UVG X160 & X245 Installation and Operation Manual

Unit 18, 7 Packard Avenue
™ Castle Hill,
NSW
2154
UV Guard Australia Pty Ltd P: 02 9631 4900

F: 02 9647 2977
ABN 79 601 193 444
W: www.uvguard.com.au
UVG X160 & X245

INSTALLATION AND
OPERATION MANUAL
Page | 1
UV-Guard – UV Disinfection Specialists – UVG X160 & X245 Installation and Operation Manual
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
CONTENTS
Page
1. GETTING STARTED 3
2. SETTING UP 4
i. Disinfection Chamber Mounting 4
ii. Power Supply Box Mounting 5
3. ASSEMBLY 6
i. Quartz thimble installation 6
ii. UV lamp installation 7
iii. Over temperature relief system installation 8
(Option)
iv. BMS alarm output connections (Option) 9
v. UV Intensity Monitor sensor installation 10
(Option)
4. SERVICING 11
i. Quartz thimble servicing 11
ii. Servicing the UV lamp 12
iii. Servicing and operating the PLC box 13
Page | 2
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
1. GETTING STARTED
Delivery Inspection.
Each unit is tested prior to packaging to ensure that the unit is operational and in good working
order.
Upon receipt of goods, be sure to check the shipment for any signs of damage, and if any
damage has occurred. Notify both the carrier and the shipper in writing within 72 hours of the
damage and retain the parts and packaging for inspection.
Check that all working parts of the unit have been received.
For the UV-Guard X series this will include:-

Disinfection Chamber (1)
Power Box (1)
The number of UV lamps, quartz thimbles and compression rings per unit are listed in the
following table. There are two o-rings provided per quartz thimble.
X1-160/245 X2-160/245 X3-160/245 X4-160/245
1 2 3 4
Spares :-
Item Part Number Quantity / System
X160 X245 X1-160/245 X2-160/245 X3-160/245 X4-160/245
a. UV Lamp (ozone free) 11160 11248 1 2 3 4
b. UV Lamp (ozone) 11161 11249 1 2 3 4
c. Electronic ballast 40162 40248 1 2 3 4
d. Quartz Thimble 20200 1 2 3 4
e. O-ring 31020 2 4 6 8
f. Compression Ring 32136 1 2 3 4
g. Sealing nut 32115 1 2 3 4
h. View port housing 42051 1 1 1 1
i. View port kit k-10001 1 1 1 1
j. Sensor for UV intensity 42054 1 1 1 1
monitor (Uvi option)
k. UV intensity sensor 42035 1 1 1 1
housing (Uvi option)
Page | 3
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
2. SETTING UP
To prevent injury, safety precautions should be observed at all

times
UV RADIATION HAZARD
NEVER OPERATE THE UV LAMP OUTSIDE THE CHAMBER.
THERE ARE HIGH CURRENTS AND VOLTAGES INSIDE THE
ELECTRICAL ENCLOSURE AND DISINFECTION CHAMBER. TO
PREVENT RISK OF FATAL SHOCK, ALWAYS DISCONNECT POWER
BEFORE PERFORMING ANY MAINTENANCE.
THE DISINFECTION CHAMBER AND ELECTRICAL ENCLOSURE

