Hydrotec HYDROWELL Compact E Series Operating instructions

Operating and Maintenance Manual
HYDROWELL®Compact E
Serial number: _____________________
HYDROTEC UK Ltd
Hydrotec House Telephone: [phone]
5 Manor Courtyard, Hughenden Avenue Fax: [phone]
High Wycombe, Bucks. HP13 5RE Website: www.hydrotec.co.uk
www.hydroteccontracts.co.uk

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Index
In the following overview you find all individual chapters listed. You will find detailed
information on respective first pages of the chapters.
Page number
Preface 3
Chapter IGeneral Information 7
Chapter II System Description / Technical Data 14
Chapter III Installation and Assembly 19
Chapter IV UV Monitor / Decommissioning 21
Chapter VInspection and Maintenance 26
Appendices 1 Installation Schematics 30
Appendices 2 Wiring Diagram 31
Appendices 3 Commissioning and Instruction Report 32
Appendices 4 Operating Log 33
Imprint 37

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Preface
Thank you for the purchase of our HydroWELL®UV disinfection system.
Our systems are constructed and manufactured with respect to and in consideration of all
current standards as well as further technical specifications and corresponds to the latest
state-of-the-art technology, allowing for maximum safety under all operating conditions.
System safety can only be assured if all necessary measures are taken beforehand. It is part
of the operator‘s diligence to plan and monitor such measures and implement them with due
care.
Special care should be taken with respect to hygiene during operation and maintenance
where the plant is used in the food industry.
The operation and maintenance manual includes important information necessary for the
correct and successful installation and operation. You should be familiar with all details prior
to operating the unit.
For any further information or if you are confronted with any problems, please contact our
service and technical staff.
Contact
Hydrotec (UK) Ltd
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks HP13 5RE
Tel.: [phone]
Fax: [phone]
email: s[email protected]

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In case you were
wondering where your
lamp/s are...
We kept them when
carrying out the pre-
delivery inspection to avoid
damage during transit and
will bring them along when
we commission the unit.
Please call us to arrange your free
commissioning within 6 months of shipping.
Hydrotec (UK) Ltd
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks HP13 5RE
Tel: [phone] Fax: [phone]
www.hydrotec.co.uk
email: [e-mail]

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NOTE!
A Hydrotec technician will make all
connections between the control box
and reactor and supply UV lamps when
the system is commissioned. If the unit
is to be connected to a BMS panel, this
is the responsibility of the BMS
installation technician. Connections to
BMS can be found within this manual in
the wiring diagram.
The control box is to be mounted within
the reach of cables the unit was
provided with! Under no circumstances
it is allowed to modify the cables in any
way!

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SAFETY WARNING
Very high intensity Ultra Violet light. Please read the following user instructions:
1. Under no circumstance look at Ultra Violet light with the naked eye.
Always wear the correctly rated protective UV glasses.
2. UV light can burn skin; protective clothing should be worn at all times.
3. Always switch the unit off at the control panel before removing lamp.
4. The UV should only be inspected by trained technician.
5. For sales or technical support please contact Hydrotec (UK) Ltd for more
information.
Hydrotec (UK) Ltd
Hydrotec House
5 Manor Courtyard, Hughenden Avenue
High Wycombe, Bucks HP13 5RE
Tel: [phone] Fax: [phone]
www.hydrotec.co.uk
email: servi[email protected]k

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Chapter I
General Information / Terms
1. Structure of this manual
You can find all important information for the operator of this system including:
• Safety information
• Technical data
• Information and instructions for: assembly
start-up
operation
maintenance
trouble shooting
The operation and maintenance manual together with all other technical information and documents
must always be kept readily accessible.
The O&M includes several chapters marked with roman numerals (see global index).
Information to the chapter content is always shown on the first page of each chapter.

