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Trojan Technologies Aquafine TrojanUVLogic Series, Installation & Operation Manual

The Aquafine TrojanUVLogic Series ensures safe and efficient water disinfection. To guide users, an in-depth Installation & Operation Manual is available for free download from manualshive.com. This manual comprehensively covers every aspect of setup, operation, and maintenance for optimal usage of this exceptional Trojan Technologies product.

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Volume Table of Contents 

 
 

Trojan

ogic

TM

 

Operations and Maintenance

 

UV

L

PREFACE  

 

 

 

 

 

 

 

 

 

 III

 

GENERAL INFORMATION ..................................................................................................................... III 

IMPORTANT CONTACTS...................................................................................................................... IV 

WARNINGS AND PRECAUTIONS ......................................................................................................... V 

GENERAL LOCKOUT PROCEDURES ................................................................................................. XI 

Lockout and Tag Procedure............................................................................................................... xi 

LIST OF ACRONYMS/GLOSSARY ...................................................................................................... XII 

TROJANUVLOGIC  MAINTENANCE REQUIREMENTS

TM

.................................................................. XIII 

Maintenance Schedule .................................................................................................................... xiv 
Maintenance Checklist..................................................................................................................... xvi 
Alarm Log........................................................................................................................................ xvii 
System Operating Parameters......................................................................................................... xix 
Maintenance Log .............................................................................................................................. xx 
Lamp Log Table ............................................................................................................................... xxi

 

1 

INTRODUCTION 

TO 

UV 

THEORY 

      1-1

 

1.1 OVERVIEW OF TROJANUVLOGIC

TM

............................................................................................1-1 

1.2 WHAT IS ULTRAVIOLET LIGHT?..................................................................................................1-1 

1.3 DISINFECTION VS. STERILIZATION.............................................................................................1-2 

1.4 APPLICATIONS OF UV LIGHT ......................................................................................................1-2 

1.5 FACTORS AFFECTING UV DISINFECTION..................................................................................1-2 

UV Transmittance:...............................................................................................................................................1-3 
Suspended Solids: ..............................................................................................................................................1-3 
Level of Total Dissolved Solids:..........................................................................................................................1-3 
Total Hardness: ...................................................................................................................................................1-4 
Sleeve Cleanliness:.............................................................................................................................................1-4 
Treatment Process:.............................................................................................................................................1-4 
Flow Rate: ............................................................................................................................................................1-4 

 

2 

 

SYSTEM 

OVERVIEW        2-1

 

2.1 SYSTEM COMPONENTS ...............................................................................................................2-1

 

UV Reactor (UVR)............................................................................................................................................ 2-1

 

Control Panel (CP) ........................................................................................................................................... 2-1

 

UV Sensor ........................................................................................................................................................ 2-2

 

Wiping Systems ............................................................................................................................................... 2-2

 

Automatic Mechanical Wiping System (AMWS).................................................................................................................... 2-2

 

Manual Mechanical Wiping System (MMWS)........................................................................................................................ 2-3

 

Power Pack................................................................................................................................................................................. 2-3

 

2.2 OPERATIONS OVERVIEW.............................................................................................................2-3 

Summary of Contents for Aquafine TrojanUVLogic Series

Page 1: ...NE DESTRUCTION CHLORINE CHLORAMINE DESTRUCTION TrojanUVLogic Series Installation Operation Manual It is imperative that those responsible for the installation of this equipment as well as operating personnel read this manual and carefully follow all instructions and guidelines EQUIPMENT OPERATORS AND INSTALLERS MUST COM PLY WITH OPERATIONAL SAFETY REQUIREMENTS A TROJAN TECHNOLOGIES COMPANY READ TH...

Page 2: ...formation please refer to Chapter 2 page2 3 System Verification Label Definitions Record system set points indicated below UV Intensity Set Point The TrojanUVLogicTM in this manual may be covered by one or more of the following United States US Patents US 6 342 188 US 6 659 431 US 6 564 157 US 6 635 613 OTHER PATENTS MAY BE PENDING COPYRIGHT 2008 by AQUAFINE CORPORATION ALL RIGHTS RESERVED ...

Page 3: ... xxi 1 INTRODUCTION TO UV THEORY 1 1 1 1 OVERVIEW OF TROJANUVLOGICTM 1 1 1 2 WHAT IS ULTRAVIOLET LIGHT 1 1 1 3 DISINFECTION VS STERILIZATION 1 2 1 4 APPLICATIONS OF UV LIGHT 1 2 1 5 FACTORS AFFECTING UV DISINFECTION 1 2 UV Transmittance 1 3 Suspended Solids 1 3 Level of Total Dissolved Solids 1 3 Total Hardness 1 4 Sleeve Cleanliness 1 4 Treatment Process 1 4 Flow Rate 1 4 2 SYSTEM OVERVIEW 2 1 2 ...

Page 4: ...ns 7 23 Wiper Screen AMWS For systems with a Wiper 7 24 Wiper Sequence Timer AMWS For systems with a Wiper 7 24 Wiper Auto Power Off For systems with a Wiper 7 24 Analog Menu Screen 7 25 Reactor Hi Temp Reactor High Temperature Configure Screen Optional 7 25 Login Screen 7 26 7 4 SYSTEM STATUS ALARM LIST 7 27 7 5 ALARM OVERVIEW 7 27 Minor Alarms 7 27 Major Alarms 7 28 Critical Alarms 7 29 7 6 INPU...

Page 5: ...8 System Controller The Control Board 7 10 Description 7 10 Board Power supply requirements AM Models 7 10 P40 Board Power supply requirements AS and AL Models 7 10 Board Diagram 7 11 RS232 Com Port 7 13 Ballast Communication Ports 7 13 Lamp Status Midflow Models Only 7 13 Board Fuse 7 13 Keypad Connector 7 13 VFD Communication Port 7 13 Battery Replacement 7 13 Input Output Features 7 13 Programm...

Page 6: ... System Operation 5 5 Specifications 5 5 Maintenance 5 5 Gear Motor Removal 5 5 Stop Plate Bushing Replacement 5 7 Drive Screw Roller Bearing O ring Seal Replacement 5 8 Sleeve Wiper Replacement AMWS 5 9 Drive Nut Removal Replacement 5 12 6 UV SENSOR 6 1 6 1 INTRODUCTION 6 1 Description 6 1 Specifications 6 1 Maintenance 6 1 UV Sensor Removal and Cleaning 6 1 UV Sensor Replacement 6 2 7 CONTROL PA...

Page 7: ... 3 For Bolt On Flange Style End Plates 20 cm Diameter Models 4 3 For Sanitary Clamp Style Up to and including 20cm diameter chambers 4 4 4 3 UV LAMP ASSEMBLY 4 4 Description 4 4 Specifications 4 4 Maintenance 4 4 Maintenance 4 5 Lamp Inspection Replacement 4 5 Elapsed Time Reset 4 7 Lamp Number Configuration 4 7 4 4 QUARTZ SLEEVES 4 7 Description 4 7 Specifications 4 7 Maintenance 4 8 Sleeve Repla...

Page 8: ...NO WIPING ANSI LG0010D01 STD UVLOGIC SHORT LONG LAMP 20 SERIES MMWS LG0011D01 STD UVLOGIC SHORT LONG LAMP 20 SERIES MMWS ANSI LG0012D01 STD UVLOGIC SHORT LONG LAMP 20 SERIES AMWS LG0013D01 STD UVLOGIC SHORT LONG LAMP 20 SERIES AMWS ANSI LG0014D01 STD UVLOGIC MIDFLOW SERIES NO WIPING LG0015D01 STD UVLOGIC MIDFLOW SERIES NO WIPING ANSI LG0016D01 STD UVLOGIC MIDFLOW SERIES MMWS LG0017D01 STD UVLOGIC ...

