Dulcodes WUV System

Assembly and operating instructions

A0767

Please stick the nameplate here

Original operating instructionsPart no.985734 BA DS 035 12/12 EN

Please carefully read these operating instructions before use! Do not discard!The operator shall be liable for any damage caused by installation or operating errors!

Technical changes reserved.

In order to make it easier to read, this document uses the maleform in grammatical structures but with an implied neutral sense. Itis aimed equally at both men and women. We kindly ask femalereaders for their understanding in this simplification of the text.

Read the following supplementary information in its entirety!The following are highlighted separately in the document:n Enumerated lists

Instructions Results of the instructions

Information

This provides important information relating to the correct operation of the system or is intended to makeyour work easier.

Safety informationSafety information are provided with detailed descriptions of theendangering situation, see Chapter 2.1 Explanation of thesafety information on page 6

General non-discriminatory approach

Supplementary information

Supplemental instructions

2

Table of contents1 About this system.................................................................. 5

1.1 Correct and Proper Use ............................................... 52 Safety chapter....................................................................... 6

2.1 Explanation of the safety information............................ 62.2 Users' qualifications...................................................... 72.3 Dulcodes safety information......................................... 82.4 Safety Equipment ...................................................... 102.5 Information in the Event of an Emergency ................. 10

3 Function.............................................................................. 113.1 Commissioning........................................................... 113.2 Normal mode.............................................................. 123.3 Auto rinse interval....................................................... 123.4 Switching off............................................................... 12

4 Control................................................................................ 134.1 Display ....................................................................... 134.2 Operating status display and parameter settings....... 154.3 Trend display.............................................................. 164.4 Change Access Code ................................................ 174.5 Setting the Language ................................................. 174.6 Ballast bus activate / deactivate................................. 174.7 Set lamp current (not for Dulcodes 75 W).................. 184.8 Sensor signal display.................................................. 194.9 Calibrating the sensor................................................. 194.10 Adjusting the display range of the trend display....... 204.11 Setting the safety threshold...................................... 204.12 Setting the warning threshold................................... 214.13 Analog output sensor signal: assigning the standard

signal........................................................................ 214.14 Activating the pump control...................................... 224.15 Setting the start rinse duration.................................. 224.16 Set maximum free rinse duration.............................. 234.17 Setting the lamp postburning duration...................... 234.18 Adjustment of off-time and auto flushing interval...... 244.19 Set minimum mains voltage...................................... 244.20 Pause function.......................................................... 254.21 Displaying/Resetting the counter.............................. 254.22 Behaviour of the system in the event of a fault......... 254.23 Alarm signal relay..................................................... 274.24 Fault switch input...................................................... 27

5 Mounting and installation.................................................... 285.1 Radiation chamber...................................................... 295.1.1 Assembly................................................................. 295.1.2 Attach the warning label.......................................... 305.1.3 Connectors, hydraulic.............................................. 305.2 Control cabinet and control......................................... 315.2.1 Assembly................................................................. 315.2.2 Connectors, electric................................................. 315.2.3 Opening the control................................................. 325.3 Fitting the lamp protection tubes................................. 34

Table of contents

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5.4 Assembly and connection of the UV lamp.................. 356 Commissioning................................................................... 37

6.1 Leak testing and ventilation of the radiation chamber 376.2 Switching on the UV system....................................... 376.3 Calibrating the UV sensor........................................... 38

7 Maintenance....................................................................... 397.1 Cleaning the UV lamp protection tube........................ 397.1.1 Cleaning After Dismantling the UV Lamp Protection

Tube......................................................................... 407.1.2 Cleaning with a Cleaning Solution .......................... 427.1.3 Cleaning the UV Sensor.......................................... 437.2 Changing the UV lamps.............................................. 447.3 Calibrating the UV sensor........................................... 457.4 Replacement of the filter mats on the fan and the air

outlet filter................................................................... 468 Troubleshooting.................................................................. 479 Technical data..................................................................... 53

9.1 Performance data....................................................... 539.2 Dimensions sheet....................................................... 569.2.1 Dimension sheet Dulcodes W 75 ............................ 569.2.2 Dimension sheet Dulcodes W 80 and 130............... 579.2.3 Dimension sheet Dulcodes W 230 .......................... 589.3 Electrical data............................................................. 61

10 Appendix............................................................................. 6310.1 Spare parts drawings................................................ 6310.2 Spare Parts List........................................................ 6310.3 Dulcodes wiring diagram ......................................... 6510.4 EC Declaration of Conformity................................... 6610.5 Dulcodes UV system unit operating log.................... 67

11 Index................................................................................... 68

Table of contents

4

1 About this system The Dulcodes UV systems are used for the photochemical treatment and disinfection of:n Drinking watern Process watern Waste watern Swimming pool waterThe water to be disinfected is subjected to short-wave UV radiationduring the UV disinfection process. This so-called UV radiationquickly and reliably kills any germs.The Dulcodes UV systems are supplied fully wired. They are available in different versions, which are defined by their identity code.The performance data can be found in the data sheet enclosedwith the Dulcodes UV system.Scope of supplyn Radiation chambern Lamp with lamp protection tuben UV sensorn Control cabinet with controln Documentation

1.1 Correct and Proper Use Correct and Proper UseThe operator is liable for damage caused by installation and operating errors! The system is intended solely for the treatment ofwater. The system may only be used in accordance withthe technical data and specifications outlined in theoperating instructions! Any other use or modification of the system is prohibited. The system may only be operated by trained andauthorised personnel! It is imperative that the information in the operatinginstructions relating to the different phases of theunit's service life is observed!

Application

About this system

5

2 Safety chapter 2.1 Explanation of the safety information

These operating instructions provide information on the technicaldata and functions of the product. These operating instructions provide detailed safety information and are provided as clear step-by-step instructions.The safety information and notes are categorised according to thefollowing scheme. A number of different symbols are used todenote different situations. The symbols shown here serve only asexamples.

DANGER!Nature and source of the dangerConsequence: Fatal or very serious injuries.Measure to be taken to avoid this dangerDanger! Denotes an immediate threatening danger. If this is

disregarded, it will result in fatal or very seriousinjuries.

WARNING!Nature and source of the dangerPossible consequence: Fatal or very serious injuries.Measure to be taken to avoid this dangerWarning! Denotes a possibly hazardous situation. If this is

disregarded, it could result in fatal or very seriousinjuries.

CAUTION!Nature and source of the dangerPossible consequence: Slight or minor injuries, material damage.Measure to be taken to avoid this dangerCaution! Denotes a possibly hazardous situation. If this is

disregarded, it could result in slight or minor injuries. May also be used as a warning about materialdamage.

Introduction

Safety chapter

6

NOTICE!Nature and source of the dangerDamage to the product or its surroundingsMeasure to be taken to avoid this dangerNote! Denotes a possibly damaging situation. If this is

disregarded, the product or an object in its vicinitycould be damaged.

Type of informationHints on use and additional informationSource of the information, additional measuresInformation! Denotes hints on use and other useful information.It does not indicate a hazardous or damaging situation.

2.2 Users' qualifications WARNING!Danger of injury with inadequately qualified personnel!The operator of the plant / device is responsible forensuring that the qualifications are fulfilled.If inadequately qualified personnel work on the unit orloiter in the hazard zone of the unit, this could result indangers that could cause serious injuries and materialdamage. All work on the unit should therefore only be con

ducted by qualified personnel. Unqualified personnel should be kept away from

the hazard zone

Training DefinitionInstructed personnel An instructed person is deemed to be a person who has been instructed and,

if required, trained in the tasks assigned to him/her and possible dangers thatcould result from improper behaviour, as well as having been instructed in therequired protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructedperson and who has also received additional training specific to the systemfrom ProMinent or another authorised distribution partner.

Trained qualified personnel

A qualified employee is deemed to be a person who is able to assess thetasks assigned to him and recognize possible hazards based on his/hertraining, knowledge and experience, as well as knowledge of pertinent regulations. The assessment of a person's technical training can also be based onseveral years of work in the relevant field.

Safety chapter

7

Training DefinitionElectrician Electricians are deemed to be people, who are able to complete work on elec

trical systems and recognize and avoid possible hazards independently basedon his/her technical training and experience, as well as knowledge of pertinentstandards and regulations.Electricians should be specifically trained for the working environment inwhich the are employed and know the relevant standards and regulations.Electricians must comply with the provisions of the applicable statutory directives on accident prevention.

Customer Service department

Customer Service department refers to service technicians, who havereceived proven training and have been authorised by ProMinent to work onthe system.

Note for the system operatorThe pertinent accident prevention regulations, as wellas all other generally acknowledged safety regulations,must be adhered to!

2.3 Dulcodes safety information WARNING!UV raysPossible consequence: Serious injuriesUV radiation is harmful to the eyes and skin Only operate the UV lamp UV-C when it is fully fittedand installed Install the UV lamp into the UV system in accord

ance with the regulations prior to commissioning

WARNING!Live parts!Possible consequence: Fatal or very serious injuries Measure: The device must be disconnected from

the power supply before it is opened Disconnect damaged, defective or manipulated

devices from the power supply

Safety chapter

8

WARNING!Insufficient water treatmentPossible consequence: IllnessPlease read the technical data sheet for your UVsystem. Calibrate the UV systems correctly.Ensure that: the maximum permissible water flow rate is not

exceeded and UV transmission does not drop below the permis

sible level as otherwise adequate treatment cannot be

guaranteed.

