Aquafine optima hx series Installation And Operation Manual Download Page 45

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Part

Part No.

O-rings – for quartz sleeves EPDM

4253

O-rings – for quartz sleeves Viton

40413

Detector O-ring – Viton

40432

Cylinder O-ring – for Optima “F” series EPDM

15601

Cylinder O-ring – for Optima “F” series Viton

40428

Cylinder O-ring – for Optima “G” series EPDM

16063

Cylinder O-ring – for Optima “G” series Viton

40429

Cylinder O-ring – for Optima “E” series EPDM

16790

Cylinder O-ring – for Optima “E” series Viton

40427

Ballast Assembly 240V

40328

Ballast Assembly 120V – 240V

41634-1

Monitoring System (Station, Detector & Cable)

41174

Monitoring System (Station, Detector & Cable) NIST

41174-4

Monitoring Station

41114-1

Detector & Cable

41174-2

Detector & Cable NIST

41174-3

Cable, 20ft

41116

Aqualogic 2000™ SDB connector for Detector Cable

41128

2” Fan 240V

4206

4” Fan 240V

3903

Cylinder Gasket for Optima HX & HX-U “C” series EPDM

3118

Cylinder Gasket for Optima HX & HX-U “C” series Viton

16673

Cylinder Gasket for Optima HX & HX-U “D” series EPDM

3244

Cylinder Gasket for Optima HX & HX-U “D” series Viton

16674

UV Lamps SE 254 NM – GOLD

for disinfection

“S” Type

GOLD-S

“L” Type

GOLD-L

Summary of Contents for optima hx series

Page 1: ...s equipment as well as operating personnel read this manual and carefully follow all instructions and guidelines EQUIPMENT OPERATORS AND INSTALLERS MUST COMPLY WITH OPERATIONAL SAFETY REQUIREMENTS SAFETY ISSUE O Op pt ti im ma a H HX X O Op pt ti im ma a H HX X U U S Se er ri ie es s I In ns st ta al ll la at ti io on n a an nd d O Op pe er ra at ti io on n M Ma an nu ua al l 1 800 423 3015 outsid...

Page 2: ...2 Setting the Low UV Alarm Level 22 Aqualogic 2000 Monitoring System 23 Setting the UV 23 24 Setting the SET 100 Level 25 Setting the Low UV Alarm Level 25 Setting the Aqualogic 2000 Status Display Board 26 27 PREVENTATIVE MAINTENANCE 28 34 Recommended Preventative Maintenance 28 Unit Maintenance 39 Quartz Sleeve Maintenance 30 Checking for Leaks 31 Lamp Operation Lamp Out Alert 32 Replacing UV La...

Page 3: ...er to the unit before servicing the unit The electrical panel is an electrical hazard Death can result if proper precautions and safety are not obeyed All electrical power to the equipment including power from signal and monitoring systems must be completely isolated Never service the system under pressure The treatment chamber must be valved off from the water source the pressure must be released...

Page 4: ...urce Summation MPSS and Computational Fluid Dynamics CFD mathematical models All wetted components made from 316L SS Lamp status indication Running time meter 150 psig rated treatment chamber The most basic differentiation within the HX product line is the designation HX or HX U HX units come with the cylinder and electrical enclosure mechanically attached together HX U units have a remote enclosu...

Page 5: ...ain the stainless steel nipples and lamp socket retainer assemblies Sample Ports Two optional sample ports are available for obtaining water samples pre and post the UV treatment chamber Sanitary sampling valves should be installed on the ports Gasket Endplate Treatment chambers greater than 4 inches in diameter are provided with 2 removal endplate assemblies The endplates are installed with seali...

Page 6: ...Quartz Sleeves The quartz sleeves provide a barrier between the UV lamp and the water Special manufactured quartz material allows the passage of the 254nm radiation that provides the energy to destroy the microorganism Alternative sleeves should not be used 3 O Ring The O ring provides the seal for the quartz sleeves The material is specially specified to withstand UV energy heat ozone and other e...

Page 7: ...red at the end of the treatment chamber and the corresponding LED light carries the same number on the display panel Main Power Switch The Main Power Switch isolates all electric power to the unit Running Time Meter Each of the UV units is furnished with a Running Time Meter that cannot be reset It is used to determine the number of hours on the equipment and for maintenance It is very important t...

Page 8: ...ector and the Cable with connector The corresponding labels identify the different controls The use of each of these controls is described in the Monitoring Station Operation section See page 20 Fig A FRONT VIEW OF THE MONITORING STATION The backside of the Monitoring Station is not accessible to the user after the unit is installed During installation the authorized technician must connect differ...

