremely eecve 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 disinfecon.
Treated water should be tested for at the least the parameters listed below. If the water exceeds
the listed parameters Calmag strongly recommends that appropriate pretreatment equipment
be installed (equipment required will depend on parameters being treated):
Hardness: <120 ppm – if hardness level is 120 ppm or slightly below the quartz
sleeve must be cleaned periodically in order to ensure ecient UV
penetraon; if above the water must be soened.
Iron (Fe): <0.3 ppm
Manganese (Mn): <0.05 ppm
Turbidity: < 1 NTU
Tannins (organics): <0.1 ppm
UVT (transmiance): >85% (Please contact Calmag if water has a UVT that is less than
80% for pre-treatment recommendaons)
You can have your water tested at a private analycal laboratory or by your local council. It
is always recommended to install pre-ltraon of at least 5 microns prior to a CalUltra UV
disinfecon system. The CalUltra 12 and CalUltra 22 models are already provided with a pre-
lter. For other models, please contact Calmag for the appropriate lter housing and cartridge.

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Parts List
Unpack the system and ensure all the components are included with the system. Your system is
shipped with the following components that are pre-assembled:
CalUltra domesc units
CONTROLLER
GLOW PLUG
RC-B56.03-CM
300016 Complete Assembly
310026 Teon Plug
310040 O-Ring
390007 Brass Nut
GLAND NUT
O-RING
SLEEVE SPRING
QUARTZ SLEEVE
CHAMBER
UV LAMP
320006
310038
310039
LAMP KEY
Either
UV-SLEEVE-QS12 12 lpm
series or
UV-SLEEVE-QS22 22 lpm
series or
UV-SLEEVE-QS41 41 lpm
series or
UV-SLEEVE-QS79 79 lpm
series
Either
UV-BULB-B12 12 lpm
series or
UV-BULB-B22 22 lpm
series or
UV-BULB-B41 41 lpm
series or
UV-BULB-B79 79 lpm
series

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System Sizing
All CalUltra UV systems are rated for a specic ow rate in water that meets the quality parameters
on page 5. PLEASE NOTE that increasing the ow above this rang or disinfecng water that
does not meet the quality parameters will decrease the dose and therefore compromise the
microorganism inacvaon.
It is important to know the maximum ow rate that your water system delivers. If you do not
have this informaon, you can simply ll a 10 litre bucket with water from the mains supply and
tome how long it takes to ll up. This can then be calculated to litres per minute and the the
approriate Calmag UV unit should be chosen.
Locaon
Choose a locaon where the main cold water line is accessible. The system must be installed
aer other water treatment equipment (soener or lters), but before any branches (See Figure
1). Calmag recommends that a 5 micron lter be installed before the UV system for a nal
polishing step before the water is disinfected (included with the CalUltra 12 and CalUltra 22
models).
Figure 1. Example Installaon

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To facilitate lamp removal, ensure there is enough space at the lamp connector end to safely
remove the UV lamp and/or quartz sleeve (See Figure 2). The controller will require a ground
fault circuit interrupter (GFCI or GFI) outlet and should be mounted beside or above the
chamber. PLEASE NOTE: All CalUltra UV disinfecon systems are intended for indoor use only as
they should not be exposed to the elements.
Installaon
Step 1: The reactor can be installed either horizontally or ver-
cally using the clamps provided. Vercal installaon allows any air
that may be in the lines to be easily purged from the system.
Step 2: The use of a by-pass assembly is recommended as it will
allow you to isolate the UV unit. This will allow for easier access in
case maintenance is required (See Figure 3).
Step 3: Use appropriate xings to mount the UV unit.
Step 4: For water supplies where the maximum ow rate is un-
known, a ow restrictor is recommended so that the rated ow of
your parcular CalUltra system is not exceeded. The ow restrictor
should be installed on the outlet port of the unit.
Step 5: It is recommended to have a competent plumber connect
the UV unit to the water supply.
Figure 3. By-pass assembly
Figure 2. Lamp Removal
Spacing
leave at least
an additonal
reactor length
to facilitate
lamp and
sleeve removal
Note: Installaon of your
CalUltra disinfecon systems
should comply with applicable
regulaons. Please check if
unsure.