WARNING!Drinking water disinfectionCause: Already contaminated pipes.Possible consequence: Illness.Measure: For applications with high disinfectionrequirements (e.g. drinking water disinfection) disinfectthe downstream pipework, e.g. by superchlorination,before commissioning.

CAUTION!Depot effect in pool waterCause: Pool water disinfected with UV radiation has noprotection against contamination.Possible consequence: IllnessMeasure: When treating pool water with UV radiation,disinfection with a depot effect e.g. chlorine is necessary.

CAUTION!Overheating of lamp and treatment chamberPossible consequence: material damage Ensure that, with the exception of when the lamp is

warming up, the radiation chamber has a sufficientflow of water through it so that the radiationchamber cannot overheat

Only switch on the UV system after the radiationchamber has been filled with water

Switch the UV system off if the flow of water isinterrupted for a long time (several hours).You can automate switch-off using the pause contact on the control. The chapter entitled "Function"describes more options for preventing overheating.

Safety chapter

9

CAUTION!Unauthorised operating parameterPossible consequence: material damageEnsure that: the installation location is dry and frost-free the protection of the UV system from chemicals,

dyes and vapours is guaranteed the ambient temperature and the radiation tem

perature in the direct vicinity of the system may notexceed 40 C

the maximum permissible operating pressure is notexceeded and

there are no solid particles and no turbidity in thewater to be treated.

if necessary, fit an appropriate treatment systemupstream of the UV system.

2.4 Safety Equipment ATTENTION: Hazardous ultraviolet radiation

UV-C UV-C radiation is harmful to the eyes and skin. The lamps mayonly be operated when installed. The system should be installed inaccordance with all pertinent regulations prior to commissioningthe lampsATTENTION: Danger

Disconnect the system from the mains power supply or switchoff the main switch prior to commencing maintenance work on thesystem. Depressurise the radiation chamber prior to commencingmaintenance work.

Disconnect the system from the mains power supply or switchoff the main switch prior to opening the cabinet.

2.5 Information in the Event of an Emergency In the event of an emergency, switch the red-yellow main switch onthe side of the control cabinet to OFF or disconnect from the mainspower supply.

Labels on radiation chamber

Labels on Control cabinet

Safety chapter

10

3 Function Shut-off valves and flushing valves do not form part ofthe scope of supplyThe shut-off valves and flushing valves do not formpart of the scope of supply of the UV system and aremade available by the site operator.

A0917

1

23

4 5 67

Fig. 1: Typical installation schematic of a UV system1 Shut-off valve (site-supplied)2 Flushing valve (site-supplied)3 Sampling tap (site-supplied), fireproof4 Shut-off valve (site-supplied)

5 Stainless steel radiation chamber6 UV sensor7 Control

The water to be treated flows through the stainless steel radiationchamber and past the UV lamps. The UV radiation kills the germsand reduces substances, such as chloramines, in the swimmingpool water.The low pressure UV lamps generate a very high output level ofUV radiation, which is particularly effective for purposes of disinfection at a wavelength of 254 nm. The UV lamps are located in lampprotection tubes made of high-grade quartz with a high level of UVtransparency. The compact design of the radiation chamber andthe optimum flow of radiation as well as the integrated turbulatorsresults in evenly-distributed irradiation of the entire flow of water.A control monitors the UV system along with a UV sensor.

3.1 Commissioning Once the Dulcodes UV-system has been switched on, the UVlamps are ignited. For UV systems on a data bus to ballasts, thebus is first activated prior to ignition. This can take several seconds, depending on the size of the UV system. Following ignition,the UV lamps need several minutes until they reach operating temperature.The UV sensor monitors the UV lamps. As soon as the UV outputhas exceeded the minimum irradiance threshold, the rinse valveopens for the start rinse.If the minimum irradiance is not exceeded within the maximum permissible warm-up time, then the rinse valve will open regardless.However, If the minimum irradiance is also not exceeded within themaximum rinse duration, then the controller switches the UV-system off and goes into fault mode.The shut-off valve is opened after the start rinse is completed. TheUV-system goes into normal mode.

Function

11

3.2 Normal mode In normal mode, the UV-C sensor continues to monitor the UVoutput:If the UV output falls below the warning threshold: a warning isemitted.If the UV output falls below the minimum irradiance threshold: Theshut-off valve closes and the rinse valve opens. However, If theminimum irradiance threshold is also not exceeded within the maximum rinse duration, then the controller switches the UV-system offand goes into fault mode.All UV lamps are monitored to ensure that they operate optimally. Ifa UV lamp fails, the shut-off valve is closed and the controllerswitches the UV-system off and goes into fault mode.

3.3 Auto rinse interval If auto rinse is active, the rinse valve opens for the auto rinseprocess after the maximum off-time has been reached.

3.4 Switching off When the UV system is switched off, the shut-off valve closes andthe UV lamps are turned off. If the UV lamps require postburning,then the lamps are switched off after the lamp postburning durationhas elapsed.

Function

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4 Control NOTICE!With the exception of sensor calibration lamp currentcalibration, modifications to the settings should only beundertaken when the UV system is switched off.

As the electronics and software are always subject to improvements, the version number is used as a means of identification.This should be stated with complaints. It can be called up on thedisplay.

The Dulcodes UV systems' controls are factory-preset. For manyapplications it is therefore not necessary to change the settings.

4.1 Display The system is provided with a graphical LCD display.

NOTICE!START/STOP buttonHold down the STOPSTART key for at least 2 seconds.The display returns to the normal display for therespective operating mode 5 minutes after the key hasbeen pressed for the last time.

In operating moden Display of the operating moden Warnings are indicated by flashing arrows and displaysn Faults are displayed by a flashing fault alertIn programming moden Flashing display of the numerical values and inputs that can be

changed.

Version

Default settings

Control

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STOPSTART

2

3

4

5

8

6

7

1

XXXXXX

Fig. 2: Display and operating unit

Position number Key Function1 Housing2 LCD display5 UP key

In programming mode: Raises the displayed numerical value orchanges an input

7 BACK keyMoves back one level in the menu

6 DOWN keyIn programming mode: Lowers the displayed numerical value orchanges an input

8 CHANGE keyIn operating mode: Changes the display windowIn programming mode: Changes adjustable parameters

3STOPSTART

START/STOP buttonSwitches on and off the UV-system

4 ENTER keyIn operating mode: Changes to programming mode or acknowledges afaultIn programming mode: Applies a set value or mode

Control

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4.2 Operating status display and parameter settings

Behaviour at faults? Plant off

A

BA

xxxx h Operationxxxx - time On

Version

Lamp current(min. x.x A)(max. x.x A)

Bus activeBus passive

Cal. factor =Time x:xx m

Safety threshold

xxx W/m 2Warning threshold

Lamp hoursLamp turn-ons

Commissioning Rinsing time

Maximum off-time

Intervall- Rinsing time

Minimum line voltage

Pause under pause contact

Operat. hoursTurn-ons

Display of sensor signal in : x

Language

Standard display

Change of displayPump control

Of f

Lamp postburnTime xx:xx

Maximum free rinsing

Trend display

FrAccess code change?

Bus xxxx

Analogue output

Windowr-sensor calibration (only appears when system running)

Display ranger Trend displayx TDay(s)

with "pump control" = "on"

Behavior at Faults = emerg.service

A0748

with "pump control" = "on"

with "max. off-time" = "0"

Fig. 3: Operating status display (with the UV system running)A + Back to Trend displayB = Change to Programming modeC = Change to "Change Access Code" mode

Control

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(adjustable numbers/ settings flash) Memory display 1s B (Request access code)

Changes are not saved Changes are savedBack to display window

Access code incorrect

P_PMA_DS_0016_SW

Fig. 4: Programming manual

NOTICE!Access codeOnce the access code has been correctly enteredonce, it is not necessary to re-enter the code for furtherprogramming processes; the flashing numbers or settings will appear directly as soon as the -key ispressed. The access code is automatically cancelled 5minutes after a key was last pressed or after a returnto the Trend or Standard display.

4.3 Trend display NOTICE!Display calibration Each calibration of the UV sensor is documented

by a vertical continuous line in the trend display The content of the trend display is deleted when

the display range changes and when the operatinghour counter is reset

1 UV sensor signal2 Warning threshold3 Safety threshold4 Switch on's/off's5 CalibrationThe trend display is used to monitor the ageing of the UV-lamps,the formation of a film coating on the lamp protection tubes orchanges to the water quality.The progress of the UV sensor signal is shown in a time frame.Horizontal lines show the safety threshold and the warningthreshold respectively. The short vertical lines show when the UVsystem is switched on. The display range of the UV sensor signallies between 0 W/m2 (or 0%) and the value which has beenassigned to the analogue output value of 20 mA. The time framecan be adjusted and guarantees an ongoing display: Once theselected time has expired, the oldest value is deleted and the newvalue is displayed.Default settingn Time frame: 100 daysn Maximum value of the UV sensor signal: 400 W/m2

Programming manual

Fig. 5: Trend display

Control

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4.4 Change Access Code CAUTION!Change access codeDefault setting "5000" Note down the access code!

Parameters can only be set once the correctaccess code has been entered

The default access code does not guarantee anyprotection from unauthorised changes

New Access codexxxx

Memory display 1 s(Request Access code)

Changes are saved

Confirm Access codexxxx

Access code incorrect Changes are not saved

C

Back to Change Access Code request P_PMA_DS_0017_SW

Fig. 6: Change Access CodeTo protect against unauthorised changes of the settings, thesystem controller has an access code for the programming mode.It can be freely selected by the operator. The programming modeis still disabled after a change of the access code. It is only enabled when the new access code is entered.