Page 9: ...S IV WARNINGS AND PRECAUTIONS V GENERAL LOCKOUT PROCEDURES XI Lockout and Tag Procedure xi LIST OF ACRONYMS GLOSSARY XII TROJANUVLOGICTM MAINTENANCE REQUIREMENTS XIII Maintenance Schedule xiv Maintenance Checklist xvi Alarm Log xviii System Operating Parameters xix Maintenance Log xx Lamp Log Table xxi ...

Page 10: ...PREFACE TrojanUVLogicTM Operations Maintenance ii ...

Page 11: ... General Lockout Procedure in this section before operating or performing any maintenance on this equipment 2 Read procedures thoroughly before starting 3 Review all warnings and cautions that accompany any procedure and review the Warnings and Precautions section each time you prepare to perform maintenance on the TrojanUVLogicTM Three types of notices are used in this manual WARNING CONTAINS INF...

Page 12: ...t Contacts AQUAFINE CORPORATION Head Office Canada 29010 Avenue Paine Valencia CA 91355 Toll Free 1 800 423 3015 outside CA within USA Canada only Phone 661 257 4770 Fax 661 257 2489 Internet www aquafineuv con Europe Aquafine GmbH Ramskamp 77 85 D 25337 Elmshorn Germany Phone 49 4121 57806 13 Fax 49 4121 57806 30 For projects in Continental Europe Local Representative ...

Page 13: ...AVIOLET RESISTANT FACE SHIELD OR GLASSES FOR SHORT TERM EXPOSURE Eye Protection Must be Worn AS ADDED PROTECTION OR AS A MINIMUM PROTECTION FOR SHORT TERM EXPOSURES TIGHT FITTING GLASSES WITH SIDE SHIELDS PROTECTION WHERE SUCH SHIELDS ARE CONTIGUOUS MUST BE WORN AT ALL TIMES WHEN THERE IS A POTENTIAL EXPOSURE TO ULTRAVIOLET LIGHT GLASSES SUCH AS WRAP AROUND STYLE ARE MOST EFFECTIVE Wear Protective...

Page 14: ...UT AND TAG PROCEDURES IN THIS MANUAL Wear Hard Hat WEAR AN APPROVED HARD HAT AND OTHER PERSONAL PROTECTIVE EQUIPMENT THAT IS REQUIRED ACCORDING TO CONSTRUCTION SITE WASTEWATER OR WATER TREATMENT PLANT SAFETY REGULATIONS Trip Hazard STAY ALERT AND BE AWARE OF POTENTIAL TRIP HAZARDS BEFORE WORKING ON EQUIPMENT Hot Surface ALLOW ELECTRONIC BALLAST AND LAMPS TO COOL BEFORE HANDLING ULTRAVIOLET LAMPS B...

Page 15: ...PREFACE TrojanUVLogicTM Operations Maintenance vii WARNING ON SUPPLY OFF SUPPLY PROTECTIVE EARTH TERMINAL PINCH HAZARD CONSULT YOUR TECHNICAL MANUAL BEFORE SERVICING ...

Page 16: ...RNS WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN HANDLING THESE MATERIALS AFTER CLEANING RINSE THE SYSTEM COMPONENTS THOROUGHLY WITH DISTILLED WATER ALWAYS FOLLOW THE SAFETY PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OF THE CLEANING SOLUTION THIS SYSTEM USES ULTRAVIOLET LIGHT TO REDUCE THE CONCENTRATION OF PATHOGENS TO A NON INFECTIOUS LEVEL NON OBSERVANCE OF THE MAINTENANCE INSTRUCTIONS OR THE ALAR...

Page 17: ...VOLTAGE SPECIFICATION IF YOUR SYSTEM RUNS WITH PULSE COMPRESSION A BUFFER TANK OR OTHER REMEDIAL MEASURE MUST BE PROVIDED THE ULTRAVIOLET EMISSION OF THESE LAMPS DECREASES OVER TIME THE UV LAMPS IN THIS SYSTEM MUST BE REPLACED EVERY 9000 HOURS OF OPERATION IN ORDER TO ENSURE PROPER OPERATION SEE CHAPTER 4 REGULAR TESTING OF SYSTEM PERFORMANCE USING STANDARDIZED METHODS E G WATER SUPPLY REGULATIONS...

Page 18: ...PREFACE TrojanUVLogicTM Operations Maintenance x CAUTION ATTENTION OBSERVE PRECAUTIUONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES ...

Page 19: ...otary Disconnect Switch to the OFF position 3 Attach your Lock and Safety Tag to the Rotary Disconnect Switch Include your name date and time and the work to be performed on the tag 4 Return to the Control Panel CP and verify correct power source has been locked out WARNING THE EQUIPMENT MAY HAVE STORED ENERGY ENSURE THAT ALL PARTS HAVE STOPPED MOVING AND ANY STORED CAPACITANCE HAS BEEN EFFECTIVEL...

Page 20: ...ns per Minute Hp Horsepower Hrs Hours in lb Inch pound Lb ft Pound Foot L s Liters per second LED Light Emitting Diode mA Milliamps MAX Maximum MGD Millions of Gallons per Day mg l Milligrams per liter MIN Minimum mJ cm2 Millijoules per square centimeter MLD Millions of Liters per Day mm Millimeters MMWS Manual Mechanical Wiping System is an optional component that provides the operator the abilit...

Page 21: ...n of system components Maintenance Requirements must be completed in order to adhere to warranty requirements Along with the Maintenance Schedule there are two Maintenance checklists simply put in the date and initial the task completed These tables must be kept up to date at all times to avoid breach of contract which could void the warranty Four other forms that are provided to make troubleshoot...

Page 22: ...lean all Quartz Sleeves If internal fouling is present replace the Sleeve 10 minute task per Sleeve with UVR drained q Check UV Sensor Window for fouling If external fouling present remove and clean the UV Sensor Window If internal fouling is present replace the UV Sensor 5 minute task with UVR drained q Note Cleaning frequencies are recommendations and should be used as a guideline Individual sys...

Page 23: ...accessed q Check Elastomer Compression Spring 5 min task per component after accessed q Check Limit Switch Rod Seals 5 min task per component after accessed q Check Busing Housing O Ring for leakage 5 min task per component after accessed 9000 Runtime Hours q Replace all Lamps 10 min task per Lamp once accessed ...

Page 24: ...l O Rings Y Check for UV Decay of Sleeve Support Washer Y Check for UV Decay of Sleeve Bushing Y Check for UV Decay of Wear Pads Y Inspect Lamp Socket Y Check UVR Chamber for heavy build up of settled solids Y Check Sleeve Wiper Y Check Rod Seal for leakage at Drive Screw Y Check Stop Plate Flange Bushing for wear Y Check for UV Decay of the Drive Nut Y Roller Bearing Y Check Elastomer Compression...

Page 25: ...Check for UV Decay of Sleeve Support Washer Y Check for UV Decay of Sleeve Bushing Y Check for UV Decay of Wear Pads Y Inspect Lamp Socket Y Check UVR Chamber for heavy build up of settled solids Y Check Sleeve Wiper Y Check Rod Seal for leakage at Drive Screw Y Check Stop Plate Flange Bushing for wear Y Check for UV Decay of the Drive Nut Y Roller Bearing Y Check Elastomer Compression Spring Y Ch...

Page 26: ...PREFACE TrojanUVLogicTM Operations Maintenance xviii Alarm Log Record All Alarms in this table DATE TIME ALARM DESCRIPTION ALARM RESOLVED Y N ...

