Assembly and operating

instructions

Ultraaqua Standard Multilamp UV-Systems:

MRX-220 SS/PP series
MRX-350 SS/PP series
MRX-440 SS/PP series
MRX-220 SS ULU Multilamp

Closed pressurized reactors and open channel systems

Please carefully read this manual before attempting

to install UV system. Keep this manual in a safe
place for future reference.

The operator shall be liable for any damage caused

by installation or operating errors!
Technical changes reserved.
Copyright
All rights reserved. The rights for this manual are owned by Ultraaqua A/S, and are protected by copyright
laws and international treaty provisions. You may not remove the copyright notice from any copy of the
written materials.
No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, electronic, mechanical, or otherwise, without the prior written permission of Ultraaqua A/S. You
may make one archival copy of this manual, provided that you reproduce the copyright notice.

Publication number: Manual LP Multilamp STD series 0117

Note:
Although every effort has been made to ensure that this manual provides up-to-date information, please
note that ULTRAAQUA UV-specifications are subject to change without notice. Ultraaqua A/S shall not be
liable for the accuracy of any information provided by third party technical support personnel, or any
damage caused, either directly or indirectly, by acts taken or omissions made by you as a result of such
technical support.

© Copyright Ultraaqua A/S 2017.

Ultraaqua A/S
Tarmvej 7
DK-9220 Aalborg O
Denmark

Email: ultraaqua@ultraaqua.com
www.ultraaqua.com

2
1. Safety information

This UV-system is equipped with extremely powerful UV-lamps. They

will also be harmful to your health. Do not expose eyes or skin to direct
radiation

Never look into light source through quartz sleeves or sensor windows

To avoid fire, electric shock and personal injury do not expose electric
parts to rain or moist

Accumulation of solids or air inside reactor chamber will reduce

efficiency and may cause damage to the reactor or lamp bank

All closed reactors must be installed in such a way that air can’t
accumulate. Installation with continuous air bleeding is recommended

3
 To protect against overheating this UV-unit must be installed with an
automatic shut-off mechanism for water flows less than 1000 L/hour

TEST THOROUGHLY

Condensing or corrosive ambient air will destroy electrical components

and void warranty
(Completely sealed control cabinets are optional)

4
Always observe the safety regulations applicable in your country to reduce the risk of fire, electric shock
and personal injury.

▪ Warning: Protect against electric shock.

▪ Read all safety instructions before attempting to operate this product.
▪ The unit must be connected to a grounded main outlet.
▪ Unplug the product before servicing and when cleaning.
▪ Place the unit on a strong, stable surface.
▪ Do not install the unit within an area subject to traffic. The power cables are sensitive and might be
damaged.
▪ Do not dismantle the electronic cabinet. Dismantling the cabinet or modifying the connections
inside the cabinet may result in electric shock or burn.
▪ Call for service if needed.
▪ Ultraviolet light can be very harmful to your health. Do not expose your eyes or skin to direct
radiation for longer periods of time. Never look directly into the light source.
▪ Only operate the UV lamp when it is fully fitted and installed.
▪ Place UV-warning label on the outer surface of the reactor top. Make sure it is clearly visible.
▪ The UV-unit must be emptied for water when installing the quartz sleeves. Otherwise the water
pressure will force the sleeves upwards.
▪ Before servicing, turn off the power supply to control cabinet.
▪ Before servicing eliminate hydraulic pressure by switching off pumps, closing relevant valves and
finally open drain valve on reactor. Otherwise water pressure may force the quartz sleeves
upwards during dismantling.
▪ Do not exceed specified rated water pressure.
▪ The electronic cabinet should be held locked and only opened by qualified personnel.
▪ The UV-unit must be turned off if the water flow is stopped for more than five minutes to avoid
unintended overheating.
▪ The power supply for the unit should be protected by PFI
▪ The operator is liable for damage caused by installation and operating errors!
▪ The system may only be used in accordance with the technical data and specifications outlined in
the operating instructions!
▪ Any other use or modification of the system is prohibited.
▪ The system may only be operated by trained and authorized personnel!
▪ It is essential that the information in the operating instructions relating to the unit's service life is
observed!
▪ The system is intended solely for the treatment of water.

▪ In the event of an emergency, switch the main switch on the side of the control cabinet to OFF or
disconnect from the mains power supply.

5
Contents
1. Safety information ................................................................................................................................... 3
2. Introduction ............................................................................................................................................. 7
2.1. Initial checking of the system .......................................................................................................... 7
3. Function .................................................................................................................................................. 7
3.1. Disinfection principle ....................................................................................................................... 7
3.2. UV dose ........................................................................................................................................... 7
3.3. Information in the event of an emergency ....................................................................................... 8
4. Installation of reactor units, general requirements ................................................................................. 8
4.1. Installation location .......................................................................................................................... 8
5. Open channel reactor units .................................................................................................................... 8
5.1. PP and stainless steel open channel reactor - mid channel installation ....................................... 10
5.2. Open channel reactor - wall mount installation ............................................................................. 11
5.3. Installation of PP and stainless steel closed pressurized reactors ............................................... 13
6. Reactor temperature control. Open channel systems and closed vessel systems. ............................ 14
7. Installing quartz sleeves and UV-lamps - all systems .......................................................................... 15
8. Installing control cabinet - all systems .................................................................................................. 16
8.1. Alarm and running signal output ................................................................................................... 17
8.2. Input for external control................................................................................................................ 18
8.3. Input for external “enable” control function (ENA-ENA) ................................................................ 18
9. Control panel - all systems ................................................................................................................... 19
9.1. Start up .......................................................................................................................................... 19
9.2. Control panel menus ..................................................................................................................... 19
9.2.1. Stand by ................................................................................................................................ 19
9.2.2. Main menu ............................................................................................................................. 20
9.2.3. System state .......................................................................................................................... 20
9.2.4. Setup menus ......................................................................................................................... 21
9.2.5. UV-sensor calibration ............................................................................................................ 23
9.2.6. Alarms ................................................................................................................................... 23
9.2.7. Replace lamps ....................................................................................................................... 23
10. Optional UV sensor ........................................................................................................................... 24
10.1. Sensor failures and calibration .................................................................................................. 24
10.2. Sensor window, manual cleaning.............................................................................................. 24
11. Maintenance ...................................................................................................................................... 25
11.1. Daily........................................................................................................................................... 26
11.2. Every Three Months .................................................................................................................. 26
11.3. Every Year ................................................................................................................................. 26
12. Faults ................................................................................................................................................. 27
12.1. Removal of glass and broken lamps from a closed reactor ...................................................... 27
12.2. System faults ............................................................................................................................. 27
12.3. Lamp faults ................................................................................................................................ 27
12.4. Quartz sleeve faults ................................................................................................................... 28
12.5. Lamp driver faults ...................................................................................................................... 29
12.5.1. Lamp driver address selector ................................................................................................ 30
12.5.2. Lamp driver LED status indicators ........................................................................................ 31
12.5.3. Lamp driver fan ..................................................................................................................... 31
13. Fault messages ................................................................................................................................. 31
13.1. Control panel alarm messages with alarm output (alarm relay) ............................................... 31
13.2. Control panel messages - no output ......................................................................................... 32
13.3. Poor disinfection performance .................................................................................................. 32
13.4. Reactor faults ............................................................................................................................ 33
13.5. Lamp faults ................................................................................................................................ 33
13.6. Quartz sleeve faults ................................................................................................................... 33
6
 13.7. UV sensor faults ........................................................................................................................ 33
13.8. Control cabinet faults................................................................................................................. 34
13.9. Lamp driver fault ........................................................................................................................ 34
14. EU Declaration of Conformity ............................................................................................................ 35
15. Electrical wiring diagram ................................................................................................................... 36
16. Installation check list ......................................................................................................................... 37