4.5 Setting the Language It is possible to select between different languages.

4.6 Ballast bus activate / deactivate For UV systems equipped with ballasts via a bus interface, switch the bus to active . The UV lamps cannotbe ignited if the bus is passive.The ballast of UV systems of type Dulcodes 75W doesnot have a bus interface. With these system types thebus must be set to passive .

Language :

German

Fig. 7: Setting the Language

Control

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The ballasts for the high-flux UV lamps (e.g. 80-W lamp, 130-Wlamp, 230-W lamp) are equipped with a bus interface. This businterface enables the UV lamps to be ignited and switched off. Inaddition, they are monitored for optimal operation. Moreover, thelamp current can be changed. When the bus is active and once theUV system is switched on, the number of ballasts is shown. Keys[UP] and [DOWN] can be used to call up the serial numbers of theindividual ballasts.

For UV systems equipped with a bus interface ballast, active , otherwise passive (Dulcodes 75 W).

4.7 Set lamp current (not for Dulcodes 75 W) CAUTION!Deterioration of UV output / premature wearCause: Incorrectly set lamp current.Consequence: Poor disinfection performance of theUV system. Any operation of the UV lamp with currents outside of the permissible range can cause theUV system to fail prematurely. Excessive lamp currentcauses the UV lamps to overheat, causing the UVoutput to deteriorate. Insufficient lamp current leads toa significant reduction in the UV output.Measure: Set the lamp current to a reliable valve.Please refer to the enclosed data sheet for the permissible range for lamp current and rated current.

The UV lamps should be operated with the default current, a deviation only makes sense and is only permitted in a few exceptional cases. Please refer to theenclosed data sheet for the permissible range for lampcurrent and rated current. For UV systems, which arealso suitable for hot water disinfection, two default currents are specified in the data sheet; for hot and coldapplications.

Bus passive

Fig. 8: Bus is passive

Bus active 10 lamps

EVG codeEVG#001

Fig. 9: Bus is activeDefault setting

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The lamp current can be freely selected within a certain range forballasts which are equipped with a bus interface. This means thatthe UV lamps can be adapted to specific operational conditions.The lamp current can also be adjusted in operating mode andflushing mode. The permissible ranges for the lamp current are notmonitored when the UV system is switched off. If a lamp current isset outside of the permissible ranges, then the Lamp current faultindication is shown once the UV system is switched on and the bushas initialised.

In the event that the UV-lamps indicate a slight reduction in UVoutput for water temperatures < 8 C, then the lamp current can beincreased slightly by 0.1 to 0.3 A above the rated current for UVoutput.

The lamp current can be increased by 0.2 to 0.4 A above the ratedcurrent for UV output towards the end of the lamp service life inorder to increase the UV output slightly.

2 ampere

4.8 Sensor signal display The UV sensor monitors the UV lamps.Reduction in the sensor signal can be caused by the following:n Coating formed on the lamp protection tubesn Significant deterioration of the UV transmission in the watern Reduction of the UV output of the UV lamps due to lamp

ageing.It is possible to select between an absolute value in W/m2 and arelative display of the sensor signal in % .

W/m2

4.9 Calibrating the sensor The UV sensor is pre-calibrated at the factory and does not have tobe calibrated again.

Lamp current = 2 A

A0769

Fig. 10: Set lamp current (not for Dulcodes 75 W)Water temperatures < 8 C

End of service life

Default setting:

Display of sensor signal

A0750

Fig. 11: Sensor signal displayDefault setting

Time

Cal.factor =

Fig. 12: Calibrating the sensor

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4.10 Adjusting the display range of the trend display The recording time of the sensor signal for the trend display can beadjusted. The value (in days) is interpreted as the time frame andthus guarantees a continuous display: Once the selected time hasexpired, the oldest value is deleted and the new value is displayed.

100 days

4.11 Setting the safety threshold WARNING!UV lamp replacementPossible consequence: Illness Check and possibly reset the safety and warning

threshold when the UV lamp is replaced! Only a correctly set safety threshold will guar

antee adequate UV radiation

Reliable and safe water treatment can no longer be guaranteed ifthe UV output falls so low that the UV sensor signal falls below thesafety threshold. In this case a shut-off valve, should one be fitted,will close. When the signal falls below the safety threshold on thedisplay, this is shown by two flashing arrows.A signal device can be connected to the [SAFETY THRESHOLD]signal relay of the control. The relay is closed when the signal fallsbelow the safety threshold.

NOTICE!The safety threshold must be below the warningthreshold. It is not possible to set it above the warningthreshold.

1. Switch on the UV system with the STOPSTART button2. Wait until the UV lamp has reached its full capacity, i.e. until

the UV sensor signal is stable3. Read the UV intensity displayed and note it down4. Switch off the UV system with the STOPSTART button5. Set the safety threshold to 50 % of the displayed UV intensity

Example: Measured UV intensity: 100 W/m2therefore follows:safety threshold = 100 W/m2 0.50 = 50.0 W/m2

6. Now set the warning threshold

Display range Trend display100 day(s)

Fig. 13: Adjusting the display range ofthe trend displayDefault setting:

Safetythreshhold

A0770

Fig. 14: Setting the safety threshold

Setting the safety threshold

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4.12 Setting the warning threshold WARNING!Poor disinfectionCause: Insufficient UV system radiation power.Consequence: Poor disinfection performance of theUV system.Check and possibly reset the safety and warningthresholds when lamps are replaced.

The warning threshold must be above the safetythreshold.It is not possible to set it below the safety threshold.

The system issues a warning should the UV output drop so far thatthe sensor signal falls below the warning threshold. To prevent thesignal falling below the safety threshold, the UV lamp protectiontubes should be cleaned, the UV lamps should be replaced or thewater quality should be improved by means of appropriate watertreatment. When the signal falls below the warning threshold, thisis indicated on the display by a flashing arrow.A signal device can be connected to the[WARNING THRESHOLD] signal relay of the control. The relay isclosed when the signal falls below the warning threshold.

Requirements:n Stable UV intensity for the UV lamps has been notedn The safety threshold has been set

Set the warning threshold to 110 % of the set safetythreshold

Example: Set safety threshold: 50 W/m2 therefore follows:warning threshold = 50 W/m2 1.10 = 55.0 W/m2

The safety and warning thresholds have been set, the UVsystem is now ready for operation. Switch on the UVsystem with the STOPSTART button.

4.13 Analog output sensor signal: assigning the standard signal The sensor signal assigned to the 20 mA is simultaneously the maximum value of the trend display. Adjustthis sensor signal value to 125 % of the maximumvalue so that the trend display can never overflow .

The signal from the UV sensor can also be recorded for documentation purposes using a recorder. To do so, connect the recorder tothe standard output of the control.

Warning thresholdA0771

Fig. 15: Setting the warning threshold

Analogue output 0 W/m2 = 0 mA400 W/m2 = 20 mA

A0751

Fig. 16: Analog output sensor signal

Control

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It is possible to choose from a 0 to 20 mA and 4 to 20 mA standardsignal:n 0 or 4 mA corresponds to the sensor signal 0 W/m2n 20 mA can be assigned to any value

0 W/m2 = 0 mA400 W/m2 = 20 mA (dependent on the settings)

4.14 Activating the pump control CAUTION!Damage to the UV lamps and radiation chamberCause: The UV-system may only be operated whenthe radiation chamber is fully filled with water. With anempty or only partially filled radiation chamber there isa risk of damaging the UV lamps and radiationchamber.Measure: It must therefore be ensured that the radiation chamber cannot run empty when the pump isswitched off.

As the feed pump generally has a certain post-rinseduration, the lamp postburning duration should be setto at least one minute. This ensures that water conveyed during the post-rinse period is disinfected.

The pump control system must be activated in order to control thefeed pump with the pump relay.The pump relay releases when the UV system is switched off andremains released with pump control off , even when the UVsystem is running.If the UV system is switched on with Pump control on , then theUV system will exit warning mode only when the warning thresholdis exceeded. The pump relay operates. If the UV system isswitched off or the UV system switches over to pause mode, thepump relay will release.If the minimum irradiance is undershot during operation or a UVlamp fails, then the pump relay releases and the UV systemswitches over to fault mode.

Off

4.15 Setting the start rinse duration In most cases, a start rinse duration of 1 min is sufficient. If there is no start rinse duration specified, thenthe start rinse duration will be set to 0 min .

Default setting

Pump control

OnFig. 17: Activating the pump control

Default setting:

Control

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The start rinse duration is intended to ensure that only optimallytreated water can flow through to the consumer. As soon as the UVlamps reach operating temperature after ignition and the sensorsignal has exceeded the minimum irradiance level, the automaticrinse valve opens (if fitted) for the start rinse process. Only thendoes the shut-off valve open.

1 min

4.16 Set maximum free rinse duration The free rinsing process is primarily used for the disinfection ofdrinking water. In doing so, a maximum free rinse duration of over10 hours is often used. After periods of heavy rainfall it is possiblethat the UV transmission will decrease, for example, if the waterhas poor natural filtering characteristics. The sensor signal undershoots the minimum irradiance value. The shut-off valve closesand the rinse valve opens.Once the water quality has improved, the UV system switchesback over to normal mode. However, If the sensor signal fails toexceed the minimum irradiance threshold within the maximum freerinse duration, then the UV system switches over to fault mode.