Page 27: ...UV Intensity UVR 3 UV Intensity UVR 4 UVR 1 Power UVR 2 Power UVR 3 Power UVR 4 Power Monday Tuesday Wednesday Thursday Friday Saturday Sunday System Alarms Y N Lamp Hours Cycling UVR1 Lamp Hours Cycling UVR2 Lamp Hours Cycling UVR3 Lamp Hours Cycling UVR4 Operator Signature and Comments Monday Tuesday Wednesday Thursday Friday Saturday Sunday ...

Page 28: ...PREFACE TrojanUVLogicTM Operations Maintenance xx Maintenance Log Use of this form to record all Maintenance DATE TIME DETAILS PARTS OPERATOR USED ORDERED INITIALS ...

Page 29: ...Reactor Lamp Lamp Hours Date Installed Date Changed This form must be completed and submitted to Aquafine Corporation with all requests for warranty replacements for Lamps Individual Lamp premature failure information should also be transferred to the outside of the Lamp packaging for the returned Lamps For Aquafine Use MTR Initials Date Received Date Completed Ref Sales Order RA Y N ...

Page 30: ...TROJANUVLogic TM ...

Page 31: ...Introduction to UV Theory Chapter 1 INTRODUCTION TO UV THEORY Trojan ogicTM Operations Maintenance 1 i UVL ...

Page 32: ...Introduction to UV Theory Trojan ogicTM Operations Maintenance 1 ii UVL ...

Page 33: ...TROJANUVLOGICTM 1 1 1 2 WHAT IS ULTRAVIOLET LIGHT 1 1 1 3 DISINFECTION VS STERILIZATION 1 2 1 4 APPLICATIONS OF UV LIGHT 1 2 1 5 FACTORS AFFECTING UV DISINFECTION 1 2 UV Transmittance 1 3 Suspended Solids 1 3 Level of Total Dissolved Solids 1 3 Total Hardness 1 3 Sleeve Cleanliness 1 4 Treatment Process 1 4 Flow Rate 1 4 ...

Page 34: ...Introduction to UV Theory Trojan ogicTM Operations Maintenance 1 iv UVL ...

Page 35: ...traviolet 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 a...

Page 36: ... 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 ionized acid based groups which are then easily removed by polishing mixed bed ion exchange equipment Chlorine Chloramines Destruction ...

Page 37: ...der 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 Note There is NO correlation between turbidity and UV Transmittance Suspended Solids Suspended Solids consist of any filterable particle in the water and are measured in parts per millio...

Page 38: ...s the amount of the UV light transmitted to the water will be reduced Treatment Process Water processing equipment located upstream of the TrojanUVLogicTM such as filters can affect performance Different treatment processes produce water with different UV transmittance characteristics and different observed cleaning frequency patterns Flow Rate The flow rate through the TrojanUVLogicTM will determ...

Page 39: ...System Overview Chapter 2 SYSTEM OVERVIEW Trojan ogic TM Operations Maintenance 2 i UVL ...

Page 40: ...System Overview Trojan ogic TM Operations Maintenance 2 ii UVL ...

Page 41: ...STEM COMPONENTS 2 1 UV Reactor UVR 2 1 Control Panel CP 2 1 UV Sensor 2 2 Wiping Systems 2 2 Automatic Mechanical Wiping System AMWS 2 2 Manual Mechanical Wiping System MMWS 2 3 Power Pack 2 3 2 1 OPERATIONS OVERVIEW 2 3 Control System Overview 2 3 2 2 SYSTEM VERIFICATION LABEL DEFINITIONS 2 4 ...

Page 42: ...System Overview Trojan ogic TM Operations Maintenance 2 iv UVL ...

Page 43: ...dal UV Lamp is a low pressure high Intensity amalgam Lamp Control Panel CP The Control Panel CP houses the main interface to the UV system and a microprocessor based controller with a Vacuum Fluorescent Display VFD that allows for local control monitoring and configuring of the system The CP also houses the power supplies that provide power distribution to the UVR and associated equipment i e Auto...

Page 44: ...n the wall of the UVR The UV Intensity seen by the UV Sensor is continuously displayed on the Operator Interface in mW cm2 milliWatts centimeter2 Wiping Systems Optional on most models Automatic Mechanical Wiping System AMWS The AMWS uses food grade rubber wipers contained within a Split Ring Wiper Housing mounted on a stainless steel Plate placed around each of the Quartz Sleeves The Wipers for a...

Page 45: ... Housing mounted on a stainless steel plate placed around each of the Quartz Sleeves The Wipers for all Sleeves are mounted together onto a common Wiper Assembly The Wiper Assembly is driven back and forth by hand using an external handle Trojan ogic TM Operations Maintenance 2 3 UVL 2 2 Operations Overview Control System Overview The heart of the control system is a microprocessor based controlle...

Page 46: ... 50 50cm CUST Custom Flange Type ANSI American National Standards Institute ANSI 150 DIN Deutsches Institut für Normung DIN the German Institute for Standardization DN10 SAN Sanitary Clamp fittings CUST Custom Flange Flange Size 1 5 1 5 2 2 3 3 4 4 6 6 8 8 10 10 14 14 40 40mm 50 50mm 80 80mm 100 100mm 150 150mm 200 200mm 250 250mm 350 350mm CUST CUSTOM Sleeve Wiping Option Manual Manual Auto Autom...

Page 47: ...y Voltage is not within the required Operating Voltage Not Required Not Provided When the Customer Supply Voltage is within the required Operating Voltage Analog Input Devices Indicates the number of A I devices provided from 1 5 Analog Output Devices Indicates the number of A O devices provided from 1 4 Remote ON OFF Required Provided Optional when Customer requested Customer must supply power fr...

Page 48: ...TROJANUVLogic TM ...

Page 49: ...Start Up Shut Down Procedures TrojanUVLogic TM Operations Maintenance 3 i Chapter 3 START UP AND SHUT DOWN PROCEDURES ...

Page 50: ...Start Up Shut Down Procedures TrojanUVLogic TM Operations Maintenance 3 ii ...

Page 51: ...Start Up Shut Down Procedures TrojanUVLogic TM Operations Maintenance 3 iii 3 Start Up and Shut Down Procedures 3 1 3 1 START UP UV SYSTEM 3 1 3 2 SHUT DOWN UV SYSTEM 3 1 ...

Page 52: ...Start Up Shut Down Procedures TrojanUVLogic TM Operations Maintenance 3 iv ...

Page 53: ...y reading on the front of the CP to stabilize for a minimum of 10 seconds If the UV Intensity display does not change during this 10 second period by pass or process water may be allowed to pass through the chamber However flow for disinfection must not be allowed to pass prior to the expiration of the 8 minute warm up timer 8 If after 8 minutes the Low UV Intensity Alarm has not cleared maintenan...

Page 54: ...is power source it is prudent to use LOCK OUT procedures and TAG all sources of power before performing any maintenance cleaning or repairs on any piece of equipment The power sources may include electrical or stored energy Refer to the general lock out and tag procedures in this manual CAUTION De Pressurize Drain the UVR Pressure must be relieved from the system prior to any maintenance to preven...

Page 55: ...UV Reactor UVR TrojanUVLogic TM Operations Maintenance May 25 2004 4 i Chapter 4 UV REACTOR UVR ...

Page 56: ...UV Reactor UVR TrojanUVLogic TM Operations Maintenance May 25 2004 4 ii ...

Page 57: ...ry Clamp Style Up to and including 20cm diameter chambers 4 4 4 3 UV LAMP ASSEMBLY 4 4 Description 4 4 Specifications 4 4 Maintenance 4 5 Lamp Inspection Replacement 4 5 Elapsed Time Reset 4 7 Lamp Number Configuration 4 7 4 4 QUARTZ SLEEVES 4 7 Description 4 7 Specifications 4 7 Maintenance 4 8 Sleeve Replacement 4 8 Sleeve Cleaning 4 11 Sleeve Cleaning Solutions 4 11 Sleeve Cleaning Procedure 4 ...

