BlueBox 1200 RORS

Operating manual

PURE WATER – ANYTIME – ANYWHERE

 BlueBox 1200 RORS
Post-chlorination and UV-disinfection features

2 PURE WATER – ANYTIME – ANYWHERE

PART 1 BEFORE USING THE BLUEBOX
ill. 1

1 Affix the three coupling hoses

on the outside of the container.

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ill. 2

2 Press red blue and black

hoses onto the quick
couplings.

Follow the colour codes: WATE
WATE
FLUSH

Red sign = red hose

OUTLE

R
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INLET

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Blue sign = blue hose
Flush water
Black sign = black hose outlet
(Red hose)

Raw Clean
water inlet water outlet
(Black hose) (Blue hose)

3 Prepare the floating device.

The floating position can be
adjusted with water. The more
water, the deeper it will sink.

ill. 3

4 Affix the float filter as shown.

ill. 4

3
 PART 2 STARTING THE BLUEBOX (electrical version)

1 Mount correct electrical plug

to the supplied mains wire.

Connect the unit to a 230 V

power supply.
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ill. 5

Pressure valve

2 Before starting the pump, the

blue pressure valve must be
opened by turning it all the way
counter-clockwise.

IMPORTANT
The BlueBox must not be
started with pressure on.

ill. 6

3 Turn the black power switch Electrical cabinet

clockwise to the ON position.

START
STOP

On
Main Power
Switch

ill. 7

4 Start the pump by pressing Electrical cabinet

the green start button.

START
STOP
Start
Main Power
Switch

ill. 8

4
 5 Let the pump run for 1-2 Pressure valve
minutes until no more bubbles
are detected from the red hose.

6 Turn the blue pressure valve

clockwise until pressure is
approximately 8 bars.

ill. 9

7 Open the grey electrical cabinet Electrical cabinet

and check that the UV display
unit is active and that the
display shows the number of
365

days left. Air filter

The UV light must be changed

after 365 days of operation. ill. 10 UV display
Please see maintenance
section.

ill. 11

8 Non-potable (not suitable for

drinking) water will come out
of the red hose (Flush water
outlet). WATE
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INLET

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Drinking water can be tapped

from the blue hose (Clean Flush water
outlet
water). (Red hose)

The flow meter shows the

volume of clean water. Raw Clean
water inlet water outlet
(Black hose) (Blue hose) Wait 3-5
minutes

WARNING!
Never drink the water from the
blue fresh-water tube before the
BlueBox has been working for at
least 3-5 minutes!

5
 PART 3 AFTER USING BLUEBOX (electrical version)

1 Carefully turn the blue pressure

valve counter-clockwise until
the pressure reads 0 bar. 0 bars

ill. 12

2 Drain the system fully by Drain

valve
opening the drain valve,
situated at the bottom of START

the BlueBox unit, next to the

STOP
Main Power

electrical cabinet.
Switch

Run the BlueBox for 1 minute

without pressure and without
ill. 13
feed water intake.

3 Stop the pump by pressing the Electrical cabinet

red Stop button.

Close the drain valve. START

STOP
Stop
Main Power
Switch

ill. 14

4 Turn the black switch counter- Electrical cabinet

clockwise to turn off the
BlueBox.
START
STOP

Off
Main Power
Switch

WARNING!
Never stop the BlueBox
ill. 15
with pressure on.

6
PART 4 MAINTENANCE

Daily

1 Cleaning of the float-filter:

Screw off the red balloon and
plastic top. Remove the nylon
and metal filters. Rinse them
in clean water with a brush.
Insert the filters and check that
the crude filter is placed on top.

ill. 16

2 Cleaning of the three filters

cartridges:

a) Unmount the three cylinders

containing the filters.

ill. 17

b) Remove the filter from the

housing and rinse both with
clean water.

IMPORTANT
The filters must NOT be wrought
or squeezed. ill. 18

3 Reinstall the used or new filter cartridges in the housings and mount back onto the
corresponding bracket.

4 The filters should be changed when plant pressure is becoming too high or when they are
judged to being too dirty. Max. 6 months operating time.

5 The air filter mounted in the door of the electrical cabinet must be inspected every day ensuring
the filter is not clocked.

