REGISTERED HANDBOOK Document: 793612 ECN: 03-1884 Revision: C Checked by: OR_ Approved by: DK Date: 03DE08 Date: 03DE08 MANUAL, O&M TrojanUVLogic TM System Systems Without Wiper AM, VM & TM Models
TROJAN TECHNOLOGIES INC. UVLOGIC MIDFLOW (AM, VM & TM) OPERATION AND MAINTENANCE MANUAL 2001 READ THIS MANUAL FIRST BEFORE INSTALLING, ADJUSTING, OPERATING OR MAINTAINING THIS SYSTEM Copyright 2001 by Trojan Technologies Inc., London, Ontario, Canada. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without written permission of Trojan Technologies Inc.
This manual is intended for use by the operator to understand, operate and maintain the UVLOGIC. Drawings and descriptions of the system parts are included, along with explanations of how the system works and what affects its performance. Included are sections on installation, and routine maintenance procedures. Further information can be obtained by contacting: TROJAN TECHNOLOGIES INC. 3020 GORE ROAD LONDON, ONTARIO, CANADA N5V 4T7 Telephone: (519) 457-3400 Fax: (519) 457-3030 Client Services: 1-800 - 265 5774 (North America only) Web Site: www.trojanuv.com UVLOGIC, Operation and Maintenance Manual MIDFLOW (AM, VM & TM)
UVLOGIC OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS WARNINGS AND PRECAUTIONS...3 Section 1.0 UVLOGIC OVERVIEW...5 1.1 Factors Affecting UV Disinfection...6 1.2 Your Model Number Identify What You Have...8 Section 2.0 INSTALLATION INSTRUCTIONS...9 2.1 Shipping Contents...9 2.2 Set-up...9 2.3 System Start-up...12 Section 3.0 FEATURES...14 3.1 Alarm ON Delay...15 3.2 UV Intensity Display...15 3.2.1 Major Alarm:...15 3.3 Lamp Elapsed Time Display...16 3.3.1 Reset the Lamp Elapsed Time:...16 3.4 Lamp Status Display...16 3.5 Temperature Switch...17 3.5.1 Minor Alarm:.....17 3.5.2 Major Alarm:...17 3.6 Power ON / OFF Counter...18 Section 4.0 OPTIONS...19 4.1 Remote Power Control...19 4.2 Common Alarm Output...19 4.3 Analog Out...20 Section 5.0 MAINTENANCE INSTRUCTIONS...20 5.1 Maintenance Schedule...20 5.2 Lamp Inspection/Replacement...21 5.2.1 Elapsed Time Reset...22 5.2.2 Lamp Number Configuration...23 5.3 Sleeve Replacement...23 5.4 Sleeve Cleaning...26 5.4.1 Sleeve Cleaning Solutions...26 5.4.2 Sleeve Cleaning Procedure...26 5.5 Sleeve Holder Removal...27 5.6 Sleeve Bushing Replacement...28 5.6 Sleeve Bushing Replacement...28 5.7 UV Sensor Removal and Cleaning...29 Section 6.0 ALARMS AND TROUBLESHOOTING...31 Section 7.0 REPLACEMENT PARTS...32 UVLOGIC, Operation and Maintenance Manual MIDFLOW (AM, VM & TM) i
7.1 Reactor Chamber Parts List... 32 7.1.1 UVLOGIC AM, VM & TM MODELS... 32 7.2 Control Panel Parts List...33 7.2.1.MODELS AM, VM & TM 33 7.3 UV Sensor Parts List...34 7.4 Wiring Harness Parts List...35 Section 8.0 ELECTRICAL REFERENCE...37 8.1 Power and Controls Schematic...37 Section 9.0 APPENDICES...38 9.1 Certificates...38 9.2 Warranty and Service Coverage...38 9.3 System Factory Settings...39 MAINTENANCE LOG...40 UVLOGIC, Operation and Maintenance Manual MIDFLOW (AM, VM & TM) ii
WARNINGS AND PRECAUTIONS FAILURE TO FOLLOW THESE PRECAUTIONS CAN CAUSE SERIOUS PERSONAL INJURY OR DAMAGE TO THE SYSTEM. 1. The lamps in this system emit ultraviolet light. Exposure to ultraviolet light can cause serious burns to unprotected eyes and skin. Never view ultraviolet light directly with the naked eye. Always view ultraviolet light through a properly rated viewing port or through properly rated protective eyewear. Always wear protective clothing when exposed to ultraviolet light. Ensure all lamps are properly secured within the reactor chamber before turning the system on. Turn the system off before servicing. 2. To prevent electrical shock, turn the system off before removing any of the covers on the reactor chamber or opening the control panel. 3. Ultraviolet lamps become hot during operation. Hot lamps can cause serious burns. Allow the lamps to cool before servicing. 4. The ultraviolet lamps, and the sleeves they are housed in, are constructed of quartz tubing. Quartz tubing is very fragile and easily fractured. Do not strike, bend or apply pressure to this material or it will break. Broken lamps or sleeves can cause serious cuts. 5. Lamp connections and end plate surfaces can become hot during normal operation. Do not touch while the unit is operating. 6. For correct installation, follow the Installation Instructions, Section 2.0. Refer to the wiring diagram included with this system for the correct connections between the control panel and the reactor chamber. 7. Acids used to clean the lamps and sleeves can cause burns. Wear protective clothing and eyewear when handling these materials. Rinse the components thoroughly with distilled water after cleaning. Always follow the safety precautions provided by the manufacturer of the cleaning solution. 8. This system uses ultraviolet light to reduce the concentration of pathogens to non-infectious levels. Failure to follow the Maintenance Instructions or respond to alarms will reduce the effectiveness of this system. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 3