Page 58: ...UV Reactor UVR TrojanUVLogic TM Operations Maintenance May 25 2004 4 iv ...

Page 59: ...h a drain port fixed to the outer wall Flow enters parallel to the Lamps and exits through a flange located perpendicular to the UV Lamps Each UVR is designed for a maximum operating pressure of 150 psi 10 Bar and has been hydrotested to 225 psi 15 Bar prior to shipment A hydrostatic pressure test certificate is furnished with each UVR The UVR is designed to accept its respective UV Lamps and Quar...

Page 60: ... optional feature available on most of the TrojanUVLogicTM systems is a manual mechanical wiping system which provides the operator the ability to wipe the sleeves during normal system operation The wiping system is driven by hand using an external handle and will allow for sleeve wiping during disinfection Most TrojanUVLogicTM models can also be provided with an automatic mechanical wiping system...

Page 61: ...n contact with it Mild soap and water should be used 4 2 End Caps Description There are different End Caps depending on system features and types All Short Long Lamp models come with End Caps The purpose of the End Caps is to help protect the equipment against accidental damage Models that come with Automatic Wiping have longer End Caps while models that come with no wiping or mechanical wiping ha...

Page 62: ...iption TrojanUVLogicTM Lamps are mounted inside the UVR Each UV Lamp is housed within its own protective Quartz sleeve which protects it from water flow The Lamps and sleeves are supported by the Sleeve Holder Wiper Assembly The entire Sleeve Holder Wiper Assembly can be removed for service The TrojanUVLogicTM germicidal UV Lamp is a low pressure high intensity amalgam Lamp preheated to promote lo...

Page 63: ...e clothing when exposed to ultraviolet light Ensure all Lamps are properly secured within the UVR chamber before turning the system on Turn the system off before servicing WARNING HOT SURFACE Ultraviolet Lamps become hot during operation Hot Lamps can cause serious burns Allow the Lamps to cool before servicing WARNING Wear UV Resistant Face Shield Unprotected exposure to ultraviolet light can cau...

Page 64: ...nal spring at the far end of the UV Lamp will push the Lamp out approximately 12 mm 0 5in Short Long Lamp Models only Gently pull the Lamp Holders 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 5in 7 Carefully disconnect the Lamp from the Lamp Holder and pull the Lamp out CAUTION Ultraviolet Lamps and the sleeves they ...

Page 65: ...pacer can be moved if needed by sliding it down the Lamp using cotton gloves If there is interference with the UV Sensor gently rotate the Lamp until it is situated correctly 10 Reconnect the Temperature Switch and Ground Wire connections locations as shown in steps 3 4 11 Replace the End Cap on the UVR chamber as per the End Cap Removal and Installation instructions located earlier in this chapte...

Page 66: ...rain the water from the chamber through the drain provided on the UVR 4 Remove the End Cap from the UVR chamber as per the End Cap Removal and Installation instructions earlier in this chapter HOW TO INFO Note Ensure that the plant has been switched to bypass or plant is shut down to avoid damage to other plant equipment CAUTION De Pressurize Drain the UVR Pressure must be relieved from the system...

Page 67: ...with next step 8 Disconnect Lamps Follow instructions for your model Midflow Models only Gently rotate the Lamp Holder a 1 4 turn counter clockwise and pull the 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 5in Short Long Lamp Models only Gently pull the Lamp Holders and UV Lamp from the Sleeve Bolt An internal spring at ...

Page 68: ...ng 13 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 is broken 14 Place the Sleeve Bolt over the Sleeve Hole and turn it clockwise by hand to tighten The Sleeve Bolt should be tightened 1 turn after hand tight to ensure proper seal Due to the soft materia...

Page 69: ...r 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 UVR chamber per Sleeve Replacement procedure found earlier in this chapter Sleeve Holder Wiper Ass...

Page 70: ...nect Lamps Follow instructions for your model Midflow Models only Gently rotate the Lamp Holder a 1 4 turn counter clockwise and pull the 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 5in Short Long Lamp Models only Gently pull the Lamp Holders and UV Lamp from the Sleeve Bolt An internal spring at the far end of the UV L...

Page 71: ...Quartz Sleeves from striking the sides of the chamber 12 Clean the sleeves according to Sleeve Cleaning procedures indicated previously in this chapter Note Follow the previous procedures in reverse order to re assemble the UVR chamber Ensure that Lamp hole 1 is aligned with the UV Sensor port and that the Stop Plate straddles the key inside the UVR where required Ensure the Flange O ring is prope...

Page 72: ...e stamped side of the Stop Plate 4 To remove the Wear Pad turn counter clockwise 5 Insert replacement Wear Pad by turning clockwise slowly until there is full engagement between the Wear Pad and the Stop Plate 6 Ensure that the Wear Pad takes up any excess play between the UVR inside diameter and the Stop Plate by adjusting its height STOP PLATE WEAR PAD SLEEVE HOLDER BUSHING LAMP 1 REMOVE INSERT ...

Page 73: ...itch is provided which will trigger a warning alarm and shut the system off if the UVR is running too hot The High Reactor Temperature alarm is factory pre set to indicate either Minor or Major alarms for REACTOR HIGH TEMPERATURE conditions Specifications Type Normally Closed Open 50 C 5 C Close 40 C 5 C 10 C Capacity 2 0A 250VAC Normal Operating Temperature 5 C TO 40 C ...

Page 74: ...UV Reactor UVR TrojanUVLogic TM Operations Maintenance May 25 2004 4 16 ...

Page 75: ...Mechanical Wiping Systems Optional TrojanUVLogic TM Operations Maintenance May 25 2004 5 i Chapter 5 MECHANICAL WIPING SYSTEMS OPTIONAL ...

Page 76: ...Mechanical Wiping Systems Optional TrojanUVLogic TM Operations Maintenance May 25 2004 5 ii ...

Page 77: ...ance 5 1 Manual Wiper Assembly Removal 5 1 Push Retainer Replacement 5 2 Sleeve Wiper Replacement MMWS 5 3 5 3 AUTOMATIC MECHANICAL WIPING SYSTEM AMWS OPTIONAL 5 5 Description 5 5 Wiping System Drive 5 5 Wiping System Operation 5 5 Specifications 5 5 Maintenance 5 5 Gear Motor Removal 5 5 Stop Plate Bushing Replacement 5 7 Drive Screw Roller Bearing O ring Seal Replacement 5 8 Sleeve Wiper Replace...

Page 78: ...Mechanical Wiping Systems Optional TrojanUVLogic TM Operations Maintenance May 25 2004 5 iv ...

Page 79: ...placed around each of the Quartz Sleeves The Wiper Housings for all Sleeves are mounted together onto a common Wiper Assembly The Wiper Assembly is driven back and forth by hand using an external handle The operator must ensure that the Wiper is returned to its home position This is accomplished by ensuring that the Wiper Handle is returned to its original position after wiping Do not force at no ...

Page 80: ...nd Cap Removal and Installation instructions in Chapter 4 UV Reactor UVR 8 Remove lamps as per the Lamp Inspection Replacement procedure found in Chapter 4 UV Reactor UVR 9 Remove the Wiper Assembly as per the Sleeve Holder Wiper Assembly Removal procedure found in Chapter 4 UV Reactor UVR Push Retainer Replacement 1 Complete the Manual Wiper Assembly Removal procedure immediately preceding this p...

