bersonInLine UV-System

Users manual

Model
Edition
Version

: bersonInLine
: February 2002
: IL-Am-20020214

Berson Milieutechniek B.V.

PO Box 90
5670 AB Nuenen
The Netherlands
Tel. : +31 (0)40 2907777
Fax. : +31 (0)40 2835755
E-mail : Sales@bersonuv.com

bersonInLine is a registered trademark of Berson Milieutechniek B.V..

Copyright 2002 Berson Milieutechniek B.V.
All rights and subsequent amendments reserved.
No part of this publication may be reproduced, printed, photocopied, stored on microfilm
and/or otherwise made public in any form whatsoever without obtaining the prior written
permission of Berson Milieutechniek B.V.

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Contents

INTRODUCTION ......................................................................................................................... 5

1.1
1.2
1.3
2

SYSTEM OBJECTIVE....................................................................................................5
DOCUMENTS ..............................................................................................................5
DOCUMENT CONVENTIONS .........................................................................................5

SAFETY ......................................................................................................................................... 6

2.1
2.2
2.3
2.4
2.5

PICTOGRAMS AND GENERAL SAFETY INSTRUCTIONS .................................................6

SYSTEM SAFETY FEATURES .......................................................................................7
BROKEN LAMPS OR QUARTZ SLEEVES ........................................................................7
RECOMMENDED USE ..................................................................................................8
NON-RECOMMENDED USE ..........................................................................................8

STORAGE AND TRANSPORT .................................................................................................. 9

SYSTEM DESCRIPTION.......................................................................................................... 10

4.1
4.2
4.3

DISINFECTION CHAMBER ..........................................................................................10

POWER SUPPLY AND CONTROL ................................................................................12
OPTIONS ..................................................................................................................14

4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7

4.4
5

INSTALLATION AND PUTTING INTO OPERATION ....................................................... 17

5.1
5.2
5.3
5.4
6

GENERAL..................................................................................................................17
MECHANICAL INSTALLATION .....................................................................................17
ELECTRICAL INSTALLATION ......................................................................................17
PUTTING INTO OPERATION .......................................................................................18

OPERATION............................................................................................................................... 19

6.1
6.2
6.3
7

Automatic control systems ............................................................................................... 14

Manual cleaning .............................................................................................................. 14
Automatic cleaning (AutoWipe) .................................................................................... 14
UltraWipe cleaning system .............................................................................................. 15
Solenoid valve.................................................................................................................. 15
Power level switch ........................................................................................................... 15
Eco control ...................................................................................................................... 15
ACCESSORIES ..........................................................................................................16

GENERAL..................................................................................................................19
MANUAL CLEANING SYSTEM (OPTIONAL) ..................................................................19
AUTOMATIC CLEANING SYSTEM (OPTIONAL) .............................................................19

CHECKS, MAINTENANCE, REPAIRS AND SETTINGS ................................................... 20

7.1
7.2

CHECKS ...................................................................................................................20
MAINTENANCE ..........................................................................................................21

7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9

7.3

Cleaning the quartz sleeves ............................................................................................. 21

UV-sensor and quartz probe............................................................................................ 22
Ventilation of the control cabinet(s) ................................................................................ 22
Ground fault circuit breaker check.................................................................................. 23
Manually operated cleaning mechanism (optional) ........................................................ 23
Automatic cleaning mechanism (optional) ...................................................................... 23
Replacing the UV lamps for InLine-20, -50, -125 and -200 ............................................ 24
Replacing the UV lamps for other InLine types............................................................... 26
Replacing the quartz sleeves............................................................................................ 27
REPAIRS ...................................................................................................................28

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Contents
7.3.1
7.3.2
7.3.3
7.3.4

Explanation of the circuit diagrams ................................................................................ 28

Troubleshooting the (optional) automatic cleaning mechanism ..................................... 29
Malfunctions to the temperature sensor .......................................................................... 29
Other troubleshooting...................................................................................................... 30
7.4 SETTINGS .................................................................................................................31
7.4.1 Calibration of the display of the UV output..................................................................... 31
7.4.2 Interval time of the (optional) automatic cleaning mechanism ....................................... 32
7.4.3 Checking the UV sensor when putting into operation and after 100 hours of use .......... 32
8

SPARE PARTS............................................................................................................................ 34

DISPOSAL ................................................................................................................................... 34

9.1
9.2

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GENERAL..................................................................................................................34
RETURNING OLD LAMPS ...........................................................................................34

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Introduction

1 Introduction
The objective of this manual is to clearly explain the installation and operation of the
bersonInLine UV-system.
Users are advised to study this manual carefully chapters 2 and 5 in particular are vitally
important in guaranteeing user safety.
The people that work with the bersonInLine UV-system are expected to have sufficient indepth knowledge of the applied techniques and a thorough command of the operating
instructions and to be aware of the possible dangers and risks.

1.1

System objective

The bersonInLine UV-system is designed to disinfect water with UV-exposure. For this
purpose, a number of UV-lamps are placed in the liquid flow and powered via a separate
control unit.
The ultraviolet disinfection process inactivates germs, viruses, bacteria, spores, fungi, algae
and other micro-organisms quickly and safely. The specific properties of treated liquids such
as colour, odour, taste and acidity remain unchanged.
Depending on the model, various options can be fitted to simplify the use of the system and
to optimize the quality.

1.2

Documents

In addition to this users manual, the system is supplied with the following documents:
Circuit diagrams
Diagram of the lamp configuration
Quality certificate
Mechanical drawings
The manual is based on current developments in UV technology. Berson UV-techniek shall
retain the right to make amendments to the documentation without being obliged to modify
preceding versions.
Store this manual carefully for future use.

1.3

Document conventions

The following terms are used to draw additional attention to specific sections of the text:

Tip
Attention!
Careful!
Warning!

Suggestions and advice for carrying out specific tasks more easily or
practically.
This remark is placed next to the text to draw the users attention to possible
problems.
If procedures are not carried out with due care and attention, the system can
be damaged.
If procedures are not carried out carefully, the user or other persons could
be injured or the system could be seriously damaged.

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Safety

2 Safety
The bersonInLine UV-system is built for easy and efficient operation. Users should
nevertheless take proper note of the remarks accompanying the text in this manual and act
accordingly.
Persons working on or in the direct vicinity of the system must be familiar with these
instructions.
In addition to the instructions in this manual, generally applicable safety rules and regulations
must be observed at all times.