1 min

4.17 Setting the lamp postburning duration In large-scale UV systems for drinking water disinfection, it cantake some time for the shut-off valve to close in some cases, or forthe water flow to be stopped by another means. In this case, thelamp postburning system prevents insufficiently disinfected waterfrom reaching the consumer while the UV system is being shutdown. In most cases, a start lamp postburning duration of 1 minuteis sufficient.

Off

Start rinse duration

1:00 min:secFig. 18: Setting the start rinse durationDefault setting:

Maximumfree rinse duration

00:01 h:minFig. 19: Set maximum free rinse duration

Default setting:

Lamp postburning Off

Fig. 20: Setting the lamp postburningdurationDefault setting:

Control

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4.18 Adjustment of off-time and auto flushing interval The off-time flushing system is used primarily for internal drinkingwater supply systems. One must always assume that there will beprolonged periods without water removal in UV systems withinternal drinking water supplies. In such cases, it is advantageousto make use of the off-time flushing system in order to avoid impermissible warming and irradiance of the water.

A flow detector or temperature switch is connected to the switchinput [FLOW TEMPERATURE] of the control. The contact closesupon exceeding of a minimum flow or the maximum temperature.The flushing valve is opened for the flushing interval, provided thatno water has been drawn during the maximum off-time.However, if the [FLOW TEMPERATURE] switch input on the control does not have a flow detector or temperature switch connectedto it, in other words, the switch input is open, then the flushingvalve opens after the maximum off-time for the auto flushinginterval (periodic flushing).In most cases, the maximum off-time is set to 5 hours. An autoflushing interval of 1 minute is generally sufficient.If the maximum off-time is set to 00:00, then no auto rinse processis undertaken.

00:00 min1 min

4.19 Set minimum mains voltage Modifications to the minimum mains voltage may onlybe carried out in agreement with the manufacturer.

Monitoring the mains voltage prevents uncontrolled failure of theUV system and the UV lamps due to insufficient mains voltage.If the mains voltage drops to the minimum value, then the controlswitches over to undervoltage mode and the UV system is shutdown.When the mains voltage exceeds the permissible minimum valueagain, then the UV system starts up again automatically.

180 V

Maximum off-time 00:00 h:min

Fig. 21: Setting the off-time

Auto rinse interval 00:00 min:sec

Fig. 22: Setting the auto flushinginterval

Default setting:

Minimum line voltage 180 V

Fig. 23: Set minimum mains voltageDefault setting:

Control

24

4.20 Pause function The UV-system can be switched on and off by opening and shutting an external contact that is connected to the Pause input of thecontroller.It is possible to select whether the UV system starts up with anopen or closed Pause contact.

Pause with pause contact closed.(UV-system starts up when the pause contact is open).

4.21 Displaying/Resetting the counter The [OPERATING HOURS] and [SWITCH ONS] counters cannotbe reset.

The [LAMP HOURS] and [LAMP SWITCH ONS] can be reset.

4.22 Behaviour of the system in the event of a fault Normally the UV system is switched off in the event of a fault. However, for certain applications it can be a good idea to continueoperating the system at reduced capacity (emerg.service).

Pause on Pause contact closed

Fig. 24: Pause functionDefault setting:

Operating hours 400 hTurn-ons 25

Fig. 25: OPERATING HOURS /SWITCH ONS

Lamp hours 400 hlamp turn-ons 25

Fig. 26: LAMP HOURS / LAMPSWITCH ONS

Behaviour at Fault?Plant off

A0752

Fig. 27: Behaviour of the system inthe event of a fault

Control

25

CAUTION!Reduced disinfection efficiency The disinfection efficiency of the UV system is

severely reduced in emerg.service mode Emerg.service mode is not permissible for applica

tions where high demands are made of the disinfection efficiency, for example, drinking water disinfection or similar applications

A significantly reduced system output must beexpected for applications where emerg.servicemode is permissible for the UV system

In emerg.service mode, a possibly equipped shut-off valve opens immediately once the STOPSTART button hasbeen pressed, and not after the safety thresholdhas been exceeded.The system does not monitor whether the UVlamps are warmed up or whether sufficient UVoutput is available. It may be necessary to manually interrupt the water flow for 5 to 10 minutesonce emerg.service mode has been activated(manual shut-off valve, manual deactivation of thefeed pump, etc.)

The operator must check prior to enabling theemerg.service mode in the programming menu thatno risk is posed to personnel and property as aresult of the significantly reduced system efficiency

ProMaqua provides no warranty and accepts noliability or claims for damages resulting from operation of the UV system in emerg.service mode.

A special code is required for reprogramming the system's faultbehaviour which can only be obtained on request from ProMaqua.Once the special access code has been entered, it is possible toselect emerg.service mode for the system's behaviour in the eventof a fault.If emerg.service mode has been selected for fault events, then thesystem switches over to fault mode as previously in the event oflamp failure or if the safety threshold is undershot after completionof the UV system's free rinse duration. Pressing the buttoncauses the UV system to switch over to emerg.service mode. Inother words, the fault is not to be acknowledged with the button.Emerg.service mode can also be triggered by means of closinggate input flow/temperature . Bridging the input causes automaticswitch-over into emerg.service mode.The UV lamps are ignited in emerg.service mode, the shut-offvalve is opened and the pump relay is activated. However, the faultindicating relay will remain dropped and lamp failure and sensorsignals are no longer monitored. The signal relay[WARNING AND SAFETY THRESHOLD] undershot remainsdropped

No auto rinse interval is possible for UV systemswhere emerg.service mode is enabled. The programming windows [max. off-time] as well as[Auto rinse interval] are permanently hidden.

Control

26

Due to the fact that in emerg.service mode the pump relay is stillactivated with pump control [Off], the pump relay can be used toindicate emerg.service mode on UV systems with the pump controlspecification [Off]. For UV systems with the specification pumpcontrol [On], emerg.service mode can be detected by the fact thatthe pump relay continues to be activated despite a dropped faultindicating relay.

4.23 Alarm signal relay A signal device can be connected to the ALARM signal relay of thecontroller.The relay drops out if there is a fault/malfunction or in the event ofa power failure.

4.24 Fault switch input CAUTION!remove bridgePossibility of faulty operationWhen a fault signalling device is connected, removethe jumper as otherwise no fault will be reported.

NOTICE!remove bridgePossibility of faulty operationThe [FAULT] switch input is bridged when the systemis delivered. If the jumper is removed, without connecting up a fault signalling device, then the control willgo into fault mode and the UV system can then nolonger be operated.

An external fault signalling device, such as a flow rate monitor, canbe connected to the [FAULT] switch input.

Control

27

5 Mounting and installation n User qualification, mechanical installation: trained qualified per

sonnel, see Chapter 2.2 Users' qualifications on page 7n User qualification, electrical installation: Electrical technician,

see Chapter 2.2 Users' qualifications on page 7

CAUTION!Unauthorised operating parameterPossible consequence: Material damage.Ensure that: the installation location is dry and frost-free the protection of the UV system from chemicals,

dyes and vapours is guaranteed the ambient temperature and the radiation tem

perature in the direct vicinity of the system may notexceed 40 C

the maximum permissible operating pressure is notexceeded and

there are no solid particles and no turbidity in thewater to be treated. if necessary, fit a suitable filter prior to the UV

system.

NOTICE!Switching on and offPossibility of increased wear to UV lampOperate the UV system in such a way that the frequentswitching on and off of the UV lamp is avoided.

Mounting and installation

28

5.1 Radiation chamber The design of the radiation chamber can be found in the encloseddata sheet:n Vertical wall installation designn Horizontal designn Free-standing design

A0772

1.2. 3. 4.5.

6. 7. 8.9. 10.

11.

12.13.

14.

15.16.

17.

Fig. 28: Construction of the radiation chamber1. Lamp cover2. O-ring3. Teflon ring4. Connector plug5. O-ring6. Water outlet7. Fastenings8. Radiation chamber9. Lamp protection tube

10. UV lamp11. Water supply12. Water drain screw with O-ring13. O-ring14. UV sensor15. Vent screw with O-ring16. UV lamp protection tube holder17. Thumb nut

5.1.1 Assembly NOTICE!Permissible installation typesIt is only permissible to install the system in accordance with the enclosed data sheet.Leave adequate room for maintenance work. Therequired room can be found on the enclosed datasheet.

Vertical wall installationn Fasten the radiation chamber vertically to the wall with suitable

mounting fixturesHorizontal installationn Fasten the radiation chamber horizontally to the wall or appro

priate frame with suitable mounting fixtures.

Mounting and installation

29

Free-standing installationn Position the radiation chamber on the floor.

5.1.2 Attach the warning label The supplied self-adhesive warning label should beattached to the radiation chamber so that it is clearlyvisible.

5.1.3 Connectors, hydraulic WARNING!Automatic shut-off valveIf the water flow is not interrupted in the event of asystem fault by means of automatic deactivation of thefeed pump, then an automatic shut-off valve is to befitted downstream of the radiation chamber. This is tobe connected to the shut-off valve output of the control. The shut-off valve must close autonomously, inorder that the water flow is interrupted in the event ofpower failure.

CAUTION!Overheating of lamp and treatment chamberPossible consequence: material damage Ensure that, with the exception of when the lamp is

warming up, the radiation chamber has a sufficientflow of water through it so that the radiationchamber cannot overheat

Only switch on the UV system after the radiationchamber has been filled with water

Switch the UV system off if the flow of water isinterrupted for a long time (several hours). Install the flushing valve (if necessary in combi

nation with a flow detector or temperature monitor) and set an appropriate flushing routing onthe control.