MUST BE GROUNDED
The Following MUST be Checked Prior to Installation:
A maximum operating pressure of 1000KPa (10 bar) must not be exceeded.
The maximum ambient temperature is 40oC
The maximum water temperature should be 60ºC
The maximum flow rate should not exceed specified rate
The Reactor must be plumbed so it remains full of water at all times while the lamp is
operating.
The X series units should not be installed so there are long periods with no flow without over-
temperature protection. Recommended maximum period with no flow is 60 minutes. Longer
periods may damage the UV lamp due to overheating. If there are going to be long periods with
no flow, it is recommended a thermostat controlled solenoid valve is installed downstream of
the UV unit so that if the temperature of the UV reactor gets too hot (more than 55ºC), the
solenoid valve will open to return a small amount of water to the source, or dump to waste.
The water flow from this action will cool the reactor.
2.i - Disinfection Chamber Mounting:-
When installing the UV disinfection chamber, considerations must be made to ensure that the
AS/NZS 3500.1 Plumbing and drainage standards are met at all times.
Page | 4
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
* The UV-Guard X series Disinfection chamber comes complete with it's own mounting
brackets.
* A one and a half metre spacing is required at the power head assembly end of the
disinfection chamber for servicing purposes.
* The treatment chamber should be mounted vertically or horizontally with the outlet port
above the main body of the chamber.
* When mounting the chamber, consideration must be made for the weight of the system due
to the stresses associated with pipe work etc.
2.ii - Power Supply Box Mounting:-
* The power supply box needs to be mounted with a maximum cable run of 2m from the box to
the chamber. The power supply box is supplied with 1.5 metre long UV lamp power cable.
Mount the power supply box in a suitable position protected from water ingress.
The UV lamp lead should be connected to the power head lid with the gland provided, making
sure that the 4 pin lamp connector is on the inside of the lid.
The earth wires on the UV lamp leads should be connected to the posts on the inside of the
power head. This would normally be done after the chamber is installed in the pipe work and
assembled with the quartz thimbles installed.
* NOTE:- POWER SHOULD NOT BE SWITCHED ON UNTIL THE UV LAMPS HAVE BEEN
INSTALLED AND SECURED
Page | 5
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
3. ASSEMBLY
DUE TO THE FRAGILE NATURE OF THE QUARTZ, CARE MUST BE TAKEN WHEN HANDLING AND
INSTALLING THE QUARTZ THIMBLE & UV LAMP.
Before attempting to assemble a UV-Guard X series disinfection unit, check that you have all
the necessary parts outlined in the delivery inspection guide.
Items required for assembly:-

* 1500 mm long broomstick handle or pvc conduit.
* Methylated spirits or pure alcohol solution.
* Soft tissue/cloth.
3.i - Quartz thimble installation:- (See diagram at Step 3.)
Step 1.
* NOTE:-During steps 3-5 it is advisable that cotton gloves or similar be worn when handling
the quartz thimble to ensure that no finger prints or markings of any sort are on left on the
quartz thimble which would have a detrimental effect on it's performance.
Remove Quartz thimble from it's protective wrapping & wipe down with soft tissue/cloth
soaked in methylated spirits or alcohol solution to remove any deposits on the quartz.
Step 2.
Take a new o-ring place it around the open end of quartz thimble, 20 mm from top. Place the
compression ring over the first o-ring. Install a second o-ring after the compression ring.
Step 3.
Slide the quartz thimble (closed end first) slowly through the opening of the UV disinfection
chamber, ensuring that no marks are left on the quartz as it is inserted. It may be helpful to use
a broom handle or piece of pvc conduit to help locate the thimble in the thimble support cup at
the far end of the chamber. When the thimble is located correctly the end of the thimble will be
approximately flush with the top o-ring within the sealing nut socket.
Page | 6
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Step 4.
Place the sealing nut on to the sealing thread socket on the chamber over the open end of the
quartz (also the compression ring and o-rings).
Step 5.
Gently screw the sealing nut in place on the disinfection chamber and begin to tighten down on
the thread (clockwise direction). Once you feel some resistance, you should only be able to give
a maximum of 1 turn, any greater pressure could result in damage to the quartz thimble. Very
firm hand tightness should be sufficient.
If all of the above steps have been followed, the quartz thimble should be sitting firmly in
place, with the O-ring well compressed onto the quartz thimble. To check, simply look through
the sealing nut. You will see the O-ring compressed onto the glass; the more compression there
is, the greater the expansion of the O-ring onto the glass. This can be done by shining a torch
down the open end of the quartz.
Repeat this procedure for each opening. The chamber should then be checked for leaks under
maximum water pressure before installing the UV lamps.
3.ii - UV Lamp Installation