2.1

Pictograms and general safety instructions

For using the bersonInLine UV-system, the following pictograms and safety instructions are
important:
Wear safety glasses to prevent eye injuries from ultraviolet light.
Do not look directly into a UV lamp that is switched on!

Do not unnecessarily expose your skin to UV-radiation.

Wear clean cotton gloves when handling the lamps.
If you do have to hold the lamps, do so by the connectors.
Remember UV-lamps remain hot for a considerable time after they have
been turned off.
Allow the lamps to cool off after use for at least 15 minutes.
The disinfection chamber and the control unit have to be wired to an
ground fault circuit breaker with sufficient capacity.
Switch the power supply off before carrying out repair work and
maintenance.
Take account of the fact that there is inadequate disinfection if the
lamps are not up to temperature or if the lamps have been switched off
Also: general safety symbol.
The UV-lamps contain mercury.
Take defective lamps to a depot for chemical waste.
See paragraph 2.3 for details of what to do if a lamp breaks.

The following points of attention should also be taken into account:

Keep your work area clean and tidy and make sure it is properly illuminated.
Keep control cabinets closed during normal use.
Only use original Berson parts.
Carry out proper maintenance on a regular basis. Read the maintenance instructions
in Chapter 7.

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Storage and transport

Tip

2.2

If the prescribed user instructions are followed correctly, there is no danger of radiation
from the UV lamps.

System safety features

The bersonInLine UV-system is fitted with the following safety features:

Effective protection against the UV-radiation produced by the lamps.
Safeguards to prevent the lamps and the power supply cabinet from overheating.
Quality control of the UV-lamps in order to monitor the liquid disinfection process.
The following safety stickers have been placed on the system:

End closure of the UV-chamber

Outside the control cabinet(s)

ENSURE OF FLOW IN THE CHAMBER

BEFORE ACTIVATING THE UNIT
CAUTION !
HOT SURFACE AVOID CONTACT
ENSURE CHAMBER IS HYDRAULICALLY ISOLATED
AND DEPRESSURIZED BEFORE SERVICING

BEFORE SERVICING
DISCONNECT

BEFORE SERVICING DISCONNECT POWER SUPPLY

POWER SUPPLY

Warning!
2.3

Replace stickers if they are damaged or lost!

Broken lamps or quartz sleeves

Warning!

The UV-lamps contain a small amount of mercury. If a lamp breaks,

the mercury has to be collected by binding it with sulphur powder.
Carefully remove the mercury after collecting it and take it to a depot
for chemical waste in accordance with local
regulations.
Avoid contact with the skin and eyes, do not
breathe in any vapours and make sure there is
sufficient ventilation!
If necessary, defective or burnt out lamps can be
sent back to Berson UV-techniek.

Warning!

If one of the quartz sleeves breaks, shut off the liquid supply pipes
immediately and switch the system off. Replace the defective parts
and only switch the system on again when all respective internal
safety procedures have been completed.

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Safety
2.4

2.5

Recommended use
The bersonInLine UV-system is designed for disinfecting UV-permeable liquids such as
drinking water, process water and waste water. For other applications it is advisable to
contact Berson UV-techniek.
There are restrictions when using liquids, which have high concentrations of dissolved
minerals or salts. High concentrations of these substances can cause corrosion of metal
components. Contact Berson UV-techniek for further information.
A high concentration of particulates in the medium can cause excess wear. Contact
Berson UV-techniek for further information.
The components that the UV-system is built of may only be used in the configuration
described in this document.

Non-recommended use
The system may never, under any circumstances whatsoever, be switched on if it is not
completely built into the adjoining pipework. The UV-lamps must be shielded at all times
to prevent harmful UV-radiation.
Do not remove plugs or other components which allow any UV-radiation to be emitted to
the outside.
Berson UV-techniek must be consulted before using transparent pipework systems.
Mechanical modifications to the system, such as drilling holes or welding on parts can
damage the system.

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Storage and transport

3 Storage and transport

On receipt:
Check the goods on receipt for signs of transport damage. Report any such cases directly to
the carrier and your supplier. Take photographs of any damage and store the packaging for
inspection.
Storage:
If you do not intend to install the system immediately, it is advisable to store the components
in their original packaging. Avoid jolts and excessive vibrations.
UV-lamps must always be stored in the original packaging.
The storage area must meet the following requirements:
Atmospheric humidity
: 10 80% RH
Temperature
: 50 86 F.
Unpacking:
Read any instructions and warning messages that may be attached to the packaging. Even
though they are packed separately, please bear in mind that the lamps are fragile and should
be handled with care. Keep the lamps in their individual original packaging until needed.
Check that your delivery is complete from the packers receipt. Report any parts that are
missing directly to the carrier and your supplier.
Transport:
If internal transport of the system is necessary, make sure that:
the UV-lamps have been removed and that they are stored in their original packaging;
the system has been completely disconnected from the electricity mains;
the system is clean and dry;
all the components are suitably protected against external contaminants and damage.
Taking the system out of use temporarily:
If the system is taken out of use temporarily, it is important to flush the system with clean
water so that no sand, salts or other corrosive materials remain behind in the system. Leave
the system in a dry state.
When the medium is stationary, dissolved minerals can even corrode high-grade stainless
steel.

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System description

4 System description
The diagram below illustrates the main aspects of the bersonInLine UV-system. The
diagram shows all possible applicable options. The actual situation can vary from the
diagram depending on the application and the size of the system.

Control / Power
supply
Disinfection
chamber

POWER ON
UV-OUTPUT
UV ALARM

150 %

WATER TEMP. ALARM

125 %

CABINET TEMP. ALARM

110 %

CABINET TEMP. WARNING

100 % ALARM

UV LAMP 1

UV LAMP 2

UV LAMP 3

UV LAMP 4

UV LAMP 5

UV LAMP 6

UV LAMP 7

UV LAMP 8

UV LAMP 9

UV LAMP 10

UV LAMP 11

UV LAMP 12

OUT

Chamber
UV-lamp

UV-sensor
Cabling

Temperature sensor

Option: Automatic lamp cleaning

Option: Manual lamp cleaning

IN

For detailed information, please see paragraph 4.1 (Disinfection chamber) and paragraph 4.2
(Power supply/control).
Paragraph 4.3 contains a list of possible options.
A number of tools are also available for manually testing the lamps and placing the quartz
sleeves. These are described in paragraph 4.4.