2. Introduction
We thank you for choosing the world’s most efficient UV-system. Design and dimensioning have been
based upon numerous tests, screening of every relevant scientific publication and lots of experiences from
several hundred ULTRAAQUA UV-systems installed worldwide.

This manual explains the precautions, specifications, installation and operation of your ULTRAAQUA UV
equipment. Please read through this manual, as it will help you get the most out of your new ULTRAAQUA
UV.

2.1. Initial checking of the system

Unpack your ULTRAAQUA UV-system. Make sure all components are free from damages. Take pictures
and contact your distributor immediately if damages are observed.

Please use the installation check list (last page in this manual) when installing the system.

3. Function

3.1. Disinfection principle

This UV system utilizes the short wavelength of UV that is harmful to microorganisms. It is effective in
destroying the nucleic acids in these organisms so that their DNA is disrupted by the UV radiation. This
removes their reproductive capabilities and kills them. As long as permissible flow rates are not exceeded
this system creates a deadly effect on micro-organisms such as pathogens, viruses and molds that are
found in aqueous environments.

Larger particles, such as flocs of bacteria, must be disintegrated or removed by direct filtration before UV
radiation.

If in doubt, please contact your distributor regarding required pre-filtration and recommended max flow rate
for your application.

All UltraAqua systems are supplied fully wired and factory tested before shipping. Installation is simple, but
if questions arise, please do not hesitate to contact ULTRAAQUA (www.ultraaqua.com) or your distributor.
The water to be treated flows through the reactor chamber past the UV lamps. The UV radiation inactivates
the microorganisms.

The low pressure high output UV lamps generate a very high level of UV radiation, which is particularly
effective for the treatment of water. The UV lamp is located in a lamp protection sleeve made of high-grade
quartz.

The reactor is hydraulically optimized to get an even distribution of irradiation to the flow of water.

3.2. UV dose
If water transmittance, UVT, and water flow rate is as specified in the design and sizing phase and if proper
maintenance is performed, UV-dose will be as calculated.

7
However, an optional UV intensity sensor will help monitoring UV-system performance. Please note that
UV-sensors are not optional for channel mount systems.

The UV-sensor continuously monitors lamp output. It is positioned in the reactor wall. Monitored irradiance
is therefore strongly influenced by water transmittance.

- Please note that following ignition, the UV lamps need several minutes until they reach operating
temperature!

The UV-system has a potential free relay denoted “RUNNING SIGNAL”. This relay is normally open. The
relay will close when the RUNNING SIGNAL DELAY" time has passed after ignition of lamps. Use this
relay to delay water flow until UV-lamps are running at max intensity.

Warm up times are as follows:

• 220W lamps: 2 min.
• 350W lamps: 3 min.
• 440W lamps: 5 min.

All main alarms will cause the system to go into alarm state. ALARM relay will come on, while the
RUNNING SIGNAL DELAY relay will go off.

All UV lamps are continuously monitored to ensure that they operate optimally. If a UV lamp fails, the
system will go into fault mode.

3.3. Information in the event of an emergency

In the event of an emergency, switch the main switch on the side of the control cabinet to OFF or
disconnect from the mains power supply.

4. Installation of reactor units, general requirements

Installation of both open channel reactors and closed pressurized reactors are described in the following.
Choose relevant chapter

4.1. Installation location

Make sure that:

• There is space for service work. Make sure it is possible to remove and re-install UV-lamps and
quartz sleeves. For channel systems that it is possible to lift up lamp frames.
• Air bubbles don't accumulate in closed reactors
• Sand, soil etc don’t settle in channel UV lamp-frames
• The installation location is dry and frost-free
• The protection of the UV system from chemicals, dyes and vapour is guaranteed
• The ambient temperature and the radiation temperature in the direct vicinity of the system may not
exceed 35 °C (Higher temperatures are possible for systems delivered with optional thermal
control)
• Control cabinet is protected against exposure to direct sunlight and rain.

5. Open channel reactor units

Channel reactor frames can be installed in different ways. In below drawing various examples
are shown. Installation principle must be determined when ordering the system. It may be difficult to
change afterwards and additional costs may apply.

Contact ULTRAAQUA or qualified distributor in order to determine optimal configuration.

8
9
5.1. PP and stainless steel open channel reactor - mid channel installation
Water can flow through the lamp frames in two ways. Using guide plates along with the lamps (below left)
or across the UV-lamps (below right). Disinfection efficacy is highest when water passes along the lamps,
however head loss will increase. For one or two lamp frames, it is generally recommended always to let
water flow along with lamps. For a high number of frames disinfection efficacy is not significantly lower
than when water passes across the UV-lamps. For systems with water flowing across lamps it is strongly
recommended always to install a perforated plate to ensure homogenous flow distribution. Optimal flow
pattern depends on application. If in doubt always contact ULTRAAQUA representative for determination
of optimal flow pattern.

