SALCOR 3G Instruction manual

SALCOR INC
P. O. Box 1090
Fallbrook, CA 92088-1090
Telephone: [phone]
Fax: [phone]
[e-mail]
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
UV DISINFECTION UNIT
MODEL 3G
Made
With
Pride in
the USA

SALCOR INC
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TWENTY-ONE SALCOR UV MODEL 3G 6-MONTH TESTS
Since 1997, Manufacturers of 21 Treatment Units Have Partnered with the
Salcor 3G UV Unit.Each Used the NSF Standard 40 and the Washington State
Fecal Coliform Reduction Protocol for 26 weeks. Salcor’s 3G UV Effluent Fecal
Coliform Count Ranged From 2 to 35 per 100 ml. (Geometric Mean).
The following is a list of the partnered manufacturers
Aero-Tech
AK Industries, Hydro Action
ANUA (Bord na Mona)
AquaKlear
Bio-Microbics, FAST
Clearstream
Consolidated Treatment Systems, EnviroGUARD
Consolidated Treatment Systems, MULTI-FLO
Consolidated Treatment Systems, NYADIC
Delta Environmental (Pentair), Whitewater
Delta Environmental (Pentair), ECOPOD
Ecological Tanks
Enviro-Flo (NuWater)
Fuji Clean USA
Hoot Aerobic Systems
Jet
Lowridge On Site Technologies
Norweco
Orenco Systems
Quanics
Solar Air

SALCOR INC
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I.INSTALLATION INSTRUCTIONS
WARNING! Improper Connection of the APPLIANCE GROUNDING
CONDUCTOR Can Result in the Risk of an Electric Shock.
Check with a qualified electrician or service representative if you are in doubt about
whether the appliance is properly grounded.
Open and carefully unpack the shipping carton. Check for any damage that may have
occurred in shipping. If there are any problems,call SALCOR INC. at 760-731-0745 or
Fax to SALCOR INC. at 760-731-2405 and explain the problem(s).
The following list describes the components that are contained in the shipping carton.
1. Disinfection chamber: 3-inch diameter ABS pipe with 4-inch inlet and outlet hubs.
2. Disinfection sub-assembly consisting of an anodized aluminum frame supporting a
Teflon®sheath containing a pure fused quartz tube.This complete item is packed
inside of the above listed 3-inch disinfection chamber.
3. Riser pipe: 4-inch diameter ABS pipe.
4. 1-inch white PVC handle which is used for inserting and removing the disinfection
sub-assembly. It is bubble-wrapped inside of the above listed 4-inch riser pipe.
5. The Long Life UV lamp is bubble-wrapped and packed inside of the 1-inch white
PVC handle.
6. Electrical sub-assembly junction box (rated NEMA 6P) with pre-wired alarm board,
electronic ballast, and the lamp cable supplying power to the UV lamp.
7. Two 4-inch Schedule 40 ABS pipe couplings.
8. Watertight connection for bringing the power and alarm wires into the junction box.
Flexible Watertight conduit should be used to connect to this fitting.
9. Dielectric Grease, to be used on the inside of the boot on the UV lamp socket.
There will be some additional items to be supplied by the installer
1. Teflon®tape for sealing PVC and Watertight connectors
2. ABS cement (also multipurpose cement if bonding to PVC pipe)
3. Isopropyl (rubbing) alcohol for cleaning the subassembly unit before installing
4. Glycerin (available from drug stores) for lubricating the gaskets of the subassembly
5. Power and Alarm Wires. Wire all circuits with insulation rated 600 VAC min.
6. Power and Alarm Wire Watertight Flexible Conduit for connecting to the Junction
Box watertight connector
7. Irrigation Valve Box if the 3G Unit is to be installed at or above ground
8. Silicon Adhesive Sealant, also called RTV
WARNING! This Device Produces Potentially Harmful UV Light.
Always Protect Your Eyes and Skin From Exposure to UV Light.
Disconnect Power Before Replacing or Servicing the 3G Unit/Lamp.