4.1

Disinfection chamber

The disinfection chamber consists of the following

components:

OUT

Chamber:
The chamber is the main component of the bersonInLine
UV-system. In all models, the liquid inlet and outlet
connections are in line with each other.
Two end plates are fitted at a right angle to the liquid flow
direction. These hold the lamps, the (optional) cleaning
mechanism and the temperature sensor. The fitted
accessories are covered on both sides with a hood that also
contains the cable glands.
The chamber also contains standard features for venting and
draining the system.

IN

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System description
The size and the design of the chamber depend on the required disinfection capacity and the
nature of the liquid.
The chamber can be fitted with an access hatch for manually removing coarse contaminants.
UV-lamps:
The number and type of UV-lamps built into the system
depend on the system size and the nature of the liquid that
has to be disinfected.
The lamps are placed in quartz sleeves and therefore do
not come into direct contact with the liquid. They can be
fitted from either flanges. This has to be done according to
a strict procedure. See paragraph 7.2.7 or 7.2.8 for further
instructions.

Attention!
Warning!
Warning!

To avoid damaging the UV-lamps, never touch them with your bare
hands!
Remember that a lamp that has just been switched off will be
extremely hot!
The UV-lamps contain a small amount of mercury. See paragraph 2.3
for what to do with broken lamps!

After switching the lamps on, it can take 1 to 5 minutes before the full UV intensity is
reached.
The life span of the lamps will be drastically reduced if they are repeatedly switched on and
off. This results in decreasing UV intensity. Any contaminants on the quartz sleeves also lead
to reduced UV output.
UV-sensor:
The standard UV-sensor is the so-called UVector. This
sensor measures the UV-intensity of the UV-lamp in a fixed
position. The UVector passes on information to the control
system so that the lamp power level can be adjusted as the
lamp intensity decreases, the quartz sleeve becomes dirty
or the quality of the liquid changes.
The UV-sensor works within a measuring range of 240
300 nm.
Temperature sensor:
The UV-lamps produce a considerable amount of heat that
is removed if the flow-rate of the liquid passing through the
system is high enough. In order to monitor the temperature
of the liquid, a temperature detector (type PT-100) is fitted in
the UV-system so that unsafe situations caused by possible
breakdowns can be prevented.
As soon as the liquid temperature exceeds the pre-set value
(113F), an alarm is given and the system shuts down.

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System description
In addition to the components described above, the following options are also available:
Automatic control system, see paragraph 4.3.1
Manually operated lamp cleaning system, see paragraph 4.3.2
Automatically operated lamp cleaning system, see paragraph 4.3.3
UltraWipe: chemical cleaning, see paragraph 4.3.4
Solenoid valve for draining or filling liquid, see paragraph 4.3.5

4.2

Power supply and control

The standard bersonInLine UV-disinfection system is connected to a power supply cabinet

and a control unit. Depending on the size of the system and specific customer requirements,
a combined cabinet can be supplied.
The cabinets are fitted with the following components:
The main switch:
This switches the whole system on and off.
With some systems, the lamps can be jointly turned on and off with a separate switch.
Cabinet ventilators:
These remove the heat produced by the lamp power supplies.
Hours counter:
This indicates the total number of hours that the system has been switched on. The counter
cannot be reset.
If an automatic cleaning system has been fitted (see paragraph 4.3.2), the hours counter is
incorporated into the display for the cleaning system.
Display:
The standard model is fitted with an ECtronic control unit. The units display is placed on the
front of the control cabinet. The display shows the status of the system. The display is
illustrated in the figure on the following page. The lights on the display have the following
meanings:
Power on

The LED lights up when the main switch is on.

UV Alarm

If the UV-intensity of the lamps drops below a pre-set

minimum value, this LED will light up. A potential-free
contact is also closed to trigger an external alarm. See the
supplied circuit diagrams for further details.

Water Temp. Alarm

If the liquid temperature, which is measured with the

temperature sensor, rises above the pre-set value, this LED
will light up and the lamps will automatically switch off. A
potential-free contact is also closed to trigger an external
alarm. See the supplied circuit diagrams for further details.

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System description
Cabinet Temp. Alarm

If the temperature in the power supply cabinet rises above

the pre-set value, this LED will light up and the lamps will
automatically switch off. A potential-free contact is also
closed to trigger an external alarm. See the supplied circuit
diagrams for further details.

Cabinet Temp. Warning

This LED lights up as soon as the cabinet temperature is in

danger of becoming too high. Check the dust filters and the
ventilators to make sure they are working!
The system is not switched off when this LED lights up.

UV-Output

The LED that lights up with the highest value indicates the
current UV-intensity level.
As soon as the intensity drops below the pre-set value, the
red LED UV-Alarm will light up.

UV Lamp ..

The number of fields that this display contains varies from 1

to 12 depending on the number of lamps in the system.
The numbered LEDs light up when the corresponding lamp
is on. In this way, attention can be drawn to defective
lamps.

POWER ON
UV-OUTPUT
UV ALARM

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100 %

WATER TEMP. ALARM

90 %

CABINET TEMP. ALARM

80 %

CABINET TEMP. WARNING

70 % ALARM

UV LAMP 1

UV LAMP 2

UV LAMP 3

UV LAMP 4

UV LAMP 5

UV LAMP 6

UV LAMP 7

UV LAMP 8

UV LAMP 9

UV LAMP 10

UV LAMP 11

UV LAMP 12

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System description
4.3

Options

It is possible that your system has a number of built in standard options. These are
discussed in the following paragraphs.
4.3.1

Automatic control systems

As an alternative to the ECtronic system described here, the bersonInLine-system can also
be fitted with a UVtronic control unit. This system can be freely programmed and can hence
be designed to be more application-specific.
This UVtronic control system is not discussed in this document; please see the respective
manual for further information.
4.3.2

Manual cleaning

Deposits of organic substances present in the liquid in the system can settle on the quartz
sleeves that contain the UV-lamps. This can block the UVradiation and thus reduce the effectiveness of the
disinfection process. The display will register a lower UVvalue.
The manually operated cleaning mechanism can be used to
remove these deposits without the system having to be
switched off and the sleeves taken out.
Using a handgrip, a wiper plate can be moved back and
forth along the quartz sleeves to wipe away the deposits,
see the adjacent photos. The actual design depends on the
size of the system (the mechanism shown here is for a
system with 2 and 3 lamps respectively).
4.3.3

Automatic cleaning (AutoWipe)

An automatic cleaning system can be used as an alternative

to the manual system.
A threaded spindle and an electric motor operate the wiper
plate with the wiper rings. Two sensors located on the
outside of the chamber signal the end position of the wiper
plate.
The electric motor is mounted on the end plate of the
chamber with several studs and covered with a protective
hood.
If the system includes an automatic cleaning system, the
display will be modified as shown on the following page.