Before installation identify minimum and maximum water level. Make sure that max water level can’t
exceed top of reactor frame and that UV-lamps are fully submerged at all times during operation. Check
channel width is as specified.

Please note that with reservoirs upstream water may accumulate in a downstream channel or reservoir
when flow is stopped.

Mount provided guide rails on channel walls

making sure they are completely aligned. Carefully
slide down lamp frames. Frames must be
positioned with alternate sideway displacement of
UV-lamps.

10
The supplied self-adhesive warning labels should be attached to the radiation chamber so that they are
clearly visible.

IMPORTANT!
The installation must be done in such a way, that it is absolutely impossible for any person to be directly
exposed to UV-rays. Shield reservoir/channel properly.

Fix lamp and sensor cables in such a way that it is possible to lift up lamp frames for service operations.

5.2. Open channel reactor - wall mount installation

Identify minimum and maximum water level. Make sure that max water level can't exceed top of reactor
frame and that UV-lamps are fully submerged at all times during operation.

Please note that water may accumulate in the channel or reservoir when flow is stopped.

Depending on water flow orientation, mount the steel bar as shown in below figure.
using M8x20 bolts and washers. Steel bar must be at the bottom when rails is mounted on the wall.

Inlet/outlet wall conduit at water Inlet/outlet wall conduit at reactor

surface frame bottom

It is very important that max/min water levels are identified so that mounting of rail plate is done in the
correct level. Make sure that water level is above UV-lamps at all times during operation.

11
Carefully slide down lamp frames. Frames must be positioned with alternate sideway displacement of UV-
lamps.

IMPORTANT!
The installation must be done in such a way, that it is absolutely impossible for any person to be directly
exposed to UV-rays. Shield reservoir/channel properly.

The supplied self-adhesive warning labels should be attached to the radiation chamber so that they are
clearly visible.

The reactor frames must be grounded properly.

Fix lamp and sensor cables in such a way that it is possible to lift up lamp frames for service operations.

12
5.3. Installation of PP and stainless steel closed pressurized reactors
It is recommended to install the unit horizontally with inlet/outlet connections pointing upwards. This is to
avoid accumulation of air in the reactor. Always check that air does not accumulate as a result of up- or
downstream piping layout.

At vertical installation, choose upper connection for outlet.

VERTICAL PLACEMENT HORISONTAL PLACEMENT

Max 2 meter

Max 1,5 meter

Relief Furnishing

In vertical installation reactors always requires continuous air bleeding. Use ¼” plug in reactor top. If
possible, water from air bleeding should be guided back to an open reservoir upstream the pump.

In horizontal installations, if inlets/outlets are pointing downwards, ½” drainage valve can be used for
continuous air bleeding. New drainage valve mounted in connecting pipe is then required. If inlet/outlets
are pointing upwards in the horizontal installation, air bleeding is not necessary unless examination of
downstream pipeline reveals that air may accumulate in UV-reactor.

Make sure that:

▪ Reactor chamber can be emptied for service work
▪ UV-lamps and quartz-sleeves can be replaced.
▪ Necessary precautions are taken in the event of flooding due to quartz sleeve
breakage.

Reactor chamber must be properly supported to avoid possible vibration during operation.

Optional stainless steel base with adaptable feet can be used for vertical installation (PP reactors only).

Use UV-resistant materials for up and down stream piping. If PVC is used, it is highly likely that the PVC
will discolour and may become brittle in the area of the connection.

Provide valves upstream and downstream of the radiation chamber to shut off the reactor for maintenance
work and consider to install valves upstream and downstream of the reactor to allow for microbiological
sampling.

The supplied self-adhesive warning labels should be attached to the radiation chamber so that they are
clearly visible.

Stainless steel reactors must be grounded properly. Mount earth grounding cable on the reactor using
provided M6 bolt and anti-reverse washer (only steel reactors).

It is strongly recommended that the UV-system is pressure tested before UV-lamps are installed and that
temperature protection has been tested.

13
6. Reactor temperature control. Open channel systems and
closed vessel systems.
The temperature sensor must be mounted in the reactor top plate. Remember, to tighten sensor
connections firmly.

To avoid heat damage, the unit will automatically shut down if temperature exceeds recommended limit
(35ºC PP reactors, 50 ºC SS reactors). Automatic start-up will begin, when the temperature has fallen app.
5 °C (only if automatic restart after alarm has been enabled in the setup menu, see control chapter).

Please note that vital parts or the complete reactor will be destroyed if the UV-system is operated with an
air-filled reactor. As soon as max reactor temperature is exceeded (35ºC PP reactors, 50 ºC SS reactors),
an alarm signal is displayed, and the system turns off automatically. If auto startup after alarm has been
enabled, the system will automatically start up after reactor temperature has decreased to 30ºC.

In open channel systems, quartz sleeves must be completely submerged when lamps are powered.

It is advisable to set the temperature limits as low as possible in order to reduce heat damages in the event
of heat accumulation.

The temperature sensor is placed on the reactor top, remember to connect

sensor cable.

Danfoss stainless steel type PT100 is used for stainless steel reactors.
Mount sensor plug and tighten screw firmly to make connector water proof.

Wire type PT100 temperature sensor used for PP (polypropylene) reactors.

For PP reactors, it is very important that the temperature sensor cable gland
is firmly tightened to make sure that the sensor head is positioned in the
bottom of the measuring hole.

14
7. Installing quartz sleeves and UV-lamps - all systems

Most systems are supplied with installed quartz sleeves. Please check that all quartz sleeves are in good
condition and that hand grip nuts are firmly tightened.

IMPORTANT!
Always depressurize reactor before commencing service work. There is a risk of serious injuries. Quartz
sleeves or pieces of broken quartz sleeve can be blown out of the reactor.

IMPORTANT!
Always use cut-protection gloves when handling quartz sleeves.

IMPORTANT!
Quartz sleeve hand grip nuts must be re-tightened after 2-4 weeks of operation!