SALCOR INC
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SALCOR INC
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II. TWO INSTALLATION OPTIONS
1. In the Ground Installation:Couple the 4-inch inlet pipe to the exit pipe of the
pretreatment unit, and couple the 4-inch outlet pipe to the drain field pipe.
See Figure 2 (Page 5).
2. In a Pump Tank Installation: Couple the UV Unit inlet pipe to the pretreatment unit
exit pipe at the entrance of the pump tank. See Figure 3 (Page 5).
Note: Figure 2 (page 5) indicates that the electrical junction box should be placed at
ground level. The junction box could be placed below grade in an irrigation valve box.
The Junction box is rated NEMA 6P. However, for safe continuous operation, the
junction box should be protected from flooding.
For in-pump tank installations, special care should be taken to prevent flooding of the
junction box.
III. DETAILED INSTALLATION STEPS
1. Install the 3-inch disinfection chamber in place at the site.
a. Position the disinfection chamber in the ground or in the tank.
b. Connect the hubs to the inlet and outlet pipes.
3-Inch Disinfection Chamber
2. Cut the 4-inch riser pipe to meet the job needs. The 1-inch lamp handle may be cut to
length after cutting the riser pipe.
a. Use the 4-inch ABS inlet pipe connection to the pretreatment
unit as a reference point.
See Figure 1 (page 3).
b. The lamp handle upper end should be cut so it will be
approximately 6 inches from the top of the riser pipe.
c. Bond the 4-inch riser pipe to the chamber sub-assembly.
d. Bond the second PVC white threaded female adapter to the
top or plain end of the white PVC pipe handle.
White PVC Handle and
4-inch Riser Pipe
6
in.
Riser Pipe &
Lamp Handle

SALCOR INC
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3. Carefully slide the lamp cable through the top of the white 1-inch PVC pipe handle.
The lamp cable wire with the 4-pin lamp socket connector should extend out about 6
inches past the bottom end of the 1-inch white PVC handle which has a threaded
female pipe adapter already bonded to it.
Top End of PVC Handle with newly bonded adapter
Threaded Bottom End of PVC Handle
4. Carefully connect the 4-pin socket connector of the lamp cable to the UV lamp pins.
Note: the pins are not arranged in a square formation.
a. Apply Dielectric Grease to the inside of the boot.
b. Push the 4-pin socket onto the pins on the UV lamp end. Make sure that the
4-pin socket connector is fully connected onto the pins. The socket to lamp
pins connection is electrically critical to maintain the proper operation of the
lamp. It is extremely important that there is a fully mated complete
connection between the socket and the UV lamp pins.
Lamp connector
Pins are not
Arranged in
a square shape
CAUTION!! The UV Lamp, the Quartz Tube,and the Teflon® Sheath
Covering ARE ALL VERY FRAGILE, So Handle Them With Care.
5. Carefully slide the UV lamp into the quartz tube in the frame assembly. Make sure
that the UV lamp has BOTTOMED OUT in the Quartz Tube, that is, that the UV
lamp is FULLY SEATED in the Quartz Tube. Do not force the UV lamp into the
Quartz Tube, as UV Lamp may break the bottom of the Quartz Tube. Make sure that
the UV Lamp is completely enclosed in the Quartz Tube.
Apply Dielectric
Grease to the inside of
the boot.
Lamp Cord Connected
and Lamp Inserted
into the Aluminum
Frame.

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6. Wrap both ends of the threaded white PVC 1-inch lamp handle pipe pieces with
Teflon® tape.
a. First, screw the bottom threaded end of the 1-inch lamp
handle onto the top end of the aluminum frame assembly.
Tighten the Gland Nut
b. Second, screw the black threaded reducer into the top end of the handle pipe. It
is important that Teflon ® tape is used to seal all of the threads to maintain
waterproof operation of the lamp.
c. Pull Any Extra Cable up Through the Gland Nut.
d. Tighten the gland nut to approximately 22 in/lb to make the UV lamp chamber
watertight. CAUTION!! DO NOT OVER TIGHTEN!
7. Inspect the Teflon® sheath.
a. If necessary, use a clean soft cloth and isopropyl (rubbing)
alcohol to clean and remove any fingerprints from the Teflon®
sheath.
b. Lubricate the rubber gaskets with either water or glycerin.
Note: Do not use silicone or petroleum based lubricants on the gaskets.
PVC handle on the anodized aluminum frame assembly
8. Gently insert the entire frame/handle assembly into the riser/chamber assembly using
the white PVC handle. Make sure that the wide part of the sub-
assembly is at right anglesto the inlet and outlet pipes. The correct
rotational orientation of the frame in the disinfection chamber is
required for successful UV Unit operation. The frame must be at a right
angle to the incoming effluent.
9. Tuck the extra lamp cord wire into the top of the riser pipe.
10.Place the round coupling on the bottom of the junction box into the top of the 4-inch
riser pipe,and secure it with the setscrew.
Top of the
Aluminum Frame
Assembly
Pull Extra Cable up
Through the Gland Nut
Black Threaded
Reducer at the Top of
the Lamp Handle