7
 EVERY WEEK
Lubrication of the pump
The pump is lubricated with grease at the
indicated area. Remove the black plug on
the front of the BlueBox to reach the grease
point. Be generous. We recommend 3-4 WATE

squeezes with a grease tool (you cannot

WATE

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overgrease the pump). Some grease might
run out of the pump if it is full, but this is not
damaging to the pump or the purifier.
ill. 19

Plug for grease lubrication

EVERY MONTH
• Check that all the connections and clamps are tightened correctly.
• Ensure that filters cartridges, membranes and UV-light bulb are fittet correctly.
• Check that the drainage pipes in the container are not blocked.
• Check all hoses for holes, tears and other signs of damage and water leakage.
• Check the pump’s membrane. If there is water leaking out of the small hole at the bottom of
the pump, the membrane is not watertight and must be changed.

EVERY YEAR
We recommend that the UV glass tube is removed from the chamber and cleaned using a damp
cloth infused with a solution of a mild cleaning agent.

PUMP MAINTENANCE
The membranes must be renewed once a year.
1 Remove the two bolts on top of the motor and replace filter.

2 Remove the four bolts either side of each cylinder and replace filter.

3 Assemble in reverse order.

1 2

ill. 20 ill. 21

IMPORTANT
The BlueBox 1200RORS must be started every 3 months in order to maintain flexibility in rubber
parts and to avoid build up of contaminants.

8
PART 5 CLEANING
After more than 14 days of standstill and before storing, the BlueBox 1200 must undergo a
complete cleaning process.

Please ensure that you have approximately 200 litres

of clean water available before you start the cleaning
process.

Cleaning procedure with Sodium

Hydroxide and Nitric Acid
(For example RoClean P303 and RoClean P111)

1 Remove the three filter housings and pull out the

filter cartridges. Mount the filter housings back ill. 22
onto the mounts without the filters in.

2 Acid Cleaning (RoClean P303)

Dilute 1 kg of RoClean P303 in 50 litres of water.
Insert all three hoses into the container with the
cleaning fluid (Flush water outlet, Raw water
inlet and Clean water).
Start the BlueBox and let the system rinse without pressure (open the blue pressure valve) for
10 minutes.

3 Turn the blue pressure valve clockwise to show approximately 8 bars of operating pressure.
Run the BlueBox at this setting for 30 minutes.

4 Open the pressure valve all the way and run the system with clean water for 10 minutes
without pressure, and then again for 10 minutes with 8 bars of pressure.

5 Alkali cleaning (RoClean P111)

Dilute 1 kg of RoClean P101 in 50 litres of water.
Insert all three hoses into the container with the cleaning fluid (Flush water outlet, Raw water
inlet and Clean water).

6 Start the BlueBox and let the system rinse without pressure (open the blue pressure valve) for
10 minutes.

7 Turn the blue pressure valve clockwise to show approximately 8 bars of operating pressure.
Run the BlueBox at this setting for 30 minutes.

8 Open the pressure valve all the way and run the system with clean water for 15 minutes
without pressure, and then again for 15 minutes with 8 bars of pressure.

9 Turn off the BlueBox, following the procedure in ‘PART 3 After using BlueBox’.
If the first filter, 25 micron, is not too damaged (clogged), it can be rinsed and brushed down
and reinstalled.

NOTE For a thorough cleaning, please repeat step 2, 3, 6 and 7, 2-3 times and/or let the
membranes soak for up to 4 hours.

Preservation of membranes during storage or period of stand-still.

If the unit is to be stored (not used) for longer than 14 days, the membranes must be treated with
a 20 % glycol solution or RoCide preservation mixture, which will also protect it against freezing
temperatures. Remember to run a cleaning process of the system before taking into use.

IMPORTANT
The cleaning fluid must not exceed 45 ºC
The pH value of the cleaning fluid must remain within 2-11 pH

9
 PART 6 UV-LAMP
Potential Hazard Safety Measures
UV Exposure Never illuminate UV Lamp outside of the UV Chamber.
Never look directly at illuminated UV Lamp, even when using protective gear.
Always use protective gear, including gloves and UV safety glasses.
If accidental exposure occurs, immediately cool affected area and consult physician.
Electrical Shock Disconnect power to system before performing any maintenance or repair.
There may be more than one source of power.
Impalement Never perform any physical inspection, repair or maintenance on UV Chamber unless UV chamber has
been isolated and depressurized.
Never service UV Lamps, Sleeves or associated hardware until depressurization of UV chamber has been
confirmed.
Hot chamber Allow UV Lamps, UV Chamber to cool for a minimum of 10 minutes before handling.
Cut or ingestion Ensure the quartz sleeve or lamp is not broken, cracked or damaged in any way when handling equipment.
Scald from water When there is no water flow, the water in the chamber will become hot.
To prevent scalding, allow the system to cool before draining the system.
Fire Do not store any combustible or flammable material close to the system.
Hg Exposure The UV lamp contains mercury. If the lamp breaks, then avoid inhalation or ingestion of the debris and
avoid exposure to eyes and skin. Never use a vacuum cleaner to clean up a broken lamp as this may
scatter the spilled mercury. Obey local regulations and guidelines for the removal and disposal of mercury
waste.
Water leak Use proper plumbing materials to avoid potential material degradation from UV exposure.

