DEALER MANUAL

INSTALLATION START-UP SERVICE

File: E309199

P/N 50003 Rev. D

CONGRATULATIONS!!!
You have just purchased the finest iron, manganese, and hydrogen sulfide removal product on the market today. This product, when properly installed and maintained will provide years of trouble free service and iron free water. Please take the time to review the six sections of this installation manual to familiarize yourself with the product. Before going any further, please unpack the WATER D.O.G. and carefully inspect the product for any obvious shipping damage. If shipping damage is observed, please call the toll free number listed below.

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TABLE OF CONTENTS

PAGE .
4

SECTION A - MANUAL OVERVIEW

HOW TO USE THIS MANUAL .

SECTION B - SYSTEM SPECIFICATIONS

WATER D.O.G. DATA SHEET . 5

SECTION C - EQUIPMENT INSTALLATION

GENERAL WARNINGS & SAFETY INFORMATION SELECTING A LOCATION . MOUNTING DEVICE & ATTACHING ACCESSORIES WATER LINE CONNECTION PRESSURE RELIEF VALVE DRAIN . FLOW SWITCH INSTALLATION SYSTEM FLUSH SYSTEM START-UP & OPERATION 7 8 9 10 10 11 12 13

SECTION D - SERVICE
ELECTRICAL DIAGRAM ... REPLACEMENT PARTS 17 18

SECTION E - GLOSSARY
PRODUCT GLOSSARY .. 21

SECTION F - WARRANTY
WATER D.O.G. Iron Hunter HD Warranty . 21

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SECTION A - MANUAL OVERVIEW

HOW TO USE THIS MANUAL
This user manual is designed to guide the installer through the process of installation, startup, operation, and service of the Water D.O.G.TM Iron Hunter HD System.

This manual is a reference and will not address every situation. The person installing this equipment should have: Training in the Water D.O.G.TM brand of oxidizers. Knowledge of filtration, water conditioning, and how to properly size the media vessels for each situation. Basic plumbing skills

Direction instructions left and right are determined by looking at the front of the Water D.O.G. unit.

ADVISORY LABELS THAT APPEAR IN THIS MANUAL

WARNING: Failure to follow this instruction can result in personal injury or damage to the equipment.

CAUTION:
Incorrect operation can result in unsatisfactory performance.

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SECTION B - SYSTEM SPECIFICATIONS

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SECTION C - PRODUCT INSTALLATION

Section C explains the installation and start-up of the Water D.O.G.TM. This includes:

GENERAL WARNINGS & SAFETY INFORMATION SELECTING A LOCATION MOUNTING THE DEVICE & ATTACHING ACCESSORIES WATER LINE CONNECTION PRESSURE RELIEF DRAIN LINE FLOW SWITCH INSTALLATION SYSTEM FLUSH SYSTEM START-UP & OPERATION

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GENERAL WARNING AND SAFETY INFORMATION

UL
GROUNDING INSTRUCTIONS - This product must be grounded. In the event of a
malfunction or breakdown, grounding will reduce the risk of electric shock by providing a path of least resistance for electric current. This product is equipped with a cord having an appliance-grounding conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is installed and grounded in accordance with all local codes and ordinances.

WARNING - Improper connection of the appliance-grounding conductor can result in

a risk of electric shock. Check with a qualified electrician or service representative if you are in doubt whether the product is properly grounded. Do not modify the plug provided with the product; if it will not fit the outlet, have a proper outlet installed by a qualified technician.

ELECTRICAL
There are no user-serviceable parts in the line voltage compartment of the control panel. In the event of failure, an authorized service representative should replace these. The system has built in safety mechanisms that will shut the system down but still allow untreated water to be supplied. These safety features include: Temperature sensor and pressure switch shut down. All electrical connections must be completed to local codes. Use only the power cord that is supplied. Power cord must be plugged into a ground fault outlet. To disconnect power, unplug A/C power cord from its power source.