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ON PRE-BUILT UNITS STEPS 6 & 7 HAVE BEEN PRE-ASSEMBLED
Step 6: Once the system has been plumbed in, gently remove the
quartz sleeve from its packaging being careful not to touch the length
with your hands. The use of coon gloves is recommended for this
procedure as oils from the hands can leave residue on the sleeve
and lamp which can ulmately block the UV light from geng to the
water.
Carefully slide the sleeve into the reactor unl you can feel it hit the
opposite end of the reactor. Align the sleeve so it centered along the
length of the reactor, then gently push it in to lock it into the internal
centering springs in the far side of the reactor. CAUTION: Pushing
too hard when the sleeve is not aligned can damage the centering
springs. Slide the o-ring onto the sleeve unl it is bued up against
the reactor.
Figure 4. Quartz
Sleeve Installaon
Step 7: Hand ghten the provided gland nut over the quartz sleeve onto the threaded end of
the reactor. It has a posive stop to prevent over-ghtening. A rm force may be required to fully
ghten the gland nut, but DO NOT USE TOOLS for this step. Insert the provided stainless steel
compression spring into the quartz sleeve. The spring works with the lamp and lamp connector
to create the proper lamp alignment. PLEASE NOTE: DO NOT install a UV lamp inside the quartz
sleeve without the sleeve spring in place.
EXTRAS
Step 8: Install the UV sensor (oponal extra). Align the at poron so it faces the gland nut
end and matches up with the half metal lip on the sensor port (see Figure 5). Insert the sensor
so it is fully seated and hand ghten the sensor nut. If no sensor is being installed insert the glow
nut into the port.
Figure 5. UV Sensor Installaon Figure 6. IEP Connecon

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Step 9: The unit is now ready for water ow. When all plumbing connecons have been
completed, slowly turn on the water supply and check for leaks. Make sure the by-pass valves
are funconing properly and that the water is owing through the unit. The most common leak
is from the o-ring not making a proper seal on the unit. For new installaons, review steps 6 and
7. For older systems drain the unit, remove the o-ring, dry it and reapply silicon grease. Reinstall
the o-ring ensuring that it is properly sealed against the unit and check again for leaks.
Step 10: Mount the controller (if required) to the wall so it is above or beside the reactor to
ensure that no moisture can deposit on any of the connecons (see Figure 1). Always mount the
controller vercally. For sensor systems, insert the sensor connector into the IEP port located on
the right side of the controller (Figure 6). For the sensor to be recognized by the controller, the
controller power must be plugged in last. Do not plug the controller power cord in before the
last step.
ON PRE-BUILT UNITS STEPS 11 - 14 HAVE BEEN PRE-ASSEMBLED
Step 11: Always hold UV lamps by their ceramic ends, not by the lamp quartz. Remove the lamp
from its packaging. Again, the use of coon gloves is recommended. Remove the lamp key from
the lamp’s connector and set it aside for the next step. Be careful to not touch the key’s exposed
contacts. Insert the UV lamp into the reactor, being careful not to drop it.
Figure 7a. Standard Output UV
Lamp Connecon
Step 12: Install the lamp key into the controller. The key always comes packaged with the lamp
and sits on the connector. With the key removed from the lamp, orient it so the label is upright
and facing you. The key will plug into the lamp key port on the right side of the controller (Figure
8).
Step 13: Plug the lamp connector into the lamp. Note the keying for proper alignment (see
Figure 7). Insert the lamp connector into the gland nut and turn the connector approximately ¼
turn to lock the connector to the gland nut as in Figure 9.

