Installation Guide for Trojan UV Systems
- Determine installation location referring to the information shown in the diagrams above.
- Attach Cell Clamp to the wall.
- Insert Reactor and tighten clamp.
- Mount power supply to wall.
- Attach both ground wire (yellow) and strain relief (red) to the screw located beside the lamp port (outlet end). Secure both wires with locknut provided.
- Insert Lamp/Sleeve assembly. Ensure o-ring and seating area are clean prior to assembly. Carefully place the lamp/sleeve assembly into the cell. Center it with the spring in the opposite end of the cell and screw the assembly into the cell. Once the o-ring begins to sit in position, place an adjustable wrench on the flats of the sleeve bolt and tighten sleeve bolt 1/4 turn. Caution: Over-tightening the sleeve bolt will break the quartz sleeve.
- Attach Lamp Harness to lamp. If you are attaching the harness for the first time, place the eyelet of the green/yellow ground wire and the red strain relief wire onto the ground stud of the cell weldment. Screw the lock nut onto the ground stud to secure the connectors of the ground wire and strain relief wire. Note: while tightening the lock nut ensure that the eyelets are turned sideways toward the sleeve bolt. This is to ensure that the eyelets and wires are not sticking out of the side of the cell weldment and will be covered by the gray plastic cap. Push the plug onto the end of the lamp while ensuring that the male tab on the lamp end meets with the female tab on the plug. Ensure the green/yellow ground and red strain relief wires are tight against the sleeve bolt so that the cap will cover them. Push or snap on the gray plastic cap while ensuring that the wires are not in the way of the snap fingers or the support ridges that are on the inside of the cap.
Once the UV system is installed, any contamination in the distribution lines between the UV system and your taps and water outlets (i.e., the downstream distribution lines) must be removed. Similarly, if your power goes out and your TrojanUVMax system is not equipped with an automatic shut-off feature, you must also disinfect the downstream distribution lines.
To perform this cleaning operation, first remove any filter housing and fill the filter container with bleach (remove the filter for this process). Plug in the power supply to illuminate the UV lamp. Replace the filter housing and allow water to flow to all faucets (hot and cold), your washing machine, and all toilets. Once you can smell the bleach, allow it to sit in the lines for two to four hours, then completely flush all the lines a minimum of five minutes and replace the filter. Any contamination will have been removed.
The lamp must be replaced after 12 months of operation. Failure to replace the lamp will reduce the disinfecting strength of the system. Note: when the UV system is first plugged in, the alarm will sound temporarily until the lamp is operational.
Power Supply
Includes an auto ranging constant current power supply that will accept 90-265v at 50 or 60Hz.
Visual Alarm
During normal operation the LED will be green. The LED will turn amber after 11 months of operation or, if the sensors detect a low UV signal. The LED will turn red if the lamp is not operating properly or if the UV signal from the sensor is below the set point. After 12 months of lamp operation, the LED will turn red, indicating that the lamp must be replaced. The LED is always on while the lamp is on.
Audible Alarm
During normal operation no beeping sound is emitted. If the lamp is not operating or the UV signal from the sensor is low, the unit's alarm will beep. After 12 months of lamp operation, the unit's alarm will beep.
Elapsed Time Meter
The Elapsed Time Meter shows you the number of months that your lamp has been operating. You should replace the lamp after it has been operating for 12 months. After 11 months the LED is amber. After 12 months the LED turns red and an alarm sounds. After 14 months the alarm postpone is disabled, indicating that the lamp should be replaced and that it is not providing proper disinfection. After lamp replacement, this meter should be reset.
Dry Contacts
This feature provides switching for the operation of a solenoid valve or remote alarm. When the LED turns red because the lamp is not operating properly or the UV sensor signals that the UV output is low, the contacts will open causing the solenoid to stop the water flow or a remote alarm to sound. The dry contact remains closed if the LED turns red because the lamp has been in operation for 12 months or more. Remote Options Cord must be ordered to use Dry Contacts.
UV Intensity Monitor
The UV Intensity Monitor measures the lamp's UV intensity and monitors whether the intensity is above the minimum required for proper disinfection. The sensor is factory calibrated and is not field adjustable.
- Shut off water supply upstream of the UV system.
- Open a tap downstream of the UV unit to release pressure, then close this tap.
- Unplug the power supply.
- Let the lamp cool for 5 minutes.
- Remove the lamp harness: Release the safety clips by gently applying outward pressure on the finger tabs and push off the gray plastic cover or gently squeeze the sides of the cover adjacent to the snap fingers. A flat screwdriver may be required to lightly pry the snap fingers over the snap ridges. Do not pry too hard on snap fingers. When the cover is removed you can pull the lamp plug off the lamp end. Caution: do not pull on the lamp harness cord to remove the plug.
- Position a pail under the black plastic end to prevent spillage.
- Unscrew the lamp/sleeve assembly and carefully remove the lamp and sleeve from the cell. (Handle lamp/sleeve at ends only). A wrench can be placed on the flat sides of the sleeve bolt, just below the snap ridges.
- To remove the lamp from its sleeve, use a glove or cloth to support and hold on to the lamp and sleeve. Unscrew the lamp from the sleeve bolt. Be careful not to drop the sleeve. Place the adjustable wrench on the flats at the side of the sleeve bolt and a screwdriver shaft into one of the slots in the top of the lamp end.