Page 81: ...air of needle nose pliers Be sure not to pry on the Wiper Housing Wiper should come out easily 6 If the Wiper Housing is damaged remove it by prying the Split Ring Wiper Housing out with your thumb or using a broad standard screwdriver to gently pry it out being cautious not to damage the Wiper Plate 7 Install a new Split Ring Wiper Housing by slowly working it into the hole in the Wiper Plate as ...

Page 82: ... Ring Vent Plug Sleeve Nut Clamp Bolt Temperature Switch Clip End Cap Strain Relief Sanitary Clamp Handle Back plate Wiper Handle UV Lamp O Ring Rod Seal Lamp Holder Wiper Plate Lamp Holder Assembly Tie Rod Outlet flange UVR Chamber Sanitary End Plate Quartz Sleeve UV Sensor Port Push Retainer Stop Plate Thrust Washer Wiper Housing Wiper Inlet Flange Sleeve Bushing Vent Kit optional ...

Page 83: ...e Electric Motor is mounted on the service end of the UVR and is protected within the End Cap The power for the Wiping System is brought in from the Control Panel CP The power requirement given for the CP includes operation of the wiping system The Wiper Assembly is mounted to the Drive Screw attached to a Carrying Nut that moves the Wiper Assembly along the Drive Screw Wiping System Operation The...

Page 84: ...re it with the Gear Motor Assembly 6 When reinstalling the Gear Motor ensure that all previously mentioned cables are reconnected but also ensure that the Ground Wire is connected as shown Stainless Washer Stop Plate Cotter Pin Elastomer Spring Flange Bushing Stainless Washer Stainless Washer Flange Bushing Wear Pad Nuts on the 28 Hex screws Typical Of 4 Ground Wire Jaw Coupling Motor Mount 28 Hex...

Page 85: ...sembly Removal procedure found in Chapter 4 UV Reactor UVR 7 Slide the Stop Plate Assembly off the end of the Sleeves and Drive Screw end 8 Remove Sleeve Bushing by pressing against the small end while supporting Stop Plate 9 Insert replacement bushings noting proper positioning in relation to the Stop Plate 10 Reassemble the Stop Plate in the reverse order CAUTION The Sleeves may be left in the W...

Page 86: ...e Figure below 5 Remove Cotter Pin from the end of Drive Screw 6 Unscrew the Motor Mount from the End Plate 7 Unscrew the Bearing Housing 8 Slide Drive Screw out through the End Plate 9 Remove the Rod Seal from the Bearing Housing noting its position 10 Remove the O Ring on Bearing Housing 11 Rest the Bearing Housing on solid surface and remove the Bearing Retaining Ring and the sealed Roller Bear...

Page 87: ...20 Ensure that the Drive Screw is free to rotate with no binding occurring 21 Reassemble Wiper Assembly into the chamber Ensure the forked tab on the Stop Plate is engaging the Locator Key on inside of chamber as shown in the following diagram This is critical to the operation of the wiper system Sleeve Wiper Replacement AMWS 1 Remove Gear Motor following Gear Motor Removal procedure earlier in th...

Page 88: ...te Ensure Wiper Lips closest to the outlet end are pointing toward the Stop Plate See Figure below Note The diagram below only shows wipers for a 4 lamp system for ease of viewing The 12_L will have 12 lamps and the 18_L 24_L and 3_L will have 18 24 and 30 lamps respectively each with two Wiper Plates CAUTION Long lamp systems AL models have two separate Wiper Assemblies mounted on to the Drive Sc...

Page 89: ...sting position of the wiper Assembly for the 30_L is at the End Plate end and for the 12_S _L 24_L the resting position is before the outlet flange Drive Screw Retaining Nut Drive Nut x2 Only one shown Lock Washer Screw Wiper Plate Assembly Wiper Plate Assembly Wiper Lip Orientation Wiper Plate Sleeve Wiper Sleeve Wiper Holder DIAGRAM REFERS TO AL MODELS ONLY Cage is only available on 30cm chamber...

Page 90: ...of the Stop Plate Bushing Replacement procedure found earlier in this chapter 5 Remove Jaw Coupling located on end of Drive Screw See Figure below 6 Unscrew Motor Mount from Bearing Housing 7 Unscrew the Bearing Housing 8 Slide the Drive Screw out through the End Plate 9 Remove the Rod Seal from the Bushing Housing noting its position 10 Remove the O Ring on Bushing Housing 11 For 12_S _L 30_L Mod...

Page 91: ...e Nut onto the Drive Screw Ensure the threaded end faces toward the End Plate For 12_S models proceed to Step 36 since 12_S s only have one Wiper Plate Assembly 22 Continue to rotate the Drive Screw until it has been threaded far enough to allow the second Drive Nut to be installed 23 Thread the second new Drive Nut onto the Drive Screw Ensure that with this nut the threaded end faces the Stop Pla...

Page 92: ...e Drive Nut in position tighten the Jam Nut against the Wiper Plate 34 Install the Lock Washer and securing hardware 8 screw nut 35 Reassemble the UVR chamber by repeating steps 1 4 in reverse order 36 Rotate the Drive Screw until it is situated through the Stop Plate Make sure that the screw turns freely by hand 37 Connect Motor Harness Proximity Sensor Limit Switch Temperature Switch and End Cap...

Page 93: ...2_S Model design is similar to this diagram except that the end plate is an ANSI DIN flange instead of a sanitary flange Manual Mechanical Wiping System AM 03_S _L 08_S _L Models No Venting Shown Outlet Flange Stop Plate Assembly Sleeve Bushing UVR Chamber Wiper Rod Assembly Wiper Seal and Wiper Housing UV Sensor Port Wiper Assembly Port Wiper Handle Assembly Sanitary End Plate Note 1 Venting is a...

Page 94: ...Mechanical Wiping Systems Optional TrojanUVLogic Operations Maintenance May 25 2004 5 16 ...

Page 95: ...UV Sensor TrojanUVLogic Operations Maintenance May 25 2004 6 i Chapter 6 UV Sensor ...

Page 96: ...UV Sensor TrojanUVLogic Operations Maintenance May 25 2004 6 ii ...

Page 97: ...sor TrojanUVLogic Operations Maintenance May 25 2004 6 iii 6 UV Sensor 6 1 6 1 INTRODUCTION 6 1 Description 6 1 Specifications 6 1 Maintenance 6 1 UV Sensor Removal and Cleaning 6 1 UV Sensor Replacement 6 2 ...

Page 98: ...UV Sensor TrojanUVLogic Operations Maintenance May 25 2004 6 iv ...

Page 99: ...ent loop 2 wire Sensor Photodiode Supply Voltage 24V DC Maintenance UV Sensor Removal and Cleaning 1 Turn off the water flow through the UVR chamber Isolate the UVR Note Ensure that the plant has been switched to bypass or plant is shut down to avoid damage to other plant equipment 2 Shut the power OFF at the Control Panel CP 3 Relieve the water pressure and drain the water from the chamber throug...

Page 100: ...nscrew the old UV Sensor from the 4 pin male connector and reattach it to the new UV Sensor CAUTION De Pressurize Drain the UVR Pressure must be relieved from the system prior to any maintenance to prevent damage to the equipment or personal injury CAUTION Acids used to clean the sensor can cause burns Wear protective clothing and eyewear when handling these materials After cleaning rinse the syst...

Page 101: ...Control Panel CP TrojanUVLogic Operations Maintenance 2006 01 19 7 i Chapter 7 CONTROL PANEL CP ...

Page 102: ...Control Panel CP TrojanUVLogic Operations Maintenance 2006 01 19 7 ii ...

Page 103: ...ption 7 5 Specifications 7 5 Maintenance 7 6 Power Pack 7 6 Description 7 6 Specifications 7 6 Electronic Ballasts 7 6 Description 7 6 Maintenance 7 7 AM Model Ballast Removal Replacement 7 7 AS AL Model Ballast Removal Replacement 7 8 System Controller The Control Board 7 10 Description 7 10 Board Power supply requirements AM Models 7 10 P40 Board Power supply requirements AS and AL Models 7 10 B...