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System description

Hours counter

Wipe counter

Wipe

Wipe Error

Hours counter: This shows the total number of hours that the system has been
switched on. The counter cannot be reset.
Wipe counter: This indicates the number of wipes that have been carried out. The
counter cannot be reset.
Wipe: After pressing this button, the sleeves are wiped.
Error-LED: This lights up if there is a problem with the wiper mechanism. See
paragraph 7.3.2 for more information.
See paragraph 7.4.2, for setting the automatic wiping cycle time interval.
4.3.4

UltraWipe cleaning system

The UltraWipe can be built into the system in combination with the automatic cleaning
system with the objective of removing stubborn deposits from the quartz sleeves. With this
system, the rocking motion back and forth sucks liquid into position around the quartz
sleeves from an external reservoir. The liquid is pushed away with the main medium with the
next wiping motion.
4.3.5

Solenoid valve

A solenoid valve can be placed in the drain plug connector to enable the liquid in the
chamber to be drained by entering an electrical command signal.
4.3.6

Power level switch

With this switch, the power of the lamps can be adjusted in several steps, in order to
generate sufficient light output with old lamps, dirty quartz sleeves or changes in the
composition of the liquid.
The power level switch can be set to 1 (design, =100%), 2 (medium, =125%) and 3 (high,
=140%).
Attention: The above percentages are related to the electric power that is used to drive the
lamps and not the UV-output shown on the display.
4.3.7

Eco control

It can be necessary to reduce the lamp power to 70% of the nominal value in order to save
energy.
In this case, the power level switch can be set to 1 (low, =70%), 2 (design, =100%) and 3
(high, =140%).
Attention: The above percentages are related to the electric power that is used to drive the
lamps and not the UV-output shown on the display.

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System description
4.4

Accessories

The following additional accessories are available:

Lamp tester:
The lamp tester gives a high-voltage pulse that can be used
to test the lamps. The tester works with a 9V-battery and
generates a safe pulse of 3.000V / 1A / 160KHz.

Jupito:
The Jupito is a mechanical aid for easily removing the
quartz sleeves that reduces the risk of damage. The device
can be extremely useful especially when the sleeves are
stuck because of dirt and contaminants.

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Installation and putting into operation

5 Installation and putting into operation

5.1

General

When installing the bersonInLine UV-system, the following guidelines must be adhered to:
The surroundings must be free of corrosive vapours, steam, excessive condensation,
dripping liquids, explosive mixtures and gasses, salt air and large amounts of dust.
Do not expose the cabinets to the outside air.
The relative humidity must be lower than 95%.
The ambient temperature must be between 40 and 105F; the average temperature
over a 24-hour period may not exceed 95F.
The system must not be subjected to heavy jolts or vibrations.
Do not expose the system to magnetic or radioactive radiation.

5.2

Mechanical installation

When installing the chamber, the following points must be adhered to:
The UV-lamps must always be placed horizontally.
For service work, a free space must be left as indicated in the supplied drawings.
Make sure the inspection hole, the drain plug, the solenoid valve (if present), the
ground connection and the UV-sensor are sufficiently accessible.
Make sure that the installation in which the UV-system will be integrated is resistant to
UV-radiation this also applies specifically to gaskets, valves and vents.
Make sure that the UV-radiation can never escape into the outside air!
Valves for taking samples must be placed approximately 3 feet before or respectively
1.5 feet behind the UV-system.
Clean the external pipework and the UV-system thoroughly before assembly.
Position the UV-system with the help of the end flanges and appropriate packing in
the pipe system. Make sure there is no mechanical stress!
Check all connections to make sure they do not leak.
Clean the whole system again after assembly.
Install the lamps according to the instructions in paragraph 7.2.7 or 7.2.8.

5.3

Electrical installation

Attention!

Installation work may only be carried out by qualified personnel!

Connect the power supply and control cabinet according to the supplied
electrotechnical diagrams and local regulations. The following points
must also be taken into account:
With the InLine-20, 50, 125 and 200 system sizes: place the
cabinets at a maximum distance of 15 feet from the disinfection
chamber. For the other systems, the maximum distance is 50 feet.
If the power supply and control cabinets are not integrated, the distance between the two
may be no greater than 15 feet.
Position the cabinets in such a way that the ventilators can freely suck in and blow out
air.

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Installation and putting into operation

Use cables with the following minimum specifications:
UV-lamps
: as delivered;
UVector
: 2x0.25 mm2, shielded;
PT-100 (temp. sensor)
: 2x0.50 mm2, shielded;
AutoWipe (optional)
: 4x1.00 mm2, shielded;
Reed switches
: 2x0.34 mm2 (2x), for the AutoWipe.
The coaxial cables of the UV-sensor and PT-100 must be grounded directly after the
cabinet entry point using the respective connection points.
Make sure the connection between the disinfection chamber and the power supply
cabinet is properly grounded (and the connection between the cabinets, if they are
separate).
Connect any external systems to the potential-free contacts of the control unit. See the
supplied circuit diagrams for further details.
Check whether the contact bridge of the remote control is in the correct position and
whether the signal is active. See the circuit diagrams for further details.

5.4

Putting into operation

After the mechanical and electrical installation work has been completed, the following
precautionary measures should be taken:
The pipework system with the UV-system must be completely filled with liquid and deaerated.
The flow-rate of the liquid medium must be sufficiently
ENSURE OF FLOW IN
high to cool the system. A flow of at least 0.1 m3/hour is
THE CHAMBER BEFORE
a typical value.
ACTIVATING THE UNIT
Check whether the circuit breakers and the ground fault
circuit breakers in the control cabinet are in the correct
position.
Check whether the correct supply voltage is present on the connection contacts in the
control cabinet.
Only switch the system on if the end closures are in position or if you
are wearing safety glasses. If the end closures are not in position, a
small quantity of UV-light can escape via the lamp holders. This can
harm your eyes!
Never look directly into a UV-lamp that has been switched on!
Turn on the main switch and, if applicable, the lamp switch; allow the lamps to warm up
for 1 to 5 minutes.
Check the display to make sure all the lamps have been switched on.
Check the output signal of the UV-sensor. See section 7.4.3.
Check the setting of the ECtronic printed circuit board in accordance with section 7.4.1.
The UV-output indicator on the display shows the current UV-intensity.
Adjust the UV-output to the required level using the power level switch on the cabinet.

