Ultraviolet Sysrtems Inc. Ultra UV2 User manual

1555 Detrick Ave. Deland, Florida 32724-2014
Toll Free: 1.866.649.5551 Phone: [phone]
[email protected] www.ultrvioletpools.com
Pool, Spa & Pond
Water Sanitizer 4BJ1
EPA Registered
#084221-AZ-001
INSTALLATION &
OPERATIONS MANUAL
IMPORTANT SAFETY INSTRUCTIONS: READ
COMPLETELY BEFORE PROCEEDING.
When using this electrical equipment, basic safety
precautions should always be followed, including the
following:
• Follow all applicable electrical codes.
•Turn off power at main source before making any electrical connections or servicing the unit.
•To reduce the risk of electric shock, injury or death disconnect unit from power supply
• Follow the instructions or risk of serious injury or death could occur!
UV EXPOSURE & PROTECTION:
UV-A and UV-B radiation can have adverse short and long term effects on the eyes and skin. Never
look directly at a UV lamp that is connected to a power source. Avoid UV skin exposure at all times.
WARNING
To Installers: Read and follow these
instructions. Give these instructions to the
facility owner to keep for future reference.
Follow all codes and regulations that apply to the design, installation and use
of suction outlet fittings.
NOTICE

2
PLEASE REVIEW THE OWNER’S MANUAL AND INSTALLATION GUIDE IN ITS ENTIRETY AND
HEED ALL SAFETY INFORMATION. Failure to follow these instructions and warnings can result in
DEATH OR SERIOUS INJURY.
DANGER DANGER indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING WARNING indicates a hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION CAUTION indicates a hazardous situation which,
if not avoided, could result in minor or moderate injury.
NOTICE NOTICE is used to address practices not related to physical
injury.
Signal Words and Symbols Used In This Manual
This Owner’s Manual and Installation Guide contains specific precautions and symbols to identify safety-
related information. You will find DANGER, CAUTION, WARNING and NOTICE symbols which require
special attention. Please read them carefully and follow these precautions as indicated! They will explain
how to avoid hazards that may endanger you or persons using or maintaining your pool or spa.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS

3
Tabl e of Contents
Welcome ............................................................................................................................................................................4
General Product Information.........................................................................................................................................4
Ultra UV2 System Sizing ...............................................................................................................................................4
Pond Sizing Considerations..........................................................................................................................................4
Pond Sizing Chart ............................................................................................................................................................5
Pool, Spa, Fountain, Water Feature and Water Fall Sizing Chart .....................................................................5
First Step In Starting Your Installation........................................................................................................................5
Locating The Ultra UV2 Unit.........................................................................................................................................6
Installing Inlet/Outlet Unions.........................................................................................................................................6
Mounting The UV Unit On A Solid Base...................................................................................................................6
Plumbing The Ultra UV2 Unit........................................................................................................................................6
Typi cal Plumbing Without and with b ypass ............................................................................................................7
Parallel Plumbing Without and with bypass ..........................................................................................................8
Multiple port Plumbing FOR 3 LAMP UNITS Without and with bypass .....................................................9
Gluing Piping To The UV Unit....................................................................................................................................10
Providing Electrical Power To The Ultra UV2 Unit...............................................................................................10
Electrical Bonding (Grounding)................................................................................................................................10
System Start-Up ........................................................................................................................................................... 11
Connecting Pressure Switch.....................................................................................................................................11
Water Chemical Balance ............................................................................................................................................11
Upgrading The Output Of The
Ultra UV2 Unit.................................................................................................................................................................11
Consumer Operating Instructions............................................................................................................................12
Quartz Tube Maintenance...........................................................................................................................................12
Scheduled UV Lamp(s) Replacement....................................................................................................................14
Lamp Replacement Procedure.................................................................................................................................14
Normal Operation .........................................................................................................................................................15
Bypass Operation ........................................................................................................................................................15
Winterization Of Your Ultra UV2 Unit .....................................................................................................................15
Troubleshooting .............................................................................................................................................................16
Ultra UV2 Part Numbers .............................................................................................................................................18