Symptom Possible cause Possible solution

No power GFCI and/or breaker tripped. Reset GFCI and/or breaker
Transient voltage surge suppressor (TVSS) damaged Replace TVSS
Power supply damaged Replace power supply and use a TVSS
GFCI or breaker Connection between lamp and lamp plug is wet Clean and dry lamp pins and lamp plug, check unit
repeatedly trips for leaks or condensation
Short-circuit in the electrical assembly Replace power supply
Leak at inlet or outlet Threaded pipe fittings are leaking Clean threads, reseal with Teflon tape and retighten
Leak detected from Condensation of moist air on cold chamber Control humidity or relocate unit
area of UV chamber (slow accumulation)
O-ring damaged, deteriorated or incorrectly installed Inspect and replace if deteriorated
Lamp/sleeve assembly not properly installed Tighten assembly hand-tight
(too tight or not tight enough)
Leak detected UV sensor o-rings are damaged, deteriorated, or Inspect and replace o-rings if deteriorated
at sensor (if so incorrectly installed
equipped)
Alarm See Display section See Display section
System is operating Equipment downstream of UV system is acting as Ensure UV is the last piece of treatment equipment
but water tests a breeding ground for pathogens
reveal bacterial
contamination Pathogens are residing in the distribution lines Ensure all distribution lines have been disinfected
post-UV with chlorine
Recontamination from pipe dead-ends Remove any pipe dead-ends and flush with chlorine
Lamp timer does not Unit is unplugged Plug unit into AC power outlet
read anything
No power at AC power outlet Replace fuse or reset breaker
Power cord is damaged Replace power cord
Power surge caused damage to electrical assembly Replace power supply and use a surge protector

10
Display
Lamp timer display Counts down from 365 days to show time for annual lamp replacement.
Lamp timer reset After installing a new lamp, press and hold for five seconds to reset Lamp timer to 365.
Alarm Press to silence audible alarm.
When the alarm is due to the lamp’s age, the mute button will silence the audible alarm for 7 days; this
may be repeated up to a maximum of 4 times. After that, the button will silence for only 24 hours.
When the alarm is due to any other issue, the mute button will silence the audible alarm for 24 hours.

SLEEVE CLEANING & LAMP REPLACEMENT

Lamp replacement
Unplug the BlueBox from the electrical socket.
Let the unit cool for 10 minutes.
Remove the UV-lamp from the container.

Sleeve cleaning
Minerals in the water slowly form a coating on the sleeve. This coating must be removed because
it reduces the amount of UV light reaching the water, thereby reducing purification performance.

Equipment required
Clean cotton Latex or plastic gloves are preferred
Scale remover Vinegar or a citrus-based product
Cloth Must be soft, lint-free, and chemical-free. No clean-wipes must be used
Cotton swab

Lamp life
The amount of UV light created by the lamp decreases over time, requiring a replacement of the
lamp every 12 months. The controller displays the total lamp life remaining in days.
At 0 (zero) days, the controller will display ‘A3’ and supply an intermittent audible chirp (1 second
on, 5 seconds off), indicating the need to change the lamp.

NOTE
The UV system is designed to operate continuously and should not be shut
off for short periods of time, such as over a period of less than three weeks.

RESETTING LAMP LIFE

1 Disconnect the lamp from the controller.

2 Hold the ‘RESET’ button down while reapplying power to the Controller until you see ‘rSet’
on the display, then release.

3 A 5 second delay will occur until your hear an audible tone and the display will once again
read ‘365’.

11
 SPARE PARTS
Please contact [email protected] for spare parts
Filter cartridges
E-XA004823309 Prefilter, 25 micron/19.5” (no.1) BB1200 RORS
E-XA004823291 Prefilter, 05 micron/19.5”. Melt blown (no.2) BB1200 RORS
E-70020146323 Activated Carbon. 7.75” cartridge filter (no.3) 2 pcs per housing = 19.5” RS1200 RORS

Filter housing
E-70020254895 SS filter housing 20”. Fitting Ø 3/4”

ACLOW34021 LOW3 4021 RO-Membrane for BB1200RORS
VE4021304BSP-BO Stainless Steel vessel 4” for RO-membrane
VECEC4BSPCLAMP-BOW Complete endcap for 4” vessel. BSP 1/2” x 1/2”
Modul_RO1200 Complete RO-membrane setup on frame

UV-disinfection system
14201-9105 UV-light bulb
14201-9205 UV quartz tube

Pump parts
750153 Hardi pump 603/7 membrane kit
210022 Bearings type 6205
60207 Bearings type 6007

Membrane rehabilitation detergents
7509846 RoClean P303, High PH cleaning granulate.
7509014 RoClean P111, Low PH cleaning granulate.
ROCSC RoCide, preservation granulate mixture.

