Crusader CWS5-031 Bedienungsanleitung

OWNERS MANUAL

Operation & Installation Instructions

CWS5-031, CWS5-061, CWS5-101, CWS5-151, CWS5-

201, CWS6-061, CWS6-101, CWS6-151, CWS6-201

www.crusaderwater.com

Congratulations on purchasing this ultraviolet disinfection system. By purchasing a Crusader Water

Systems UV Disinfection system you are receiving not only a high quality product but also peace of

mind. Protecting your water supply with a UV system gives you reassurance that your family will

have access to safe drinking water throughout your entire home with no chance of microbiological

contamination. This is chemical free process which is simple in its concept and effective in its

abilities to inactivate microorganisms present in the water supply. Simple maintenance, continuous

disinfection and ultimately safe water, Crusader makes it that easy.

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TABLE OF CONTENTS

Safety Considerations........................................................................................... 4

Before You Begin .................................................................................................. 4

Water Quality Parameters: .................................................................................. 5

Assembly .............................................................................................................. 6

System Sizing ........................................................................................................ 6

Location................................................................................................................ 7

Installation............................................................................................................ 7

System Disinfection ............................................................................................ 11

Cleaning the Quartz Sleeve ................................................................................ 12

Operation ........................................................................................................... 13

Crusader5.0 & Crusader6.0 Controller .............................................................. 13

Crusader5.0 & Crusader6.0 Power-up Sequence .............................................. 14

Crusader5.0 Operational Screens ................................................................... 15

Crusader6.0 Operational Screens .................................................................... 16

Crusader6.0 % UV Intensity ............................................................................. 16

Crusader5.0 & Crusader6.0 Lamp Countdown Sequence ................................. 17

Crusader5.0 & Crusader6.0 Lamp Countdown Reset Sequence ....................... 18

Crusader5.0 & Crusader6.0 Failure Modes ....................................................... 18

Crusader5.0 & Crusader6.0 QR Codes .................................................................. 19

Crusader5.0 & Crusader6.0 Expansion Modules .................................................. 20

Warranty Registration ........................................................................................ 21

Crusader6.0 Specifications.................................. Error! Bookmark not defined.22

Crusader5.0 Specifications...................................................................................23

Limited Warranty Statement: ............................................................................ 24

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Safety Considerations

Although your UV system has been manufactured to the highest safety standards, extreme care

must be followed when operating and/or maintaining your system.

1. Whenever you are servicing this equipment, always disconnect the power cord from the

electrical outlet.

2. As the energy given off by the UV lamp can be harmful to your eyes and skin, NEVER

look directly at an illuminated UV lamp without adequate eye protection and always

protect your skin from direct exposure to the UV light.

3. To ensure the system provides adequate disinfection, ALWAYS replace any component

(lamp and sleeve) with a genuine manufacturer’s replacement part.

4. Do not operate the unit if it has any damaged or missing components.

5. To avoid possible electrical shock, use only with a properly grounded electrical outlet.

6. Never perform any maintenance to the system unless you are comfortable in doing so.

Contact the manufacturer for service instructions if required.

7. Do not use this system for any purpose other than what it was intended for. Misuse of

this system could potentially cause harm to the user.

8. Your system is intended to be installed indoors and away from leaking plumbing. DO

NOT plug the unit in if the system or any of the components are wet.

9. The disinfection system should be directly installed into a ground fault circuit interrupter

(GFCI). If the use of an extension cord is required, the cord must be manufactured with a

minimum of 16 gauge wire and care should be taken to avoid potential tripping hazards.

10. We recommend that a licensed plumber or certified technician perform the installation

Before You Begin

Before you begin, you’ll need the following:

Tools

Pipe cutter, hacksaw or other specialized tools required to cut into your existing

plumbing (e.g. if you have PEX piping)

Soldering tools (torch, flux, emery cloth and solder)

Wrench (for tightening fittings)

Other Materials

Inlet/outlet connections

Teflon™ tape

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Water Quality Parameters:

UV disinfection is extremely effective against microorganisms but only if the UV light can pass

through the water it needs to treat. This means that the quality of your water is very important in

order to ensure complete disinfection.