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Figure 8. Lamp Key Installaon
Figure 9. Lamp Connector
Step 14: Tighten the capve ground screw to the ground lug on the UV reactor to ensure proper
grounding.
Figure 10. Ground Screw Connecon
Step 15: Your system is now ready to be plugged into the appropriate GFCI protected outlet.
Refer to the following secon before any water is allowed to ow through the system.
System Disinfecon
With a new installaon, or any me the UV system is shut down for service, without power, or is
inoperave for any other reason, the lines in the home or facility could be contaminated. Use the
following steps to fully disinfect the lines throughout the enre home or facility.
Step 1: Check for and remove any “dead legs” in the lines throughout the home as these can
harbor bacteria. Plug in the UV system and wait unl it is ready for operaon.
Step 2: Remove the lter cartridge from the lter housing and ll it with 1-2 cups of household
bleach (most are 5.25% chlorine). Replace the lter housing and slowly turn on the water supply.
Step 3: At a water outlet, run the water unl bleach can be smelled. Repeat this for all taps,
toilets, shower heads, refrigerators, outdoor taps, washing machine, dishwasher, etc. at the
home or facility. Once nished, wait a minumum of 30 minutes before connuing.

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Step 4: Reinstall the lter cartridge into the lter housing and ush the chlorine soluon by
opening all taps unl chlorine can no longer be detected. Your home has now been completely
disinfected with your CalUltra UV system ready to inacvate any microorganisms that enter the
home.
Cleaning the Quartz Sleeve
Depending on the water quality, the quartz sleeve may require periodic cleaning. At a minimum,
the quartz sleeve should be cleaned on an annual basis. The following steps outline a basic
cleaning procedure.
Step 1: If a by-pass assembly is installed, shut the inlet valve o to prevent water ow through
the system. Otherwise, turn o main water inlet valve (and/or turn o the water pump).
Step 2: Disconnect power cord of UV system from electrical outlet.
Step 3: Release water pressure by opening a downstream tap and then close the outlet shut-
o valve (if any). If there is no outlet shut-o valve, expect water to drain from the system as the
head pressure in the system will cause the water to ow back down.
Step 4: Remove the capve ground screw from the ground lug on the UV unit.
Step 5: Remove the lamp connector from the unit (gland nut) by pushing the lamp connector
in and turning it ¼ turn counter-clockwise. Disconnect the lamp connector from the lamp.
CAUTION: the lamp may be hot!
Step 6: Being careful to touch only the ceramic ends, remove the lamp out of the unit.
Step 7: Unscrew the gland nut from the unit exposing the end of the quartz sleeve.
Step 8: Remove the quartz sleeve and o-ring by gently twisng and pulling the quartz sleeve.
Step 9: Using a so, lint-free cloth or towel wipe the sleeve down using a commercial scale
cleaner. This removes scaling or iron deposits that may be on the outside of the quartz sleeve.
Be careful not to get any moisture or liquids inside of the sleeve.
Step 10: Dry the sleeve with separate cloth.
Step 11: Replace the o-ring and slide the sleeve back into the reactor following steps 7 and 8
from the installaon secon of the manual.
Cleaning the UV Sensor (if applicable)
Depending on the water quality, the UV sensor may require periodic cleaning. At a minimum,
the UV sensor should be cleaning on an annual basis. The following steps outline a basic clean-
ing procedure.

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Step 1: If a by-pass assembly is installed, shut the inlet valve o to prevent water ow through
the system. Otherwise, turn o main water inlet valve (and/or turn o the water pump).
Step 2: Disconnect power cord of UV system from electrical outlet.
Step 3: Release water pressure by opening a downstream tap and then close the outlet shut-
o valve (if any). If there is no outlet shut-o valve, expect water to drain from the system as the
head pressure in the system will cause the water to ow back down.
Step 4: Place something under the unit to catch any water that may come out of the unit
during the removal of the UV sensor.
Step 5: Unscrew (counterclockwise) sensor nut from the unit and pull the sensor slowly out of
the sensor port.
Step 6: Holding the sensor in your hand wipe the at poron (sensor face) of the sensor with
isopropyl alcohol using a clean lint-free cloth.
Step 7: Replace sensor following step 9 from the installaon secon of the manual.
Operaon
CalUltra systems come with a feature laden controller that incorporates both the lamp driver
(ballast) and control features in one water-ght case. Four main controllers are available for the
CalUltra systems (depending on your model). All four models feature a power factor corrected,
constant current lamp driver with a universal power input.
Please Note: While the display screen is red and the buzzer is sounding the water from the system
should NOT be consumed. If any water does pass through the system during this period, please
follow the disinfecon procedure as outlined in this manual before the water is consumed. Even
though they have a visual and audible warning built into the controller, a “normal” status screen
does not necessarily indicate that the water coming from this system is in fact potable (safe to
drink). These systems do not measure the level of disinfecon; they simply measure the “on-
o” status of the lamp. Please have your water checked for microbiological contaminants on a
regular basis.