- Ensure o-ring and seating area are clean prior to assembly. Place the o-rings and the sleeve bolt on the quartz sleeve and put the lamp into the quartz sleeve. Be careful not to angle the lamp while inserting it into the quartz sleeve. If excessive force is applied, the outward pressure on the inside diameter of the quartz sleeve will cause it to fracture.
- Slide the lamp into the quartz sleeve until the top of the sleeve meets the bottom of the groove in the lamp end. Screw the lamp end and sleeve bolt together while ensuring that the quartz sleeve remains at the bottom of the groove in the lamp end. Once the o-ring begins to sit in position, place a screwdriver shaft in one of the slots in the top of the lamp end and an adjustable wrench on the flats at the side of the sleeve bolt. Further tighten the lamp end 1/5th of a revolution. Caution: do not over tighten. Over tightening will break the quartz sleeve.
- Ensure o-ring and seating area are clean prior to assembly. Carefully place the lamp/sleeve assembly into the cell. Center it with the spring in the opposite end of the cell and screw the assembly into the cell. Once the o-ring begins to sit in position, place an adjustable wrench on the flats of the sleeve bolt and tighten sleeve bolt 1/4 turn. Caution: Over-tightening the sleeve bolt will break the quartz sleeve.
- If you are attaching the harness for the first time, place the eyelet of the green/yellow ground wire and the red strain relief wire onto the ground stud of the cell weldment. Screw the lock nut onto the ground stud to secure the connections of the ground wire and strain relief wire. Note: while tightening the lock nut ensure that the eyelets are turned sideways toward the sleeve bolt. This is to ensure that the eyelets and wires are not sticking out of the side of the cell weldment and will be covered by the gray plastic cap. Push the plug onto the end of the lamp while ensuring that the male tab on the lamp end meets with the female tab on the plug. Ensure the green/yellow ground and red strain relief wires are tight against the sleeve bolt so that the cap will cover them. Push or snap on the gray plastic cap while ensuring that the wires are not in the way of the snap fingers or the support ridges that are on the inside of the cap. If the sleeve required cleaning, the UV intensity sensor will also need cleaning. Refer to Cleaning the UV Sensor section
- of the instructions.
- Reconnect the power supply and check that the LED is green. The alarm will sound until the lamp operates properly.
- Close the downstream faucet that you opened earlier, open the waterline, and check for leaks.
Note: During lamp replacement, the ground and strain relief wire of the lamp harness should always remain connected to the stud on the water reactor chamber. Wires are fastened to the stud by a lock nut.
- Always disconnect the power to the power supply before installing, servicing or maintaining the UV system. To avoid injury, avoid directly exposing skin or eyes to UV light. After disconnecting the power, allow the system to cool for five minutes. Shut off the water to the unit and open a downstream tap to release the pressure.
- Inspect the o-ring on the UV sensor for damage or wear. Ensure that the o-ring and seating area are clean prior to assembly. Insert the UV sensor into the port in the water reactor chamber. Screw the brass nut on finger tight (a wrench should NOT be needed for tightening, although a 15/16" open-ended wrench or adjustable wrench with 1" jaws may be lightly used).
- Connect the power to the power supply and check that the LED is green. The alarm may sound until the lamp is operating properly.
- Close the downstream tap and open the water supply line to pressurize the system and check for leaks.
- Shut off the water.
- Open a tap downstream from the unit to release pressure.
- Unplug the power supply.
- Let the lamp cool for five minutes.
- To remove the UV sensor, undo the large brass nut holding the UV sensor in place and withdraw the UV sensor. A 15/16" open-ended wrench or adjustable wrench may be required to loosen the brass nut.
If the water is not sufficiently pre-treated, the lamp quartz sleeve in the water reactor chamber may require periodic cleaning to remove accumulation of iron or hardness.
- Follow the steps in the Installation or Replacement of UV lamp/sleeve section to remove the lamp/sleeve.
- Clean the lamp/sleeve by using a commercial scale remover such as Lime-A-Way or CLR on a high-quality lint free cotton swab. When using acidic solution (scale remover) follow the manufacturer's directions for proper use and safety. After the lamp/sleeve is cleaned, handle it by the ends only.
- Follow the steps in Installation or Replacement of UV Lamp/sleeve section to install the lamp/sleeve.
Note: Keep lamp and lamp pins dry. Handle lamp/sleeve at the ends only. If the lamp/sleeve requires cleaning, the UV sensor will likely require cleaning as well. Refer to the Cleaning the UV Sensor section for instructions.
- Follow the steps in the UV Intensity Monitor and Installation Removal section to remove the UV sensor.
- Clean the quartz window of the UV sensor with a commercial scale remover (such as Lime-A-Way or CLR) on a high-quality lint free cotton swab. When using acidic solution (scale remover), follow the manufacturer's directions for proper use and safety. Inspect the window to ensure that it is clean, clear and dry.
- Follow the steps in the UV Intensity Monitor and Installation Removal section to install the UV sensor.
Note: Do not attempt to tighten, loosen or open the sealed UV sensor probe. Contamination of the UV sensor or loss of function may result. Note: You may need to use other types of cleaners depending upon the minerals in your water supply. Vinegar or isopropyl alcohol or both can be used to remove grease and film on the UV sensor, but they may not fully remove scaling. In such cases, use a commercial scale remover such as Lime-A-Way or CLR.
Note: If you find that you have to clean the sensor frequently, you should have your pre-treatment equipment evaluated and possibly upgraded.
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