* Note:-Cotton gloves or similar should be worn when handling the UV lamp-finger prints or
marks of any nature have a detrimental effect on the UV lamp performance.
Step 1.
Check that the quartz thimble is in place and that the O-rings are well compressed onto the
thimble itself. Apply full water pressure and check for leakage through the O-ring seal.
Step 2.
Wearing cotton gloves or similar, remove the UV lamp from it's protective wrapping and wipe
down with soft tissue / cloth soaked in methylated spirits or similar. Do not leave any finger
marks on the lamp.
Step 3.
Insert the UV lamp into the quartz thimble through the power head assembly and push the UV
lamp up into the chamber. IMPORTANT: if the chamber is vertical then the UV lamp must be
held securely at all times until the lamp is in place. If the UV lamp is dropped into the quartz
thimble, then both the thimble and the UV lamp may break.
Page | 7
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Step 4.
Ensuring that the power supply power is off, connect the lamp lead from the power supply box
to the lamp ensuring the connector is pushed firmly home so there is no gap between the lamp
and the connector. Also connect the earth lead inside the power head. Push the UV lamp gently
up into the chamber until it will go no further.
Step 5.
Replace power head lid and secure with screws provided.
3.iii - Over temperature relief system installation (Option)
The following parts have been included and form part of the over termoerature relief system:
• Siemens clamp on thermostat
• 1“ Brass solenoid valve
• 12V DC coil kit
• 5m cable from PLC box
Step 1.
Clamp thermostat onto reactor using stainless steel clamp provided
Step 2.
Install 1” T connection in the pipework after the outlet connection of the reactor
Step 3.
Install 1” solenoid on the T connection and connect outlet to drain a connection. Alternatively,
the outlet can be connected back to a storage tank to preserve water.
Page | 8
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Step 4.
Connect coil onto solenoid valve and refer to the following wiring diagram to run the cable
exiting the PLC box to the thermostat and 12V DC coil kit.
Step 5.
To check that the solenoid is working, turn the power to the PLC box on. Turn the thermostat
dial down to the lowest temperature and then turn it up slowly. As the thermostat dial passes
the temperature of the reactor, the solenoid should open. If this does not occur, refer back to
the wiring diagram to ensure it is installed correctly.
Step 6.
Set the dial on the thermostat to 55 Degrees C.
3.iv - BMS alarm output connections (Option)
Use the BMS connection cable existing the PLC box to connect to a BMS.
Lamp fail output (volt free contact)

This relay will energise when the power is applied and the lamp operating correctly (i.e Blue
wire = lamp operating correctly, black wire = lamp fail)
Blue wire = Normally open contact (closes when lamp is ON)

Brown wire = Common
Black wire = Normall closed contact
Low UV intensity
The Low UV Intensity relay will be energised when the lamp is on and the intensity drops below
the low alarm level (alarm will also sound)
Page | 9
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Blue wire = Normally open contact (closes on low UVi)

Brown wire = Common
Black wire = Normall closed contact
3.v - UV Intensity Monitor sensor installation (Option)
Step 1.
The UV monitor is supplied with a 1500 mm conduit from the power box to the sensor assembly.
Step 2.
Install sensor assembly into viewing port.
Step 3.
Screw down ss nut to secure installation.
Your UV monitor is now ready for operation.
Turn power on. The UV lamp will strike, however it will take between 2 & 5 minutes for the
lamp to reach full output. Refer to
Page | 10
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
4. SERVICING
The following service schedule should be followed:-
Quartz Thimble
* Thimbles should be replaced every 2-3 years.
UV Lamp (UV lamp).

* UV Lamps should be replaced every 12,000 hours.
O Ring.
* O rings should be replaced every time the quartz is removed or every 13,000 hours,
whichever is the soonest.
Tools required for servicing:

* 1500 mm long broomstick or similar
* Cleansing cream
* Methylated spirits or alcohol solution.
* Soft tissue/cloth
* Cotton gloves.
THE DISINFECTION CHAMBER MUST BE HYDRAULICALLY ISOLATED AND DRAINED BEFORE