NOTICE!Execute the hydraulic Connectors on the radiationchamber in compliance with the applicable generalguidelines and local installation regulations.Use UV-resistant materials for the hydraulic connector.If PVC is used, it is highly likely that the PVC will discolour in the area of the connection. In unfavourablecircumstances the material may become brittle andcrack.

Mounting and installation

30

Provide valves upstream and downstream of the radiation chamber to shut off the radiation chamber formaintenance work.Provide suitable fireproof valves upstream and downstream of the radiation chamber to allow for microbiological sampling.

5.2 Control cabinet and control 5.2.1 Assembly

The connecting cable for the lamp and the sensorcable may not be lengthened.

The switch cabinet or the mounting panel with controller andpower supply unit should be fitted to the wall or a suitableframe in such a way that the UV lamps and the UV sensorscan be connected to the cables provided.

5.2.2 Connectors, electric WARNING!Mains voltage on protective low voltagePossible consequence: Fatal or very serious injuries.Measure: If connecting the protective low voltage(SELV) to one of the X4 terminals, the X4 terminalsmust not be connected to mains voltage.

NOTICE!General notes on the electrical installation The electrical installation must be carried out by an

authorised electrical technician Ensure a continuous power supply by means of a

suitable fault current protection switch Connect a protective earth conductor to the radia

tion chamber.

The connecting cable for the lamp and the sensorcable may not be lengthened.

Mounting and installation

31

5.2.3 Opening the control WARNING!Electrical installationCause: Danger from electrical voltage.Possible consequence: Fatal or very serious injuries.Measure: Before opening the control, ensure that control is switched off (in a zero-volts state).

Opening of the control is only necessary, if the controlis not fitted in the control cabinet.

5.2.3.1 Opening the device

Fig. 29: Opening the device1. Loosen the 4 captive screws (1).2. Lift the upper section of the device from the lower section (2).

A wide flathead screwdriver may be of assistance.3. Insert the upper section with both guide rails into the lower

section (3 and 4) (parked position)

Mounting and installation

32

5.2.3.2 Electrical Installation when wall mounted (Dulcodes 75 W)

NOTICE!Threaded holesUsing a suitable tool( approx. 4 mm), punch out thethreaded holes according to the number of cables. Punch aids are provided to punch out the threaded

holes

A0014

Fig. 30: Punching out the threaded holes

1. Screw connection M20 x 1.5 2. Thrust collar M203. Thrust collar M20 4. Dummy washer M20

1. Remove cable sheathing over a sufficient length2. Fit screw connection (1), thrust collar (2) and seal (3) onto

cable3. Insert cable and fittings into the threaded hole4. Align the cable and push in until enough cable is in the con

trol housing5. Screw in screw connection and tighten firmly6. Shorten cable wires to the precise overall length and strip off

approx. 8 mm insulation7. Fit cable end sleeves to the wires.8. Connect the wires to the terminals in accordance with the

electrical terminal diagram

Mounting and installation

33

Punched out threaded holes can be resealed with the M20 dummywashers (4) provided.The M12 x 1.5 screw connections and brass lock nuts are used forthe 4 openings in the front row.

Fig. 31: M12x1.5 screw connections

5. Screw connection M12 x 1.5 6. Lock nut M12x1.51. Fit lock nut M12x1.5 (6) on the inside2. Fit screw connection M12x1.5 (5) from the outside and

tighten firmly

5.3 Fitting the lamp protection tubes Check the UV lamp protection tubes for damagebefore fitting.Damaged UV lamp protection tubes may not be fitted.

1. Loosen the attachment screws of the UV lamp protectiontube holders using the supplied Allen key

2. Remove the holders of the UV lamp protection tube from theradiation chamber by screwing out

3. Carefully push the O-ring provided approx. 40 mm over theopen end of the UV lamp protection tube.

4. Feed the UV lamp protection tube into the radiation chamber.

Mounting and installation

34

5.Ensure that the lamp protection tube is sittingcorrectly.The lamp protection tube may not project outmore than 30 mm and may not be offset at anangle.Installing the lamp protection tube holders at anangle can cause the UV lamp protection tubes tobe damaged.

Check whether the Teflon ring on the lamp protection tubeholder is lying in the groove provided. If it is not, insert theTeflon ring supplied into the UV lamp protection tube holderuntil it pops into the designated groove.

6. Push the UV lamp protection tube holder over the UV lampprotection tube and screw into the radiation chamber; tightenby hand

7. Tighten the UV lamp protection tube holder with the suppliedsickle spanner; only minimal force is required.

5.4 Assembly and connection of the UV lamp WARNING!Electrical installationCause: Danger from electrical voltage.Possible consequence: Fatal or very serious injuries.Measure: Prior to assembly and connection of the UVlamp, switch off the master switch or pull the mainsplug out of the socket.

WARNING!UV-C radiationCause: Danger due to UV-C UV radiation.Consequence: UV radiation is harmful to the eyes andskin.Measure: Only operate the UV lamps when they areproperly installed.

NOTICE!Premature UV lamp failureNever touch the glass of the UV lamp with bare hands.Fingerprints burn into the glass and can result in earlyfailure. Clean off fingerprints from the lamp with a clothmoistened with alcohol before installing.

Mounting and installation

35

The UV lamp of the UV system should be installed inaccordance with all pertinent regulations prior to commissioning.Do not modify the fitted lamp connection cable withoutauthorisation.Do not modify the gap between the plug and the lampcover. Otherwise, it can not be guaranteed that the UVlamp lies against the closed end of the UV lamp protection tube. This is a prerequisite for safe disinfection.

1. Lay the O-ring into the UV lamp protection tube holdergroove provided.

2. Insert the UV lamp into the UV lamp protection tube andallow it to project out approx. 100 mm

3.The connector plug can only be plugged on incertain positions, if necessary turn through 90before trying again.

Insert the connector plug onto the UV lamp4. Insert the UV lamp fully into the UV lamp protection tube5. Secure the lamp cover on the UV lamp protection tube holder

using the knurled nut; apply only minimal force to the knurlednut

Mounting and installation

36

6 Commissioning n User qualification, commissioning: trained user, see

Chapter 2.2 Users' qualifications on page 7

WARNING!Contaminated pipework / tubingCause: The following pipework / tubing, etc. could becontaminated.Possible consequence: Serious illnesses.Measure: The pipework / tubing requires disinfectionafter the commissioning process (e.g. by superchlorination).

6.1 Leak testing and ventilation of the radiation chamber 1. Open the air vent on the radiation chamber2. Slowly open the shut-off valve upstream of the radiation

chamber3. Fill the radiation chamber until water emerges from the bleed

valve4. Close the bleed valve5. Check that the radiation chamber is not leaking6. Open the shut-off valve downstream from the radiation

chamber (only necessary with a manual shut-off valve)

6.2 Switching on the UV system NOTICE!Only switch on the UV system after the radiationchamber has been filled with water.

1. Switch on the main switch or connect to the mains powersupply

2. Check the parameters in programming mode and change ifnecessary

NOTICE!Ensure that the UV lamps are operated at the ratedcurrent.

3. Switch on the UV system using the [START/STOP] key. Inorder to do so, the [START/STOP] key must be held down forat least 2 seconds

4. Should the controller go into [PAUSE] mode, activate thePause contact Once the UV lamp has ignited, it will take several minutesuntil the full UV output has been reached.

Commissioning

37

6.3 Calibrating the UV sensor Raw water with very low UV-transmission propertiesIf raw water with very low UV-transmission propertiesis used, it may occur that the safety threshold is notexceeded. In this case, you must adapt and adjust thesafety threshold and the warning threshold duringstartup of the UV system.

All new UV lamps need a burn-in time of 100 to 200hours. For this reason, the safety threshold andwarning threshold should be checked approx. 200operating hours after commissioning.

The UV sensor is pre-calibrated at the factory and does not have tobe calibrated again.

Commissioning

38

7 Maintenance WARNING!Background information about maintenance The UV lamps should be replaced at the latest

after their maximum permissible service life. Otherwise, the operating safety of the UV system cannotbe guaranteed

The maximum permissible service life is 10,000operating hours, unless otherwise stated in theenclosed data sheet

Before any maintenance work, disconnect thesystem from the mains power supply or switch offthe main switch

Depressurise the radiation chamber before commencing any maintenance work

UV radiation is harmful to the eyes and skin Only operate the UV lamp when it is correctly fitted The UV system should be installed in accordance

with all pertinent regulations prior to commissioningthe UV lamps

Dirty filter mats on the fan and air outlet filter canlead to the control cabinet overheating andbecoming damaged

Carry out the following maintenance work at regular intervals:n Replace the UV lamp at the end of its useful service lifen Clean and check the lamp protection tube (normally only nec

essary when replacing the lamp)n Replace the filter mats on the fan and the air outlet filter on the

control cabinet (normally annually)An operating log should be kept as a record. A form is enclosed inthe appendix for this purpose.

7.1 Cleaning the UV lamp protection tube Deposits of, for example iron, manganese or limescale, can formon the lamp protection tubes during operation. As these depositsabsorb UV radiation, they should be removed at regular intervals.

Clean the tube at the very latest when the sensorsignal falls below the warning threshold, without thisbeing based on other causes, such as ageing of thelamp or serious deterioration of the UV transmission.