It is imperative that you have your water tested for at the least the parameters listed below. If the

water exceeds the listed parameters Crusader strongly recommends that appropriate pretreatment

equipment be installed (pretreatment will depend on parameters being treated):

Hardness: <7 gpg (120 mg/L) –if hardness level is 7 gpg or

slightly below the quartz sleeve must be cleaned

periodically in order to ensure efficient UV

penetration; if above the water must be softened

Iron (Fe): <0.3 ppm (0.3 mg/L)

Manganese (Mn): <0.05 ppm (0.05 mg/L)

Turbidity: < 1 NTU

Tannins (organics): <0.1 ppm (0.1 mg/L)

UVT (transmittance): >85% (Please contact Crusader if water has a UVT

that is less than 80% for pre-treatment

recommendations)

You can have your water tested at a private analytical laboratory or by your local dealer. It is

always recommended to install pre-filtration of at least 5 microns prior to a Crusader UV

disinfection system.

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Assembly

Step 1: Unpack the system and ensure all the components are included with the system. Your

system is shipped with the following components:

System Sizing

All Crusader UV systems are rated for a specific flow rate under specific water quality parameters.

The equipment has been designed to ensure that the appropriate dose will be delivered provided

all parameters are followed. PLEASE NOTE that the flow rate for each system can be higher or lower

than what the system is rated for however this will change the dose level that the system will

deliver. A lower flow is not a concern as the dose will increase however a higher flow rate will

decrease the dose and therefore compromise the microorganism inactivation.

It is important to know the maximum flow rate that your water system delivers. If you do not have

this information you can simply fill a 1 gallon bucket with water and time how long it takes to fill up.

This will be the maximum flow rate for the home. Choose a Crusader system that is suitable.

PLEASE NOTE: It is always better to oversize your system then to undersize. For example, if your

pump delivers 8 gpm it is recommended to install any of the Crusader 10 gpm systems. There will

come a time where your home is using water at the pump’s maximum capacity.

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Figure 1. Lamp Removal

Spacing

Location

Step 1: Find a suitable location to mount the

UV reactor and the accompanying controller. In

choosing your location ensure the controller is

located within 5 feet of a ground fault circuit

interrupter (GFCI) and that there is easy access to

the main cold water line prior to any branch lines

and before the hot water heater. If you have any

other water treatment equipment, such as a

softener or water filter, ensure that the UV is the

last piece of treatment equipment. PLEASE

NOTE: All Crusader UV disinfection systems are

intended for indoor use only as they should not

be exposed to the elements.

Step 2: Your system includes mounting

hardware for both the UV reactor and the

controller. If the supplied fasteners are not

compatible with the structure in which you are

mounting the device, please ensure you use the

correct fasteners.

Step 3: To facilitate lamp removal, ensure

there is enough space at the lamp connector end

to safely remove the UV lamp and/or quartz

sleeve (a space equal to the length of the unit will

suffice) (see Figure 1.).

Installation

Step 1: The UV disinfection system should

always be the last piece of treatment before the

water branches off to the hot and cold water lines

if the intent is for Point of Entry (POE) (see figure

2). If the intent for the UV system is for Point of

Use (POU) the system should be the final step before the

faucet.

Step 2: Crusader strongly recommends that a 5 micron filter be installed before the UV system

for a final polishing step before the water is disinfected.

Step 3: The reactor can be installed either horizontally or vertically using the clamps provided,

however vertical installation is the preferred method with the inlet at the bottom (lamp connection

at the top) as it allows any air that may be in the lines to be easily purged from the system.

Step 4: If the water supply flow rate is unknown, it is recommended that you use a flow

restrictor so that the rated flow of your particular Crusader system is not exceeded and the UV dose

is not compromised. The flow restrictor should be installed on the outlet port of the reactor.

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Step 5: It is strongly recommended to have a licensed plumber connect the UV reactor to the

water supply and may be a requirement depending on where you are located. If you are attempting

this yourself, ensure you have all the necessary tools and fittings to accomplish this task.