Page 104: ...rator Access Level Screens 7 20 Technician Level Access Screens 7 20 System Settings Screens 7 21 Operator Access Level Screens 7 21 Technician Level Access Screens 7 22 Trend Screens 7 24 Wiper Screen AMWS For systems with a Wiper 7 24 Wiper Sequence Timer AMWS For systems with a Wiper 7 25 Wiper Auto Power Off For systems with a Wiper 7 25 Analog Menu Screen 7 25 Reactor Hi Temp Reactor High Tem...

Page 105: ...ediately go into a Warm up mode refer to the Normal Operation Start up heading before the UV System returns to the previous operational mode Normal Operation Start up The UVR will be placed into an 3 minute Warm up mode until the UV Intensity has stabilized During the first 18 seconds of the 3 minute Warm up mode all alarms are temporarily suspended except for Reactor HiTemp Critical Reactor High ...

Page 106: ...d automatically as scheduled by the CCB CP controller In Automatic mode the interval between cleaning sequences is determined by the cleaning sequence timer which is normally pre set at 8 hours and adjustable to 0 0 5 1 2 3 4 6 8 12 24 48 or 96 hours For systems with greater than 30 cm chambers they will use the Home Limit Switch At the start of a wiping sequence the UVR Wiper extend sequence is e...

Page 107: ...d be controlled by the Plant PLC by remote means Communication can be received from the Plant PLC to the Control Panel as well as transmitted from the Control Panel to the Plant PLC The following are a general list of communication commands that can be exchanged Receive from Plant PLC examples Turn ON OFF Remote ON OFF External Interface and System Operation Modes Initiate Wiper Sequence if provid...

Page 108: ...twice If this fails to resolve the issue refer to Chapter 8 for troubleshooting Should the Wiper Fault continue to appear the Wiper system should be disassembled and the problem diagnosed Reactor Proximity Switch Input Rev Counter The Proximity Sensor is used to count the number of revolutions that the Motor makes to extend the Wiper Plate to the end of the chamber This number is factory set and i...

Page 109: ...ure that houses the control electronics and power supplies The CP may be fan cooled depending on Model requirements and is suitable for indoor installation Refer to the System Label located at the front of this manual for the specifications for your system Specifications Material of Construction Type 12 is epoxy painted carbon steel or Type 4x which is 304 SST optional Rating Type 12 or optional 4...

Page 110: ...entially an independent transformer that is housed in its own Type 3R enclosure The enclosure may reside wherever needed however it should preferably be installed in a Plant s Distribution Panel Electrical Room Based on your system size and the power being provided by the plant an appropriate Power Pack will be provided when necessary Specifications Material of Construction Painted Steel Rating Ty...

Page 111: ...lace the new Ballast onto the Back Plate align the 2 hex Mounting Screw holes and fasten the Ballast into place 7 Reinstall the Connector that provides power to the Lamps on the new Board 8 Reconnect the Lamp Ballast status digital Contact Wires to the correct locations 9 Reinstall the Power Cable to the Ballast 10 The system is now ready to power up WARNING HOT SURFACE Allow electronic ballast an...

Page 112: ...y include electrical or stored energy Refer to the general lock out and tag procedures in this manual 2 Disconnect the power to the Ballast as shown below 3 Disconnect the Communication Cables for Lamp Ballast Status as shown above 4 Remove the Connector that distributes power from the Ballast to the Lamps 5 Remove the 2 hex Mounting Screws on either side of the Ballast and lift it out 6 Take note...

Page 113: ...rs that provide power to the Lamps on the new Board 10 Reconnect the Lamp Ballast status Communication Cable to the correct locations as shown on previous page 11 Reinstall the Power Plug to the Ballast 12 The system is now ready to power up Note Incorrect alignment of the Lamp Ballast status Communication Cable will damage the pins and ruin the Ballast Dip switches Lamp Ballast Status Communicati...

Page 114: ... its original factory settings If for some reason someone accidentally changes parameters and is uncertain what they have done these factory settings are stored right on the Board and can be retrieved at any time Board Power supply requirements AM Models The AM Model requires 2 Input power connections to the P40 Board 120 or 240VAC for Ballast Power 24VDC for LC Display and Board Power The Board p...

Page 115: ...2006 1 19 7 11 Board Diagram See the following page Note The terminations required by the contractor include The Main Power to the Disconnect Switch as shown in the Previous figure The Alarm terminations Optional Digital Inputs if applicable Remote ON OFF ...

Page 116: ...ol Wiper Control Discrete Outputs Typ of 2 120 240 Input Power for Ballasts Midflow Models 120 240 VDC Output Power to Ballasts Midflow Models Only Fuse Blown Indicator LED 1 Amp Slo Blow Fuse 24 VDC Board Input Power 24 VDC Input Power for LCD 24VDC Analog inputs Typ of 5 24VDC NO Discrete Alarm Outputs Typ Of 7 Wiper Proximity Sensor Wiper Home Limit Switch Temperature Switch SCADA Comm Module F...

Page 117: ...e solder side of the Board is the Keypad Connector which simply provides the connection of the keypad to the Board for navigation and control VFD Communication Port The VFD Vacuum Florescent Display Communication Port is on the solder side of the Board as well The function of this connection is to provide power and communication from the Board to the Display Screen Battery Replacement The time and...

Page 118: ... have variable power this option is only available on the Long Lamp Models Wiper Limit SW Input Limit Switch if Wiper is provided Used only on systems with larger than 30cm chambers the Wiper Limit Switch acts as a digital signal to send a message to shut the Motor OFF In normal operation the Wiper Plate sits in the Park position until a wipe sequence is initiated For details on the operation of t...

Page 119: ...face will display an alarm on the screen and will keep track of them in an Alarm History With AMWS the controller will monitor wiping sequences the frequency of wiping as well as the status The variables on cleaning frequency can be adjusted to suit varying site conditions The buttons at the bottom of the following screens take the Operator to the respective screens HIST Alarm History Screen ACTI ...

Page 120: ... Lamps Displays the of Lamps in the system Power Mode The Power is displayed as a percentage for Long Lamp Models only The mode will be displayed as either Local or Remote There is no Power display for Midflow or Short Lamp models Local Control override by Operator at the CP Remote Control by the UV System CP Final Line Status Line This line will display one of the following status lines 1 During ...

Page 121: ...ar if the Reactor Temperature options are configured This screen provides an overview of the following Reactor Temp Displays the current reactor temperature Bar Graph The bar graph depicts live readings The Reactor Temp graph works indicates both the High Temperature Major and High Temperature Critical respectively from left to right as ...

Page 122: ...w Section in this chapter Alarm History Screen The Alarm History Screen can be accessed from the Active Alarm Screen by pressing the HIST button This screen provides the Operator with a history of all active and all resolved alarms including the time of their occurrence The screen is capable of storing up to 18 alarms If the list exceeds 18 entries the oldest alarm entry will drop off the list Ala...

Page 123: ...und indicating that change mode has been entered These screens enable the Technician to select which Digital Inputs and Outputs they wish to be present at the Operator Level To designate Inputs and Outputs move the cursor to the line of choice and press enter to scroll through the list of items that could be connected to that particular input or output on the board Once the corresponding item is d...

Page 124: ...ss Screens To access these screens you must have entered the Technician s Password Then from each of the previous Analog Input Output Screens select the Change button The text will reverse dark text with light background indicating that change mode has been entered Within these screens the Technician is able to select which Analog Inputs and Outputs they wish to utilize The UV Intensity Input is m...