9. This system has been designed to be effective under operating conditions described by the customer. Any changes in these conditions can reduce the effectiveness of the system to disinfect. The factors affecting operation are found in the UVLOGIC Overview, Section 1.0. 10. This system must be installed indoors. 11. This system is meant to treat liquids water only. 12. Intermittent operation of the system requires that a minimum flow be circulated through the system in order to remove heat from the lamps. Never operate the unit empty or without flow for extended periods of time. 13. Connect this system to an AC electrical outlet with voltage and power specifications matching those on the serial label of the system. 14. Do not operate the system unless the reactor chamber is completely filled with flowing water. 15. If your piping system is subject to impulse pressure, a surge tank or other means of removing this condition must be provided. 16. The ultraviolet output of these lamps decreases with time. The ultraviolet lamps in this system must be replaced every 12 months of use to ensure proper operation. 17. Periodic evaluation of the system performance through standard methods is recommended. Space should be allocated for sampling ports at the inlet and outlet piping of the UVLOGIC system. 18. Installation and Maintenance to be performed by qualified persons only. 19. All repairs to be performed by Trojan Technologies Inc. service technicians or qualified personnel. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 4
Section 1.0 UVLOGIC OVERVIEW The Trojan UVLOGIC uses ultraviolet light to disinfect drinking water and process water. The simple effective design makes it suitable for many large scale applications in water treatment. Unlike chemical disinfection, UV does not require the handling of dangerous substances and adds no toxic compounds to the water. The UVLOGIC sealed and pressurized reactor chamber allows a high volume of water flow to be disinfected. It is a closed system that prevents outside particles from contaminating the treated water. The modular design of the UVLOGIC makes it versatile and permits easy access to the equipment. What is Ultraviolet (UV) Light? UV light is defined as electromagnetic radiation having a wavelength less than that of visible light (400 nm) and greater than that of X-Rays (100 nm). The unit of wavelength used is a nanometer (nm) equal to 10-9 meters. The optimum UV wavelength for germicidal effect is 265 nm, which is found only in small amounts in solar radiation because energy at these wavelengths is absorbed by the atmosphere. The primary source of UV energy in current technology is a special short wave arc lamp (like the ones supplied with your system). The primary reason for its use is that a significant amount of its UV energy output is near the wavelength of 265 nm. This radiation is generated by striking an electric arc through a metallic compound vapor. Discharge of the energy generated by excitation of the metallic molecules results in the emission of the UV light. Applications of UV Light Ozone Destruction: Ozone is typically used in high purity water systems to oxidize trace chemicals and to disinfect stored water. Often ozone cannot be tolerated in the final product water and therefore any residual must be removed. 254 nm UV energy is absorbed by ozone, causing it to break down into dissolved oxygen. TOC Reduction: In high purity water systems, UV is often used in conjunction with ion exchange equipment for the reduction of trace organics, referred to as TOC (Total Oxydizable Carbon). High-energy UV lamps, emitting UV energy below 200 nm, are used to trigger the photolysis of water, producing very powerful hydroxyl free radicals (OH). These hydroxyl free radicals attack organic compounds, breaking them down into carbon dioxide and water when fully oxidized. Some organic materials are broken down into weakly ionised acid-based groups which are then easily removed by polishing mixed bed ion exchange equipment. Industrial Disinfection: The most common application of UV light is disinfection. 254 nm UV energy penetrates the cell membrane of micro organisms and alters the genetic material of the cell (DNA) destroying its ability to reproduce. In this application, UV is commonly used as an alternate disinfectant to chlorine and other chemical oxidants and also as a protection for other technologies in a complete water treatment system. Disinfection versus Sterilization Sterilization implies the total elimination of pathogens or disease carrying microorganisms. In contrast, disinfection is a reduction in the concentration of pathogens to non-infectious UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 5
levels. Section 1.1 Factors Affecting UV Disinfection Ultraviolet light kills bacteria and viruses by destroying their genetic material. The performance of a UVLOGIC to disinfect water is expressed in terms of reduction of bacteria, or "kill". Each system is designed to reduce bacteria counts to a certain allowable level, which depends on the requirements of the specific application. The dose of UV light available to kill bacteria is measured in microwatt-seconds/cm 2, which is equivalent to the product of the light intensity and the duration of exposure, or retention time. Any factor that affects light intensity or retention time will affect performance. Dose = Intensity (µw/cm 2 ) x Retention Time (sec) The UVLOGIC is designed to deliver a dose that takes into account lamp aging. Factors Affecting Performance DOSE = INTENSITY X RETENTION TIME Water Quality UV Transmittance Suspended Solids Level of Dissolved Organics Total Hardness Lamp Condition Sleeve Cleanliness Aging Treatment Process Flow Rate UV Transmittance: UV transmittance is defined as the percentage of UV light at 254 nm not absorbed after passing through 1 cm of water sample. Transmittance depends on dissolved and suspended matter in the water. Reduced transmittance lowers the intensity of the light in the water, thus requiring longer exposure time in order to deliver the proper UV dose. The visual clarity of a water sample is not always a good indicator of its UV transmittance since water that is clear to visible light may absorb invisible ultraviolet wavelengths. Suspended Solids: Suspended solids consist of any filterable particle in the water and are measured in parts per million (ppm) or (mg/l). They lower UV transmittance by scattering and absorbing the light. They can also reduce kill by protecting bacteria from exposure to the UV light. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 6