MECHANICAL
Do not use petroleum based lubricants such as Vaseline, oils, or hydrocarbon based lubricants. Use only 100% silicone lubricants. Your Iron Hunter HD unit comes equipped with an internal check valve which prevents oxygenated water from flowing into your pressure tank and well. Canada and some local U.S. codes may require the use of additional back-flow prevention devices. All plumbing must be completed according to local codes.

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SELECTING A LOCATION
The location of the Water D.O.G.TM Iron Hunter treatment system is important. following conditions are required. 1. 2. 3. 4. 5. 6. 7. 8. Indoor location -- the Water D.O.G. Iron Hunter HD is rated for indoor use only. Sturdy supporting wall or studs Mount the device using the hangers that are provided Adequate space to access equipment through the housing door. 120 volt A/C, 50/60 Hz, 15 amps GFIC power source. Local drain for pressure relief valve. Water line connections with shut-off. Comply with all state and local codes. The

OTHER LOCATIONS/GARAGE
When the system is installed in other locations, such as a garage, several items must be considered: Temperature Extreme hot or cold temperature could cause damage to the system. Freezing temperatures will cause the water to freeze and cause damage to the plumbing and internal parts. The product is rated for a maximum operating ambient temperature of 100 F. Care should be taken in choosing a location that meets this requirement. Insects The control panel has been designed to keep all but the smallest insects out of critical areas.

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MOUNTING THE DEVICE & ATTACHING ACCESSORIES

Before mounting the device to the wall attach the two top mounted accessories packed with the unit. See Figure 1. Pressure Relief Valve with Barb Adapter Honeywell Braukmann Air Vent

FIGURE 1

Apply pipe joint compound to the threads of the two accessories before installing them. WATER D.O.G. WORKS recommends Spears Blue 75 or Rectorseal T Plus 2 thread sealant. DO NOT USE TEFLON TAPE. The pressure relief valve has been factory calibrated to 125 psi. No adjustment is required. Turn the Braukmann Air Vent counterclockwise to the open position. (NOTE: the black upper body of the Air Vent rotates relative to the brass base).

Four mounting brackets on the back of the Water D.O.G. cabinet have been factory installed. The open slotted brackets at the base of the cabinet are intended to ease installation.

When you are ready to mount the Water D.O.G. unit to a stud wall, plan for a two-person installation as the unit weighs approximately 90 lbs.

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WATER LINE CONNECTIONS

The Water D.O.G. comes with factory installed 1 MNPT, PVC fittings for inlet and outlet piping connections. We recommend installing a bypass device or bypass plumbing to isolate the Water D.O.G unit from the water supply for routine maintenance. Plumbing connections must be made by an authorized installer familiar with local plumbing codes. PRECAUTIONS - THREADED PLUMBING CONNECTIONS: DO NOT USE TEFLON TAPE USE A QUALITY GRADE THREAD SEALANT ONLY WARNING: SOME PIPE JOINT COMPOUNDS OR TEFLON PASTES MAY CONTAIN SUBSTANCES THAT COULD CAUSE STRESS CRACKING TO PLASTIC. Water DOG Works recommends the use of Spears BLUE 75 or Rectorseal T Plus 2 Thread Sealant, which has been tested for compatibility with our PVC fittings. Choice of an appropriate thread sealant other than those listed above is at the discretion of the installer and may void warranty. Thread sealant must be NSF 61 Listed and compatible with PVC fittings.

PRESSURE RELIEF VALVE DRAIN

The pressure relief valve is a safety feature on the system. If high pressure is seen by the Water D.O.G., the relief valve opens to prevent any risk of damage to the plumbing in the system. The valve is and the drain line should not be less than . For drain line connection, a barb fitting adapter, provided for assembly to the pressure relief valve and is sized to accommodate plastic tubing. The drain line may be elevated up to 8 feet as long as the run is no longer than 30 feet. Comply with state and local codes for the proper anti siphon or air gap. WARNING: Never insert a drain line directly into a drain, sewer line, or trap. Always allow an air gap between the drain line and the wastewater to prevent the possibility of sewage being backsiphoned into the system.