An annual clean of the lamp protection tubes when replacing theUV lamp suffices for many UV systems. For UV systems used forwaste water disinfection, then cleaning may sometimes be necessary every one to two months. All lamp protection tubes must becleaned in systems with multiple UV lamps. The UV lamp protection tubes can be cleaned manually when dismantled or can becleaned by filling the radiation chamber with a cleaning solution.Acids, such as diluted phosphoric acid, acetic acid or diluted nitricacid, are particularly suitable for cleaning.

Maintenance

39

WARNING!Safety data sheet for the cleaning agent selectedCause: Danger due to cleaning agent.Possible consequence: Damage to the health. Property damage.Measures: Observe the safety data sheet for thecleaning agent selected. Wear protective clothingwhen cleaning (protective eye wear, protective gloves).Do not use corrosive acids or acids that could causestress cracks, such as hydrochloric acid. Ensure thatno cleaning solution penetrates the lamp protectiontube. Ensure, when cleaning UV systems that nocleaning solution enters the pipework.Dispose of the waste cleaning solution in accordancewith the pertinent guidelines and regulations.

7.1.1 Cleaning After Dismantling the UV Lamp Protection Tube WARNING!UV raysPossible consequence: Serious injuries.UV radiation is harmful to the eyes and skin Only operate the UV lamps UV-C when they are properly installed Install the UV lamp into the UV system in accord

ance with the regulations prior to commissioning

WARNING!Live parts!Possible consequence: Fatal or very serious injuries Measure: The device must be disconnected from

the power supply before it is opened Disconnect damaged, defective or manipulated

devices from the power supply

CAUTION!Fingerprints on the UV lampPossible consequence: Early failure of the UV lamp Only touch the glass of the UV lamp with cotton

gloves Fingerprints or impurities burn into the glass and

can result in early failure For this reason always clean the lamp thoroughly

with a cloth moistened with alcohol before installing it

Then wipe the UV lamp with a soft cloth

Maintenance

40

Cleaning the UV SensorEvery time you clean the UV lamp protection tube, alsoclean the UV sensor

1. Close the shut-off valves upstream and downstream of theradiation chamber

2. Switch off the UV system with the STOPSTART button3. Switch off the main switch or disconnect from the mains

power supply4. Drain the radiation chamber5. Open the water drain screw and the vent screw, drain the

radiation chamber6. Undo the UV lamp protection tube holder by hand7. Screw out the lamp cover far enough to permit disconnection

of the connecting cable plug from the UV lamp8. Fully remove the UV lamp and lay it to one side9. Loosen the UV lamp protection tube holder using the sup

plied sickle spanner10. Remove the holder of the UV lamp protection tube from the

radiation chamber by screwing out11. Pull out the lamp protection tube12. Remove the O-ring from the lamp protection tube13. Wash the lamp protection tube with cleaning solution or

immerse it in cleaning solution until the film has beenremoved without leaving a trace

14. Rinse the lamp protection tube with clean water and dry thoroughly with a soft cloth

15. Carefully push the lamp protection tube into the radiationchamber until it reaches its stop position

16. Push a new O-ring onto the end of the lamp protection tube -the sealing surfaces of the O-ring must be smooth and clean

17.CAUTION!Check the lamp protection tube for damagebefore fitting A damaged lamp protection tube may not be

refitted Ensure that the lamp protection tube is sitting

correctly The lamp protection tube may not project

out more than 40 mm and may not beoffset at an angle

Feed the UV lamp protection tube into the radiation chamber.18. Push the UV lamp protection tube holder over the UV lamp

protection tube and screw into the radiation chamber; tightenby hand

19. Tighten the UV lamp protection tube holder with the suppliedsickle spanner; only minimal force is required.

20. Assembly and connection of the UV lamp, see Chapter 5.3Fitting the lamp protection tubes on page 34

Maintenance

41

21. Screw in the water drain screw and tighten; very little effort isneeded for this

22. Slowly open the shut-off valve upstream of the radiationchamber

23. Fill the radiation chamber until water emerges from the ventscrew

24. Close the air vent screw and tighten; very little effort isneeded for this

25. Open the shut-off valve downstream from the radiationchamber (only necessary with a manual shut-off valve)

26. Check that the radiation chamber is not leaking27. Switch on the main switch or connect to the mains power

supply The UV-system is again ready for operation.

7.1.2 Cleaning with a Cleaning Solution NOTICE!Handling the cleaning solution It is also recommended in case of radiation cham

bers regularly cleaned by filling with a cleaning solution that the water drain connector and the airvent plug be replaced by appropriate valves

With larger radiation chambers, it is recommendedthat they are filled through the water drain openingusing an appropriate acid-resistant pump

If the radiation chamber is filled with a pump, it isalso useful to circulate the cleaning solutionthrough the air vent opening This shortens the cleaning time and achieves a

better result If the cleaning solution is collected in a suitable

container and stored, it can be reused severaltimes

1. Switch off the UV system using the STOPSTART key2. Switch off the main switch or disconnect from the mains

power supply3. Close the shut-off valves upstream and downstream of the

radiation chamber4. Empty the radiation chamber5. Screw in the water drain screw again and tighten; very little

effort is needed for this6. Fill the radiation chamber with the cleaning solution through

the vent opening Allow the cleaning solution to work for at least 20 minutes

7. Open and remove the water drain screw8. Empty the radiation chamber and dispose of the cleaning sol

ution in accordance with the pertinent regulations9. Flush the radiation chamber thoroughly with clean water until

all the remains of cleaning solution have been removed

Cleaning the lamp protection tubes byfilling the radiation chamber with acleaning solution:

Maintenance

42

10. Screw in the water drain screw and tighten; very little effort isneeded for this

11. Slowly open the shut-off valve upstream of the radiationchamber

12. Fill the radiation chamber until water emerges from the ventplug

13. Close the air vent plug and tighten; very little effort is neededfor this

14. Open the shut-off valve downstream of the radiation chamber(only necessary with a manual shut-off valve) Check that the radiation chamber is not leaking

15. Switch on the main switch or connect to the mains powersupply The UV-system is again ready for operation.

7.1.3 Cleaning the UV Sensor 1. Loosen the sensor connection cable from the UV sensor2. Turn the UV sensor out of the radiation chamber3. Clean the quartz window with a cloth that has been saturated

with cleaning solution until the coating has been removedwithout leaving a trace

4. Rinse the quartz window with clean water and dry with a softcloth

5. Examine the O-ring for damage and replace any damagedseals

6. Screw in the UV sensor again and tighten; very little effort isneeded for this

7. Connect the sensor connection cable to the UV sensor8. Slowly open the shut-off valve upstream of the radiation

chamber9. Fill the radiation chamber until water emerges from the vent

screw10. Close the air vent screw and tighten; very little effort is

needed for this11. Open the shut-off valve downstream from the radiation

chamber (only necessary with a manual shut-off valve) Check that the radiation chamber is not leaking

12. Switch on the main switch or connect to the mains powersupply The UV-system is again ready for operation.

Maintenance

43

7.2 Changing the UV lamps The UV lamps should be replaced by new lamps at the very latest:n when the sensor signal approaches the minimum irradiance

threshold without this being based on other causes, such asthe formation of a coating on the lamp protection tubes or aserious deterioration of the UV-transmission;

n when the operating life of the lamp is approaching the maximum service life of the lamp or has exceeded it

WARNING!UV raysPossible consequence: Serious injuriesUV radiation is harmful to the eyes and skin Only operate the UV lamp UV-C when it is fully fittedand installed Install the UV lamp into the UV system in accord

ance with the regulations prior to commissioning

NOTICE!Never touch the glass of the UV lamp with bare hands.Fingerprints burn into the glass and can result in earlyfailure. Clean off fingerprints from the lamp with a clothmoistened with alcohol before installing.

The UV lamp of the UV system should be installed inaccordance with all pertinent regulations prior to commissioning.Do not modify the fitted lamp connection cable withoutauthorisation.Do not modify the gap between the plug and the lampcover. Otherwise, it can not be guaranteed that the UVlamp lies against the closed end of the UV lamp protection tube. This is a prerequisite for safe disinfection.

Note regarding multiple UV lamp systems: When UV lamps are being exchanged at the endof the maximum lamp service life, all of the UVlamps should be exchanged for new ones. When UV lamps are being exchanged due to lampwear, all of the UV lamps should be exchanged fornew ones. When exchanging faulty UV lamps, only new UVlamps may be used. In the event that only the faulty UV lamp is beingreplaced, then the new UV lamp should always beinstalled in the UV lamp protective tube which isthe furthest away from the UV sensor measuringposition. In the event of lamp failure towards the end of themaximum lamp service life, all of the UV lampsshould be exchanged for new ones.

Maintenance

44

Clean the lamp protection tubes each time a lamp isreplaced.Dispose of the used UV lamps in accordance with theapplicable guidelines and directives. Usually these canbe disposed of together with used fluorescent tubes.

1. Switch off the UV system using the [START/STOP] key2. Switch off the master switch or disconnect from the mains

power supply3. Undo the UV lamp protection tube holder by hand4. Screw out the lamp cover far enough to permit disconnection

of the connecting cable plug from the UV lamp5. Fully remove the UV lamp and lay it to one side6. Check whether the O-ring on the UV lamp protection tube

holder is lying in the groove provided and is not damaged.Damaged seals are too be replaced.