Empty the reactor or lift up the lamp frames. It is almost impossible to install quartz-sleeves when
submerged in water. Gently insert the quartz sleeve through the top holes and into the bottom steer. A light
downward pressure is required for the quartz sleeve bottom to pass the rubber liner placed inside the
bottom steer. Make sure that the quartz sleeve is positioned into the corresponding bottom steer. Grease
the quartz sleeve O-ring with a very small amount of pure silicon grease. Position O-ring and tighten the
knurled quartz hand grip nut by hand only.

IMPORTANT!
To protect the bottom of the quartz sleeve, a supplied 24 mm silicon ball (220w and 350W lamp series) or
metal spring (440W series) must be inserted before UV-lamp.

Loosen the hand grip plug cable gland so that the cable can be adjusted to the length of the UV-lamp.
Insert the UV-lamp into the quartz sleeve without touching it with your bare hands. Use paper or gloves.
Before the lamp is fully inserted connect the cable plug to the lamp. Tighten the cable gland firmly after
adjusting cable length.

If lamps have become stained they should be cleaned with a cloth soaked in methylated spirit.

15
When reinstalling the UV-lamps it is important to make sure that the lamp wires (connecting far end with
connection end) are positioned so that they don’t block UV-light in the direction of the UV-sensors (option).

Check cable gland is tightened.

8. Installing control cabinet - all systems

An authorized electrical engineer must carry out the electrical installation. Follow generally applicable
guidelines and local installation regulations. Only carry out installation work on the UV system if it is
disconnected from the mains power supply.
The control cabinet should be fitted to the wall or a suitable frame in such a way that UV lamps,
temperature sensor and the optional UV sensor can be connected using the respective cables. The cables
can be shortened, but may not be lengthened. Please, contact your distributor if longer cables are needed.
The cabinet needs grounding for safety reasons and stable operation.

IMPORTANT!

To avoid fire, electric shock and personal injury do not expose electric
parts to rain or moist

Saline aerosols and condensing ambient air will destroy electrical

components and void warranty

(completely sealed control cabinets are optional)

The cabinet must be mounted at a dry and cool (max 35C) place with good ventilation. The cabinet must
not be exposed to direct sunlight. It is very important to make sure that the cabinet cooling air inlet and
exhaust is free. If the air is not free from significant amounts of dust, saline aerosols or it is condensing, the
cabinets must be equipped with non-ventilating climate control.

16
PLEASE NOTE

Make sure that all cables have enough

length to reach reactor unit. For channel
systems, it must be checked that the lamp
bank can be lowered to correct operating
position as well as being lifted up for
service operations.

Always connect the protective earth

conductor to the radiation chamber (steel
reactors, only).

Please see chapter “Input/output signals”

for correct wiring of output signals
(warnings and operation) and external
control.

8.1. Alarm and running signal output

For external information on system performance two potential free relays are located in the cabinet. One
relay is for alarms and the other is for the running signal. The latter will not come on before:

System starts to ignite the lamps and “Running signal delay” time has passed (set in the setup menu).

The alarm relay will come on in the event of:

▪ Too high reactor temperature

▪ Lamp fault
▪ Lamp driver fault

Max. loading for both relays are 230 VAC/1000 watt.

Please see, faults section for more information on alarm issues.

17
8.2. Input for external control
The UV-system can be started and stopped externally if a connection is made to a potential free relay (e.g.
another PLC-system). In the cabinet two contacts are marked “external control”. Wires connecting to an
external potential free relay must be mounted for remote control.

The UV will ignite the lamps if:

• The two terminals in the cabinet are connected.

• Remote control is selected in the setup menu.

The lamps will turn off when this connection is stopped.

Please note that the “ON”/”OFF” buttons on the main screen is replaced by a “REMOTE CONTROL”
button when the system is in remote control mode. Pressing the “REMOTE CONTROL” button will enable
manual lamp control.

The UV-unit must be powered (i.e. the main switch in on-position). When externally controlled, it is possible
to manually turn off the UV-lamps on the PLC panel by selecting manual control in the setup and then
pressing ”OFF”.

In emergency situations, switch off the UV-system using the main switch.

NOTE!
When controlling externally it is recommended also to connect to the alarm and running signal. Doing so
system will know if lamps have been unintended switched off manually or due to an alarm situation. After
an alarm situation, fault state must be reset manually on the panel and a remote "lamps OFF" signal sent,
before lamps can be re-ignited be a remote "lamps ON" signal.

Wiring principle for external control is illustrated below

Outside cabinet
ALARM

COM
RUN

ON
ON

8.3. Input for external “enable” control function (ENA-ENA)

Enable signal may be used for safety related control of lamp on/off switching. A potential free relay such as
a water level switch can be used. When the switch is OFF lamps will automatically switch off and the
following screen is displayed.

18
The UV system is delivered default with a short wire closing the enable circuit. Remove this wire to install
external control.

In the setup, a delay can be applied to both on and off. This is useful if there is a risk that the connected
switch will open and close repeatedly with short intervals, like a level switch affected by waves.

9. Control panel - all systems

9.1. Start up
Check the following:

▪ UV-lamps have been plugged.

▪ PT100 sensor is connected and in place.
▪ Grounding cable has been mounted on reactor (steel reactors, only)
▪ Channel system UV-frames have been completely installed
▪ Water is flowing and that no water leakage can be observed at the quartz sleeve o-rings.
▪ Quartz sleeves are dry inside before start-up. Condensate may develop inside a sleeve when
lamps have been turned off for a longer period.

The UV-system is powered by turning the main switch to its “ON” position. You may check that no red
diodes are lit on any of the lamp drivers.

The cabinet has one digital display and blue diodes representing each UV-lamp. The blue diodes will only
come on if corresponding UV-lamps are switched on and electrical parameters are within acceptable limits.
The lamp driver continuously analyses electrical data for each lamp in order to determine if the lamp
performs correct.

9.2. Control panel menus

The display screen is used to control and setup the system.

9.2.1. Stand by
Turning the main switch into it ON-position will power the system. The following will be displayed.

If the system was left in remote control (setup menu) the display will also show REMOTE CONTROL. In
this mode, the system will switch on the lamps by a remote signal. Change to local control can be done in
the setup menu.