4
WELCOME
The Ultra UV2 unit is designed for use in swimming pools, spas, fountains, water features, waterfalls, fish
ponds and the like. It is not designed for use in potable (drinking) water installations. Use of this product
in applications other than those indicated above will void your warranty and could be harmful to your
health or the health of others.
GENERAL PRODUCT INFORMATION
Water circulates through the Ultra UV2 chamber and around the quartz tube where the UV-C lamp(s) (1
to 3 lamps depending on the model) are housed. The UV-C lamp emits a light wave spectrum (253.7 nm
wavelength) to immediately inactivate 99.9% of micro-organisms such as Crypto, Giardia, other single
celled waterborne microorganisms and algae which are resistant to chlorine. This provides a cleaner,
clearer swimming environment with zero harmful by-products and dramatically reduces the amount of
chlorine needed to maintain an adequate level of residual sanitizer. The Ultra UV2 unit has been sized to
produce these important UV rays in the same intensity as is required for Class A potable drinking water,
which is 30,000 micro watts/cm2 (30 mJ). Confirm the size unit your application needs by using the
sizing charts on page 5, to obtain the proper maximum system killing power.
Please note the minimum and maximum flow rates for each Ultra UV2 lamp configurations.
CAUTION DO NOT USE THIS UNIT FOR POTABLE (DRINKING)
WATER SANITATION.
ULTRA UV2 SYSTEM SIZING
In order to ensure that your Ultra UV2 unit functions with the proper water exposure time to achieve the
desired water sanitation, it is important to provide the proper water flow rate through the Ultra UV2 unit. If
water passes through the unit too quickly, the microorganism’s exposure time to the UV lamp(s) produced
rays will not be sufficient to obtain the desired rate of sanitation. Please note that the minimum
posted flow rate must be met or exceeded to ensure proper system performance. The water
flow rate through the UV unit is governed by the piping of your water vessel and the size and output of
your circulation pump. Consideration to the application for the UV unit must be determined. Fish ponds,
as an example, have different requirements than swimming pools, spas, water features, fountains, or
waterfalls, as noted elsewhere in this manual.
POND SIZING CONSIDERATIONS
Most fish pond experts agree that there is no simple or set formula for the sizing of circulation pumps and
UV systems for fish ponds. The best advice is to consult a fish pond expert to determine what the flow
rate for your pond should be, and use the appropriate sized Ultra UV2 for that flow rate see “Fig. 1” on
page 5.

5
FIRST STEP IN STARTING YOUR INSTALLATION
Inspect the Ultra UV2 unit for damage, paying close attention to
the quartz tube.
NOTICE
POND SIZING CHART
Fig. 1
See Chart Below.
Ultra UV2 Part Number
Minimum
Flow Rate
(GPM) /
(m3/hr)
Maximum
Flow Rate
(GPM) /
(m3/hr)
Max Pond
Volume
2 Hr.
Turnover
(GPM) /
(m3/hr)
Max Pond
Volume
3 Hr.
Turn o v er
(GPM) /
(m3/hr)
Minimum
Operating
Pressure
(psi) / (bar)
Maximum
Operating
Pressure
(psi) / (bar)
004-422-2025-00
230V w/ 1 UV-C Lamp
004-422-2021-00
120V w/ 1 UV-C Lamp
10 / 2.27 46 / 10.4 5520 /
20.9
8280 /
31.3 5 / .345 50 / 3.45
004-422-2026-00
230V w/ 2 UV-C Lamps
004-422-2022-00
120V w/ 2 UV-C Lamps
20 / 4.54 80 / 18.2 9600 /
36.3
14400 /
54.5 5 / .345 50 / 3.45
004-422-2027-00
230V w/ 3 UV-C Lamps
004-422-2023-00
120V w/ 3 UV-C Lamps
*30 / 6.81 *130 /
*29.5
15600 /
59.1
23400 /
88.6 5 / .345 50 / 3.45
All capacities are nominal. Note: Multiple Ultra UV2 units installed in parallel can be used for flow rates
beyond those specified herein. (See page 9)
* Header size should be 2½” or 3” and split to two 2” pipe headers at the inlet and outlet connections.
(See page 10)
POOL, SPA, FOUNTAIN, WATER FEATURE AND WATER FALL SIZING CHART
Fig. 2 Swimming pools and similar water vessels are simple to calculate. See chart below.
Ultra UV2 Part Number
Minimum
Flow Rate
(GPM) /
(m3/hr)
Maximum
Flow Rate
(GPM) /
(m3/hr)
Max
Pool Volume
12 Hr.
Turn o v er
(Gallons) /
(m3/hr)
Max
Pool Volume
8 Hr.
Turn o v er
(Gallons) /
(m3/hr)
Minimum
Operating
Pressure
(psi) / (bar)
Maximum
Operating
Pressure
(psi) / (bar)
004-422-2025-00
230V w/ 1 UV-C Lamp
004-422-2021-00
120V w/ 1 UV-C Lamp
10 / 2.27 46 / 10.4 33120 /
125.4
22080 /
83.6 5 / .345 50 / 3.45
004-422-2026-00
230V w/ 2 UV-C Lamps
004-422-2022-00
120V w/ 2 UV-C Lamps
20 / 4.54 80 / 18.2 57600 /
218.0
38400 /
145.4 5 / .345 50 / 3.45
004-422-2027-00
230V w/ 3 UV-C Lamps
004-422-2023-00
120V w/ 3 UV-C Lamps
*30 / 6.81 *130 /
*29.5
93600 /
354.3
62400 /
236.2 5 / .345 50 / 3.45
All capacities are nominal Note: Multiple Ultra UV2 units installed in parallel can be used for flow rates
beyond those specified herein. (See page 9)
* Header size should be 2½" or 3" and split to two 2" pipe headers at the inlet and outlet connections.
(See page 10)