7. Insert the new UV lamp into the UV lamp protection tube andallow it to project by approx. 100 mm

8. Plug the connector plug onto the plug9. Secure the lamp cover on the UV lamp protection tube holder

using the knurled nut, apply only minimal force to the knurlednut

10. Switch on the main switch or connect to the mains powersupply

1.Adjusting the warning and safety thresholdsAfter fitting a new UV lamp and cleaning of theUV system, the warning and safety thresholdsmust be checked and if necessary adjusted, see Chapter 4.12 Setting the warning thresholdon page 21 and Chapter 4.11 Setting thesafety threshold on page 20.

With the system switched off, use the [CHANGE] key to display the lamp hours and lamp turn-ons

2. Confirm with the [ENTER] key - [Request Access Code] willappear on the display

3. Enter the access code and confirm with the ENTER key -[Reset] will appear in the display4. Confirm with the [ENTER] key - the display will now be reset

7.3 Calibrating the UV sensor All new UV lamps need a burn-in time of 100 to 200hours. For this reason, the safety threshold andwarning threshold should be checked approx. 200operating hours after exchanging the lamp.

Reset UV lamp hours and UV lampturn ons

Maintenance

45

The UV sensor is pre-calibrated at the factory and does not have tobe calibrated again.

7.4 Replacement of the filter mats on the fan and the air outlet filter CAUTION!Soiled filter matsCause: Dirty filter mats on the fan and air outlet filtercan lead to the control cabinet overheating andbecoming damagedPossible consequence: Material damage.Measure: Replace the filter mats on the fan and the airoutlet filter at least once per year. The filter matsshould be replaced at shorter intervals in unfavourableambient conditions.

1. Switch off the UV system using the [START/STOP] key2. Switch off the main switch3. Remove the cover of the fan. To do so, insert your fingers

into the recesses on the bottom of the cover and remove thecover

4. Remove the dirty filter mat and insert a new filter mat with thewhite side facing inwards (control cabinet side)

5. Replace the filter mat on the air outlet filter as describedabove

6. Switch on the main switch Switch on the UV system.

Maintenance

46

8 Troubleshooting n User qualification, troubleshooting: trained user, see

Chapter 2.2 Users' qualifications on page 7

NOTICE!Troubleshooting on the open switch cabinet and thereplacement of components may only be done by anauthorised electrical engineer.

Message: Flashing downward arrow

Message: Flashing upward arrow The remaining free rinsing duration is displayed (instead of seconds, 2 squares flash).

Fault Minimum irradiance level undershot (after maximumfree rinse duration has expired)

Fault alert: UV sensor

Acknowledge fault alert with the [ENTER] key

Transition to emerg.service mode with display [CHANGE]key

55. 0 W/m210 h Operation20 On/Off

A0761

Fig. 32: Warning threshold transgressed

40.0 W/m2 F-rinseTime 00:11

A0762

Fig. 33: Safety threshold transgressed

Fault

UV sensorA0726

Fig. 34: Fault

Troubleshooting

47

Emerg.service: Safety threshold transgressed

System continues to run in emerg.service mode

Acknowledge fault alert with the [ENTER] key.

Fault description Cause RemedyWarning threshold undershot / safetythreshold undershot

Coating formed on the lamp protectiontubes

Clean the lamp protectiontube

Insufficient UV-transmission in thewater to be treated

Improve water quality

UV lamp at the end of its UV emissionservice life

Replace with new UVlamps

Incorrect lamp current Operate with rated current

UV sensor not correctly calibrated Recalibrate the UVsensor

1. Acknowledge fault alert with the [ENTER] key2. Transition to emerg.service mode with display [CHANGE]

key

em.serv.

UV sensorA0763

Fig. 35: Emerg.service

Faultxx lamp faulty Lamp #xx

A0765

Fig. 36: Fault: Lamp failureFault indication: xx lamp faulty

Troubleshooting

48

System continues to run in emerg.service mode

The number of failed UV lamps is indicated.In the event that more than one UV lamp has failed,the failed UV lamp can be called up using the [Up] and[Down]-keys.

Acknowledge fault alert with the [ENTER] key.

Fault description Cause RemedyFault: Lamp failure UV lamp xx defective Replace with new UV lamps

Incorrect lamp current Operate with rated currentBallast faulty Replace ballast

Fault alert: Other fault

Acknowledge fault alert with the [ENTER] key.

Fault description Cause RemedyOther faults External fault signal device triggered Eliminate cause of external fault

No external fault signal device connected and the contacts at the fault input are not bridged.

Jumper contacts at fault input

em.serv.xx lamp faulty Lamp #xx

A0764

Fig. 37: Emerg.service: Lamp failure

Fault Misc. fault

A0737

Fig. 38: Other faults

Troubleshooting

49

Fault alert: Voltage supply too low

Fault description Cause RemedyVoltage supply too low The supply voltage is or was lower than the minimum per

missible supply voltageCheck supplyvoltage

Fault alert: Bus fault

Fault description Cause RemedyBus fault Bus connection interrupted Restore bus connection

Insufficient supply voltage toone or more ballasts

Check the supply voltage and micro fuse in the ballast(only an electrician is authorised to do so)

Ballast faulty Replace the ballast (only an electrician is authorised todo so)

Fault alert: Memory error

Fault description Cause RemedyMemory error During self-testing, the control has

detected an error in the memoryReplace the control (only an electrician isauthorised to do so)

Faultline voltage too low

A0766

Fig. 39: Line voltage too low

Fault Bus fault

A0739

Fig. 40: Bus fault

Fault Memory fault

A0740

Fig. 41: Memory error

Troubleshooting

50

Fault alert: Default setting

Fault description Cause RemedyDefault setting During self-testing, the control has

detected an error in the memoryReplace the control (only an electrician isauthorised to do so)

Message: Lamp current

Fault description Cause RemedyLamp current fault Lamp current configured outside of per

missible rangeConfigure the lamp current within permissible range (see datasheet)

n User qualification, bus fault: Qualified electrician, see Chapter 2.2 Users' qualifications on page 7

Bus with ring topologyAs the data bus is configured in a ring topology, defective ballasts or an interrupted data connection meanthat the subsequent ballasts can no longer communicate.

Function and fault indications on ballastsThe three red LEDs on the ballasts serve for checkingfunctionality and fault finding. When the supply voltageis applied, all three LEDs light up for approx. 1 second.

Fault Basic Setting

A0741

Fig. 42: Default setting

Fault Lamp current

A0731

Fig. 43: Lamp current fault

Function and fault indications on ballasts

Troubleshooting

51

LED "supply voltage" (designation on board "Power")n on

Supply voltage to ballast is sufficientn off

despite the fact that the master switch is on and the mainsplug is inserted

Check supply voltage (only electrical technician) Check micro fuse

LED "lamp" (designation on board "Fault")n flashes approx. 1 to 15 sec

= lamp electrodes are preheated prior to ignitionn on

UV lamp fails to light up. If the supply voltage is switchedoff and on again, the LED goes out and will only light upagain after a further attempt to ignite

Check UV lamp

LED "Bus" (designation on board "Tx")n lights up every 0.1 to 3 sec

The ballast is in communication with the controller.n fails to light up

despite the UV system being switched on: The bus connection to the ballast is interrupted or the bal

last is faulty

Troubleshooting

52

9 Technical data This technical data supplements the enclosed datasheet.If in doubt, the information on the data sheet applies.

9.1 Performance data Type Quantity

UV lampUV lampPerformance(Watt)

ConnectorPerformance(Watt)

Max. flow rate(98%/cm transm.,400 J/m2)(m3/h)

Nominal widthConnector

1x75W 1 75 90 5.7 G 1 1/4 "1x80W 1 80 100 5.4 G 1 1/4 "1x130W 1 130 150 8.7 G 2 "1x230W 1 230 250 20.0 DN 652x230W 2 2x230 500 64.0 DN 1253x230W 3 3x230 750 117.0 DN 1504x230W 4 4x230 1000 184.0 DN 2005x230W 5 5x230 1200 228.0 DN 2006x230W 6 6x230 1400 273.0 DN 2007x230W 7 7x230 1700 369.0 DN 2508x230W 8 8x230 1900 418.0 DN 2509x230W 9 9x230 2100 467.0 DN 25010x230W 10 10x230 2400 514.0 DN 25011x230W 11 11x230W 2600 561.0 DN 25012x230W 12 12x230 2800 600.0 DN 250

Technical data

53

Type mm

Radiation chamber lengthmm

Min. free space forexchanging lamps(mm)

Empty weightOperating weight(kg)

1x75W 140 1115 910 12/271x80W 114 630 600 8/141x130W 114 940 900 10/201x230W 140 1,468 1400 24/462x230W 220 1,640 1500 41/963x230W 273 1,665 1500 53/1384x230W 324 1,690 1600 65/1505x230W 324 1,690 1600 70/1906x230W 406 1,790 1600 75/2007x230W 406 1,920 1600 115/3108x230W 406 1,920 1600 115/3109x230W 406 1,920 1600 130/32010x230W 406 1,920 1600 130/32011x230W 406 1,920 1600 130/32012x230W 406 1,920 1600 130/320

Technical data

54

Permissible operating temperatures:n Water temperature: 5 ... 70 C; 5 ... 30 C for Dulcodes 75Wn Ambient temperature: 5 ... 40 CRequirements of the water to be treated:n Maximum operating pressure: 10 bar*

* The permissible operating pressure is possibly lower withsystems that have a non-standard design, see the UVsystem data sheet

n No corrosive or abrasive properties, chloride content < 250ppm

n No tendency for sedimentationn Iron: 50 g/ln Manganese 20 g/ln Turbidity: 0.3 FNU

NOTICE!Chemical cleaning processesWhere UV systems are cleaned using chemicalcleaning processes (CIP), you must observe the following: do not use any corrosive cleaning chemicals, e.g.