Attention!

After the lamps have been switched off, you must wait at least 15
minutes before switching them on again.
Repeatedly switching the lamps on and off considerably shortens
their life span!

Warning!

If the lamps are not fully heated up, there is no guarantee of an

adequate UV-dose. The flow of liquid is however required for cooling
the lamps!

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Operation

6 Operation
The bersonInLine UV-system is extremely easy to operate. The way in which it works is
described below:

6.1

General

Make sure that the pipework system is completely filled with liquid and that the flow rate is
sufficiently high.
Turn the system on using the main switch or the lamp switch (if present). The lamps
immediately start working and reach the correct output level after 1 to 5 minutes.
Optional: Adjust the lamp power to the required UV-intensity using the power level switch
on the cabinet. Change the setting as soon as the UV-intensity decreases.
If necessary, turn the system off using the main switch.

6.2

Manual cleaning system (optional)

Manual cleaning can take place while the system is operating. The required cleaning
frequency depends on the medium and the UV-intensity given on the display.
Remove the locking pin.

Warning!

By removing the locking pin the handle of the wipe unit can
be pressed forcefully to the outside by the pressure in the
chamber!

Pull the wiper system completely out with the handle or handgrip and then push it back in
again. If necessary, repeat this action several times.
Replace the locking pin.

6.3

Automatic cleaning system (optional)

Automatic cleaning takes place at set intervals during the normal operation of the UVsystem.
The way in which the interval time is set is described paragraph 7.4.2.
One can also activate an immediate wipe by means of the control panel (see paragraph
4.3.3).

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Checks, maintenance, repairs and settings

7 Checks, maintenance, repairs and settings

7.1

Checks

Every day, the following points on the display have to be checked:

The status of the UV-intensity. If the value is too
low:
POWER ON
Clean the quartz sleeves, or
UV-OUTPUT
UV ALARM
100 %
Set the (optional) power level switch to a higher
WATER TEMP. ALARM
90 %
value.
CABINET TEMP. ALARM
80 %
UV-Alarm. If this LED lights up:
CABINET TEMP. WARNING
70 % ALARM
Clean the quartz sleeves, or
Set the (optional) power level switch to a higher
UV LAMP 2
UV LAMP 1
UV LAMP 4
UV LAMP 3
value, or
UV LAMP 6
UV LAMP 5
Replace defective lamps (check the lamp
UV LAMP 8
UV LAMP 7
indicators on the display), or
UV LAMP 10
UV LAMP 9
Replace all lamps because of their age. See
UV LAMP 12
UV LAMP 11
the instructions in paragraph 7.2.7.
Check the composition of the liquid.
Water Temperature Alarm. If this LED lights up, the flow rate of the liquid is too low or the
medium is stationary and the system will shut down.
Cabinet Temperature Alarm. If this LED lights up, the temperature in the power supply
cabinet is approximately 158F and the system will shut down.
Check whether the cabinet ventilators are obstructed.
Clean the cabinet ventilator dust filters.
Cabinet Temperature Warning: If this LED lights up the temperature in the power supply
cabinet is approximately 140F and the system is in danger of shutting down.
Check whether the cabinet ventilators are obstructed.
Clean the cabinet ventilator dust filters.

Tip

Note all relevant changes, settings and other actions which have been carried out in
the logbook which is supplied with the product-specification part of this
documentation.

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Checks, maintenance, repairs and settings

7.2

Maintenance

7.2.1 Cleaning the quartz sleeves

The quartz sleeves have to be cleaned on a regular basis. The optimum frequency for doing
this depends on the medium and has to be established on the basis of on-hand experience
working with the system.
If the optional cleaning mechanism is used, cleaning can take place while the system is
operating. If there is no cleaning mechanism, one of the following methods has to be used:
Chemical cleaning:
Turn off the liquid flow and the main switch of the UV-system.
Place appropriate chemicals in the disinfection chamber via an external connection.
Drain the liquid off via the drain plug or the (optional) solenoid valve after the time the
chemicals need to work has elapsed. Remember to remove the ventilation plug before
draining.
Rinse the disinfection chamber with the normal liquid medium used in the system, and
drain once again via the drain hole.
Replace the drain and ventilation plugs.
Manual cleaning:

Warning!

Turn the main switch off and

disengage the automatic fuses in the
power supply cabinet!
Turn off the flow and drain the liquid.
Remember that the lamps can be
hot!

Attention!

Wear clean cotton gloves to avoid damaging the

lamps.

Loosen the cable glands on the hood and remove it. Disassemble the end closure on the
other side of the disinfection chamber as well.
For InLine-20, -50, -125 and 200: Remove the lamp holders on the side where the
lamps have to be taken out of the disinfection chamber. Then remove the lamps from the
quartz sleeves.
For the other versions: remove the lamps as described in section 7.2.8.
Disassemble the threaded bushes at both ends of the quartz sleeves with the supplied
spanner.
Take the quartz sleeves carefully out. Use the black mandrel to press the sleeves out of
the end plates (the cylindrical part of the mandrel has to be pushed into the end of the
sleeve).
Clean the sleeves with alcohol or replace them.
End plate
Place the sleeves (without sealing rings) back in
the disinfection chamber.
Quartz sleeve
Use a new set of seals and place them in the
following way:
Make the (black) O-ring wet with clean water
and slide it over the end of the sleeve.
Slide the white support ring over the sleeve.
Threaded
Place the threaded bush over the end of the
bush
quartz sleeve and tighten it by hand into the

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Checks, maintenance, repairs and settings

end plate.
Assemble the O-ring and the support ring on the other side of the disinfection
chamber.
Fasten the threaded bush using the supplied fitting and a ring spanner (hand tight) so
that the O-rings push against the collar in the end plate. The sleeves must never be
subjected to excessive force!
Fill the disinfection chamber with liquid, increase the pressure to the normal working
level and check the system for leaks.
Now place the UV lamps in the quartz sleeves according to the detailed instructions in
section 7.2.7 and 7.2.8.
Assemble the end closure.
Switch the system back on.
7.2.2

UV-sensor and quartz probe

If the system does not have an (optional) built-in cleaning mechanism, the quartz sleeve
window will have to be cleaned chemically as described in paragraph 7.2.1, or by using the
following manual method:

Warning!