Level of Total Dissolved Solids: Specific organic compounds in the process water will absorb some energy, which is emitted in the germicidal wavelength region of the spectrum. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 7
Total Hardness: The presence of high levels of inorganic magnesium or calcium carbonates in a water stream may contribute to coating of the quartz sleeve. Sleeve Cleanliness: To ensure maximum performance from the unit, it is essential that the quartz sleeves be kept clean. If a coating is allowed to build up on the sleeves, the amount of the UV light transmitted to the water will be reduced. Treatment Process: Flow Rate: Water processing equipment located upstream of the UVLOGIC, such as filters, can affect performance. Different treatment processes produce water with different UV transmittance characteristics and different observed cleaning frequency patterns. The flow rate through the UVLOGIC will determine the retention time, which in turn determines the delivered UV dose at a given UV light intensity. Section 1.2 Your Model Number Identify What You Have Example: System Part Number No. Of LAMPS LAMP TYPE REACTOR SIZE SENSOR TYPE WIPER OPTION MOUNTING BRACKETS SYSTEM VOLTAGE PANEL MATERIAL PANEL RATING PANEL LOCATION 02 AM 20 D - - M N 2 2 2 1 System Description COMPONENT MODEL FLANGE TYPE FLANGE SIZE PANEL TYPE ANALOG OUT OPTION REMOTE ON/OFF OPTION SYSTEM, UVL A 1.5 PST AO RM1 * NOTE: When ordering replacement parts please provide the serial number for your system. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 8
Section 2.0 INSTALLATION INSTRUCTIONS Installation and maintenance to be performed by qualified personnel only. All Trojan products are carefully inspected and tested before shipment from our plant. Upon delivery, check the packaging and equipment for damage incurred during shipment. In case of damage, notify the shipping company that made the delivery. CLAIM FOR ALL DAMAGES WITH THE SHIPPING COMPANY. Section 2.1 Shipping Contents The system consists of two major components, the reactor chamber and the control panel. The components are disconnected at the reactor chamber for shipment. Section 2.2 Set-up 1. Connecting pipes to UV system should be supported to avoid any undue strain on the unit. 2. Avoid vibration from close proximity to heavy equipment or from erratic pumps. 3. Allow sufficient service access clearance for the unit. Also when preparing the site for installation allow for valves, drain and bypass as part of your plumbing circuit. 4. When mounting the control panel on the wall, ensure there is at least a 15-cm (6") air space around the sides of the panel for sufficient cooling of the inner electronic components. The more air space there is around the control panel the more efficient the cooling will be. You will need gaskets, mounting brackets (optional) and appropriate hardware to attach the reactor to the piping system. 5. The reactor chamber can be installed in a horizontal or vertical position. All models require a minimum clearance of 0.8 meter (2-8 ) at the service end of the reactor chamber for removal of the UV lamps and sleeves and 0.2 meter (6 ) at the sensor port for removal of the UV sensor. Avoid any installation where the UV sensor might be placed at top of reactor. To avoid trapping air, ensure the outlet is at the highest point. OUTLET 0.8 m CLEARANCE FOR LAMP INLET SENSOR PORT UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 9
6. After the reactor chamber is installed, slowly open the inlet valve and fill with water ensuring that all air pockets are removed. Check carefully for leaks. If leaks are detected, drain the reactor chamber and reseal the inlet or outlet as required. All reactor chambers are pressure tested at 1.55 MPa (225 psi) at the factory unless indicate otherwise. 7. Flush a few gallons of water through the reactor chamber to remove any particles or dust that may have collected during installation. To prevent electrical shock, turn the system off before removing any of the covers on the reactor chamber or opening the control panel. 8. Connect the control panel to the reactor chamber. The individual lamp connectors are numbered with wire tags for convenient connection; match these numbers to their corresponding number on the chamber end plate. (Single lamp reactor shown for clarity). 9. Connect the lamp socket to the corresponding lamp. Align the locking tabs of the lamp socket with the sleeve bolt. Insert the lamp into the sleeve until lamp socket sits against sleeve bolt then turn approximately ¼ turn to secure lamp in place. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 10
10. Temperature switch installation: For horizontal installations place temperature switch at the highest point possible. I. Slide retaining clip over sleeve bolt from the open end until it sits in groove. II. Place switch under clip as shown and maintain cables for switch close to sleeve bolt and lamp harness. III. Route harnesses through grommet allowing approximately 6 of slack for each harness. Keep harnesses together using provided tie wraps. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 11
