Lifegard Aquatics R450107 Pro-max Ultraviolet Sterilizer Instruction Manual

LIFEGARD AQUATICS R450107 Pro-MAX Ultraviolet Sterilizer

Lifeguard Aquatics introduces the Pro-MAX™ UV Sterilizer, featuring a patent-pending, flow-through design with less restrictive angled inlet and outlet ports requiring less plumbing. This unique design enables easy installation of new or replacement systems as it can be positioned in multiple ways to fit any tight space. Available with 3ʺ housing in 25, 40, 55, 90 and 120 Watt models and 5ʺ housing in 55, 90 and 120 Watt sizes. Each Pro-MAX™ features a High Output UV Bulb, Internal Protective Sleeve, and UL Listed Ballast which counts down the number of days until you need to replace the bulb. Maximum Operating Pressure 30 PSI.

3″ Amalgam High Output UV 55W, 90W and 120W	5″ Amalgam High Output UV 55W, 90W and 120W	3″ Standard High Output UV 25W and 40W

When you receive your Pro Max UV Sterilizer open the box and familiarize yourself with the parts breakdown in line drawing at the end of the instruction booklet.

Setup Instruction:

• The UV comes semi-assembled. You need to install the quartz sleeve (#14), the gaskets (#16 and #19), the bulb (#17) and connect the ballast.
• Remove to 2” nuts (#1) holding the inlet/outlet elbows (#23), on the UV clear cap  (#15) and UV end cap (#2) (total 4 individual 2” nuts on the UV). Once the parts are removed you will see the O-rings (#3). Make sure they’re installed properly .
• Once a year these O-rings (#3, 8, 16, 19 )need year servicing by applying aquatic friendly silicone lubricant to make sure they don’t get brittle or crack.
• Look at the UV clear cap (#15). It has a tapered hole on the inside of the threads.
  The other end of the sterilizer is the UV end cap (#2). It has a hold on that holds the Quartz sleeve (#14) and acts as the quartz sleeve guide. When you are installing the quartz sleeve it will sit inside the UV end cap. It makes sure that the quartz sleeve is perfectly aligned and in the center of the sterilizer.
• When you look inside the 2” openings you will notice there is a white protective sleeve (#7, 13) on the inside of the UV. This is the replaceable sleeve that you need to service once a year to make sure that the UV light damaged does not extend to the black UV housing. We will cover this again in the service section at the end.
• Now put the clear fittings back and hand tighten the nuts and make sure they close and seal properly.
• When you open the UV box you will notice two additional boxes. The smaller box contains the UV ballast and the larger box contains the UV bulb (#17) and quartz sleeve (#14). Please note that the 3” Size UV in 25 watt and 40 watt have a standard UV bulb and a standard UV ballast. The 3” and 5” Size UV’s in 55 watt, 90 watt and 120 watt have an amalgam UV bulb and a amalgam UV ballast with a day counter.
• Remove the ballast from the box you will see the parts .
• The small bag in the UV box containing one O-ring (#19) and a larger tapered/flat Gasket (#16).
• Familiarize yourself to the part and note where the White 4-pin connector of the UV ballast is located.
• From right to left you will see the white 4-pin connector followed by the plastic quartz sleeve cap (#20) followed by the tapered rubber gasket ‘seal’ (#21) to seal the cable and finally the UV sealing cap (#22).
• Install the small O-ring (#19) inside the quartz sleeve cap as shown in the image below. Make sure the O-ring fits properly in the round gap. You can use the quartz sleeve to gently push it in or just use your fingers to make sure it’s flashed all the way. This is where the Quartz Sleeve will slide in to make a moisture resistant seal.
• Open the do box for the quartz sleeve. You have to be very careful and gentle when working with the quartz sleeve and UV bulb as it can break or crack with force and can result in injury. Take Extreme Caution and don’t use force when installing the quartz sleeve and UV bulb.
  Install the tapered/flat quartz sleeve rubber gasket (#16) as shown below with the tapered end going on to the quartz sleeve first and the flat end close to the quartz sleeve opening. NOTE: As precautions make sure to wipe off any fingerprints or oil residue from the quartz sleeve and the UV bulb if it comes in contact with your hand. Quartz sleeve and bulb need to be residue-free otherwise it can result in a burn mark which can reduce the effectiveness of the UV. Gently slide in the quartz sleeve into the UV Housing as shown in the figure below and make sure it reaches the back and of the UV end cap and sits into the guide assembly as discussed earlier.
• First time setup – It is easier if you stand the Pro Max UV on the Flat view port side and install the quartz sleeve. Let gravity hold it in place.
• Open the tube for the UV bulb (#17). Here just for reference and amalgam bulb has one or two mercury dots close to the middle of the bulb. This mercury dot is an indication of the amalgam bulb. The standard high-output UV bulb for 25 and 40 watt UV are not Amalgam so they don’t have this dot.
• Before you install the bulb inside the quartz sleeve – note that the male end 4-pin connector of the bulb has to match the 4-pin connector of the ballast. They’re not Square they more rectangular so you need to align them properly otherwise you can damage the bulb or the ballast end. Make sure the two 4-pin connector (bulb end and ballast end) are flushed all the way.
• Gently slide the bulb inside the quartz sleeve. Followed by the thin wires (In order to properly place the wire of the UV bulb inside the  quartz sleeve – you can ring the wire around your finger and gently slide  it inside the quartz sleeve), followed by the two connected 4-pin connectors.
• Push the bulb into the quartz sleeve using the ballast 4-pin connector. Be careful and gentle – Applying force can damage the quartz sleeve. As shown in the image below press the quartz sleeve cap on to the quartz sleeve so it is flushed with the tapered/flat rubber gasket. Make sure the tapered/flat rubber gasket fits flat on top of the quartz sleeve cap and there is no space. Press the tapered rubber  gasket onto the quartz sleeve cap and press it in. This will make the seal on the cable and the sleeve so that moisture does not get in.
• Now Slide the UV bulb and Quartz sleeve into the UV housing through the UV Cap Clear and make sure it goes into the back and slides into the quartz guide as discussed before.
  First time setup – It is easier if you stand the Pro Max UV on the Flat view port side and install the quartz sleeve. Let gravity hold it in place.
  Close the UV Cap nut on to the UV clear cap. Hand tighten it to make sure it is closed properly.
  