6
LOCATING THE ULTRA UV2 UNIT
Your unit can be installed indoors or
outdoors. When considering the location
for your Ultra UV2 unit, keep it close to your
power source. Check the silver product
label for the voltage of the unit. The Ultra
UV2 unit will need to be powered from
either a 120V/15A/50/60Hz or 230
V/15A/50/60Hz electrical circuit (which
MUST match the unit power requirement
noted on the silver product label on the
Ultra UV2 unit). DO NOT CONNECT TO
ELECTRICAL POWER NOT SPECIFIED
FOR YOUR UNIT. Plug in units must be
installed on a GFCI outlet. The GFCI must
be outdoor rated if installed outdoors. 230V
Ultra UV2 units can be wired for 120V or
230V.
NOTICE
DO NOT CUT OFF the plug from the 120V Ultra UV2 units
and hardwire it. This does not meet the U.L. installation
method and voids the U.L. listing.
MOUNTING THE UV UNIT ON A SOLID BASE
Before you make the permanent plumbing connections be sure the ULTRA UV2 unit is on a solid level
base making sure your plumbing connections align. After making your plumbing connections, anchor the
unit to the base using the four ¼” mounting holes. FAILURE TO PROPERLY SECURE THE UNIT
MAY CAUSE NOISE OR VIBRATION.
INSTALLING INLET/OUTLET UNIONS
The Ultra UV2 unit comes with female socket glue-in inlets and outlet openings. ABS to PVC
multipurpose glue and appropriate primer must be used to glue fittings into the ULTRA UV2 body. The
4 outlets (top) and 4 inlets (bottom) provide the most versatile piping alternatives for the installer. The
ULTRA UV2 unit comes with (2) unions (See page 19 for part numbers). Multiple inlets and outlets can
be used to the manage higher flow rates of 3 lamp units.
NOTE: The use of multiple inlets/outlets will require additional unions. Use the plugs provided with the
Ultra UV2 in the unused inlets and outlets. To install the unions onto the Ultra UV2 unit, glue and insert
the unions spigot end into the inlet and outlet opening selected. Then, using the six plugs provided, glue
the plugs into the remaining unused plumbing openings. Hand tightening the union nuts until snug is
sufficient. DO NOT OVER TIGHTEN. Over tightening may break the molded plastic parts of the unions.
Once you are confident that you have installed the inlet and outlet union halves successfully, you will be
ready to glue your plumbing into the union sockets once the Ultra UV2 unit is positioned on the mounting
surface. A 24 hour cure time is required before pressure can be applied to the Ultra UV2 unit.
Fig. 3
Power
Requirement

7
PLUMBING THE ULTRA UV2 UNIT
All plumbing methods are illustrated with and without the bypass option. Your Ultra UV2 unit will need
to be plumbed into the circulation system. The Ultra UV2 unit must be installed directly after the
filter. Installing a bypass is not recommended. The only reasons for installing an Ultra UV2 bypass:
1. To allow for removal of the UV unit, while still allowing the system to operate with water flowing through
the bypass. 2. If system pressure testing above 50 psi is required (max Ultra UV2 pressure is 50 psi/ 3.45
bar). The acceptable reasons for removal include winterization, servicing, off site repairs and replacement.
If a bypass is required it must be installed & operated per instructions on pages 9 - 10.
Before bypassing the Ultra UV2 for removal, turn off all pumps and allow the pool system’s pressure to
drop to zero.
AN IMPROPERLY USED BYPASS INSTALLATION MAY NOT MEET THE
MINIMUM REQUIRED FLOW RATE AND COULD POTENTIALLY DAMAGE
THE ULTRA UV2 UNIT.
Do not plumb the Ultra UV2 with a bypass unless absolutely
needed. Failure to follow the instructions can result in damage
to the Ultra UV2 that is not covered by the warranty.
NOTICE
Turn o ff the power at th e main source befor e disconnect ing or
connecting the Ultra UV2.
DANGER