REMOVING THE QUARTZ THIMBLES.
THE POWER SUPPLY MUST BE SWITCHED OFF AND ELECTRICALLY ISOLATED BEFORE REMOVING
THE UV LAMPS.
4.i - Quartz thimble servicing:-
It is important to service one quartz thimble at a time to help maintain wiper alignment. So each quartz
thimble should be removed and cleaned or replaced and reinstalled before the next quartz thimble is
service. This will ensure there are always a quartz thimble in place at all times to as to make re-installing
the thimbles easier. For installations where the chamber is mounted horizontally, position the wiper
arm so it is fully extended, using the ‘MANUAL’ wiper option on the front panel controls.
Step 1.
Isolate water supply to UV unit.
Step 2.
Switch off mains power supply to the UV disinfection unit. Drain water within UV disinfection
chamber.
Page | 11
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Step 3.
Refer to ‘Servicing the UV Lamp section’ to remove the UV lamps.
Step 4.
Note: service one quartz thimble at a time and service each quartz completely before
proceeding to the next, so there is at least one quartz in place at all times. For chambers with
the lamp mounted horizontally, it may be useful to place broomstick or pvc conduit into quartz
thimble. Gently unscrew the sealing nut, once the sealing nut is off, remove the compression
ring and keep with the sealing nut. Use the broomstick to help support the quartz thimble as it
is removed. For vertically mounted chambers, carefully twist and pull the thimble. Take care
when removing the quartz thimble, as it comes out of the wiper rings it will suddenly become
free.
Step 5.
* Note:-Cotton gloves or similar should be worn when handling clean quartz thimble.
Remove the old O ring and scrape off any remaining residue of the O ring. Wipe down the
quartz thimble with cleansing cream and wash down with water. Repeat this until the quartz
thimble is clean. If there is material deposited on the inside of the quartz then you may need to
immerse the quartz in an acid bath (10% hydrochloric acid) for 30 minutes, then rinse with
clean water. Next wipe the thimble down with soft tissue/cloth soaked in methylated spirits or
alcohol solution.
Take care not to leave marks of any nature on the thimble as this will have a detrimental
effect on the performance of the thimble.
Step 6.
Reinstall the quartz thimbles and UV lamps as described in the ‘ASSEMBLY’ section of this
manual.
4.ii - Servicing the UV lamp:-
Step 1.
Switch off power to the UV disinfection unit. Allow at least 10 minutes for the UV lamps to cool
down.
Step 2
Remove the end cap from sealing nut assembly by unscrewing the three retaining screws. Be
Careful! The UV lamp will come out with the sealing nut end cap. Disconnect lamp from power
supply cable. Warning: The lamp may be very hot if it has not been allowed to cool for at least
10 minutes.
Page | 12
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Step 3.
Remove UV lamp from chamber.
Step 4.
Note:-Cotton gloves must be worn when handling UV lamp.
Wearing cotton gloves or similar, remove replacement UV lamp from protective wrapping and
wipe down with soft tissue/cloth soaked in methylated spirits.
Step 5.
Install new lamp as described in the ‘ASSEMBLY’ section.
4.iii - Servicing and operating the PLC box:-
The UV Guard display provides the user with a series of screens which provide information on
the status of the unit as well as fault warnings and actions. Fault warning or action screens only
appear when the red FAULT light is illuminated or flashing and no action has been taken.
Each screen is described below. Screens marked with an asterisk are fault related screens and
may not always be visible.
When the power is first switched on the HOME screen will be displayed. If the power is
already on and the HOME screen is not displayed; press the MODE button.
• The MODE button is used to enter the STATUS screen or to exit back to the HOME
screen.
• Press the UP or DOWN buttons to display other STATUS screens in sequential order.
Page | 13
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
• Press the MODE button at any time to return to the HOME screen.
• Press the ENTER button to accept the YES option; press any other button to ignore
changes.
Screen Descriptions and Actions
Information
Fault Screen Description and Action
Descriptor
The FAULT light will flash and the alarm will sound every 20 seconds when
* Near end of life
Mute the Alarm?
the lamp is nearing the end of its effective life. The user can mute the alarm
by accepting “YES” when this STATUS screen is selected. The FAULT lamp
will continue to flash and the alarm will be muted for 24 hours.
The FAULT light will flash and the alarm will sound every second when the
* End of life
Mute the Alarm?
lamp has reached the end of its effective life. The user can mute the alarm
by accepting “YES” when this STATUS screen is selected. The FAULT lamp
will continue to flash and the alarm will be muted for 24 hours.
The FAULT light will flash and the alarm will sound every second when the
* Low UVi
Mute the Alarm?
UV intensity is less than 60%. The user can mute the alarm by accepting
“YES” when this STATUS screen is selected. The FAULT lamp will continue to
flash and the alarm will be muted for 24 hours.
New Lamp Fitted? After the power has been switched OFF; a new lamp has been installed; and
* the power has been turned back ON this STATUS screen can be accessed.
Accepting YES will:
• Cancel all alarms;
• Stop the FAULT light from blinking;
• Reset the “Lamp Operating Time” to zero; and
• Commence a sequence to automatically re-calibrate the UV
intensity monitor. During this time the percentage value will blink
to indicate that the re-calibration process is taking place, this will
take approximately 20 minutes.
• Note: If there is a power failure during the re-calibration process,
the process will recommence from the beginning once power is
restored.
Lamp Operating Indicates the total number of hours that the current lamp has been
operating. This will be reset to zero when the lamp is replaced.
Lamp Errors Indicates the cumulative total of lamp errors that have occurred with the
unit. This will be recorded across multiple lamps.
Lamp Replaced This is a cumulative total and Indicates the number of times the lamp has
been replaced.
Page | 14
™ Castle Hill,
NSW
2154