11. System ground wire installation: I. Secure ring terminal to stud on reactor as shown. 12. Provide AC power to the Control Panel matching voltage and power specifications on the serial label of the system. The system is now ready for operation. Section 2.3 System Start-up 1. Allow the reactor chamber to slowly fill with water. 2. Turn the lamps ON for the UVLOGIC by pressing the switch located on the face of the control panel. A twenty-second delay timer is initiated when the lamps are turned ON. The system will not register any alarms until this warm-up timer has expired. This feature prevents any false alarms from registering while the system is warming up. 3. If no alarms are registering after the system has warmed up for 20 seconds, water may be allowed to pass through the chamber. 4. Allow any untreated water present in the system to flush through before using. 5. Monitor the system periodically to determine if any alarms are present. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 12
UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 13
Section 3.0 FEATURES The UVLOGIC consists of a reactor chamber located remotely from a control panel. The lamps are controlled via an ON / OFF switch located on the face of the control panel. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 14
Section 3.1 Alarm ON Delay This feature is used to prevent nuisance false alarms from occurring during system start-up. If this feature is turned OFF then there will be no alarms displayed during the first 20 seconds of the system start-up. After 20 seconds have elapsed from the power reset or system start-up the alarms response time will be 2 seconds. If the setting is ON then no alarms will be displayed during the first 2 seconds of the system start-up. This feature is factory preset to OFF for a 2 second delay. To change this setting locate DIP-switch #6 on the reverse side of the operator interface (inside the control panel): 1. Turn the panel power OFF and wait one minute. 2. Set DIP-switch #6 to ON for two-second response. 3. Close panel and turn the power back ON. Section 3.2 UV Intensity Display The display indicates the UV intensity at the inside wall of the reactor (measured in milliwatts/cm 2 ). This is a three-digit display, which upon a low UV intensity condition will begin to flash. The intensity level for the alarm set point is set at the factory based on sitespecific parameters provided by the customer. (See Section 9.3 System Factory Settings) 3.2.1 Major Alarm: This fault condition indicates that the UV intensity is below the system required UV intensity and maintenance is required. Intensity display will begin to flash at one-second intervals and a Common Alarm output relay is energized. (See Section 9.3 System Factory Settings) UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 15
Section 3.3 Lamp Elapsed Time Display The elapsed time display indicates the total number of hours the system has run. This fivedigit display begins to flash when Elapsed Time equals End of Life setting (EOL) 8750 hrs minus 250 hours (indicating that lamp replacement is imminent). 3.3.1 To reset the Lamp Elapsed Time (After lamp replacement): 1. Follow appropriate safety procedures while working within control panel. 2. Provide power to the control panel. 3. Locate DIP-switch #3 at the back of the operator interface. 4. Set DIP-switch #3 to the ON position. 5. The lamp elapsed time is now set to zero. Set DIP-switch #3 back to the OFF position Section 3.4 Lamp Status Display The lamp status display indicates the number of lamps in the system and whether the UV lamps in the system are functioning. If a lamp fails the number of the lamp will flash on the display. If more than one lamp fails their lamp numbers will alternate on the display at three-second intervals. The common alarm output relay is energized upon lamp failure. 3.4.1 Setting Number of Lamps: 1. Follow appropriate safety procedures while working within control panel. 2. Provide power to the control panel. 3. Locate DIP-switch #1 at the back of the operator interface. 4. Set DIP-switch #1 to the ON position. 5. The LAMP STATUS display will begin to scan in increments of one, wait until the auto scan feature reaches the desired value then set DIP-switch #1 to the OFF position Note: If auto scan goes beyond the desired value wait until it reaches the UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 16
Section 3.5 Temperature Switch top of the scale and restarts from zero. High reactor temperature alarm is displayed in the upper UV Intensity display and the middle Elapsed Time display by flashing the message HI TEMP in the respective display locations. This feature can be set to indicate either Minor or Major alarms for HI TEMP conditions. Major alarm is the default factory setting. 3.5.1 Minor Alarm: A discrete alarm in which a HI TEMP message begins to flash when the temperature switch on the reactor is triggered. To set this alarm as the default response: 1. Follow appropriate safety procedures while working within control panel. 2. Turn OFF power to the control panel. 3. Locate DIP-switch #7 at the back of the operator interface. 4. Set DIP-switch #7 to the ON position. 5. Return power to the control panel. 3.5.2 Major Alarm: A HI TEMP message begins to flash when the temperature switch on the reactor is triggered. The lamps will be turned OFF and the common alarm output relay is energized. 1. Follow appropriate safety procedures while working within control panel. 2. Turn OFF power to the control panel. 3. Locate DIP-switch #7 at the back of the operator interface. 4. Set DIP-switch #7 to the OFF position. 5. Return power to the control panel. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 17