19
9.2.2. Main menu
If the “READY” screen is touched the following main menus will be displayed when systems are in local
control mode and remote control mode, respectively:

BACK – button:
Display will return to previous screen

SETUP – button:
First setup menu screen will be displayed.

ALARMS – button:
Alarm screen will be displayed.

REPLACE LAMPS – button.

This button is used to reset hour counter after lamp replacement.

ON – button:
Will switch on UV-lamps.

OFF – Button:
Will switch off UV-lamps.

REMOTE CONTROL: Is not a button.

Will be displayed instead of ON-OFF buttons when remote control is selected in the setup.

9.2.3. System state

When lamps have been switched on locally or by the remote input, the following screen will be displayed.
POWER LEVEL is selected in the setup menu. LAMP LIFE TIME must be checked regularly in order to
replace lamps before disinfection efficiency is reduced. Press the screen to return to main menu.

If optional UV SENSOR is installed: Measured UV intensity is displayed below POWER LEVEL. Sensor
settings are found in the SETUP menu.

Each blue diode represent a UV-lamp. The blue diodes will only be lit if the corresponding UV-lamp is
switched on and electrical parameters are within acceptable limits. The lamp driver continuously analyses
electrical data for each lamp in order to determine if the lamp performs correct.

20
9.2.4. Setup menus
Pressing the MAIN MENU setup button will open the first setup screen.

POWER LEVEL SETPOINT: Intensity of the UV-lamps can be dimmed down to 70% if e.g. the water flow
is significantly reduced.

REMOTE CONTROL: If NO is selected, the lamps can be switched on and of locally in the main menu. If
YES is selected, lamps will be switched on and off by the external signal. Please see chapter “External
Control”. To switch of UV-lamps in an emergency situation turn main cabinet switch.

RESTART AFTER ALARM: Lamps will automatically be switched OFF if reactor temperature is too high. If
YES is selected, lamps will automatically switch ON when reactor temperature has decreased. NO is
strongly recommended in order to identify temporary alarm situations.

RUNNING SIGNAL DELAY: The UV-lamps will need 2-5 min to heat up before max intensity is reached.
The running signal can be used for delayed opening of valves or pump starts allowing lamps to reach full
disinfection capacity before enabling flow. See below table for warm up times.

Water temperature Water temperature Lamp warm up

Lamp type Lamp life time
generally < 25 C generally > 25 C time

220W LAMP ID = 27 LAMP ID = 26 2 min 16000 H

350W LAMP ID = 17 LAMP ID = 16 2 min 16000 H
440W LAMP ID = 35 LAMP ID = 34 5 min 12000 H

SETUP 2/4 (no UV-sensor):

SETUP 2/5 (with optional UV sensor:

LAMP LIFE TIME: See above table.

21
SETUP 3/4 (no UV-sensor):
SETUP 3/5 (with optional UV sensor:

TEMPERATURE [°C]: Current reactor temperature.

TEMP. ALARM [°C]:. Factory setting is 35ºC equivalent to max setting for PP reactor based systems. 50
ºC can be used for SS reactor based systems. It is recommended to set these values as low as possible to
avoid unintended fouling of sleeves.

TEMP PRE-ALARM [°C]: Factory setting is 30ºC

SETUP 4/4 (no UV-sensor):

SETUP 4/5 (with optional UV sensor:

The UV system is delivered default with a short wire closing the enable circuit. Remove this wire to install
external control.

OFF DELAY [SEC]: Delay time before switching off UV-lamps when connection between ENA terminals
are broken,

ON DELAY [SEC]: Delay time before switching on UV-lamps when connection between ENA terminals are
re-establihed,

SETUP 5/5 (will only appear if system is equipped with optional UV sensor):

PRE-ALARM LEVEL: Normally 50-70% is selected.

ALARM LEVEL: Normally 30-50% is selected.

SET REF:

UV-sensor reference level setting.

22
ACTUAL%-VALUE: Shows current UV-sensor level relative to value at last reference setting.

REFERENCE %-VALUE: With representative water quality, clean sensor port and quartz sleeves, choose
110% for completely new and unused lamps. Should be set to 100% for lamps with up to 100 operating
hours.

SENSOR OUTPUT [W/m2]: Sensor output raw value in W/m 2.

Press SET REF when ready to store new reference value:

Confirm storing of new reference value.

9.2.5. UV-sensor calibration

Calibration of UV-sensors is done bi-annually by sending the sensor to ULTRAAQUA. Sensor output
drifting varies depending on operating conditions. Sensor replacement should be considered every 4-6
years.

9.2.6. Alarms
Pressing ALARMS menu will show list of active alarms. If AUTOMATIC RESTART AFTER ALARM is not
enabled, faults must be reset before start up is possible. RESET FAULT must be pressed after lamp or
lamp driver faults.

9.2.7. Replace lamps

If the REPLACE LAMPS button is pressed the following will be displayed. Press OK and CONFIRM if
lamps have been replaced. Lamp life time hour counter will be reset to lamp life time.

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10. Optional UV sensor

Warning UV rays!

If the UV sensor(s) is removed, harmful UV radiation will be emitted from the sensor window(s). There is a
risk of irreversible damage to the skin and eyes.

The UV sensor may only be operated with components that have been approved for use by the
manufacturer (UV lamps, lamp protective tubes, UV sensors, etc.). Optimal disinfection can otherwise not
be guaranteed.

The UV sensor are installed in accordance ¨with Önorm and DVGW worksheet W 294.

Maintenance of the UV sensor system includes the following tasks.

• Sensor should be checked with a reference radiometer bi-annually.

• Cleaning of the sensor window is required. Determine necessary cleaning interval.

10.1. Sensor failures and calibration

Designated protective gear must be worn when checking and recalibrating the UV sensor (goggles and
gloves etc.)

A reference radiometer approved by Önorm/DVGW cant be used for checking the UV sensor.
(contact your distributor or ULTRAAQUA.

UV lamps must have been switched on for app. 30 min before starting sensor calibration.

If fogging of the sensor window is to be expected, then a lint free paper cloth is required as well as a pair of
tweezers in order to remove the moisture from the sensor window.

