WQ0034367_Operation & Maintenance Plan_20220711

OWNER'S MANUAL
ONWASA NW, NC
PROJECT NO.:512254
IMPORTANT CONTACTS
HEAD OFFICE - CANADA
Trojan Technologies
3020 Gore Road,
London, Ontario,
Canada, N5V 4T7
Tel.: [phone]
Fax: [phone]
htt:.jwwwtIoi_�uvu�ii
TOLL F!' ;USER:
1-800-291-0851
TOLL I-.-k IUMBER:
1-800-291-0127
To schedule SERVICE or ORDER PARTS, contact your LOCAL REPRESENTATIVE
EW2 Environmental, Inc.
Address: 7245 Pineville -Matthews Road, Suite 100 Charlotte, NC 28226
Tel: [phone]
Fax: [phone]
l you are unable to reach your Local Representative and have a TECHNICAL EMERGENCY, contact TROJAN TECHNOLOGIES'
TECHNICAL ASSISTANCE CENTER:
Toll Free Phone: [phone]
Email: [e-mail]
TROJAN!1�
/Water
Confidence"

Section 8 Basic Operation
A DANGER
Obey all warning and caution statements. Refer to Section 2 .
Read and understand this Operation and Maintenance Manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment.
Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance .
8.1 Hydraulic System Center
The hydraulic system is operated remotely from the System Control Center (SCC) Operator Interface or
locally from HSC Controller. As an option, the system can be operated Remotely using SCADA if the facility
has a SCADA system .
8.1.1 HSC Overview
Figure 17 Hydraulic System Center
Basic Operation
Item No Description Icon Function
RET It applies to wipes and functions when any wiper 1s switched from OFF to LOG position.
p= Note: Once a function has been performed, switch item 2 to OFF before
selecting another Extend or Retract function
The wiper will move from the parked position on to the opposite end on the UV Module.
1 Wiper Operation Switch EXT
�
The wiper will move from the non-parked position to the parked position on the UV Module.
SEQ
�
Wiper will extend and retract if wiper is in the parked position, otherwise wiper will retract back to parked position and perform a full cycle of wiping.
OFF 0 Wiper disabled or wiping will be stopped if the wiper is wiping before it is switched to OFF.
REM Wiper operates in Remote mode. In the is mode, wiper can:
2 UV Bank 1,2,3 etc. [2f' . Perform a manual wipe upon receiving wiping command from HMI. Wiper Mode Switch . Wipe automatically under control of internal wiping cycle timer .
LOG
[Z( When the wiper is switched from OFF to LOG, wiper will start the specified wiping operation depending on the Wiper Operation Switch position
8.1.2 Wiper Control Modes
8.1.2.1 Wiper Remote Control
sec will control the operation of the HSC Wiping function.
1.HSC Disconnect---+ "ON".
2.HSC operation switch---+{55:.J or (WIPE).
3.UV Bank wiper mode switch---+[2f or (REM).
8.1.2.2 Wiper Local Control
Note: Used for Service purpose only.
1.HSC Disconnect---+ "ON".
2. HSC operation switch ---+ {55:.J or (WIPE).
3. Wiper Mode Switch ---+ @ or (LOC) for required UV Bank.
8.1.2.3 Wiper Sequence Control
50
Note: Used for Service purpose only.
1.HSC Disconnect---+ "ON".
2.HSC operation switch ---+{55:.J or (WIPE).
3.Wiper Operation Switch ---+fS or (SEQ) for required UV Bank.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Basic Operation
8.1.3 Manually Operate the Wiper
Prerequisites:
•Put the Wiper into Local Control Mode .
Materials: OtJO
Procedure:
Retract (Home) the Wiper
1.Select Applicable Wiper Group -jo-=-or (RET) until the wiper has moved across the UV
Module.
2.UV Bank wiper mode switch -Q or (OFF) .
Extend the Wiper �
1.Applicable wiper operation switch - � or (EXT) until the wiper moves across the UV Module .
2.UV Bank wiper mode switch -Q or (OFF) .
8.1.4 Reset HSC Latched Alarms
1.Resolve the cause of the latched alarm.
2.Bank Mode Switch -Turn from [2J or (REM) to Q or (OFF) to [2J or (REM) .
8.2 Navigate the Human Machine Interface
The HMI for the controller uses touchscreen technology. Do not use the writing tips of pens or pencils or
other sharp objects to make selections on the screen. Use only a clean, dry finger tip or the eraser tip of a
pencil.
Icon
The operation of the SCC can be completely bypassed by the UV Bank mode selector switches on the
PDC. These switches must be in the Remote position to allow control of the UV Banks through the user
interface of the sec .
All interface screens show navigation buttons along the bottom of the screen (Table 2) .
Table 2 Navigation Screen Icons
Function Description
@ System Overview An operational summary of all UV channels and UV Banks. Allows access to Priority
Assignment screen and to manually enter flow and UVT values
Alarm Status Screen Navigates to the active alarms and allows access to Alarm History screen, if
anyalarm is active .
@: Trend Screen Displays trend data for flow, UVT and dose
§ Log in/log out Login and logout buttons on the navigation bar to allow control of user security level
Original Instructions 51
Basic Operation
Table 2 Navigation Screen Icons
Icon Function Description
(0 Information Screen Shows information about the control system hardware and software. It also allows
access to change clock time and other user interface maintenance functions
I System Settings Screens Allows access to system configuration settings as allowed by current security level.