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FLOW SWITCH INSTALLATION

The flow switch is shipped as a separate subassembly that needs to be installed downstream of the filter, (See Figure 5). This allows only filtered water to pass the switch. The flow switch is factory calibrated to turn on at 0.5 gallons/minute.

FIGURE 5

Figure 5 show the flow switch mounted in the horizontal position which is preferred. Should the flow switch assembly need to be mounted vertically, insure that the water flow is from bottom to top.

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The flow switch comes factory installed as a special plastic flow switch assembly, See Figure 6. Note, that there is an arrow on the assembly that shows the proper direction of water flow to insure the switch operates correctly.

OUTLET

FLOW

INLET

FIGURE 6

CAUTION:
Do not alter the flow switch assembly, as it will change the calibration of the flow switch. Finally, after installing the flow switch, connect the ten-meter flow switch cable from the bottom of the enclosure to the flow switch.

SYSTEM FLUSH
A. After the installation steps have been completed, the supply water piping system must be flushed. This will remove any soldering flux from the piping before it enters the Water D.O.G.TM system. If soldering flux enters the Water D.O.G. unit it can coat the electrodes, which will impede oxygen production. B. With the Water D.O.G bypassed from the supply water, perform a two (2) minute flush of the supply water piping by opening a water faucet located as close to the system as possible.

CAUTION:
Failure to flush piping of residue or flux from soldering may result in coating of the electrodes, which will impede oxygen production, thus decreasing the Water D.O.G.s ability to oxidize iron. C. After the flushing the supply water piping, put the installed iron filter and water softener (if present) into by-pass operation. Open the supply water to the Water D.O.G. and flush the Water D.O.G. for 15 minutes. NOTE: If dealing with high levels of hydrogen sulfide, it may be desirable to flush this water into a floor drain or outside.

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SYSTEM START-UP & OPERATION

System start-up assumes that the following steps have been taken. 1. The Water D.O.G. Iron Hunter HD has been firmly mounted to a supporting wall or studs. 2. The correct water connections have been made to the inlet/outlet piping connections and the flow switch. 3. The system has been thoroughly flushed, and any trapped air has been vented. 4. The system has been. 5. There is no water flowing to any outlet of the house. When 1 through 5 are completed, Plug the system into a ground fault outlet. With the power switch turned off, all indicators should be off. Turn on the power switch. If the red fault light is on, reset it by pushing the Red Reset push button in the left middle of the PWB. The condition of the set/reset relays on the printed circuit board may have changed due to shipping effects. This will reset the system to the right conditions. To push the Red Reset push button, you must first remove the three screws from the swing panel and open the panel. WARNING: With the swing panel open there is exposed line voltage on the electrical panel, which is located above the PWB. Turn on a faucet to get water flowing. After a time delay of approximately 5 to 10 seconds, the flow light, one of the electrode polarity lights, and the fan should turn on. The chamber will be producing oxygen. The water flow LED indicates that water flow has been sensed and the DC power supply has been energized. The electrode polarity LED indicates 12V DC has been applied to the chambers. Turning the faucet off will result in the flow light and the electrode polarity light turning off after approximately a 5 to 10 second delay. The electrode polarity is factory set to reverse every 15 minutes (this is a self-cleaning feature to prevent build up on the electrodes). See Polarity Reversal section on the next page for details on how this feature works.

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The unit is now fully operational and ready for use.

CAUTION:
The power switch on the Water D.O.G. Iron Hunter HD must be turned off before placing the unit into the by-pass mode for service or maintenance. If the power supply shuts down after several minutes of operation, see page 16, Series/Parallel Wiring Harness, PN 60038. Polarity Reversal Timing: The timing of polarity reversal to the electrodes is factory set to 15 minutes. This is indicated by the 6 position DIP switch on the printed wiring board as shown in Figure 7 below. It can be field changed by trained personnel, if warranted, to 3.7, 7.5, 15, 30, 60, and 120 minutes per the table below:
ON

FIGURE 7

Polarity Reversal Timing

OFF

TIMING 3.7 Min. 7.5 Min. 15 Min. 30 Min. 60 Min. 120 Min.