Go to the UV-sensor menu to change calibration value.

10.2. Sensor window, manual cleaning

Disconnect the system from the mains power supply or switch off the main switch prior to commencing
maintenance work on the system. Make sure reactor is completely depressurized and that reactor has
been drained.

Remove UV sensor by unscrewing the nut. No tools are required. Take out UV sensor. Don’t touch sensor
head. Protect it from water splashes. Remove sensor housing by use of a spanner. Clean the sensor
housing window by use of a soft cloth.Check O-ring for damage and grease with silicon grease.Check that
the sensor housing is complete dry inside.

Reinstall sensor housing and sensor. Check sensor cable connection is completely tightened.

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11. Maintenance
Disconnect the system from the mains power supply or switch off the main switch prior to commencing
maintenance work on the system.

Always depressurize reactor before commencing service work. There is a risk of serious injuries. Quartz
sleeves or pieces of broken quartz sleeve can be blown out of the reactor.

IMPORTANT!
Quartz sleeve hand grip nuts must be re-tightened after app. 2-4 weeks of operation!

Warning UV rays!
Protect both eyes and skin

High voltages are present on

lamp connectors and cables!

25
11.1. Daily
Check lamp hour-counter and remember to renew UV-lamps according to below table. Reset hour counter
if lamps are replaced.

ULTRAAQUA quartz-sleeves have unlimited life time if clean and not scratched. However, in order to
ensure optimal UV-performance it is recommended to replace sleeves every 25000 H.

Lamp type Lamp life time

220W 16000 H
350W 16000 H
440W 12000 H

Check that reactor air bleeding is effective if accumulation of air in the reactor is possible.

11.2. Every Three Months

After the first three months of operation the quartz sleeves should be checked and cleaned if necessary.
From the observed condition of the quartz sleeves estimate appropriate cleaning intervals. In most cases a
12 months interval is sufficient. Quartz sleeves can be cleaned using the supplied Woeste® sponge or in a
weak citric acid solution.

Whenever checking quartz sleeves remember to check the condition of the O-rings and change if
necessary.

Check that no water (condensate) has accumulated in the quartz sleeves.

Check all cabinet fans, fan filters and heat exchangers/air-conditioners.

Check all cable glands on UV-lamp cables in order to assure watertight connections.

11.3. Every Year

Remember to replace the UV-lamps in time and to reset hour counter. The depreciation in UVC-output is
caused by internal chemical deposits and by solarisation of the lamp-quartz. Always replace O-rings when
replacing UV-lamps and quartz sleeves.

Check functionality of temperature sensor and thermal protection of reactor unit. this can be done by
dismantling the sensor and heat it up manually.

UV-sensor should be calibrated or replaced. Recalibration can be done by sending the sensor to
ULTRAAQUA or by using a reference UV-sensor. Contact your distributor.

Stainless steel enclosures should cleaned for rust and wiped in anti-oxidizing oil.

Check cabinet, panel, and LED seals for water tightness.

Check reactor unit for accumulation of solids.

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12. Faults
If alarms are present, the panel colour will change to red. Go to alarm screen to see active alarms.

UV-lamp and lamp driver defects are extremely rare. Contact your distributor if consecutive failures are
observed. The following alarms can be seen:

▪ Reactor temperature
▪ Lamp driver fault
▪ Lamp fault

12.1. Removal of glass and broken lamps from a closed reactor

UV lamps contain small quantities of mercury. Mercury is harmful to people and the environment. For this
reason, it is imperative to wear protective gear (gloves and breathing apparatus, etc.) in the event of lamp
breakage. Dispose of broken UV lamps in accordance with the applicable local guidelines and directives.

Wear protective gear (gloves and safety goggles, etc.) when removing glass and broken lamps in order to
avoid cuts.

Remove all quartz sleeves and UV lamps. Remove reactor from piping system. or remove top plate (some
steel reactors). Top plate can very heavy so removal may require proper lifting device.

Remove all broken glass.

Thoroughly spray out the interior of the reactor with water.

Before re-installation of reactor examine all UV-lamps and UV lamp cable plugs for water. Replace if
necessary.

12.2. System faults

A system failure will occur in case of:
• Intake air temperature too high or too low.
• Lamp drivers Internal heat-sink temperature too high. Possible cause: blocked air outlet or blocked
air inlet.
• Input voltage too high. High limit 305V.
Please note: When input voltage is below 180V the lamp will be automatically dimmed to attempt to

12.3. Lamp faults

Disconnect the system from the mains power supply or switch off the main switch prior to commencing
maintenance work on the system.

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A lamp failure alarm (MAIN screen and ALARM LOG) will occur if the lamp driver has tried to ignite the
lamp 7 times (8 seconds interval) without success or if operating parameters for the lamp are out of range.

UV-lamp defects are extremely rare. Do the following check before replacing the lamp. Turn off the UV-
system. Switch cables between the defective UV-lamp and a working lamp. Turn on the UV-system and
turn on the UV-lamps. If the other lamp goes off, the problem is the lamp driver or wiring. If the same UV-
lamp goes off, this lamp is defective.

Possible causes:
• Lamp end of lifetime exceeded
• Lamp defect
• Cable/wiring faults
• Wrong lamp type

Check lamp cable and connector.

Replace UV-lamp. If problem persist, contact ULTRAAQUA representative.

Insert the UV-lamps into the quartz sleeves without touching it with your bare hands. Use paper or gloves.
Grease blue O-rings on the cable plugs (silicon grease), before re-positioning. Check all cable glands.

Note: It is very important that new lamps are placed furthest away from the optional UV-sensor
window!

12.4. Quartz sleeve faults

Note: Always use cut-protection gloves when handling quartz sleeves.

Disconnect the system from the mains power supply or switch off the main switch prior to commencing
maintenance work on the system.

Depressurize the UV-reactor by closing valves upstream, downstream, by opening drainage valve and
removing bleed ¼” plug (closed reactors).

It is necessary to drain reactor completely before removal of quartz sleeves (closed reactors).

Remove UV-lamps.

To ease the process of quartz sleeve service operations remove the ½” peep-hole plug. A flashlight may
also be helpful (closed reactors).