Section 3.6 Power ON / OFF Counter This feature keeps track of the power ON / OFF cycles of the lamps. This counter is displayed in the Elapsed Time field and cannot be reset. To display the number of cycles on the system to date: 1. Follow appropriate safety procedures while working within control panel. 2. Locate DIP-switch #4 & #5 at the back of the operator interface. 3. Set both DIP-switches to the ON position. 4. The number of ON/OFF cycles is displayed in the Elapsed Time display. 5. Set both DIP-switches back to their original settings. This system uses ultraviolet light to reduce the concentration of pathogens to non-infectious levels. Failure to respond to alarms can reduce the effectiveness of the system. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 18
Section 4.0 OPTIONS There are a variety of options available for increased control. Please check your model number for upgrade options. Section 4.1 Remote Power Control This option enables the user to switch the lamps ON/OFF for the UVLOGIC from a remote location. A relay in the control panel controls the normally open (NO) dry contact. To make use of the dry contacts, power must be supplied to the relay terminals inside the control panel as seen on the Power and Controls schematic. The relay rating limits the usersupplied power to 120 Volts AC or 250 Volts AC and 5 Amperes depending on the input voltage for the system. This option is configured at the factory. Refer to the wiring diagram supplied with the system and local electrical codes for proper wiring. Settings: DIP-switch #8 set to ON for systems without the remote power option. DIP-switch #8 set to OFF for systems with remote power control option. Note: 1 This option is factory set or through special instructions from Trojan Technologies since it requires additional hardware. 2 If power is lost to the control panel to restart the lamps the operator must manually depress the Lamp ON/OFF switch located on the front of the control panel. Section 4.2 Common Alarm Output UVLOGIC, features a remote option, which can be used with a Major alarm condition to control remote devices. Accessible dry contacts are located on the reverse side of the operator interface (inside the control panel). The location of the dry contacts is shown in the power and controls schematic. A relay on the operator interface controls the normally open (NO) and normally closed (NC) contacts. The terms NO and NC refer to the status of the contacts in the alarm or power OFF state. To make use of the dry contacts, power must be supplied to the common (COM) terminal. The relay rating limits the user-supplied power to 250 Volts AC or 28 Volts DC and 16 Amperes. Refer to the wiring diagram supplied with the system and local electrical codes for proper wiring. During normal operation the relay is energized, the NO contact is closed and the NC contact is open. In the event of a power failure or system alarm the relay is de-energized, the NO contact is opened and the NC contact is closed. Example: A normally shut solenoid valve, placed in the water line, is connected to the NO contact on the interface. When the system is operating normally the NO contact would be closed, power would be supplied to the solenoid valve and it would allow flow. In the event of a power failure or an alarm the NO contact would open, the solenoid valve would lose power and it would shut, cutting off the water supply. Similarly a remote warning light or siren is connected to the NC contact. During normal operation the NC contact is open and the light or siren is off. In the event of a local or panel power failure or alarm condition the NC contact is closed and the remote warning light or siren would be activated. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 19
Section 4.3 Analog Out This option enables the user to monitor the system s UV intensity from a remote location. The 4-20 ma, 24 VDC signal is provided by the current module analog output contacts located inside the control panel. To make use of this feature power must be provided to the input terminals of the power supply in the range of 100-240 VAC, 0.25 Amps. This option is configured at the factory, same as Remote Power Control. To prevent electrical shock, turn the system off before removing any of the covers on the reactor chamber or opening the control panel. Section 5.0 MAINTENANCE INSTRUCTIONS This system uses ultraviolet light to reduce the concentration of pathogens to non-infectious levels. Failure to follow the Maintenance Instructions will reduce the effectiveness of this system. Periodic inspection and service can extend service life, especially under extreme operating conditions such as batch production scenarios where the internal temperature of the reactor may vary greatly. In such applications it is recommended that an internal inspection be completed periodically. Routine maintenance typically consists of partial disassembly, cleaning and visual evaluation of the following: Section 5.1 Maintenance Schedule COMPONENT WHAT TO LOOK FOR FREQUENCY Lamps Burned out lamps On Lamp Status alarm. Change in color of lamp glass At End of Lamp Life Sleeves Fouling or coating of the Clean monthly or when low quartz sleeves UV alarm occurs. UV Sensor Fouling or coating of the Clean monthly or when low quartz window. UV alarm occurs. Sleeve Seal, O-Ring Sleeve Support Washer Sleeve Bushing Wear Pads Lamp Socket UV decay and embrittlement. Signs of pins overheating or moisture. Corrosion of the pins. Once a year or when sleeves are removed. With Lamp Status alarm or when lamps are disconnected. Reactor Chamber Heavy build-up of settled Clean once a year. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 20