Page 125: ...de This mode selector can be changed to Local control at the CP by the controller Remote control by an external device by powering a voltage loop into the CCB s voltage sensing circuit SCADAR SCADA Remote control by an external device through SCADA communications On Off Power This is a counter that keeps track of the number of times the power to the system i e Board is cycled ON OFF On Off Lamps T...

Page 126: ... when the analog Reactor Temperature is available Dose Units The operator can select either mJ cm2 or J m2 units to view UV Dose UV Sensor Alarm Delay This field allows the Operator to adjust the delay for a UV Sensor alarm to any value between 0 and 8 minutes Default 0 The following system settings screen information should not be reconfigured unless otherwise authorized by Trojan The information...

Page 127: ...d allows the Technician to have the controller wipe the Lamps regardless if the Lamps are powered or alternatively only wipe when the Lamps are on This screen allows the Technician to adjust the following Set Clock This field allows the Technician to adjust the system Time Set Date This field allows the Technician to adjust the system Date Change Technician Password This field allows the Technicia...

Page 128: ...d in hours Wiper Cycle Indicates how often the Wiper will cycle Rev Number of revolutions the Wiper has turned during extend or retract sequence L Represents the Limit Switch The L will blink and fault will appear on the screen if a fault associated with the switch occurs M Represents the motor M Represents the motor C Represents Revolution Switch Count The C will blink and fault will appear on th...

Page 129: ...off Wiper Auto Power Off For systems with a Wiper If the Wiper encounters significant resistance while operating the Gear Motor will automatically turn off protecting both Wiper Assembly and Quartz Sleeves The display will flash Fault which indicates the Wiper is not functioning properly The Operator can reset the Wiper system by turning the CP off waiting 10 seconds and turning the power on again...

Page 130: ...1 and 15 minutes a delay will occur before the alarm occurs and the lamp de energize Setting a delay of 0 minutes causes the alarm to occur and the lamps to de energized immediately Full Scale This value is preconfigured at 100 C or 212 F depending on the Reactor Units set It cannot be adjusted Login Screen If a password has not been entered the system will automatically allow Operator level acces...

Page 131: ...Control Panel CP TrojanUVLogic Operations Maintenance 2006 1 19 7 27 ...

Page 132: ... a Wiper only Appears when any of the Wiper Alarms are occurring 7 5 Alarm Overview Minor Alarms On a minor fault the UVR will remain On Line Minor alarms will display on the CP and alarm relays will be deactivated On a Minor alarm action should be taken to correct the problem soon after the alarm but disinfection may not be in jeopardy Alarm Description Wiper Revolution Alarm For systems with a W...

Page 133: ...p Alarm XX Major Appears when a lamp has ceased to function lost power or lost communication Ballast XX Alarm Major Appears when a ballast has ceased to function lost power or lost communication SCADA Communication Alarm Major Appears when the SCADA Communication connection has been lost No Flow Signal Major When flow signal is not detected the system automatically jumps to 100 power until the sig...

Page 134: ...Temperature Critical The Reactor Temperature has exceeded the maximum factory set point Customer can decide if they want to set a timed delay from 0 15 minutes A setting of zero 0 minutes causes Lamps to de energize immediately Any value greater than zero minutes will activate the alarm relay but will not turn off the Lamps till the delay time has expired For the Reactor High Temperature Alarm a t...

Page 135: ...pically override standard provided Inputs and Outputs Analog 4 Output Analog 4 20mA System I O Remote ON OFF Input Digital Voltage Sensing Input Customer I O Wiper Option Revolution Sensor Input Digital 9 4Hz Pulse System I O Max Power Response Loop Jumps to 100 power Input Digital Voltage Sensing Input Customer I O Wiper Option Limit Switch Input Digital Normally Closed NC System I O Wiper Option...

Page 136: ...nto our system by these analog inputs The controller will provide a graphical display of the information only Also if a signal is brought in it can then be wired out of our system to another if required If you have a specific request please contact your representative Additional Inputs and Outputs cannot typically override standard provided Inputs and Outputs It is possible to have up to 5 Analog ...

Page 137: ...Control Panel CP TrojanUVLogic Operations Maintenance 2006 01 19 7 33 ...

Page 138: ...Control Panel CP TrojanUVLogic Operations Maintenance 2006 01 19 7 34 ...

Page 139: ...Control Panel CP TrojanUVLogic Operations Maintenance 2006 01 19 7 35 ...

Page 140: ...TROJANUVLogic TM ...

Page 141: ...Alarms and Troubleshooting TrojanUVLogic TM Operations Maintenance May 25 2004 8 i Chapter 8 ALARMS AND TROUBLESHOOTING ...

Page 142: ...Alarms and Troubleshooting TrojanUVLogic TM Operations Maintenance May 25 2004 8 ii ...

Page 143: ...Alarms and Troubleshooting TrojanUVLogic TM Operations Maintenance May 25 2004 8 iii 8 Alarms and Troubleshooting 8 1 8 1 ALARM INDICATORS 8 1 8 2 GENERAL TROUBLESHOOTING 8 10 ...

Page 144: ...Alarms and Troubleshooting TrojanUVLogic TM Operations Maintenance May 25 2004 8 iv ...

Page 145: ...Alarm Major The respective Lamp has failed Replace the Lamp with working Lamp Activate redundant system or if necessary close upstream valve Lamp Power Cable from Ballast failed faulty or disconnected Remove and replace or reconnect faulty Power Cable between Ballast and Lamp Communications Ribbon Cable from Ballast to CCB has single broken conductor to Ballast Remove and replace faulty Communicat...

Page 146: ...m Ballast failed faulty or disconnected Remove and replace or reconnect faulty Power Cable s between Ballast and Lamp Communications Ribbon Cable s from Ballast to CCB faulty or disconnected Remove and replace faulty Communications Ribbon Cable s between Ballasts and CCB Configured lamp s have failed i e the lamp in front of the sensor Failed or Faulty Lamp Ballasts Replace the Lamp Ballasts Balla...

Page 147: ...leshooting TrojanUVLogic TM Operations Maintenance May 25 2004 8 3 Wiper Alarm General Minor One of the 3 following Wiper Alarms has been triggered Refer to the specific Alarm and follow the appropriate troubleshooting ...

Page 148: ...its cycle due to Proximity Sensor is not counting properly Check distance between Proximity Sensor and Sensor screw to ensure Sensor is counting revolutions Wiper Assembly has failed to complete its cycle due to Debris in Chamber Disassemble Chamber and remove obstruction Loss of Proximity Sensor signal for more than the programmed delay period during a wipe sequence Adjust Proximity Sensor air ga...

Page 149: ...mp Cables are not run near the Sensor end of the Proximity Sensor Wiper Home Alarm Minor Wiper Assembly has failed to complete its Homing function Turn Control Panel OFF ON to re initiate Homing function Repeat if required Service to UV Reactor necessary Schedule Maintenance Debris in Chamber Disassemble Chamber clean and replace components as needed Loss of Proximity Sensor signal for more than 5...

Page 150: ...ailed or faulty Wiper Motor Proximity Sensor signals pulse count value reaches 300 during a HOME operation Ensure Wiper Motor is properly connected to Wiper Plate shaft Ensure Wiper Plate is properly connected to Wiper Plate shaft Ensure proper shield grounding for Cable between Proximity Sensor and CCB Ensure Lamp Cables are not run near the Sensor end of the Proximity Sensor Wiper Limit Switch A...

Page 151: ... and replace faulty Cable between Wiper Home Limit Switch and CCB Lack of Wiper Home Limit Switch signal for more than 3 revolutions of the Wiper Motor while Wiper Plate is moving towards the HOME position during a HOME operation Ensure Wiper Home Limit Switch and pin is adjusted correctly Remove and replace failed or faulty Wiper Home Limit Switch Remove and replace faulty Cable between Wiper Hom...