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2. Safety information
2.1. General safety instructions
All declared safety instructions must be absolutely observed to prevent an endangerment of persons,
environment and the system itself. The following warning signs are included in this manual:
Warning signs:
Danger!
Adverse health effects or property damage may occur in case of non-
compliance!
Electric voltage!
Safety signs:
Wear an eye protection!
Wear suitable protective gloves!
Wear suitable protective clothing!

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2.2. Operator’s duty of care
The system is constructed and manufactured with respect to and in consideration of all current
standards as well as further technical specifications, and corresponds to the latest state-of-the-art
technology, allowing for maximum safety under all operating conditions.
System safety in operation can only be assured if all necessary measures are taken beforehand. It is
part of the operator’s diligence to plan and monitor such measures and implement them with due
care.
The operator must ensure that
-the system is used in accordance with the specified purpose.
-the system is maintained in a serviceable condition, with the safety facilities being monitored
for correct function in regular intervals.
-the operation and maintenance manual is always in a legible condition and available next to
the unit.
-the operation, maintenance and repair work is carried out by qualified and authorised
personnel only.
- all safety and warning information attached to the system must not be removed and must be
kept in a legible condition.
- the supplied log book must be kept up to date.
2.3. Appropriate use
The system is manufactured to the latest German technical safety standards employing the latest
state-of-the-art technology.
If incorrectly treated, not maintained properly at regular intervals or not used for the correct purpose
according to the specifications, the unit may incur risks and/or damage.
Operation of system shall only be within the technical parameters and limit values stated in chapter II.
The HYDROWELL unit is to be operated and maintained in good working order and according to the
specification it was designed for only.
Important! Any other use of the system, other than described, is deemed to be not in
accordance with the specification.
The manufacturer / supplier do not accept any liability resulting from the
improper use of the system. Such risks are borne by the operator alone.
All regulations and instructions in the operating and maintenance manual and
such regulations as are applicable locally must be strictly adhered to.
Any malfunctions must be corrected immediately.

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2.4. Basic safety measures
Prior to starting the system it must be ensured that:
-no one can suffer injury due to the system operation
-all safety facilities are in a perfectly serviceable condition
The system must be operated in good condition only. All faults must be notified to the person
responsible immediately after being noticed.
In order to avoid flooding of installation site, there is a drainage and / or leak
control with alarm to be provided locally.
Maintenance, repair and electrical work
-All inspection and maintenance intervals specified in this operation and maintenance
manual must be adhered to
-Prior to any repair work, the system must be disconnected from mains
-The system is to be depressurised prior any work on the system and shall be protected
from accidental restart
-Only suitable and correctly functioning load-supporting devices shall be used when
replacing heavy components or system elements
-Prior to any work on electrical components the system must be disconnected from the
mains
-Electric equipment must be checked in regular intervals
-Any possible loose connections must be re-secured and damaged electric wiring
must be replaced immediately
-Casings of electric equipment and system compounds must never be cleaned with
a water hose (spray)
-Electric components must never be touched with wet hands
-During work at the plant suitable and corresponding protective clothing is to be worn for
protection against UV radiation. Direct contact with UV radiation must be prevented.
•Protective goggles resistant against UV radiation
•Light-tight protective gloves
•Light-tight protective clothing

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Start-up after maintenance and repair work
-Check screw connections for tight fit
-Ensure that any components removed beforehand are installed and restored to their correct
operational position
-It is to be ensured that all materials, tools and other appliances which were necessary for
maintenance and repair work are removed from the working area of the system
-Any liquid that has leaked is to be removed
-Ensure that all safety equipment is in a perfectly serviceable condition
Regulations in respect of environmental protection
When working on and with the system, all legal regulations in respect of waste minimisation and
proper disposal (if appropriate) must be observed and respected.
The elements listed below in particular must not be allowed to contaminate the soil or enter the
drainage system during installation, maintenance and repair work:
-Grease and lubrication oils
-Hydraulic oils
-Cooling agents
-Acids and alkalis (bases)
-Disinfection agents
Such substances must be stored, transported and collected in suitable tanks and
disposed of in accordance with the applicable regulations!