solids Section 5.2 Lamp Inspection/Replacement The ultraviolet output of these lamps decreases with time. UV lamps must be replaced every 12 months of operation even if lamp failure has not occurred. The lamps in this system emit ultraviolet light. Exposure to ultraviolet light can cause serious burns to unprotected eyes and skin. Never view ultraviolet light directly with the naked eye. Always view ultraviolet light through a properly rated viewing port or through properly rated protective eyewear. Always wear protective clothing when exposed to ultraviolet light. Ensure all lamps are properly secured within the reactor chamber before turning the system on. Turn the system off before servicing. Ultraviolet lamps become hot during operation. Hot lamps can cause serious burns. Allow the lamps to cool before servicing. To prevent electrical shock, turn the system off before removing any of the covers on the reactor chamber or opening the control panel. 1. Switch the power off to the control panel. 2. If necessary remove the temperature switch to allow better access to the lamp. 3. To release the locking mechanism for each lamp, gently pull the lamp socket against the sleeve bolt while turning counter clockwise when the locking tabs are aligned with the slots of the sleeve bolt the lamp socket will slide out of the sleeve bolt. 4. Gently pull the lamp socket and UV lamp from the sleeve bolt. An internal spring at the far end of the UV lamp will push the lamp out approximately 12 mm (0.5 ). UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 21
Ultraviolet lamps, and the sleeves they are housed in, are constructed of quartz tubing. Quartz tubing is very fragile and easily fractured. Do not strike, bend or apply pressure to this material or it will break. Broken lamps or sleeves can cause serious cuts. 5. Carefully disconnect the lamp from the lamp socket and pull the lamp out. 6. Use only quality replacement parts from Trojan Technologies Inc. Use clean gloves (cotton or latex) to install the new lamp. Touching the lamp with bare hands will contaminate the quartz. Wipe the replacement lamp with alcohol and a non-abrasive cloth to ensure that it is free of fingerprints, dust, or other contaminants. 7. Insert the replacement lamp into the sleeve leaving the stepped lamp end sticking out of the sleeve bolt in order to connect the lamp socket to the lamp. Slide the lamp gently into the sleeve bolt while aligning the lamp socket locking tabs with the slots of the sleeve bolt. Push the lamp socket into the sleeve bolt until it cannot go any further then turn clockwise to lock in place. Confirm the lamp socket is secure by tugging on it slightly. 8. Replace the temperature switch to its mounting position if necessary. 9. Re-establish power to the control panel and turn the lamps ON by pressing the switch on the face of the control panel. Confirm that the operator display on the control panel does not show an alarm. 5.2.1 Elapsed Time Reset When the set-able hours equals the system run hours the Elapsed Time display will begin to flash for the next 250 hours indicating an EOL alarm condition. The Elapsed Time display will begin to flash again at the next EOL set point (eg: 8750 hrs then at 17500 hrs). To reset the Elapsed Time counter back to zero (See Section 3.3.1) UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 22
5.2.2 Lamp Number Configuration The number of lamps in an UVLOGIC is factory pre-set. If this number needs to be changed (See Section 3.4.1) Section 5.3 Sleeve Replacement Note: Sleeve replacement can either be done by replacing each sleeve within the reactor or by removing the Sleeve Holder assembly (See Section 5.5). 1. Turn off the water flow through the reactor chamber. Relieve the water pressure in the chamber. 2. Shut the power off to the control panel. 3. Relieve the water pressure and drain the water from the chamber. 4. Repeat steps per Lamp Replacement/Inspection. (Section 5.2 up to step #4) 5. Remove the sleeve bolt by hand, turning it in a counter clockwise direction. 6. Use clean gloves (cotton or latex) to remove the sleeve. Touching the sleeve with bare hands will contaminate the quartz. Gently remove the sleeve being careful not to let it drop once the sleeve end leaves the Stop Plate. 7. Place the sleeve O-Ring into the sleeve socket of the end plate as shown. Ensure that O-Ring does not get damaged while inserting into sleeve socket. Replace the O-ring whenever the sleeve is removed. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 23
8. Use clean gloves (cotton or latex) to install the new sleeve. Touching the sleeve with bare hands will contaminate the quartz. Wipe sleeve clean with alcohol and a nonabrasive cloth before installation. 9. Insert the new (or cleaned) sleeve into the sleeve socket while keeping the sleeve aligned with the chamber, insert the sleeve through the sleeve bushing located inside the chamber until flare of sleeve bottoms out against O-Ring. 10. Place the sleeve support washer into the sleeve bolt as shown. Ensure that the washer seats flat on the recess of the sleeve bolt. Replace this washer whenever the sleeve is removed or the seal broken. 11. Place the sleeve bolt over the sleeve socket and turn it clockwise by hand to tighten. Tighten by hand until sleeve bolt will not turn any further 1.36 N*m (1 lb*ft). Do not use tools to tighten the sleeve bolt or damage to the sleeve or internal parts may result. 12. After the sleeve bolts are installed, slowly open the inlet valve and fill reactor chamber with water. CHECK CAREFULLY FOR LEAKS. If leaks are detected, inspect interior of sleeves for water, if there is water inside the sleeve follow Sleeve Cleaning Procedure, Section 5.4.2. 13. Flush a few gallons of water through the reactor chamber to remove any particles or dust that may have collected during installation. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 24