HCl (hydrochloric acid) the maximum temperature of the CIP process must

not exceed the following values: 90 C for alkaline cleaning media 50 C for acidic cleaning media

Switch the UV system off during the CIP process

Technical data

55

9.2 Dimensions sheet 9.2.1 Dimension sheet Dulcodes W 75

Mains cable length approx. 0.3 m

Sensor cable length approx. 5 m

UV lamp cable approx. 1.3m

View

low

A0836

Fig. 44: Dimension sheet Dulcodes W 75* Fittings are not contained in the scope of supply

Type L1mm

L2mm

L3mm

L4mm

L5mm

LAmm

LFmm

LSmm

DKmm

ThreadDIN 2999

VolumeLitre

75W 250 935 1050 1115 1180 2150 124 605 139.7 Rp 1 1/4 15

Technical data

56

9.2.2 Dimension sheet Dulcodes W 80 and 130

UV lamp cable length approx. 2m

Sensor cable length approx. 5m = 80W/130W

low

A0837

Fig. 45: Dimension sheet Dulcodes W 80 and 130* Fittings are not contained in the scope of supply

Type L1mm

L2mm

L3mm

L4mm

LAmm

LMmm

R"

W 80 85 425 630 570 1230 96 1 1/4W 130 100 715 940 875 1840 98 2

Technical data

57

9.2.3 Dimension sheet Dulcodes W 230

FlangeUV lamp cable length

low

Flange

Sensor cable length approx. 5m

A0838

Fig. 46: Dimension sheet Dulcodes W 230 single UV lamp system* Fittings are not contained in the scope of supply

The radiation chamber can also be fitted with the flange aligned upwards

Single UV lamp system

Technical data

58

UV lamp cable length

low

Flange

Sensor cable length

low

A0839

Fig. 47: Dimension sheet Dulcodes W 230 two or three UV lamp system* Fittings are not contained in the scope of supply

The radiation chamber can also be fitted with the flange aligned upwards

TypeW

L1mm

L2mm

L3mm

L4mm

LAmm

LFmm

Hmm

DFmm

DKmm

FlangeDIN 2576 PN 10

2x230 300 1030 1640 1523 3140 190 193 250 219.1 DN 125x139,73x230 300 1030 1665 1532 3155 250 220 285 273 DN 150x168,3

Two or three UV lamp system

Technical data

59

UV lamp cable length

low

Flange

Flange

Sensor cable length

low

A0840

Fig. 48: Dimension sheet Dulcodes W 230 multiple UV lamp systemFittings are not contained in the scope of supplyThe radiation chamber can also be fitted with the flange aligned upwards

TypeW

L1mm

L2mm

L3mm

L4mm

L5mm

L6mm

L7mm

4x230/32 270 1000 1690 1531 175 230 10805x230/32 270 1000 1690 1531 175 230 10806x230/32 270 1000 1790 1590 175 230 10807x230/40 340 1050 1920 1720 215 300 11308x230/40 340 1050 1920 1720 215 300 11309x230/40 340 1050 1920 1720 215 300 113010x230/40 340 1050 1920 1720 215 300 113011x230/40 340 1050 1920 1720 215 300 113012x230/40 340 1050 1920 1720 215 300 1130

Multiple UV lamp system

Technical data

60

TypeW

LAmm

LFmm

DFmm

DKmm

FlangeDIN 2576 PN 10

4x230/32 3290 276 340 323.9 DN 200x219.15x230/32 3290 276 340 323.9 DN 200x219.16x230/32 3390 300 395 323.9 DN 250x2737x230/40 3520 350 395 406.4 DN 250x2738x230/40 3520 350 395 406.4 DN 250x2739x230/40 3520 350 395 406.4 DN 250x27310x230/40 3520 350 395 406.4 DN 250x27311x230/40 3520 350 395 406.4 DN 250x27312x230/40 3520 350 395 406.4 DN 250x273

9.3 Electrical data The fuses are located in fuse boxes with a bayonetlock, on the right of the terminal box of the control.

Radiation chamber:Lamp type Lamp current:HighFlux 130/230 W normal: 2.0 A

Maximum: 2.3 AMinimum: 2.0 A

Long Life 75 W not adjustable

ControlFuse Site of installation Part no.230 V AC,50/60 Hz

Upper fuse(self-supply by the control)

712048

230 V AC,50/60 Hz

Lower fuse(switched mains outputs XR1-XR3)

712033

Technical data

61

Nominal voltage230 V AC 10 %50/60 Hz

Contact inputs (-X3:1 ... -X3.6):for contacts or switching transistors:Open circuit voltage: 5V 0.5 VInput resistance: 10 kOhm

Voltage outputs (-X1:1 ... -X1.10):Type of contact: NOCLoad capacity: 250 V AC / 3 A / 100 VAWith inductive loads provide RC protection circuits!

Relay outputs (-X4:1 ... -X4.6):Type of contact: NOCLoad capacity: 250 V AC / 3 A / 100 VAWith inductive loads provide RC protection circuits!

Alarm relay (-X4:7 ... -X4.9):Type of contact: Changeover contactLoad capacity: 250 V AC / 3 A / 100 VAWith inductive loads provide RC protection circuits!

Standard signal output mA (-X3:7 ... -X3.8):0/4...20 mA, potential-freeMaximum load: 600 Ohm

Control cabinet

Technical data

62

10 Appendix 10.1 Spare parts drawings

A0773

1. 2.3. 4. 5. 6. 7.

8.9.

10.

12.13.

11.

Fig. 49: Spare parts drawings

10.2 Spare Parts List No. Description Part no. Replacement interval each1 UV lamp cable 3.5 m for UV systems from 2002

year of manufacture1017867 on request 1

1 UV lamp cable 7.5 m for UV systems prior to2002 year of manufacture

1024826 on request 1

2 O-ring UV lamp protection tube 31.75-3.53EPDM/P

1004920 after every opening ofthe radiation chamber

1

3 Teflon Ring 36.9/30.7 x 3 PTFE white 1002751 on request 14 O-ring UV lamp protection tube 31.75-3.53

EPDM/P1004920 after every opening of

the radiation chamber1

5 UV lamp protection tube 40 x 2 x 1000 mm Qfor 75 W UV systems

1020845 1

5 UV lamp protection tube 32 x 2 x 600 mm Q for80 W UV systems

1002467 on request 1

5 UV lamp protection tube 32 x 2 x 900 mm Q for130 W UV systems

1002468 on request 1

5 UV lamp protection tube 32 x 2 x 1400 mm Qfor 1 x 230 W UV systems

1002469 on request 1

5 UV lamp protection tube 32 x 2 x 1500 mm Qfor 2-5 x 230 W UV systems

1002470 on request 1

5 UV lamp protection tube 32 x 2 x 1600 mm Qfor 6-12 x 230 W UV systems

1002471 on request 1

6 UV lamp 75 W Long Life 1020911 10 -14,000 h 16 UV lamp 80 W High Flux 1002485 8 -10,000 h 16 UV lamp 130 W High Flux 1002486 8 -10,000 h 1

Appendix

63

No. Description Part no. Replacement interval each6 UV lamp 230 W High Flux 1002487 8 -10,000 h 1-127 O-ring screwed plug G 1/4 " 10.82-1.78 EPDM/P 1002754 on request 18 Screwed plug DIN 910 G 1/4 /71.4571 1002752 on request 19 O-ring for UV sensor 22.00-3.00 EPDM/P 1002175 on request 110 UVC-U-Sensor P/D/W/R G 3/4 " 71.4571 1028115 on request 110 UV conversion kit from 80 W conversion from I to

U sensor incl. UV sensor, sensor cable and compact control

1029846 on request 1

11 2m sensor cable for UV sensor 1029262 on request 111 5 m sensor cable for UV sensor 1021041 on request 111 10 m sensor cable for UV sensor 1028063 on request 112 O-ring screwed plug G 1/4 " 10.82-1.78 EPDM/P 1002754 on request 113 Screwed plug DIN 910 G 1/4 /71.4571 1002752 on request 1

Components in the control cabinetDescription Part no. Replacement interval eachBallast for Dulcodes 75 W 1029051 on request 1Ballast for Dulcodes 80 W, 130 W, 230 W 731210 on request 1-12Replacement filter mat for the control cabinet ventilation

1004212 on request 2

Appendix

64

10.3 Dulcodes wiring diagram WARNING!Mains voltage on protective low voltagePossible consequence: Fatal or very serious injuries.Measure: If connecting the protective low voltage(SELV) to one of the X4 terminals, the X4 terminalsmust not be connected to mains voltage.

9PE

Relay outputsDigital inputs

SHUT-OFF VALVE

OUTPUT 230V

FLUSHING VALVE

FEED PUMP

WARNING THRESHOLDRELAY

SAFETY THRESHOLDRELAY

ALARM RELAY

FLOW / TEMPERATURE

PAUSE

FAULT

INTERFACE

DEFAULT OUTPUT

INPUT

XR7:2

UV SENSOR

Defaultsignal

output(only internal)

Voltage outputs

Fan(optional)

A0774

Fig. 50: Dulcodes wiring diagram