Remove quartz sleeve knurled hand grip nut. Take out quartz sleeves and clean with a rough sponge and
water. It may be necessary to immerse sleeves into a 5% acetic acid solution for 30 min.

Discard sleeves if scratched or irreversibly fouled.

Check reactor for accumulation of solids and fouling of reactor interior. Clean if relevant.

Make sure that all quartz sleeves are completely dry inside.

Before re-installing sleeves it is important to clean the optional sensor window.

Reinstall quartz sleeves. Examine O-rings for damage. Grease O-rings with small amounts of pure silicon
grease. Place the white washers over the O-rings and tighten the nut by hand only.

If possible, apply full water pressure to the reactor and test for leakages before inserting UV-lamps.

28
For 220W/350W series: Put one silicone rubber ball into each quartz sleeve.
For 440W series: Put one lamp spring ball into each quartz sleeve.

Check remaining lamp life time and replace if necessary (reset lamp hour counter).

Insert the UV-lamps into the quartz sleeves without touching it with your bare hands. Use paper or gloves.
It is important to make sure that the lamp wires (connecting far end with connection end) are positioned so
that they don’t block UV-light in the direction of the UV-sensor.

Grease blue O-rings on the round plugs (silicon grease), before re-positioning. Check all cable glands.

12.5. Lamp driver faults

Disconnect the system from the mains power supply or switch off the main switch prior to commencing
maintenance work on the system. Wait at least 1 minute before touching any parts.

High voltages are present internally and on the input and output connectors and
cables.
The electronic lamp drivers may only be installed and operated by qualified
technically trained people

Lamp driver wiring must be done according to below photos.

Note that outputs 2 and 4 on the driver are not in use for 350W and 440W lamps. Do not use outputs 2 and
4 for 350W and 440W lamps. Only two lamps per lamp driver.
For 220W lamps all outputs are in use.
If only one lamp is connected to the driver, output one should be used.

Right photo shows power and grounding connections. Patch cables are for Modbus daisy chain
connection.

29
Always set modbus address selectors (left side of ballast on left photo) when replacing a lamp driver (next
chapter).

Lamp driver failure will occur if:

▪ Intake air temperature too high or too low. Control cabinet low limit 0°C, high limit
50°C
▪ Internal heat sink temperature too high. Possible course: blocked control cabinet air
outlet
▪ Input voltage too high or too low. Lamp driver voltage limits are 180-305V. Please
note that these limits are for the lamp driver only. Not for the complete control
cabinet.
▪ When input voltage is below 180V the lamp will be automatically dimmed to attempt
to continue operation.
▪ Lamp driver fan defect.
▪ Internal error

12.5.1. Lamp driver address selector

Always select the address according to below illustration before the AC is switched on.
Please note that it is the groove on the side of the address selector that defines its position.
When replacing a lamp driver, make sure that the address selector of the new lamp driver has the same
setting as the replaced driver.
In general:

First lamp driver Address no. 11

Second lamp driver Address no. 12
Third lamp driver Address no. 13
Fourth lamp driver Address no. 14
…… ……
…… ……

The setting of the address selectors is 12. Remember to note where the groove is.

30
12.5.2. Lamp driver LED status indicators
For visual diagnosis, communication status and device status are indicated by LEDs.

Please note that each lamp driver max handles two lamps and that these lamps are connected to output 1
and 3. Green LED no. 2 and 4 are therefore not in use.
If only one lamp is connected to the driver, output one should be used.

12.5.3. Lamp driver fan

Keep airflow area open and clean for maximum cooling capacity.
After removing AC-mains input power wait at least 1 minute before working on the fan. After 1 minute the
fan can easily be removed, using a screw driver.

Note: Re-position the fan wiring exactly

in the same way as the original fan
wiring!

Fa

13. Fault messages

13.1. Control panel alarm messages with alarm output (alarm relay)
Note! In remote control mode, if an alarm has switched of lamps, the remote on signal must be switched
off. When the alarm signal goes off, lamps can be switched on again by the remote signal, when the fault
has been reset in the panel alarm menu

Alarm: LAMP FAULT [X]

Description: Lamp has faulted. Driver has tried to ignite lamp more than 7 times.
Action: Check lamp. Lamp faults are very rare. Check also lamp cables. Replace with new lamp.

Alarm: LAMP DRIVER X: SYSTEM FAULT

Description: Lamp driver external error
Action: Check cabinet air temperature. Max is 45 C
Internal heat-sink temperature may be too high. Possible cause: blocked air outlet or
blocked air inlet of lamp driver.
Input voltage may be too high. High limit 305V. Remark, when input voltage is below 180V
the lamp will be automatically dimmed to attempt to continue operation.

31
Alarm: LAMP DRIVER X: INTERNAL FAULT
Description: Lamp driver has faulted
Action: Check lamp driver fan.
Lamp driver defective. Replace lamp driver.

Alarm: LAMP DRIVER X: TPFC

Description: Lamp driver has faulted due to high internal temperature
Action: Check lamp driver fan.
Lamp driver defective. Replace lamp driver.

Alarm: ALARM: REACTOR TEMPERATURE

Description: Reactor temperature has exceeded alarm temperature level
Action: Check alarm setting. Increase slightly if necessary. Evaluate pre-alarm level.
Check that there is no accumulation of air in reactor
Check water flow.
Check temperature sensor.

Alarm: PRE-ALARM LEVEL UV INTENSITY

Description: Intensity below pre-alarm level
Action: Check water UVT.
Check quartz sleeves and sensor window and evaluate cleaning frequency
Check lamp lifetime.

Alarm: ALARM LEVEL UV INTENSITY

Description: Intensity below alarm level
Action: Check water UVT.
Check quartz sleeves and sensor window and evaluate cleaning frequency
Check lamp lifetime.

13.2. Control panel messages - no output

Message: REPLACE LAMPS SOON
Description: Lifetime will soon be exceeded
Action: Check lamp stock or order new.

Message: REPLACE LAMPS SOON

Description: Lifetime exceeded for UV lamps.
Action: Replace UV-lamps

Message: PRE-ALARM: REACTOR TEMPERATURE

Description: Reactor temperature has exceeded pre-alarm temperature level
Action: Check pre-alarm setting. Increase slightly if necessary. Evaluate alarm level.
Check that there is no accumulation of air in reactor
Check water flow.
Check temperature sensor.