F: 02 9647 2977
ABN 79 601 193 444
Total On Time Indicates the cumulative total of hours that all lamps have been operating.
Lamp Restarts Indicates the number of times that the current lamp has been started.
Service Required The service screen will only appear if the lamp has stopped operating. The
* unit should be turned off and service called.
Page | 15

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Unit 18, 7 Packard Avenue

UV Guard Australia Pty Ltd P: 02 9631 4900

UVG X160 & X245

UV Guard Australia Pty Ltd P: 02 9631 4900

UV Guard Australia Pty Ltd P: 02 9631 4900

For the UV-Guard X series this will include:-

UV Guard Australia Pty Ltd P: 02 9631 4900

To prevent injury, safety precautions should be observed at all

THE DISINFECTION CHAMBER AND ELECTRICAL ENCLOSURE

The Following MUST be Checked Prior to Installation:

A maximum operating pressure of 1000KPa (10 bar) must not be exceeded.

The maximum ambient temperature is 40oC

The maximum water temperature should be 60ºC

The maximum flow rate should not exceed specified rate

2.i - Disinfection Chamber Mounting:-

UV Guard Australia Pty Ltd P: 02 9631 4900

2.ii - Power Supply Box Mounting:-

UV Guard Australia Pty Ltd P: 02 9631 4900

Items required for assembly:-

3.i - Quartz thimble installation:- (See diagram at Step 3.)

UV Guard Australia Pty Ltd P: 02 9631 4900

3.ii - UV Lamp Installation

UV Guard Australia Pty Ltd P: 02 9631 4900

3.iii - Over temperature relief system installation (Option)

UV Guard Australia Pty Ltd P: 02 9631 4900

3.iv - BMS alarm output connections (Option)

Lamp fail output (volt free contact)

Blue wire = Normally open contact (closes when lamp is ON)

UV Guard Australia Pty Ltd P: 02 9631 4900

Blue wire = Normally open contact (closes on low UVi)

Your UV monitor is now ready for operation.

UV Guard Australia Pty Ltd P: 02 9631 4900

The following service schedule should be followed:-

UV Lamp (UV lamp).

Tools required for servicing:

THE DISINFECTION CHAMBER MUST BE HYDRAULICALLY ISOLATED AND DRAINED BEFORE

4.i - Quartz thimble servicing:-

UV Guard Australia Pty Ltd P: 02 9631 4900

4.ii - Servicing the UV lamp:-

UV Guard Australia Pty Ltd P: 02 9631 4900

4.iii - Servicing and operating the PLC box:-

UV Guard Australia Pty Ltd P: 02 9631 4900

Screen Descriptions and Actions

UV Guard Australia Pty Ltd P: 02 9631 4900

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UVG X160 & X245 Installation and Operation Manual

UVG X160 & X245 Installation and Operation Manual