POS 1 ON OFF OFF OFF OFF

POS 2 OFF ON OFF OFF OFF

POS 3 OFF OFF ON OFF OFF

POS 4 OFF OFF OFF ON OFF

POS 5 OFF OFF OFF OFF ON

POS 6 OFF OFF OFF OFF OFF FACTORY SETTING

OFF OFF OFF OFF OFF ON (Note: Time is counted only when water is flowing)

Reset Switch Operation (Red Button on PWB) The Water D.O.G. is designed to give years of trouble free operation. It does have built in safety features in the event of system malfunction. These include: A High Pressure Limit Switch Two High-Temperature Limit Switches A Pressure Relief Valve If the system were to sense high temperature or high pressure, it will de-energize the chambers and turn on the fault light. A trained technician must diagnose the problem. The system will remain locked out (no power to the chambers) until it is put back into service by depressing the Red Reset push button in the left middle of the PWB. As stated previously, the reset switch may also be needed during initial set-up to put the relays in the proper state.
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Series/Parallel Electrode Wiring Harness, P/N 60038 The 60038-A Series/Parallel Wiring Harness is a special purpose part included in the Accessory box with every unit, but is intended for use only if required. Do not use this part unless you meet the requirements defined below. In applications where the water conductivity is excessively high, the electrical current required by the chambers will exceed the amount of current that the 12 VDC power supply can deliver, resulting in the power supply safely shutting down due to the internal current overload feature. To re-start the system, the on-off switch must be turned off, and then turned back on to reset the power supply. However, with high conductivity water, this same safety shutdown will occur shortly after power is re-applied the system will not continue to run. We estimate that water conductivities in excess of 1400 MicroSiemens will cause each of the six sets of electrodes to draw 8.33A or greater (a total of 50A), resulting in the power supply over current shutdown. If you encounter applications where the current to each set of plates exceeds 8.33A, and the power supply is shutting down, the Series/Parallel Wiring Harness can be installed to correct the problem. This wiring harness re-configures the 12 VDC wiring to the 6 sets of electrodes. Without the harness, as the Water D.O.G. is shipped from the factory, each set of electrodes is wired in parallel across the 12 VDC Power Supply. With the wiring harness installed, two electrodes are placed in series (3 sets) across the 12 VDC, so each electrode gets the voltage (6 VDC) and the current. CAUTION: The wiring harness will allow the Water D.O.G. to work in water conductivities up to approximately 4000 MicroSiemens. Do not operate the Water D.O.G. with the installed series/parallel wiring harness in water conductivities above 4000 MicroSiemens. The current to each electrode must not exceed 9A with the series/parallel wiring harness installed.

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Installing the 60038-A Series/Parallel Wiring Harness is very simple: 1. Disconnect the 6 pin Molex connector going to each electrolytic chamber. 2. Connect the Plug (with male pins) of the 60038-A wiring harness to the upper Molex connector coming from the barrier wall. (The lower connector coming from the barrier wall is not used.) 3. Plug the Receptacles (with female pins) from the 60038-A wiring harness into the Molex plugs connected to each electrolytic chamber. Make sure the plug is fully inserted. 4. Start the Water D.O.G. system and confirm there is power to each set of electrodes in the electrolytic chambers using a clamp on ammeter.

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SECTION D - SERVICE
ELECTRICAL DIAGRAM

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REPLACEMENT PARTS
The Water D.O.G. Iron Hunter HD is intended to be installed by water treatment professionals who have completed a training program at WATER D.O.G. WORKS on the operation, maintenance, and service of the device. The device has been designed to allow the following components to be field replaceable by trained personnel who have been certified by WATER D.O.G. WORKS.