14. Proceed to install lamps per Lamp Replacement/Inspection. (See Section 5.2) UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 25
Section 5.4 Sleeve Cleaning 5.4.1 Sleeve Cleaning Solutions The following cleaning solutions are recommended for the removal of scale build-up and coatings from the quartz sleeves. Mild acid solutions are recommended. Acid solutions can be bought commercially or diluted from industrial strength acids. (Cleaners such as Lime-A-Way and CLR may be used.) 15% Phosphoric Acid 5% Nitric Acid 10% Citric Acid* * Citric acid solutions cannot be reused. All other types can be stored indefinitely and reused until they no longer have the strength to effectively clean the sleeves. Acids used to clean the quartz sleeves can cause burns. Wear protective clothing and eyewear when handling these materials. Rinse the components thoroughly with distilled water after cleaning. Always follow the safety precautions provided by the manufacturer of the cleaning solution. 5.4.2 Sleeve Cleaning Procedure 1. Remove the quartz sleeves as directed in Sleeve Replacement. (See Section 5.3) 2. Using a non-abrasive cloth soaked in one of the cleaning solutions listed in Sleeve Cleaning Solutions, Section 5.4.1, and wipe along the length of the quartz sleeve. 3. After cleaning, rinse the acid solution thoroughly from the sleeves with distilled water. Inspect the interior of the sleeve before installation to make sure they are clean and dry. Clean the interior of the sleeves with alcohol if they have been exposed to water or acid solutions. 4. Insert the sleeve in the reactor chamber per Sleeve Replacement. (See Secion 5.3) UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 26
Section 5.5 Sleeve Holder Removal The entire Sleeve Holder Assembly may be removed as an alternative to removing the quartz sleeves from the reactor chamber individually for cleaning. 1. Turn off the water flow through the reactor chamber. Relieve the water pressure from the system. 2. Shut the power off at the control panel. 3. Drain the water from the system. 4. Remove the temperature switch from the reactor chamber. 5. Disconnect the lamp sockets from the UV lamps per Lamp Replacement/Inspection, Section 5.2. up to step #4. 6. Remove the flange bolts or sanitary clamp and pull the entire sleeve assembly from the reactor chamber in a direction parallel to the reactor chamber to prevent the quartz sleeves from striking the sides of the chamber. 7. Clean the sleeves according to Sleeve Cleaning Instructions. (See Section 5.4.2) 8. Follow the above procedure in reverse order to re-assemble the reactor chamber. Ensure that lamp hole #1 is aligned with the UV sensor port. Always replace O-ring when Sleeve Holder is removed. Ensure the Flange O-ring is properly seated in its groove. Torque the flange bolts to: 38 N.m (28 ft lb) 1/2-inch diameter bolts 80 N.m (60 ft lb) 5/8-inch diameter bolts Sanitary clamp Tighten by hand until wing will not turn any further. 9. Repeat steps 1 through 5 of Section 2.3 for system start-up. (Check carefully for leaks) 10. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 27
Section 5.6 Sleeve Bushing Replacement 1. Remove sleeves per Sleeve Holder Removal. (See Section 5.5) 2. Remove bushings by sliding them through the opening in the stop plate. 3. Insert replacement bushings with the larger diameter facing towards the end plate. Ensure that shoulder of sleeve bushing sits properly on corresponding stop plate socket. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 28
Section 5.7 UV Sensor Removal and Cleaning 1. Turn off the water flow through the reactor chamber. Relieve the water pressure from the system. 2. Shut the power off at the control panel. 3. Drain the water from the system. 4. Using a 15/16 open end wrench, remove the brass compression nut by turning it counter-clockwise. SENSOR PORT BRASS COMPRESSION NUT SENSOR 5. Gently remove the sensor from the sensor port. It is normal for the O-ring to pull out with the sensor. The O-ring should be replaced whenever the sensor is removed. SENSOR PORT COMPRESSION NUT O-RING SENSOR UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 29
6. Clean the optical window on the end of the sensor with a cotton swab moistened with a cleaning solution as specified in Sleeve Cleaning Solutions, Section 5.4.1. Rinse the optical window with a clean cotton swab moistened with distilled water. Dry with a clean lint free cloth or another swab. Acids used to clean the optical window can cause burns. Wear protective clothing and eyewear when handling these materials. Rinse the components thoroughly with distilled water after cleaning. Always follow the manufacturer s safety precautions. OPTICAL WINDOW SWAB SENSOR 7. To re-install the sensor follow steps 4 and 5 in the reverse order. The brass compression nut should be snug. Do not over torque. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 30