Miscellaneous parts
0001014 Pressure gauge. 16 BAR. Glycol filled
703032 Suction wind chamber
334553 Membrane for suction wind chamber

UV quartz tube
14201-9205

Filter cartridge
8944502541 (25µ)
80105410000 (5µ) Float filter
871005906 (AC) 841481

Filter Housing
E-70020254895

100 micron filters

165767

UV-light bulb
14201-9105

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 WATE
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Flush water outlet
(Red hose)
DH10008

Raw water inlet Clean water outlet

(Black hose) (Blue hose)
DH10009 DH10007

Electrical cabinet

Suction chamber
703032

START
STOP
Main Power
Switch

Membrane
(kit of four filters)
750153
365

Bearings
6205 – 210022
6007 – 60207

Ballast Air filter

(UV display) 5712014732
550910300

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 If any faults should occur…
SYMPTOM REASON SOLUTION

Pump cannot Float-filter is clogged. Dismantle red float and clean net-filters with brush
produce any (see ill. on page 7)
pressure
Absorption tube is not filled with water. Dismantle black absorption hose and fill with water.

Contra vent in absorption tube is stuck. Take apart contra vent and clean inside.

Membranes in pump are defective. Pump is dismantled by loosing the bolts –

membranes are loosened and changed.
(see Motor maintenance on page 8).

Vent valves in pump Are defective or Pump is dismantled by loosening bolts and vents
clogged. are cleaned or changed.

The pump is letting in air. Tubes are tightened on absorption side of pump.

Check reasons in pump section. Check solutions in pump section.

Clean water The system must undergo a cleaning Follow the cleaning guide.
capacity fails process. (see Part 5, ‘Every month’)

The system is not working at normal Adjust work pressure to 8 bars (see ill.) and check
work pressure. that the manometer on main-block shows 8 bar.

The lifting height (max. 6 meters) has The lifting height must be reduced to
been exceeded. under 6 meters.

Clean water tube is blocked or clogged. Make sure that there is free passage in the blue
clean water hose and that the flow meter are not
clogged by obstacles.

UV-light bulb Plug for light is not connected. Insert plug.

gives no light
UV-light bulb is not connected. Dismantle UV-housing and tighten bulb in its socket.

Defective bulb. Change bulb and check if the light

housing is tight (avoid looking directly at UV-light for
more than a couple of seconds).

Beeping noise Transformer is defective. Change transformer, please contact Much More
Water A/S or your local distributor for further
assistance.

There is water Defective membrane -or membranes. Change membrane- or membranes.

coming out
from the bot-
tom of the
pump

14
IMPORTANT NOTE
Please be aware of the following:

• Make sure that the electricity supply is stable.

• The Reverse Osmosis membranes (RO filters) in the BlueBox system normally have to be changed
every 2 years depending on the working hours and quality of feed water.

• Please do not place the system in directly sunlight. Heat may affect the electronics in the switch
board box.

• As the UV-light contains glass, the system must not be affected by hard shock.

• The system must be free of dust and dirt.

• The system must not be exposed for frost. Temperatures below 0 ºC (zero degrees Celsius) can ruin
the RO membranes. E.g. during a long-haul flight, the BlueBox should be started with low pressure
for a while in order to defrost the membranes without damaging them. For long term storage in
freezing temperatures, please contact Much More Water at [email protected].

• As an industrial standard for Reverse Osmosis, the output of the membranes decreases in
proportion with the temperature of the raw water: 3 % reduction per 1 ºC measured from 25 ºC.

• Beware of silt, humus and high levels of iron in the raw water. These compounds will eventually spoil
the membranes, since very small ‘plates’ from these compounds will fill up the membranes over
time. The only way to deal with this is to install an improved pre-filtration system.

• Beware of high content of iron/manganese. Especially coming from boreholes, high levels of iron
and manganese will clog the membranes and render them useless. It may be advisable to install an
improved pre-filtration system, using anti-scalants.

15
PURE WATER – ANYTIME – ANYWHERE

Much More Water A/S

Staerkendevej 43 • DK-4000 Roskilde
phone: +45 8020 8020
July 2017

[email protected]
www.MuchMoreWater.com