P/N 10000 HIGH PRESSURE SWITCH

P/N 10001 AIR VENT

P/N 10003 PRESSURE RELIEF VALVE

P/N 10004 HIGH TEMPERATURE SWITCH

P/N 10006 CHECK VALVE

P/N 10050 SOLID STATE RELAY

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P/N 10052 RELAY

P/N 10096 COOLING FAN

P/N 40010 ELECTRICAL PANEL ASSEMBLY

P/N 40033 FLOW SWITCH ASSEMBLY

P/N 40028 PCB PANEL ASSEMBLY

P/N 40029 CHAMBER ASSEMBLY

P/N 60015 FLOW SWITCH CABLE

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SECTION E PRODUCT GLOSSARY

INTERNAL COMPONENTS
1. Check Valve A valve that permits flow in one direction only. 2. Drain This is used when the system is in bypass and water needs to be drained out of the system. 3. Electrolytic Chambers Creates micro bubbles of oxygen from the water itself using electrolysis. 4. Hi-Temp Limit Switch Safety switch that can disable power to chambers. 5. Electrical Subassembly Power supply & line voltage components. 6. Printed Wiring Board Subassembly Contains low voltage control & safety circuitry.

EXTERNAL APPEARANCE
1. 2. 3. 4. Air Vent (Braukmann Valve) Vent any excess gases from the machine. Data Plate Contains Device ratings and manufacturer information Pressure Relief Valve Safety feature to release any excess pressure. Power Cord Supplies power to the machine.

CONTROL PANEL
1. A/C Power Shown as an illuminated Power Switch On/Off 2. Electrode Polarity Shown as alternating green and yellow LEDs that indicate the polarity is being reversed. (Note: polarity reversal keeps the plates clean). 3. Fuse Holder Fuse for the device (and holds a spare fuse). 4. Fault Shown as a red LED to indicate a safety shut-off. An Authorized Service Technician is needed to reset the device. 5. Water Flow Water flow light is illuminated to indicate flow of water through device.

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SECTION F WARRANTY

Limited Lifetime Warranty

WATER D.O.G. WORKS Products are warranted to be free of defects in material and workmanship for as long as the original consumer owns the product. If a defect is found in normal residential usage, WATER D.O.G. WORKS will at its election, repair, replace or make appropriate adjustment where WATER D.O.G. WORKS inspection discloses any such defects after installation. WATER D.O.G. WORKS is not responsible for removal, installation or shipping costs. Warranty Limitations This Limited Warranty is void if: WATER D.O.G. WORKS or its designated representative determines that the product has been subjected to alteration, neglect, misuse or abuse, or freight damage caused by common carrier; any repairs have been attempted by anyone other than a authorized representative; or if the failure is caused by accident, acts of God or other causes beyond the control of the manufacturer. Neglect misuse and abuse include any installation, operation or maintenance of the product other than in accordance with the instructions contained in the owners manual provided with the product. Limited Lifetime Warranty does not apply to: Normal wear and tear. Any Alterations or modifications and unauthorized repairs. Chamber Assembly, the chamber assembly has a limited 2 year warranty. The manufacturer or its designated representative must perform all warranty service. This Limited Warranty gives you specific legal rights, and you may also have other rights that vary from country to country or state to state. This Limited Warranty is void if the label bearing the serial number has been removed or defaced or if the product is not purchased from an authorized reseller. EXCEPT TO THE EXTENT PROHIBITED BY LAW, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THE PRODUCT IS LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY Your Limited Warranty rights are not diminished if you do not complete and return the product registration form or complete and submit the online product registration form. WATER D.O.G. WORKS thanks you for your product purchase. We hope it will give you years of satisfaction.

WARRANTY REGISTRATION
DEALER
NAME ADDRESS __________________________ __________________________ __________________________ __________________________ NAME ADDRESS

INSTALLATION
____________________________ ____________________________ ____________________________ ____________________________

PHONE NUMBER _____________________ E-MAIL __________________________ INSTALLER __________________________

PHONE NUMBER ________________________ E-MAIL ____________________________ DATE INSTALLED ________________________ SERIAL NUMBER _______________________

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WATER D.O.G. WORKS 6101 Baker Rd., Suite 206 Minnetonka, MN 55345

WATER D.O.G. WORKS 6101 Baker Rd., Suite 206 Minnetonka, MN 55345

ATTN: WARRANTY DEPT.

FOLD HERE

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