Page 9: ...resence of oxygen and water The semiconductor sensor signals are then processed within the sensor and sent via the cable into the Monitoring Station Do not attempt to remove any of the screws that seal these ports By doing so you may damage the Detector and will void the warranty and the optional NIST traceable calibration certification if included See page 12 for sample certificate The Detector i...

Page 10: ...g time and unit ON OFF cycles Available through dry alarm contact lamp status high temperature status low UV intensity and remote Start Stop functions FIG A AQUALOGIC 2000 SYSTEM IN OPTIMA HX Elements to identify the Aqualogic 2000 System are See Fig A above 1 Control Cabinet 2 Main Power Switch 3 Aqualogic 2000 UV Monitoring System Control Cabinet The control cabinet is available as a remote or f...

Page 11: ...ALOGIC 2000 STATUS DISPLAY BOARD FRONT The backside of the Monitoring Station is not accessible to the user after the unit is installed During installation the authorized technician must connect different inputs and outputs and select the proper position of some switches depending on the installation and unit requirements See Fig C below FIG C AQUALOGIC 2000 STATUS DISPLAY BOARD BACK 1 2 3 4 5 6 7...

Page 12: ...xygen and water The semiconductor sensor signals are then processed within the sensor and sent via the cable into the Monitoring Station Do not attempt to remove any of the screws that seal these ports By doing so you may damage the Detector and will void the warranty and the optional NIST traceable calibration certification if included See below The Detector is provided with an O ring This O ring...

Page 13: ... 3kg for 2 3 50 lbs 23kg for 4 and 75 lbs 34kg for 6 or above If your piping system is subject to impulse pressure resulting in a water hammer condition a surge tank or other means must be provided to remove this condition otherwise the extreme momentary pressure may rupture and fracture the quartz sleeves D All units are rated for a maximum operating pressure of 150 psig 10 3 bar E Ultra pure wat...

Page 14: ... AND DON TS Do s A Install the UV treatment unit in a horizontal position The UV treatment chamber should be firmly mounted and secured For units with remote enclosures HX U suitably rated fasteners should be used B Provide ample ventilation Ambient temperatures surrounding the unit should be between 35 F 2 C and 110 F 43 C C Protect the equipment from the environment Do not expose the equipment t...

Page 15: ...ling fan intake and exhaust ports Depending upon the model there are generally one or more exhausted fans that should be cleaned and maintained Some units have mesh filter which should be cleaned frequently depending upon the operating environment Don ts A Do not exceed maximum operating pressure of unit B Do not exceed the maximum flow rate of the model C To maintain standard rated performance do...

Page 16: ...nd slowly push the sleeve into the chamber through to the second endplate Repeat for all quartz sleeves For HX and HX U units with operating flow above 1 000GPM some resistance may be felt from the support Teflon bushing 9 Install the compression nut and O ring by placing the O ring into the internal relief of the compression nut below the threaded area 10 Place the compression nut and O ring onto...

Page 17: ...breakage will occur 7 Twist the lamp into the locking mechanism of the compression nut This ensures that the lamp is secure within the quartz sleeve 8 Each lamp socket is identified with a number that corresponds to each lamp position marked on the endplate Match the lamp socket and connect to the appropriate lamp 9 The two pins in the lamp must be pushed down to fit securely into the pins with th...

Page 18: ... should illuminate yellow when the lamp is on For the Aqualogic 2000 units the Lamp Status LED should change from RED to GREEN GREEN indicates the lamp is ON RED indicates the lamp is OFF 4 Connect the Monitoring Detector Cable if equipped CAUTION PRIOR TO ENERGIZING THE BALLASTS AND LAMPS ENSURE THERE IS NO WATER LEAKING INTO THE QUARTZ SLEEVES AND COMPRESSION NUT CAVITIES BY PROPERLY INSTALLING ...

Page 19: ... elastomers are recommended With these components sanitization up to 250 F 121 C is allowed in a non operating state 4 Intermittent operation is allowed as long as the water temperature does not exceed 120 F optional devices T 120 or monitoring stations are available to prevent this problem Should the unit be used for batch flow operations it can be turned ON and OFF manually Make sure the unit is...

Page 20: ...000 0 to 100 0 with 0 1 resolution and temperature values in F or C 32 0 to 212 0 F or 000 0 to 100 0 F with 0 1 resolution 2 TEMPERATURE DISPLAY button Hold down this button to display the water temperature otherwise the LCD shows the irradiance value 3 UV DISPLAY UNITS button With two fixed positions this allows the user to toggle between absolute irradiance values µW cm2 or in percentage 4 SET ...

Page 21: ...set the alarm level the LED is ON and the µW cm2 is OFF indicating that the alarm level is set only in percentage value 9 UV IRRADIANCE LOW LED When the UV radiation levels fall under the alarm pre set level the low level UV alarm protocol is activated This will cause the LED to blink intermittently along with activation of a 2kHz sound for 30 seconds In addition the DPDT relay contact will be tri...