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2.5. Risks in the event of safety instructions being disregarded
The consequences of disregarding safety instructions can be dangerous to the system,
material and personnel, and the loss of any warranty claims.
We shall accept no liability for possible water damage caused due to disregard of the safety
instructions.
3. Special safety instructions regarding to the UV disinfection system
Operator
- Only briefed and skilled personnel shall operate the system.
- Corresponding protective clothing (protective goggles, light-tight protective gloves and light-tight
protective suit) is to be provided for operating staff.
- Installation of system must only be carried out by a skilled companies.
After longer periods of inactivity, the system must be recommissioned according to instructions!
- The inspection and maintenance intervals must absolutely be observed!
Special dangers
- Risk of injuries to eyes and skin by direct, unprotected contact with high-
energy UV radiation!
Protective clothing shall be worn according to accident prevention regulations.
- Safety-related or functional changes to system are strictly forbidden!
Disregarding may result in damage and injury to staff or system!
Safety and monitoring facilities of the system
- The system is in permanent operation.
- A sufficient irradiation dose is continually provided and monitored due to the
application of an installed UV sensor.

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3. Warranty
Claims under warranty will only be accepted in the meaning of our General Conditions of Sale and
Supply subject to the following conditions:
- The system is used and operated in accordance with information and instructions in the
operation and maintenance manual
- The system is treated properly
- Repair work is to be carried out exclusively by authorised specialists
- Original spare parts or parts recommended by Hydrotec (UK) Ltd shall be used exclusively
- No modifications are carried out on the system by users themselves
- The stipulated operation parameters (pressures, flow volume, temperature) are maintained
- Start-up of the system has been carried out by our service personnel
- A yearly maintenance is carried out by our service personnel
Excluded from warranty claim are all parts subject to wear and tear such as:
- All seals, radiators, filters etc.
Warranty claims cannot be accepted in cases of:
- Operation and installation errors
- Faulty maintenance
- Deliberate damage or negligent handling
Any unauthorised modifications are not permitted for safety reasons. Original spare parts and
accessories are especially designed for the unit as described.
Original spare parts shall be used exclusively!
Important information for any queries and spare parts orders:
-Plant type (model number)
- Serial number
- Date of manufacture
- Site address / name

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Chapter II
System Description / Technical Data
UV systems
For disinfection of the water supplies a UV system should be installed. Ideally the HydroWELL®units
should be located in the incoming water main or after the site booster pump set where water storage
tanks are employed. The necessary radiation of 254 nm (wave length) is generated via application of
special mercury low-pressure UV lamps.
HydroWELL®Compact E systems comprise a high-quality stainless steel housing vessel. All
components are constructed and manufactured with respect to and in consideration of all current
standards as well as further technical specifications and corresponds to the latest state-of-the-art
technology.
HydroWELL®Compact E systems consist of the housing containing the UV lamp, with UV sensor to
monitor the transmission of UV light to ensure maximum exposure of the water within the housing and
a microprocessor control. For the most optimum monitoring of the unit performance a visual light
intensity display and NO or NC BMS contacts are available from the control box.
The unit has a doped quartz glass to prevent the formation of ozone and nitrate. An insert shim is
provided for the protection of the internal o-rings from the exposure to the UV light.
The unique flow path of the water should ensure shadow-free radiation of the water. HydroWELL®
unit is flow directed and the inlet pipe is on the same side with the sensor and water will exit the unit
via outlet pipe on the opposite side.
Designs:
UV sensor
Fault message
HydroWELL®
Compact 2E
YES
YES
HydroWELL®
Compact 5E
YES
YES
HydroWELL®
Compact 10E (7/16000)
YES
YES
HydroWELL®
Compact 10E
YES
YES
Vertical installation of the UV housing vessel (in the horizontal pipeline) must be observed.
Water isolation valves should be fitted either side of the unit. If site require continuous water
supply to the building during maintenance works and no down time is required, then a suitable
by-pass should be fitted. By-pass should be suitably arranged to minimise dead legs.
Minimum of 500mm clearance above the unit is required for lamp exchange and cleaning
purposes. If a UV unit is to be installed around a booster pump set, it must be sited on the
outlet side of that pump. Some level of water flow through the UV chamber is required at all
times. This is to ensure that the UV lamp doesn’t overheat.
Suitable pre-filtration unit should be installed prior of the UV unit to minimize the level of
particulates in the water that may cause shadowing.