Turn of the main switch and the circuit breakers in

the power supply cabinet!
Turn of the flow and drain the liquid in the
disinfection chamber.

Loosen the connector on the top-side of the sensor.

Unscrew the sensor by hand.
Use a hook spanner to remove the NW25 ring nut.
Take the probe of the sensor out of the chamber.
Remove the locking nut using a (15mm) open-end
spanner.
Take the quartz pen out, then clean it and the sealing
rings with alcohol.
Assemble the parts in reverse order. In the adjacent
photo the parts are shown in the correct order.
Use new seals if necessary.
Switch the system back on.

Attention!

7.2.3

In the point of the sensor, there is an adjusting screw for setting the
correct distance from the UV-lamp. This screw is set in the correct
position in the factory and may not be tightened or loosened!

Ventilation of the control cabinet(s)

Regularly check and, if necessary, replace the dust filters in the cabinet ventilators.

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Checks, maintenance, repairs and settings

7.2.4

Ground fault circuit breaker check

Every month check the ground fault circuit breaker to make sure it is working properly by
pressing the test button. The system should shut down immediately.
7.2.5

Manually operated cleaning mechanism (optional)

Several parts have to be replaced after approximately 7,000 wiper movements or at least 1x
per year. The parts should be replaced as follows:

Warning!

Turn the main switch off and

disengage the circuit breakers in the
power supply cabinet!
Turn of the flow and drain the liquid.
Remember that the lamps can be hot!

Attention!

Wear clean cotton gloves to avoid damaging the

lamps.

Remove the lamps and the quartz sleeves as described in paragraph 7.2.1.
Remove the end plate of the disinfection chamber.
Remove the cleaning mechanism.
Replace the wiper rings and the seal on the wiper shaft.
Reassemble the parts, replace lamps and the quartz sleeves according to the
instructions in paragraph 7.2.1.
7.2.6

Automatic cleaning mechanism (optional)

Several parts have to be replaced after approximately 7,000 wiper movements or at least 1x
per year. The parts should be replaced as follows:

Warning!

Turn the main switch off and disengage

the circuit breakers in the power supply
cabinet!
Turn of the flow and drain the liquid.
Remember that the lamps can be hot!

Attention!

Wear clean cotton gloves to avoid damaging the

lamps.

Remove the end closure of the UV-system.

Remove the nuts of the motor plate, then remove motor (4) together with motor plate (5).
Take the lamps and the quartz sleeves out as described in paragraph 7.2.1.
Remove the end plate of the disinfection chamber.

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Checks, maintenance, repairs and settings

Take out the cleaning mechanism.
Replace the wiper rings (1), the
seal on the threaded spindle (7)
and the plastic threaded nut (3) if
necessary.
Disassemble the bearing casing
(6), remove the bearing and
replace the seal.
Reassemble the parts. Replace
the lamps and quartz sleeves
according to the instructions in
paragraph 7.2.1.
Assemble the end closure.
7.2.7

Replacing the UV lamps for InLine-20, -50, -125 and -200

Attention!

If the lamp located nearest the UV-sensor has to be replaced because

of a defect, it must be replaced with a lamp that is already being used
in the system. In this way, lamps with differing outputs will least affect
the UV-measurement.

Attention!

See the Detail Lamp Configurations diagram for the position of the
lamps in the disinfection chamber. This is important in obtaining an
optimum distribution of the UV-illumination in the liquid flow.

Warning!

Turn the main switch off and

disengage the automatic fuses in the
power supply cabinet!
Turn off the flow and drain the liquid.
Remember that the lamps can be
hot!

Attention!

Wear clean cotton gloves to avoid damaging the

lamps.

1. UV-lamps are supplied in

cardboard packaging that
includes a cleaning cloth and
instructions.

Page 24

2. Do not touch the lamps with

your bare hands!

3. Do not hold the lamps on one

side.

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Checks, maintenance, repairs and settings

4. Wear gloves.
Only hold the lamp at the ends.

5. Clean the glass with the

supplied cloth.

6. Slide the lamp carefully into the

quartz sleeve. The lamp must be
kept on a straight horizontal line!

7. Make sure that the lamp

remains free of the large lock
nut. Pay particular attention to
thickening in the middle of the
lamp.

8. Push the lamp as far into the

sleeve as shown in the photo.

9. Position the lamp holder

carefully and cleanly in line with
the lamp; hold the lamp steady
while doing so.

10. Place the lamp holder in the

quartz sleeve, keep the
connector screw facing
downwards.

11. Slide the lamp holder over

both threaded ends, until the
back of the lamp is secure in the
lamp holder. Only apply
minimum force!

12. Release the lamp holder,

which will spring back slightly.
Tighten the M4 nuts by hand.
Make sure that the lamp is not
touching anything.

Attention!

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The adjacent pictogram indicates that the lamp holder

has to be placed in the quartz sleeve with the
connector screw facing downwards (because of
condensation).

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Checks, maintenance, repairs and settings

7.2.8

Replacing the UV lamps for other InLine types

Attention!

If the lamp located nearest the UV-sensor has to be replaced because

of a defect, it must be replaced with a lamp that is already being used
in the system. In this way, lamps with differing outputs will least affect
the UV-measurement.

Attention!

See the Detail Lamp Configurations diagram for the position of the
lamps in the disinfection chamber. This is important in obtaining an
optimum distribution of the UV-illumination in the liquid flow.

Warning!

Turn the main switch off and

disengage the automatic fuses in the
power supply cabinet!
Turn off the flow and drain the liquid.
Remember that the lamps can be
hot!

Attention!

Wear clean cotton gloves to avoid damaging the

lamps.

1. Remove the black cover plate

on both sides.

2. Loosen the retaining nuts of

the sealing cover on the nonservice side (see mech.
drawings) so that the lamp
connections are accessible.