Page 22: ...ted with a plastic screw and O ring set 1 First set 100 level as described above 2 Unscrew and remove the plastic screw and O ring set 3 Press and hold UV ALARM SET button 5 and use a 2mm 5 64 flat blade jewelers screwdriver to adjust the SET ALARM LEVEL potentiometer in Set the alarm level at 80 4 Replace and tighten the plastic screw and O ring set into place after setting the SET ALARM LEVEL Fa...

Page 23: ...TING THE AQUALOGIC 2000 1 Gradually start the normal flow rate 2 Bring the unit up to normal operating pressure and temperature 3 Turn on the UV lamps wait a minimum of 15 minutes 4 Set the SET100 LEVEL See page 25 FIG A AQUALOGIC 2000 STATUS DISPLAY BOARD FRONT Elements to identify the Status Display Board are See Fig A above 1 Running Time LED Indicator 2 Cycle and Hour Display 3 Cycle Mode LED ...

Page 24: ...tional Indicator will be illuminated During any fault conditions this indicator lamp will not illuminate 7 Low UV Intensity LED The Detector is a sensing probe place in the treatment chamber that monitors the relative change in lamp output through the fluid as detected by the UV sensor at the endplate of the UV treatment chamber As time passes the sensor reading will decline as the lamps age quart...

Page 25: ...upon sizing of the equipment and if any redundancy is built into the system Therefore in a Lamp Out condition the action of the operator will be based upon the overall design Setting the SET 100 LEVEL 1 To set the SET 100 LEVEL the initial value 100 should be set 2 The unit should be operating under normal operating conditions flow temperature with new lamps and clean quartz sleeves 3 The Aqualogi...

Page 26: ...intensity 100 set point When pressed the relative intensity is set into the memory this is the 100 set point When 80 of the value is reached the low UV intensity indicator is activated 3 SW 2 Reset Time Cycle Counter The SW 2 switch resets the total elapsed time and cycle counter to zero This switch is used when the lamps are replaced 4 SW 8 Status Display Board Lamp Assignments Model Lamp Quantit...

Page 27: ... lamp replacement based on elapsed time At the set level the running time display will flash The elapsed time and cycle counted must be reset to ZERO when the lamps are changed 9 000 hours DEFAULT 8 000 hours SW7 6 Allows the user to set the temperature display in F or C Deg C Deg F DEFAULT SW7 7 Allow the user to reinitialize the Aqualogic 2000 system Deactivated DEFAULT Active SW7 8 For setting ...

Page 28: ...t Process status continuous intermittent Because of these variables each UV unit may have to be serviced differently For instance those with continuous high flow or with lower quality water require more frequent cleaning of the quartz tubes than those exposed to cleaner water lower flow rates and or intermittent usage Regarding UV lamp replacement the rule is to replace the lamps every 9 000 hours...

Page 29: ...e source power at the equipment s main panel breaker and use appropriate tag out or lockout procedures to prevent accidental power up by other personnel Only properly qualified service personnel should perform service E Remove pressure before servicing units The UV unit has components under pressure Before completing any service the pressure should be removed Operating Conditions Never operate the...

Page 30: ...n Place CIP cleaning is sometimes effective in the removal of debris from the sleeves A test should be completed to determine the effectiveness of a CIP cleaning After a chemical CIP has been completed the quartz sleeves should be visually inspected for the removal of material If CIP cleaning is not effective then a manual cleaning or replacement of the sleeves will be required Cleaning the Quartz...

Page 31: ...ter level is below the leaking tube 5 Unscrew the lamp socket and lamp from the leaking nut 6 Unscrew the compression nut counterclockwise CCW and remove it and its O ring from the end of the quartz tube Be sure not to pull the quartz tube out of the opposite compression nut or you may have to reassemble all items on that side as well 7 Place a new O ring into the leaking compression nut and reass...

Page 32: ...d no longer allow sufficient 254 N M short wave UV the germicidal ray of the lamp through the glass to effectively kill bacteria Color Coded Ceramic Lamp Bases BASE COLOR LAMP TYPE 254 N M For Disinfection 254 N M For Validated Disinfection Standard Lamp GOLD BURGUNDY S Type GOLD S BURG S L Type GOLD L BURG L COLORGUARD UV LAMP CERAMIC BASES ARE EXCLUSIVE TO AQUAFINE AND MAKE MIXING OF DIFFERENT L...

Page 33: ... In case any of these descriptions are not prevalent replace the entire lamp socket assembly Ballast Replacement Ballast replacement is not part of the UV unit s routine maintenance However in the event that the ballast needs to be replaced the following procedure should be followed 1 Power down the UV unit by returning the unit isolator switch if installed to the OFF position If not ensure that t...