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CalUltra Controllers
A full colour LCD screen provides the user with a detailed descripon of the
system’s performance in addion to providing any applicable fault messages
and system diagnoscs. The controllers used in both the un-monitored and
monitored systems are idencal. The dierence is that the monitored series
of products include a UV intensity monitor. All CalUltra controllers include
an “innite expandability port” located on the right side of the controller.
Simply plug in an oponal UV sensor module into the expandability port of a
CalUltra controller and the system will now monitor the UV intensity of the
system!
Power-up Sequence
On start up, the controller will run through a diagnosc start-up and the sequence will be
displayed as follows on the colour LCD:
Next, the controller checks for and inializes any oponal modules that may be aached to the
system.
UV Sensor
Module Check
OR
Solenoid
Module Check
OR
4-20 mA
Module Check
OR

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Ethernet
Module Check
OR
Remote Alarm
Module Check
OR
A nal module screen is displayed showing which specic modules were inialized.
The controller then displays the lamp opmizaon screen for 60 seconds to allow the lamp to
reach its opmum output. Finally, a nal “start-up complete” screen is displayed. The system will
now be ready to disinfect water ow.
all detected modules lamp reaching max output successful start-up
Operaonal Screens (standard product)
On systems without the UV monitor, the default screen shows the CalUltra Home Screen. At
any point during operaon the user is able to scroll through the CalUltra Home Screen, Lamp
life remaining, QR Code, Contact Info and Maintenance Parts screens by pressing the buon
located on the front of the controller.
Operaonal Screens (with UV monitor)
On systems with the UV monitor, the system will display the same screens as on the un-monitored
version except the UV Intensity replaces the home screen. The UV Intensity screen displays the
level of UV light detected by the sensor. UV intensity can be aected by poor water quality,
scaling on the quartz sleeve and/or sensor, lamp failure or lamp expiring. The following screens
show the UV Intensity dropping.

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Below 56%, the numbers and warning sign turn red and an audible chirp is given by the ballast
every 15 seconds. Below 51%, the screen is solid red and a constant audible alarm is given. This
alternates with a screen indicang “water may be unsafe for consumpon”. With the solenoid
module, the controller de-acvates the solenoid valve, shung o all water ow.
audible chirp every
15 seconds
audible chirp every
15 seconds
constant audible
alarm
cycles with red low
uv screen
Lamp Countdown Sequence
The system counts down the number of days unl a lamp change is required.
At thirty days remaining, the LED or display screen will change to a yellow cauon indicator.
At seven days remaining, the sytem will addionaly repeat an audible chirp. Past the zero day
threshold, the LED or display screen changes to solid red with a connuous buzzer.
At any point during this sequence, the audible chirp or alarm can be deferred for seven days
by holding the controller buon down for a period of ve seconds. The number of deferrals
used will be displayed as below. Once the deferral expires, the alarm will sound once again. The

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deferral can be repeated up to three mes. PLEASE NOTE: At any point aer lamp expiraon,
the water may be unsafe for consumpon and should not be consumed without another form
of disinfecon.
Lamp Replacement
Aer the lamp is expired, it must be replaced with the same part number as indicated on the
Maintenance Parts screen or on the label on the unit. With the system powered down, remove
and discard the lamp key from the controller. The replacement lamp is packaged with a lamp
key on the connector at the end of the lamp. Remove the key from the lamp and place it in the
controller. Refer to Installaon, starng with step 11 (page 10) for instrucons on installing the
new lamp.
QR Codes
A QR code (Quick Response code) is a matrix barcode rst designed for the
automove industry. Calmag uses the QR code to store a link to a specic
page on our website. Users with a camera phone equipped with the correct
reader applicaon can scan the image of the QR code and over a wireless
network connect to a Calmag web page in the phone’s browser. Calmag’s QR
webpage has informaon on how to purchase replacement components as
well as a helpful video directory on system servicing (i.e. How to change a UV
lamp or quartz sleeve). To access the QR code on the Calmag controller, press
the control buon unl the QR code screen appears.