3. Remove the lamp holder plate

(2 M4 nuts) and loosen the lamp
wire of the wiring connector.

4. Remove also the lamp holder

plate on the service side.

5. Loosen the lamp wire of the

wiring connector.
Take the old lamp out of the
quartz sleeve, together with the
two glass tubes.

6. New UV lamps are supplied in

cardboard packaging, together
with cleaning cloth and
instructions.

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Checks, maintenance, repairs and settings

7. Do not touch the lamp with

bare hands!

8. Do not hold the lamp on one

side.

9. Wear clean cotton gloves.

Only hold the lamp at the ends.

10. Clean the glass with the

cloth supplied.

11. Slide the lamp carefully into

the quartz sleeve. Hold the lamp
exactly horizontal!
Make sure that the two glass
tubes do not get mixed up as
there may be a difference in
length.

12. First connect the lamp wire on

the non-service side, so that the
wiring connector is easily
accessible.
Then connect the lamp wire on
the service side.

13. To keep the lamp in position 14. Slide the sealing cover
15. Fit the two cover plates. Do
the lamp holder plate must be
against the disinfection chamber not forget to attach the two plastic
slid over the wire ends and
again and tighten the nuts.
rings.
secured with the M4 nuts. Do not
use any tools for this!

7.2.9

Replacing the quartz sleeves

For replacing the quartz sleeves, see the instructions in paragraph 7.2.1: Manual cleaning.

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Checks, maintenance, repairs and settings

7.3
7.3.1

Repairs
Explanation of the circuit diagrams

The circuit diagrams consist of several sheets with columns that are numbered as follows:
Sheet 1: columns 0 19,
Sheet 2: columns 20 39 etc.
The components are numbered with an alphanumeric character followed by the column
number.
Applied component characters:
C
F
H
K
M
P
R
S
SD
T
Tr
U
V
X

Capacitor
Fuse
Hours counter
Relay
Motor, ventilator
Pulse counter
Resistor
Switch
Lamp current detector
Bimetal switch
Transformer
Power supply unit
LED, Diode, Transistor
Connection, cable sleeve

For relays, the diagrams contain tables listing the relay contacts. The number indicates the
column in which the contact is used (NC = normally closed and NO = normally opened).
Colour coding for the wiring:
Black
Blue
Red
Green-yellow
White

Connection voltage (phase)

(Low voltage) direct current or zero voltage
(Low voltage) alternating current
Ground
Potential-free

External connections of the control cabinet (when using the ECtronic):

Use
Remote on-off
Water temperature alarm
Cabinet temperature alarm
UV alarm

Page 28

Explanation
If these contacts are closed, the system will start up.
When the alarm is activated, the potential free two-way contact
is switched over.
When the alarm is activated, the potential free two-way contact
is switched over.
When the alarm is activated, the potential free two-way contact
is switched over.

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Checks, maintenance, repairs and settings

Ground fault

If the ground fault circuit breaker is activated, the potential

free two-way contact is switched over.

Cleaning-alarm
Solenoid valve
UV-signal

7.3.2

If a problem occurs in the automatic cleaning mechanism,

the potential free two-way contact is switched over.
230V AC has to be connected to these contacts to switch
the solenoid valve on and off.
The output current of the UV-sensor from these contacts
can be used for measuring purposes.
A galvanic isolation is recommended.

Troubleshooting the (optional) automatic cleaning mechanism

If the mechanism is not functioning, check the working of the reed contacts with an external
magnet.
Also make sure the interval between cleaning is longer than 10 minutes to prevent
overloading the motor. If the motor shuts down due to overheating, it has to be allowed to
cool down before being switched back on again.
Note that the wiper fail alarm can only be cleared by powering down the unit.
7.3.3

Malfunctions to the temperature sensor

The temperature of the liquid is continuously measured by the control system to avoid
overheating of the UV-lamps.
If it is suspected that the temperature sensor (PT100) is defective, the correct functioning of
the sensor can be checked by measuring a current value on the control printed circuit board
(only for the ECtronic control system).
Measure the liquid temperature using an external thermometer. Connect an ammeter in
accordance with the diagram below and check whether the measured current agrees with the
value in the table. The value may deviate by a maximum of 0.15 mA.

Cable connectors: 17-18

A
Ammeter
PT100

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Temp [F]
32
41
50
59
68
77
86
95
104
113
122
131
140
149
158
167
176
185
194

Current [mA]
4.00
4.76
5.53
6.30
7.07
7.84
8.61
9.38
10.15
10.92
11.69
12.46
13.23
14.00
14.76
15.53
16.30
17.07
17.84

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Checks, maintenance, repairs and settings

7.3.4

Other troubleshooting

The UV-Alarm is active, but the lamps and quartz sleeves are in proper working order:
Check the liquid.
The UV-lamps do not switch on:
Check whether the ground fault or the circuit breakers have dropped out.
Check whether the contact bridge of the remote control is in the correct position and
whether the signal is active. See the circuit diagrams for further details.
If there are any other problems, contact the service department of Berson UV-techniek.

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Checks, maintenance, repairs and settings

7.4
7.4.1

Settings
Calibration of the display of the UV output

The settings on the ECtronic printed circuit board are dependent on the T10-value and
volume of flow of the liquid. The setting is made at the factory, but should be made again
when putting into operation. Follow the procedure below to do this:
Calculate the following quantities:
Quantity
Unit
Description
2
UV-C
[mJ/cm ]
This is the required UV-C dose. It depends on the nature of the
liquid medium *.
Flow-cap
[m3/hour]
This is the flow capacity of the system with UV-transmission T10.
See the capacity table in the annex and calculate the Flow
capacity for the specific T10-value*.
3
Norm-flow [m /hour]
This is the normal quantity of liquid that has to be disinfected.
If this is not always constant, take the maximum value.
* If any of these quantities are unknown, contact Berson UV-techniek.
Calculate the UV-output value using the following formula (example):
25 [mJ/cm2]
UV-output =

Flow-cap
X

UV-C

X 100%
Norm-flow

The correct setting must now be made on the ECtronic printed circuit board using the value
calculated with the above formula.
Work out the necessary target value
from the table below:
UV-output
100 %
94 %
88 %
85 %
78 %
75 %
70 %
63 %
57 %

Target value
6.30 V
6.00 V
5.70 V
5.55 V
5.40 V
5.10 V
4.80 V
4.50 V
4.20 V

Calculate if necessary the interim target value or the target value above 100%.
Connect a voltmeter to terminals 26 (-) and 41 (+) of the printed circuit board. Then adjust the
potentiometer P1 until the measured value corresponds with the appropriate target value in
the table.