Page 34: ...V lamp you need to verify the electrical output of the ballast connected to that specific UV lamp Testing the ballast open circuit voltage does this This should be done by an electrician or qualified facilities personnel Follow these recommended procedures 1 Turn the power to the UV unit OFF 2 Remove the socket cover 3 Identify the faulty UV lamp which corresponds to the number on the LED display ...

Page 35: ... performance Piping Contamination System sanitation is critical If the pipe system is contaminated then performance may be flawed UV SYSTEM NON PERFORMANCE BACTERIA Leaking Leaking can result in system contamination UV Temperature Monitoring System optional UV and Temperature monitoring system option The unit will automatically shut OFF when the temperature exceeds 120o F When the water temperatur...

Page 36: ...rial will block the transmission of the UV energy into the water The quartz sleeves must be replaced or cleaned CIP does not always properly clean the quartz sleeves Water Quality Any changes in the water transmission or quality will cause the sensor reading to change In some applications where the water is blended the transmission properties can change UV SENSOR DECLINING OR IF EQUIPPED WITH MONI...

Page 37: ...ure will cause the sealing material to fail Gasket Failure The gasket and O rings should be inspected for deterioration These materials can be subjected to UV ozone and heat which is damaging to the material O Rings O rings which are not compressed properly will cause the quartz sleeves to leak Reinstall and replace the O ring Sealing Material O ring and gasket material that are damaged due to UV ...

Page 38: ... F Check sensor probe and connector connection Check connection on J9 of SDB SH IS DISPLAYED Wire connections from temperature probe to the SDB are OPEN Inspect wire connections from the temperature probe to board Fluid in treatment chamber exceeds set points Check water temperature is less than 100 F and greater then 40 F HIGH TEMPERATURE LED IS ILLUMINATED Temperature Connections If connections ...

Page 39: ...the ballast automatically shuts OFF When the ballast cools down the ballast will reenergize Excessive continuous heat will destroy the ballasts Cooling fan not operating Ballast Overheating Fan filter blockage Wiring Inspect wire connections LAMP LED IS RED AND LAMP OUT ALERT LED IS ILLUMINATED CSB SDB Components Replace defective boards High Temperature UV Shutdown If the High temperature LED is ...

Page 40: ...ions non RO DI minerals or debris will attach to the quartz sleeves The material will block the transmission of the UV energy into the water The quartz sleeves must be replaced or cleaned CIP does not always properly clean the quartz sleeves Water Quality Any changes in the water transmission or quality will cause the sensor reading to change In some applications where the water is blended the tra...

Page 41: ...s and unsupported piping can cause excess stress to the lamp filament and equipment Compression Nut Inspect the compression nut and O ring to insure that they are installed properly Over Pressure System pressure greater than the design pressure will cause the sealing material to fail PREMATURE LESS THAN 9000 HOURS LAMP FAILURE Gasket Failure The gasket and O rings should be inspected for deteriora...

Page 42: ...e obtained from a source laboratory and should have been autoclaved and contained within a plastic outer wrapping 2 The inside diameter of a sample valve must not exceed 6mm to ensure proper velocity Prior to taking the sample it is imperative that the test sample valve be fully opened under full pressure for a full three and a half minutes Temporary tubing or some other material may be used to di...

Page 43: ...lation and or maintenance procedures 5 Failure to avoid excessive stops and starts Not more than three 3 ON OFF cycles per 24 hours of operation 6 Operation of visibly damaged equipment 7 Failure to avoid undue overhead piping stress which can result in structural damage to the UV unit Limit the load to 25 lbs for 2 3 50 lbs for 4 and 75 lbs for 6 or above Torsion loads or side loading of the rise...

Page 44: ...44 ...

Page 45: ...eries Viton 40427 Ballast Assembly 240V 40328 Ballast Assembly 120V 240V 41634 1 Monitoring System Station Detector Cable 41174 Monitoring System Station Detector Cable NIST 41174 4 Monitoring Station 41114 1 Detector Cable 41174 2 Detector Cable NIST 41174 3 Cable 20ft 41116 Aqualogic 2000 SDB connector for Detector Cable 41128 2 Fan 240V 4206 4 Fan 240V 3903 Cylinder Gasket for Optima HX HX U C ...

Page 46: ...t 90 Lead Wires 40569 8 Lamp Socket 16 Lead Wires 40569 16 Lamp Socket Cap for lamp socket 17489 Compression Nut CPVC 25mm 19685 Compression Nut 316L Stainless Steel 25mm 40357 Compression Nut Cap fixed 17489 1 Compression Nut Tool 18517 UV Temperature Detector 41115 Aqualogic 2000 Status Display Board SDB 12 Lamp 41177 12 Aqualogic 2000 Current Sensing Board CSB 12 Lamp 19385 12 Bushing Quartz 25...

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