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11.Install the Watertight Conduit connector to the side of the
Junction Box and secure it with the nut on the inside. Use a little
Silicone Adhesive Sealant, also called RTV, on the O-ring of the
watertight conduit connector to assist in waterproofing.
Installing Watertight Conduit Connector
12.Attention Installers!! The SALCOR Model 3G Unit requires a specific
separate independent 10-15-amp circuit breaker on the main electrical panel.
The Salcor UV Unit circuit breaker should be separate from the circuit
breakers for the pumps, etc.
No other electrical unit should be connected to the Salcor 3G Unit circuit
breaker.
13.The UV Unit operates on 120 VAC single-phase (50 or 60 Hz) power and consumes
40 watts.
14.Bring the power wires and alarm wires into the junction box via the waterproof
conduit connection. Seal the outside of the flexible conduit pipe to the waterproof
connector with Silicone Adhesive Sealant. The installer is responsible for ensuring
that the external flexible wire conduit connection(s) containing
the power and/or alarm wires to the junction box are
WATERTIGHT!!
Watertight Conduit Connector Nut Inside of the Junction Box
15.Attach the power and alarm wires to the appropriate terminal
block connections on the alarm board. See Figure 4 (Page 10).
The alarm contacts are compatible with external alarm circuit units furnished by
others that use either normally open (N/O) or normally closed (N/C) contacts. Note:
N/O means the contacts are OPEN when there is NO POWER to the alarm board
relay. The contacts are rated for up to 240 volts and up to 2 Amps. Select the common
connection terminal screw and then use either the N/C or N/O connection terminal
screw that complies with the external receiving alarm circuit requirement.
16.Attach the lid to the junction box with 4 screws.
17.Allow the effluent to start flowing through the 3G Unit.
18.Turn on the circuit breaker at the main electrical control panel. The Green Indicator
Light on the junction box lid should now be shining, indicating that the 3G Unit is
operating properly. The installation is now complete.
IV. MAINTENANCE AND SERVICE

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It is recommended that the disinfection sub-assembly be removed and
serviced (cleaned) a minimum of once per year to insure proper effluent
disinfection.
The Salcor Model 3G UV disinfection Unit is designed to provide a long service life;
It is recommended that the UV lamp be replaced every 2years to insure proper
disinfection.
UV LAMP REPLACEMENT PROCEDURE
1. Turn off the dedicated circuit breaker located on the main electrical control panel
that supplies power to the UV Unit.
2. Remove the electrical junction box from the 4-inch riser pipe by loosening the
junction box to riser pipe setscrew. Then carefully set the junction box aside.
3. Using the white PVC handle connected to the disinfection sub-assembly, lift the sub-
assembly out of the disinfection chamber/riser pipe and set it aside.
4. After pulling out the sub-assembly, check the disinfection chamber to make sure
there is no mud, debris, or other flow-impeding non-liquid material present at the
bottom of the disinfection chamber.
5. If there is non-liquid material present in the bottom of the disinfection chamber, use
a shop vacuum cleaner to vacuum out the excess material. Do not let the material
flow downstream.
6. Loosen the lamp cable cord grip at the top of the white PVC handle so that the lamp
cable can move through the cable grip and thus allow the handle to move away from
the top of the aluminum frame assembly.
7. Unscrew the bottom threaded end of the 1-inch white PVC handle from the upper
end of the aluminum frame assembly. Separate the handle from
the assembly.
8. Disconnect the four pin socket connector attaching the
lamp cable to the UV lamp. Remove the old UV lamp.
9. Use dielectric grease on the boot of the connector. Connect the 4-
pin socket connector to the new lamp.
Apply Dielectric Grease to the inside of the boot.
Lamp Cord Connected
Lamp Inserted into the Aluminum Frame
Make sure that the connector mates COMPLETELY onto the UV lamp pins.
10.Lower the new UV lamp into the quartz tube of the UV sub-assembly, making sure it
bottoms out in the quartz tube. Do not use force that would break the quartz tube.
11.Screw the bottom threaded end of the 1-inch lamp handle onto the upper end of the
aluminum frame assembly. Use Teflon®tape to ensure a waterproof connection.

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12.Using the white PVC handle, gently insert the entire frame/handle assembly into the
riser/chamber assembly. Make sure that the wide part of the sub-assembly is at right
angles to the inlet and outlet pipes.
13.Tuck the remaining lamp cable into the top of the riser pipe. Tighten all cord grips.
14.Put the junction box back onto the riser pipe. Tighten the setscrew.
15.Turn on the power to the UV Unit.
16.Check the green indicator light on the lid of the junction box for proper operation.
17.If the green indicator light is on, the installation procedure is finished.
TO CLEAN THE TEFLON®SHEATH AND DISINFECTION SUB-ASSEMBLY
1. Use a soft sponge and detergent to clean the surfaces, especially the Teflon®sheath.
Be careful when cleaning the Teflon®sheath, as it is Very Fragile.
2. Use a soft cloth with isopropyl alcohol to remove difficult stains such as finger prints
or other films from the Teflon®sheath.
V. ELECTRICAL CONNECTIONS ON THE ALARM BOARD
Grounding Post Power Inlet Terminal Block Alarm Wire Terminal Block
Figure 4
UV LAMP
BALLAST