Message: Shutting down

Description: UV lamps are being switched off due to local or remote command.
Action: No fault. No action.

Message: INITIALIZING LAMP DRIVERS

Description: When cabinet has been switched on the BUS communication circuit is being integrity tested.
Action: No fault. No action.

13.3. Poor disinfection performance

Fault: Water flow rate is higher than expected
Action: Check flow meters, transmitters etc.

Fault: Air has accumulated in the reactor

32
Action: Establish continuous air bleeding

Fault: Solids has accumulated in the reactor

Action: Establish proper pre-filtration

Fault: Water UVT is lower than expected

Action: Contact ULTRAAQUA representative

Fault: UV lamps have not been replaced as specified

Action: Replace UV-lamps

Fault: Large particles are present in the water

Action: Establish proper pre-filtration. UV-systems are only effective upon separate
microorganisms in suspension or in very small agglomerates.

13.4. Reactor faults

Fault: Reactor leaking
Action: Check all O-rings and thread packaging material
Check system pressure do not exceed max specification.

Fault: Reactor heats up

Action: Check that no air has accumulated
Check that water temperature does not exceed setting for ALARM TEMPERATURE in
SETUP/TEMPERATURE
Check water flow rate
Check functionality of temperature sensor

13.5. Lamp faults

Fault: Lamp will not ignite
Action: Replace lamp with a new lamp or another working lamp to assure that the suspected is
defective. Premature lamp faults are caused by:
Too many daily ignitions
Water is present in the quartz sleeve
Fingerprints on lamp glass

Fault: Lamp output is low

Action: Check that lamp wirers don’t block UV-rays in the direction of the sensor.

13.6. Quartz sleeve faults

Fault: Broken quartz sleeve
Action: Check that there is a silicon ball (220W and 350W series) or a metal spring (440W series) in
the bottom of the sleeve. Extremely important for vertically installed reactors.
Check that there are no big objects in the reactor (stones, bolts etc.)
Check that there are no sudden pressure peaks (water hammer) due to fast closing valves.
Check that the reactor body is firmly supported and don’t vibrate.
Check that the O-ring type is correct and that the white PTFE washer is in place.

13.7. UV sensor faults

Fault: Low or no output

33
Action: Check that sensor head and sensor housing is completely dry.
Make sure sensors are replaced or calibrated regularly.

13.8. Control cabinet faults

Fault: Lamp driver internal temperature too high. Air temperature in the control cabinet may be
high.
Action: Check cabinet main fan is running.
Clean cabinet main fan filter pads.

13.9. Lamp driver fault

Fault: Lamp driver faulted
Action: As the data bus is configured in a ring topology, defective ballasts or an interrupted data
connection mean that the subsequent ballasts can no longer communicate.

34
14. EU Declaration of Conformity
EU Declaration of Conformity

We, hereby declare that: ULTRAAQUA A/S

Niels Jernes vej 2-4,
9220 Aalborg Ø
Denmark

On the basis of its functional and design in the version marketed by us, the product specified in the
following complies with the relevant, fundamental safety and health stipulations laid down by EC
regulations.
Any specifications to the product not approved by us will invalidate this declaration.

Product description: UV disinfection system

Product type: UVC

Serial number: Please refer to the type plate on the system

Relevant EC Reg.: EU - Low voltage directive (2006/95/EC)

EU – EMC Directive (2004/108/EC)
EU Pressure Equipment Directive (97/23/EC)

Harmonised standards: DS/EN 60204-1, DS/EN 60335-1, EN 60529

EN 610000-3-2, EN 610000-6-1/-2/-3/-4

Harmonised national standards and other

technical specifications applied, in particular:

Technical documents have been

Complied by:

The undersigned: Jens Skjølstrup, Manager, M.Sc.,Env.Eng.

35
15. Electrical wiring diagram
Electrical wiring diagram is placed inside electrical cabinet

WARNING:
Mains voltage on projective low voltage
Possible consequence: Fatal or very serious injuries.

36
16. Installation check list

Please read manual before installation

Actions ✓
Check all components for damages related to freight. Take pictures and
contact distributor immediately if damages are observed
There is space for service operations on reactor frame, quartz sleeves and
lamps
Channel reactor systems:
Actions have been taken to avoid operation of UV-system if water level
doesn’t cover the full length of the UV-lamps.
Closed reactor systems:
Actions have been taken to avoid accumulation of air in the reactor

Quartz seals have been tested before lamps are installed

Lamp cables can reach reactor or reactor frame in both submerged and
elevated position
Fan ventilated cabinets must be installed in dry environments. Saline
aerosols will destroy electronics and void warranty

Functionality of temperature control system has been tested

Temperature sensor has been installed in reactor frame top

Power to UV-system will be disconnected if flow is stopped

Airflow to and from cabinet fans is un-hindered

Stainless steel reactors:

Both reactor and cabinet is properly grounded
Channel reactor systems:
Channel is covered to protect from direct exposure of UV-rays

Connecting pipes have been properly supported

UV warning labels are clearly visible

37
Installation checklist

Please read manual before installation

Actions ✓
Check all components for damages related to freight. Take pictures and
contact distributor immediately if damages are observed
There is space for service operations on reactor frame, quartz sleeves and
lamps
Channel reactor systems:
Actions have been taken to avoid operation of UV-system if water level
doesn’t cover the full length of the UV-lamps.
Closed reactor systems:
Actions have been taken to avoid accumulation of air in the reactor

Quartz seals have been tested before lamps are installed

Fan ventilated cabinets must be installed in dry environments. Saline

aerosols will destroy electronics and void warranty
Lamp cables can reach reactor or reactor frame in both submerged and
elevated position

Functionality of temperature control system has been tested

Temperature sensor has been installed in reactor frame top

Power to UV-system will be disconnected if flow is stopped

Airflow to and from cabinet fans is un-hindered

Stainless steel reactors:

Both reactor and cabinet is properly grounded
Channel reactor systems:
Channel is covered to protect from direct exposure of UV-rays

Connecting pipes have been properly supported

UV warning labels are clearly visible

ULTR QUA
WATER RESOURCES TECHNOLOGY

38