Warning!

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Remember that the supply voltage is switched on!

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Checks, maintenance, repairs and settings

7.4.2

Interval time of the (optional) automatic cleaning mechanism

The interval time for automatic cleaning can be adjusted

on the EC-Wipe printed circuit board via contact bridge
(X1) and a trimming potentiometer (P1).
Range of the trimming potentiometer:
Contact bridge present : 2 hours 24 hours.
Contact bridge absent : 10 min. 120 min.
Turning the trimming potentiometer clockwise increases
the interval time.
The factory setting is approximately 1 hour.

7.4.3

X1

P1

Checking the UV sensor when putting into operation and after 100 hours of use

The UV dose of the lamps is stabilised after about 100 hours of use. After this period the
measurement value of the UV sensor should therefore be set again.
This applies also 100 hours after all lamps have been replaced due to their age, but also
when the system is first put into use.
Make sure that the UV system is working normally.
Check that the T10 value (T10 actual) of the liquid is the same as the T10 value in the
technical specifications supplied (T10 spec).
If this is not the case, calculate the required sensor current as follows:
T10-actual
UV-signal =

X 7,5 + 4 [mA]
T10-spec

If the actual T10 value does not differ from the specification value, the sensor current
should be 11.5 mA.
Measure the output current of the UV sensor, as
shown in the diagram on the next page.
Remove the plug from the UV sensor (see
photograph).
Correct the position of the trimming potentiometer
behind the plug, so that the output current (Iuv)
corresponds with the value just determined.
Fit the plug again.

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Checks, maintenance, repairs and settings

Measuring the output current of the UV-Sensor:

Cable connectors: 14-15

A
Ammeter
UV-sensor

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Spare parts and disposal

8 Spare parts
See the annex, for a list of spare parts.

9 Disposal
9.1

General

If the UV-system is no longer used and has to be disassembled, the following steps should
be carried out:
Ensure that the liquid flow has been shut down and that the entire pipework system is
empty.
Ensure that the control cabinet and operating console have been disconnected.
Remove the electricity mains connections (plugs) and remove the plugs from the cables.
Disassemble the disinfection chamber, remove the UV-lamps carefully according to the
instructions of paragraph 7.2.1.
Dispose of the lamps according to local regulations or send them
back to Berson UV-techniek.
Disassemble the system further working from top to bottom. Use
appropriate tools for this and observe safety procedures!
The disinfection chamber and the control cabinet must be disposed
of in accordance with local regulations; preferably by sending them
to a company that can recycle the materials.
Attention:
These points only apply to parts supplied by Berson UV-techniek and described as such in
this manual.

9.2

Returning old lamps

Used lamps can be returned to Berson UV-techniek. To do this, ask for the required RMA
number beforehand.

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Specifications

Customer

AQUIONICS INC.
21 KENTON LANDS RD
ERLANGER, KY 41018
U.S.A.

Specifications:
Type number
Article number
Series number
Berson order number
Year of construction
Area of use
Flow capacity [m3/hr]
Transmission value T10 [%]
Nominal liquid temperature [C]
Nominal work pressure [Bar]
UV-C value [mJ/cm2]
Electrical configuration [V, Hz, phases]
Material disinfection chamber
Connecting flanges
Quartz tubes
Lamp type
Cleaning mechanism
Control system
UV-detection
Power adjustment

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

InLine 4250 spc

1HZS06WRUE*3
7906
27610
2002
Ballast Water
487
65
10
25
480V, 60, 3F
SS316L
none
F200
B3535H
Automatic
EC-Tronic
UVector
Manual

:
:
:
:
:
:
:
:
:
:
:
:
:

014-386-01

Diagrams:
Power/Control Module
Layout
Component View
Wiring Diagrams
Wiring Charts
Layout Inline 4250 Special
UV-Lamp Positions
PT100 Probe
UVector
Quartz Probe
Automatic Wiper Mechanism
Wire Lamp Detail
Air Bleed Taps
Supplemental: Step-Down Transformer

Annex

040-088-01
040-032-01
003-129-01
003-123-01
003-130-01
004-267-01
003-195-01
045-106-01
EDB 168920

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Specifications
Recommended spare parts:

BERSON UV-DISINFECTION UNIT RECOMMENDED SPARES

INLINE 4250

EVERY YEAR
Part No.
0.43.101
2.11.384
2.11.385
2.11.165
2.21.315
2.21.316
2.58.090
2.43-190
2.55.013
2.56.299
2.56.301
2.56.124
2.56.105
2.56.200
2.56.024
2.58.015
2.56.141

Description
Fan Filter
Ball bearing 26*9*8
Circlip
Splitpen 32*4
Boss for trapezium spindle
Boss for trapezium spindle
Cleaning wiper ring
UV-lamp B3535H
Quartz sleeve 867mm F200
Seal 15*25*8 (hand wiper)
Seal 10*25*10 (auto wiper)
O-ring 32*5 (q-sleeve)
O-ring 20*3 (T-stop)
O-ring NW25
O-ring 10*4 (sensor)
O-ring 15*3 (pt100 - 1/2"plug)
O-ring 365*6

no wiper

hand wipe

6
6

EVERY THIRD YEAR

auto wipe

no wiper

hand wipe

SECURITY STOCK

auto wipe

6
6
6

6
1

12
2
1
1
2
2

12
1
1
1
2
2

12
1
1
1
2
2

no wiper hand wipe

1
1

1
1

1
1

Attention:
The recommendations for spare parts are only valid for a year.
Only use original Berson parts.
All guarantees and liability will expire if other parts are used than those specified by Berson
UV-techniek.

Annex

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auto wipe
1
1
1
2
1
1
1
1

Specifications
Capacity table:
The adjacent table is important in adjusting the UV-sensor.

UV-dosage = 25mJ/cm2
at end of lamp life
Transmission
Flow capacity
over 10mm
(%)
(m3/h)
100
4509
98
3599
96
2930
94
2429
92
2047
90
1750
88
1516
86
1327
84
1174
82
1047
80
940
78
849
76
771
74
704
72
645
70
593
68
547
66
506
64
469
62
436
60
406

Annex

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