Page 152: ...UV Reactor temperature is above normal operating specifications Ensure flow rate through UV Reactor is within operating specifications Water temperature is above normal operating specifications Ensure water temperature is within operating specifications Low UV Sensor 1 Major Critical Lamp failure Replace Lamp s Activate redundant system or if necessary close upstream valve Divert Flow Lamp aging R...

Page 153: ...e Wiper Screen in Chapter 7 Control Panel Investigate decreasing period between wipe sequences Lamps no longer able to supply required UV Intensity Check Total Lamp Hours value Remove and replace UV Lamp s as necessary and reset the Total Lamp Hours value See the Technician Level Access Screens of the System Settings Screens in Chapter 7 Control Panel CP Investigate decreasing EOL Hours value Insu...

Page 154: ... of Lamp glass Replace Component On Lamp Status Alarm At End of Lamp Life Lamps UV Lamps are off even if the ON switch was activated Check if the Remote control has been activated Check the system for short circuits and or damaged fuses if necessary replace fuses As required Sleeves Fouling or coating of the Quartz Sleeves Scratches Replace Component Clean monthly or when low UV Alarm occurs UV Se...

Page 155: ...ay and brittle pieces Replace Component Once a year or when Sleeves are removed Lamp Socket Signs of pins overheating or moisture Corrosion of the pins Replace Component With Lamp Status Alarm or when Lamps are disconnected UV Reactor Chamber Heavy build up of settled solids Clean Chamber Once a year ...

Page 156: ...ive Screw exit thru Bushing Housing Replace Component Once year or as needed Drive Nut UV decay and brittle pieces Home function problems Replace Component Once year or as needed Roller Bearing Significant vibration Replace Component Once year or as needed Elastomer Compression Spring Home function problems Replace Component Once year Bushing Housing O Ring Water leakage at End Plate and Bushing H...

Page 157: ...Installation Instructions TROJANUVLogic TM Operations Maintenance May 25 2004 9 i Chapter 9 INSTALLATION INSTRUCTIONS ...

Page 158: ...Installation Instructions TROJANUVLogic TM Operations Maintenance May 25 2004 9 ii ...

Page 159: ...OJANUVLogic TM Operations Maintenance May 25 2004 9 iii 9 Installation Instructions 9 1 9 1 OVERVIEW 9 1 9 2 SHIPPING CONTENTS 9 1 9 3 SET UP 9 1 9 4 AUTOMATIC MECHANICAL WIPING SYSTEM AMWS INSTALLATION 9 4 9 5 SYSTEM START UP 9 4 ...

Page 160: ...Installation Instructions TROJANUVLogic TM Operations Maintenance May 25 2004 9 iv ...

Page 161: ...en preparing the site for installation allow for Valves Drain and Bypass as part of your plumbing circuit 4 When mounting the CP on the wall ensure there is at least a 15 cm 6in 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 While larg...

Page 162: ...1 55 MPa 225 psi at the factory unless indicated otherwise 7 Flush a few gallons of water through the UVR chamber to remove any particles or dust that may have collected during installation 8 Connect the CP to the UVR 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 9 Connect the ...

Page 163: ...ce the Temperature Switch under the Clip as shown and maintain cables for the Temperature Switch close to Sleeve Bolt and Lamp Harness Route Harnesses through Grommet allowing approximately 6in of slack for each Harness Keep Harnesses together using provided tie wraps 11 System Ground Wire installation I Secure ring terminal to stud on UVR as shown 12 Provide AC power to CP matching voltage and po...

Page 164: ...o match wire tag numbers 9 5 System Start up 1 Allow the UVR chamber to fill slowly with water 2 Turn the lamps ON by pressing the switch located on the face of the CP 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 CAUTION Connect this system only to AC power that conforms to the information in the rating plate...

Page 165: ...ng while the system is warming up 3 If no alarms are registering after the system has warmed up and LAMPS ON is indicated in the status line water for disinfection 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 ...

Page 166: ...Installation Instructions TROJANUVLogic TM Operations Maintenance May 25 2004 9 6 Acceptable Reactor Installation Orientations ...

Page 167: ...Appendix A Warranty TrojanUVLogic TM Operations Maintenance May 25 2004 Appendix A WARRANTY ...

Page 168: ...Appendix A Warranty TrojanUVLogic TM Operations Maintenance May 25 2004 ...

Page 169: ...Appendix A Warranty TrojanUVLogic TM Operations Maintenance May 25 2004 WARRANTY ...

Page 170: ...Appendix A Warranty TrojanUVLogic TM Operations Maintenance May 25 2004 ...

Page 171: ... will direct Customer to acquire at Aquafine s expense such part from a third party and then install such part as directed by Aquafine In the event that Aquafine determines that the problem cannot be resolved by way of telephone support and or shipment by Aquafine or acquisition by the Customer of a replacement part for installation by the Customer Aquafine will send one or more persons to make an...

Page 172: ...Appendix A Warranty TrojanUVLogic TM Operations Maintenance May 25 2004 ...

Page 173: ...Appendix B Replacement Parts List TrojanUVLogic TM Operations Maintenance Jan 02 2006 Appendix B REPLACEMENT PARTS LIST ...

Page 174: ...Appendix B Replacement Parts List TrojanUVLogic TM Operations Maintenance Jan 02 2006 ...

Page 175: ...Appendix B Replacement Parts List TrojanUVLogic TM Operations Maintenance Jan 02 2006 B Replacement Parts List 1 ...

Page 176: ...Appendix B Replacement Parts List TrojanUVLogic TM Operations Maintenance Jan 02 2006 ...

Page 177: ...t 1 lamp 903988 001 Short Long Lamp Model Ballast 2 lamps SEALS O RINGS 792437 Sleeve O rings 792931 Sleeve Support Washer SENSOR 793048 005 UV Sensor Germicidal MISCELLANEOUS 931067 Analog Output Module 931066 001 Interface Board 792932 Sleeve Bolt Short Long Lamp Models 793860 Sleeve Bolt MidflowModel 792718 002 Lamp Holder Short Long Lamp Models 793415 020 Lamp Harness Midflow Model 793363 Wipe...

Page 178: ...TROJANUVLogic TM ...

Page 179: ...Appendix C Layout Drawings TrojanUVLogic TM Operations Maintenance May 25 2004 Appendix C LAYOUT DRAWINGS ...

Page 180: ...Appendix C Layout Drawings TrojanUVLogic TM Operations Maintenance May 25 2004 ...

Page 181: ...Appendix C Layout Drawings TrojanUVLogic TM Operations Maintenance May 25 2004 C LAYOUT DRAWINGS Refer to the system overview section to determine which layout to use ...

Page 182: ...Appendix C Layout Drawings TrojanUVLogic TM Operations Maintenance May 25 2004 ...

Page 183: ...Appendix D Electrical Drawings TROJANUVLogic TM Operations Maintenance May 25 2004 Appendix D ELECTRICAL DRAWINGS ...

Page 184: ...Appendix D Electrical Drawings TROJANUVLogic TM Operations Maintenance May 25 2004 ...

Page 185: ...Appendix D Electrical Drawings TROJANUVLogic TM Operations Maintenance May 25 2004 D ELECTRICAL DRAWINGS Refer to the system overview section to determine Information applies to your system ...

Page 186: ...upply environmentally safe products through manufacturing and marketing of ultraviolet equip ment world class in quality technology delivery and cost with maximum value to our customers while enhancing the safety and development of our employees We are committed to serving our customers our col leagues our company and our community Our Vision To be the dominant most respected supplier of Ultraviol...

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