Section 6.0 ALARMS AND TROUBLESHOOTING The guide below offers assistance when troubleshooting problems related to operation of the UVLOGIC system. SYMPTOM CAUSE REMEDY A number(s) is /are flashing Damaged lamps. Replace lamps. on the Lamp Status display. Damaged ballast. Replace ballast. Lamp Status indicates a number which differs from the Wrong number of lamps setting actual number of lamps in the system The Elapsed Time display is flashing. A HI TEMP message is flashing on the control panel displays A HI TEMP message is flashing on the displays and the lamps are turned OFF. A OFF message is flashing on the Hours display A PAUSE message is flashing on the Hours display. UV Intensity Display is flashing. Lamps have reached their EOL. Minor Alarm: Reactor has reached its upper temperature operating limit due to: The reactor is operating empty. There is water in the reactor but no flow. Major Alarm: Reactor has reached its upper temperature operating limit and the common alarm relay has been activated due to: The reactor is operating empty. There is water in the reactor but no flow. Lamp(s) have been turned OFF. There has been a power failure. Remote Power feature has been activated. UV intensity at the sensor has dropped below the alarm set point due to: Lamp failure. Lamp aging. Sleeves fouled. Sensor window fouled. Low UV transmittance. Reset the number of lamps for the system. Replace all lamps in the system and reset Elapsed Time counter. Check that there is water flowing through the reactor, when temperature drops to an appropriate level the alarm will clear itself. Check that there is water flowing through the reactor, when temperature drops to an appropriate level the alarm will clear itself and system will restart. Depress Lamp ON/OFF switch to turn lamp(s) ON. Check cause for Remote Power activation. Replace lamp(s) Replace lamp(s) Clean sleeve(s) Clean UV sensor window Check source of turbidity UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 31
Section 7.0 REPLACEMENT PARTS Section 7.1 Reactor Chamber Parts List 3.3.1 UVLOGIC AM, VM & TM MODELS ITEM PART NUMBER LAMP TYPE DESCRIPTION 1 792931P AM, VM & TM WASHER, SLEEVE SUPPORT 2 792437 793064P AM & VM TM SLEEVE O-RING SLEEVE O-RING 3 793074 AM, VM & TM SLEEVE BOLT 4 793465 793418 792929 AM, VM & TM 4 END PLATE O-RING 6 END PLATE O-RING 8 END PLATE O-RING 5 6 794113 793658 794107 793075 793017 AM VM TM AM & VM TM UV LAMP GERMICIDAL UV LAMP GERMICIDAL UV LAMP TOC DESTRUCTION SLEEVE, GERMICIDAL SLEEVE, TOC DESTRUCTION 7 792942P AM, VM & TM SLEEVE BUSHING 8 792986 AM, VM & TM LAMP SPRING UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 32
Section 7.2 Control Panel Parts List 7.2.1. MODELS AM, VM & TM ITEM PART NUMBER VOLTAGE 1 912491 120V DESCRIPTION BOARD, UVLOGIC AM, VM & TM BOARD, UVLOGIC AM, VM & TM UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 33
912492 230V 2 912513 BALLAST Section 7.3 UV Sensor Parts List ITEM PART NUMBER SENSOR TYPE DESCRIPTION 1 793200-004 D UV SENSOR ASSEMBLY Standard 5m 2 002026 O-RING UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 34
Section 7.4 Wiring Harness Parts List ITEM 1 2 PART NUMBER 793416-001 793416-002 793416-007 793415-001 793415-002 DESCRIPTION HARNESS ASSY., TEMP. SWITCH 50 C, 5m HARNESS ASSY., TEMP. SWITCH 50 C, 10m HARNESS ASSY., TEMP. SWITCH 90 C, 5m LAMP HOLDER, UVLOGIC 5m LAMP HOLDER, UVLOGIC 10m UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 35
UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 36
Section 8.0 ELECTRICAL REFERENCE 8.1 Power and Controls Schematic * SEE ATTACHEMENTS UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 37
Section 9.0 APPENDICES 9.1 Certificates SEE ATTACHMENTS 9.2 Warranty and Service Coverage All Trojan UVLOGIC reactor chambers are guaranteed to be free of material defects for five years. All Trojan UVLOGIC control panels, hardware and electrical systems are guaranteed to be free of material defects for one year. Products that have been improperly used in the opinion of the company are not subject to the terms of this warranty. Neither the seller nor the manufacturer is liable for any injury, loss or damage arising either directly or consequently from the use or misuse of this product. The user assumes all responsibility and liability whatsoever in connection with the installation and use of the system. No expressed, implied or statutory warranty or condition other than herein set forth is made, or authorized to be made. Trojan Technologies offers technical support through its factory authorized and trained Distributors, and through its factory based Application Engineering and Inside Sales department. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 38
9.3 System Factory Settings UVLOGIC SYSTEM SETTINGS S/N: Lamp Status: ON OFF Hi-Temp Major Alarm: ON OFF Hi-Temp Minor Alarm: ON OFF (EOL) UV dose: mj cm - ² Maximum flow rate: US GPM Major UV Alarm: ON OFF Minor UV Alarm: ON OFF Set Point: mw cm - ² Set Point: mw cm - ² Analog Out: Yes No Automatic Wiper: Yes Wiper Frequency: Hrs. No Remote ON / OFF: Yes No 12OVAC 5-28VDC 240VAC * Note: This UVLOGIC system has been configured for your application. The system will deliver the required (EOL) UV Dose based on the site-specific parameters. The major UV Alarm set point is configured to activate when the required dose is no longer being met. UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 39
MAINTENANCE LOG UVLOGIC 1 UV LAMPS SLEEVES UV SENSOR SLEEVE, O-RING SLEEVE SUPPORT WASHER SLEEVE BUSHING WEAR PADS LAMP SOCKET DUE: COMPLETED: DUE: COMPLETED: DUE: COMPLETED: DUE: COMPLETED: DUE: COMPLETED: 2 3 4 5 6 7 8 9 10 UVLOGIC, Operation and Maintenance Manual - MIDFLOW (AM, VM & TM) Page 40