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System Troubleshoong
Hard Alarms: The following give a constant audible alarm. If present, the solenoid valve is closed,
and the 4-20, remote alarm and ethernet modules transmit the alarm.
System Display Problem Resoluon
The system has detected
a problem with the
lamp.
Reset lamp protecon circuit
-unplug unit for 10 seconds.
Replace the lamp with the
part as indicated on the
silver label on the unit or
on the Maintenance parts
screen.
Although the lamp is
powered and visibly
illuminated, due to the
lamp’s age its UV output
is no longer sucient for
proper disinfecon.
Replace the lamp with the
part as indicated on the
silver label on the unit or
on the Maintenance parts
screen.
Low UV Intensity.
Remove and clean the
quartz sleeve and sensor.
Check water quality meets
requirements on page 5 and
add ltraon as required.
Replace lamp.
Wrong lamp or sensor
installed.
Replace component with
proper model as indicated.
The UV sensor is no
longer communicang
with the system.
Ensure all modules are
connected properly to the
system and to each other.
Modules can be tested
individually by plugging in
one at a me and cycling
power to the system.
Replace any module that is
not detected when plugged
directly into the controller.
A bad connecon has
been detected in the IEP
port.

19|Page
Missing or incorrect
lamp key.
Ensure the lamp key
(packed with the lamp, on
the connector) is installed.
Unplug and reinstall the
key. Ensure the key part
number matches Lamp on
Maintenance Parts screen.
So Alarms: The following remaining errors give a 15 second audible chirp only
System Display Problem Resoluon
The module indicated is
no longer communicat-
ing to with the system.
Ensure all modules are
connected properly to the
system and to each other.
Modules can be tested
individually by plugging in
one at a me and cycling
power to the system.
Replace any module that is
not detected when plugged
directly into the controller.
Warning: Aer any hard alarm, the home or facility should be disinfected. Follow the steps
under the “System Disinfecon” heading.
Boil Water Advisory: If any failure occurs on a CalUltra UV system, the water
must not be used for human consumpon unl the system is returned to a
safe operaonal mode. If the water is used for human consumpon during this
period, the water must be boiled (minimum 20 minutes at a full boil) prior to
consumpon.

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OPTIONAL EXTRAS
Temperature Management Devices
Your CalUltra UV system is designed to run connuously to ensure opmal disinfecon. However,
during periods when no water is drawn through the system, the energy from the disinfecon
process can cause the temperature of the water inside the chamber to rise. In extreme situaons
elevated water temperature or the uctuaon in temperature can lower the output of the UV
lamp. In these cases, or if the elevated water temperature is a nuisance, Calmag recommends
one of the following forms of temperature management devices.
Cooling Fan
Designed for use on the 20 gpm system, the fan runs connuously to cool the
water by forced convecon. The long-life fan is powered independently using a
compact modular power adapter that operates from 90-265V (47-63Hz). Contact
Calmag for details.
Temperature Relief Valve (TRV)
On reaching a higher temperature, the TRV is designed to drain a small amount
of water to allow fresh, cooler water to enter the system. The TRV works without
power and comes complete with 10’ of drain line. Contact Calmag for details.
Expansion Modules
CalUltra controllers incorporate an “Innite Expandability Port” (IEP) which allows for expansion
to the UV sensor and all other modules. Each module (including the sensor) comes with both a
male and female connecon. Connect any device to the controller and all subsequent devices
are then connected into the female end of last device added in a “daisy chain” conguraon.
The following oponal expansion modules are available for use on all CalUltra controllers.
Contact Calmag for further informaon.