• Connect the power cable into the ballast. Please note that for the amalgam style ballast have a day counter and the power cable is detachable from the ballast. While for the standard 25 watt and 40 watt UV ballast does not have a counter and the ballast has the cable permanently connected.
• Connect the UV ballast power cable to a GFCI protected socket. Make sure to Loop the cable so moisture or water does not go near the power cables. Press the counter button, you will hear a beep and the day counter will begin with 365. The green LED light indicated that the UV bulb and UV ballast are working properly. In case something is wrong or the bulb goes out or there is moisture or water damage the red light will show.
• Your UV has to clear view ports on either end where you can see the blue UV light indication your Pro Max UV is working fine.

Service

UV requires annual servicing. You need to change the bulb once every 12 months. After 12 months of use the bulb light may be on but the UV output gets reduced beyond effectiveness. So it is recommended you change the bulb every 12 months even if it is working. Turning the UV on/off reduces the life of the UV bulb.
In addition you also need to service the O-rings and Gasket. You can use silicone lubricant to protect the gaskets. If you notice any gasket has cracks or is dry promptly change it to avoid any further damage.
But protective sleeve on the inside of the UV needs to be replaced once a year to make sure the UV does not damage the actual housing.

• To service your UV unscrew the four stainless steel housing bolts or Housing Lock Nuts (#4, #6).
• When you remove the inlet/outlet or end caps you will notice the large O-ring – the Housing O- ring (#8).
  Once the sides are removed you will see the white protective / reflective sleeve (#7, #13).
  These sleeves have a reflective coating that increases the efficiency of the UV contact and output.
  Every Pro Max UV has three sections of protective sleeves one large sleeve for the center housing pipe (#12) and two for the end caps (#5).
• Note there is a notch on one end of the protective sleeve for the end caps. Aligning the notch with the guide makes you’re your protective sleeve is installed properly and the inlet/outlet openings are not restricted.
  Once you replace all the protective sleeves and have serviced all the O-rings you can close and seal the end caps by gently tightening the stainless steel nuts.

Replacement Parts

Match the parts to the diameter of your Pro Max UV 3” or 5”. Several parts are common

Lifeguard Aquatics, 16301 Carmenita Road, Cerritos, CA 90703
Phone – 562 404 4129
Fax – 562 404 4159
Email – [email protected]
www.lifegardaquatics.com