8
TYPICAL PLUMBING WITHOUT AND WITH BYPASS
The inlet(s) is at the bottom of the unit and the outlet(s) at the top. The maximum operating pressure for
the Ultra UV2 is 50 PSI / 3.45 BAR. The minimum operating pressure is 5 PSI / .345 BAR. Please refer
to the silver label on the unit for max. operating pressure.
Filter
Pump
Without bypass (RECOMMENDED)
Fig. 4
Filter
To Heater
or Pool
Outlet Fully
Opened
Inlet Fully
Opened
Bypass
Fully
Closed
Pump
With bypass
Fig. 5
Installing An Optional Flow Switch If The Top Of The Unit Is Below Water Level
The pressure switch will always be on if the Ultra UV2 unit is plumbed below water level. To prevent damage
to the unit and its surroundings an optional flow switch must be installed. If the Ultra UV2 unit is plumbed on
a bypass, the optional 2 inch Flow Switch (part #004-402-0010-00 for 220v or part #004-421-3824-00 for
120v), must be on the outlet side of the Ultra UV2 unit and plumbed after the two way valve and before the tee
into the return line. Please refer to the instructions supplied with the flow switch for plumbing and wiring.
Flow Switch
Filter
To Heater
or Pool
Pump
No bypass with optional flow switch
Fig. 6
Filter
To Heater
or Pool
Pump
Flow Switch Outlet Fully
Opened
Inlet Fully
Opened
Bypass
Fully
Closed
Bypass with optional flow switch
Fig. 7

9
PARALLEL PLUMBING WITHOUT AND WITH BYPASS
Plumbing Ultra UV2 units in parallel for large bodies of water with high flow rates.
Without bypass (Recommended)
Fig. 8
Filter
To Heater
or Pool
Pump
With bypass
Fig. 9
Filter
To Heater
or Pool
Pump
Outlet Fully
Opened
Inlet
Fully
Opened
Inlet
Fully
Opened
Bypass
Fully
Closed
Installing An Optional Flow Switch If The Top Of The Unit Is Below Water Level
The pressure switch will always be on if the Ultra UV2 unit is plumbed below water level. To prevent damage
to the unit and its surroundings an optional flow switch must be installed. If the Ultra UV2 unit is plumbed on
a bypass, the optional 2 inch Flow Switch (part #004-402-0010-00 for 220v or part #004-421-3824-00 for
120v), must be on the outlet side of the Ultra UV2 unit and plumbed after the two way valve and before the tee
into the return line. Please refer to the instructions supplied with the flow switch for plumbing and wiring.
Filter
To Heater
or Pool
Pump
Flow Switch
No bypass with optional flow switch
Fig. 10
Filter
To Heater
or Pool
Pump
Flow Switch
Outlet Fully
Opened
Inlet
Fully
Opened
Inlet
Fully
Opened
Bypass
Fully
Closed
Bypass with optional flow switch
Fig. 11
Pump Filter
To Heater
or Pool
Inlett
Fully
Opened
Inlet
Fully
Opened
Outlet Fully
Opened
Bypass Fully
Closed
Pump Filter
To Heater
or Pool

10
MULTIPLE PORT PLUMBING FOR 3 LAMP UNITS WITHOUT AND WITH BYPASS
See figures 12 through 15. Ultra UV2 3 lamp units require 2 inlets and 2 outlets be plumbed, see page 5.
Without bypass (Recommended)
Fig. 12
Pump Filter
To Heater
or Pool
OUTIN
OUT
IN
2" PLUMBING2½" OR 3" PLUMBING 2½" OR 3" PLUMBING
With bypass
Fig. 13
Outlet Fully
Opened
Bypass Fully Closed
In Normal Operation
Pump Filter
To Heater
or Pool
OUTIN
OUT
IN
2" PLUMBING2½" OR 3" PLUMBING 2½" OR 3" PLUMBING
Installing An Optional Flow Switch If The Top Of The Unit Is Below Water Level
The pressure switch will always be on if the Ultra UV2 unit is plumbed below water level. To prevent damage
to the unit and its surroundings an optional flow switch must be installed. If the Ultra UV2 unit is plumbed on
a bypass, the optional 2 inch Flow Switch (part #004-402-0010-00 for 220v or part #004-421-3824-00 for
120v), must be on the outlet side of the Ultra UV2 unit and plumbed after the two way valve and before the tee
into the return line. Please refer to the instructions supplied with the flow switch for plumbing and wiring.
Pump Filter
To Heater
or Pool
OUTIN
OUT
IN
Flow
Switch
2" PLUMBING2½" OR 3" PLUMBING 2½" OR 3" PLUMBING
No bypass with optional flow switch
Fig.14
Outlet Fully
Opened
Pump Filter
To Heater
or Pool
Bypass Fully Closed
In Normal Operation
OUTIN
OUT
IN
Flow
Switch
2" PLUMBING2½" OR 3" PLUMBING 2½" OR 3" PLUMBING
Bypass with optional flow switch
Fig. 15