Step 6: Although there are many methods of installation, this manual will provide a

recommended procedure using copper plumbing and standard soldering methods. Crusader

recommends the use of unions, a by-pass assembly and shut-off valves as this will allow you to

isolate and remove the UV reactor if necessary (this method is a recommended method only

however it allows for the maximum convenience but it requires extra components and more time

for installation. Please refer to Figure 3 for the recommended installation.

Figure 2. Recommended POE Installation

Figure 3. Recommended Installation

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Step 7: Before you cut into the cold water line, measure and cut all piping as per the

recommended layout. Once all the components are ready, start by installing the female adapters

onto the ports of the reactor. To ensure a proper seal, the use of Teflon™tape is recommended on

all threaded connections.

Step 8: Next solder all the assembly together, including ball valves and unions and finally

connected the by-pass assembly to the cold water feed line (water in and water out).

Step 9: You can now gently remove the quartz sleeve from its packaging being VERY careful not

to touch the length with your hands. The use of cotton gloves (not included) is recommended for

this procedure as oils from our hands can leave residue on the sleeve and lamp which can

ultimately block the UV light from getting to the water. In the package, you will find a lubricated o-

ring. Place the o-ring over the open-end of the sleeve as shown in Figure 4.

Figure 4. Quartz Sleeve Installation

Step 10:Carefully slide the sleeve into the reactor until you can feel it hit the opposite end of the

reactor. Slightly push the sleeve in to feel it lock into the spring inside the reactor. Ensure that the

o-ring is butted up against the reactor. Assemble the provided gland nut onto the threaded end of

the reactor and tighten. The gland nut has a positive stop to avoid over-tightening, hand tighten

ONLY. Install the provided stainless steel compression spring inside the quartz sleeve. This spring

simply sits in the bottom of the quartz sleeve and works with the lamp and lamp connector to

create the proper lamp alignment. PLEASE NOTE: DO NOT install a UV lamp inside the quartz sleeve

without the sleeve spring in place.

Step 11: (Applies only if you have a UV sensor… Crusader6.0)The UV sensor for the system is

packaged in a separate plastic bag. Carefully remove the sensor from its packaging and insert the

sensor into the UV sensor port (remove the protective cap on the UV reactor first). The sensor can

only go in one way. Ensure that the flat portion of the UV sensor matches up with the half metal lip

on the sensor port (flat portion should face the lamp connection end) (see Figure 5.). Ensure that

the sensor is fully seated in the sensor port and then tighten (turning clockwise) the sensor nut.

PLEASE NOTE: DO NOT over tighten the nut as this could damage the Teflon sensor body. Plug the

male connector into the IEP port located on the right side of the controller, Figure 6, (make sure the

controller is not plugged in as the sensor MUST be attached before power is applied to the

controller.)

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Figure 5. UV Sensor Installation Figure 6. IEP Connection

Step 12: The reactor is now ready for water flow. When all plumbing connections have been

completed you should check for any possible leaks. Slowly turn on the water supply and check for

leaks. Make sure the by-pass valves are functioning properly and that the water is flowing through

the reactor. The most common leak is from the o-ring not making a proper seal on the reactor. If

this is the case turn the water off, drain the reactor, remove the o-ring, dry it and reapply silicon

grease. Replace o-ring ensuring that it is properly sealed against the reactor and check again for

leaks.

Step 13: The controller can now be mounted on the wall. The controller should always be above

or beside the reactor to ensure that no moisture can deposit on any of the connections (see Figure

2.). Always mount the controller vertically. For safety purposes the controller should be connected

to a ground fault circuit interrupter (GFCI) (also known as a ground fault interrupter (GFI)).

Step 14: You can now remove the UV lamp from its packaging being careful not to touch the lamp

quartz with your hands. Again, the use of cotton gloves is recommended to avoid deposited oils on

the lamp glass. Always hold the lamp by the ceramic ends. With the lamp outside of the reactor,

affix the UV lamp to the lamp connector as shown in Figure 7.

Figure 7. UV Lamp Connection

Step 15: Carefully insert the UV lamp into the reactor sliding it inside the quartz sleeve located

inside the reactor (do not drop the lamp into the reactor). Affix the lamp connector into the gland

nut by inserting the connector into the nut and turning the connector approximately ¼ turn to lock

the connector to the gland nut.

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