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Technical Data
Type
HydroWELL®
Compact 2E
HydroWELL®
Compact 5E
HydroWELL®
Compact 10E
(7/16000)
HydroWELL®
Compact 10E
Approval
WRAS
Flow rate at:
400 J/m2(40 mJ/cm2) [l/s]
0.8
1.25
2.00
2.57
300 J/m2(30 mJ/cm2) [l/s]
1.12
1.75
2.8
3.62
250 J/m2(25 mJ/cm2) [l/s]
1.28
2.0
3.2
4.14
Water temperature (°C)
5 - 50
5 - 30
5 - 50
Ambient temperature (°C)
max. 30
Reactor
Nominal size
R 1”
R 1½”
R 2”
R 2”
Connection
External thread (BSP)
Length A(mm)
275
275
275
275
Depth B(mm)
90
115
140
140
Height C(mm)
600
700
790
790
Gap D(mm)
> 500
Pressure drop (bar)
< 0.1
Operating pressure (bar)
16
Material
Stainless Steel 1.4571 (316Ti)
Weight empty (ca. kg)
5
8
13.5
13.5
Power supply
Electrical connection
230V, 50Hz
Height (mm)
305
305
305
305
Width (mm)
330
330
330
330
Depth (mm)
170
170
170
170
Power consumption (W)
60
100
130
130
Casing
Plastic with inspection glass
Protection class
IP 54
UV lamp
Type
Mercury low pressure with
indium-amalgam
Mercury low
pressure
Longlife
Mercury low
pressure with
indium-amalgam
Model
Ecolux 20N
Ecolux 30N
Ecolux PL95
Ecolux 40N
UV power (W) new
17
27
27
32
after 8000 operating hours
10
16
23
after 16000 operating hours
20

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Reactor
Dimensional drawing with parameters from technical data sheet

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UV sensor
Housing made of
stainless steel
Drain tap
Connection mains supply
Vent screw
Water outlet
Water inlet
Lamp head

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Control Box
Power switch
ON / OFF
UV monitor
Cable fittings

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Chapter III
Installation & Assembly
Installation
Vertical installation of the UV housing vessel (in the horizontal pipeline) must be observed.
Water isolation valves should be fitted either side of the unit. If site require continuous water
supply to the building during maintenance works and no down time is required, then a suitable
by-pass should be fitted. By-pass should be suitably arranged to minimise dead legs.
Minimum of 500mm clearance above the unit is required for lamp exchange and cleaning
purposes.
If a UV unit is to be installed around a booster pump set, it must be sited on the outlet side of
that pump.
Some level of water flow through the UV chamber is required at all times. This is to ensure that
the UV lamp doesn’t overheat.
Suitable pre-filtration unit should be installed prior of the UV unit to minimize the level of
particulates in the water that may cause shadowing.
There are flow directional arrows attached at the unit connections for the ease of installation.
Please ensure that there is sufficient space available under the drain valve for drainage.
Free space under the system shall be min. ca. 30 cm.
It is highly recommended that the unit operates and is powered up continuously, 24/7. Switching the
lamp on and off regularly can significantly reduce the life span of the lamp.
OUT
IN
DRAIN

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The related control must be mounted on a wall or a rigid surface. It shall be mounted on eye level and
next to the reactor, within the reach of cables provided. A permanent power connection via a
switchable fused spur (230V/1pH/50Hz; 5A) must be provided in close vicinity to the system.
ATTENTION:
Electrical connections must only be done by an authorised expert according to VDE
requirements! All works must be done only by authorised and instructed experts.