Settings are organized in pages by function
Wiper Overview Screen Allows access to control wiper/cleaning system
y Bank Overview Screens Allows access to control UV Banks and display UV Bank specific information
Q Channel Overview Allows access to control slide gates.
Screen Allows access to control and display channel specific information.
® Help Shows help text for the currently selected screen.
The interface screens use color codes to help identify types of data at a glance:
Text I Symbol Background Definition
52
Color Color
Gray Static text or numeric data that is unable to be changed by an operator or current
security level
Black Yellow Function is manually controlled
White Active button or numeric entry field that will either change the currently displayed
screen, or will allow entry of numeric data
Black Not running status for UV Lamps Any White Running status for UV Lamps
Section 8.3 shows the basic structure of the user interface screens, with a brief description of each function.
System settings can affect the disinfection properties of the system. These settings should only be changed
by trained personnel under the guidance of the manufacturer. Refer to Section 9 for information about
system settings.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• • ••
Basic Operation
8.3 Interface Navigation
SYSTEM OVERVIEW screen (Section 8.4.1)
PRIORITIES/NEXT
ROTATION
INTENSITY
RETENTION
CHANNEL PRIORITY I
GATE MODE
CHANNEL STATUS
BANK PRIORITY
Original Instructions 53
Basic Operation
8.3 Interface Navigation (continued)
Current control mode of the UV Bank:
Local Off -set at the control switch on the UV Bank PDC to force UV Bank to stay off
Local On-set at the control switch on the UV Bank PDC to force UV Bank to stay on at
full power
Remote Off-the control switch at the UV Bank PDC is in the Remote position, and the UV
Bank has been selected in the Off mode on the Bank Overview screen
Remote Hand-the control switch at the UV Bank PDC is in the Remote position, and the
UV Bank has been selected in the Hand mode on the Bank Overview screen. In this mode
BANK MODE the UV Bank is operating and the power level is set by the operator
Remote Auto-the control switch at the UV Bank PDC is in the Remote position, and the
UV Bank has been selected in the Auto mode on the Bank Overview screen. In this mode
the UV Bank's on/off status and power level are controlled as required to meet dose, by
the UV PLC.
SCADA Permissive-with the Control switch on the UV Bank PDC in the Remote position
and the System In SCADA Control Mode. The SCADA Permissive Run Signal can bring a
Bank In and out of service. If the UV Bank SCADA permissive run signal is off the bank
will run in auto mode. If the UV Bank SCADA Permissive Run Signal is On the UV Bank
will shutdown and be removed from Auto Requests.
BANK POWER Current power level of the UV Bank. An icon is shown beside the power level indicator to
indicate a condition that may affect the current UV Bank power level (Table 3).
Total UV lamp accumulated runtime. When a UV Bank is placed in either the MANUAL ON
UV LAMP LIFE HOURS or AUTOMATIC ON modes of operation this value will increment by one for every hour of
UV lamp operation. This value will increase throughout the entire life span of the UV Bank
UV lamps until the UV lamps are changed and the value is reset to zero.
ALARMS Screen
Current active alarms. The 100 most recent UV alarms are shown. When an alarm
ACTIVE ALARMS condition is corrected and no longer active, it is removed from the Alarm Status screen.
Refer to Section 11 for information on specific alarm conditions.
Archive of the previous 100 alarm events. When the alarm buffer is filled with the
ALARM HISTORY maximum number of alarms (100), the oldest alarm is deleted from the archived history on
a first in/first out basis. Each alarm is time and date stamped to show when it occurred.
TRENDS Screen
FLOW Pause or trace flow trends. Current numerical value is shown outside the graphical
representation.
DOSE Pause or trace dose trends. Current numerical value is shown outside the graphical
representation.
UVT Pause or trace UVT trends.Current numerical value is shown outside the graphical
representation.
LOG IN/LOG OUT Screen
LOG IN Log in as user or administrator
LOG OUT Log out of current user status
INFO (Information) Screen
FIRMWARE Controller revision
CONTROLLER STATUS Status (OK or Fault condition) and Mode (Run or Stop)
Mode (Run or Stop)
PROJECT REVISION Display only
EXIT PROJECT Leave the current setup project
Limit-Time-out limit
SCAN TIME (milliseconds) Max-Maximum scan time to date
Present-Real-time scan
54 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
Basic Operation
8.3 Interface Navigation (continued)
Note:
WIPERS OVERVIEW Screen
BANK OVERVIEW Screen
CHANNEL OVERVIEW Screen
Original Instructions
Basic Operation
8.3 Interface Navigation (continued)
SETTINGS Screens
Call Trojan Technologies before changing system settings.
BANK settings
BANK Setup
WIPER settings
FLOW settings
UVT settings
UVI settings
DOSE settings
GENERAL settings
CHANNEL settings screen
8.4 System Control Center (SCC) Operation
The SCC contains the control program for the UV system. The SCC is configured at the factory with inputs
and outputs as required for each system. The manufacturer configures the functionality of each of the
signals in the control strategy.
Daily operation includes monitoring the system functions, and may occasionally require the operator to
manually initiate or control processes.
8.4.1 System Overview Screen @ The System Overview screen provides a summ ary of all UV Banks, reports the current UV Dose
and displays associated signals relating to dose calculation . Icons indicate faults and UV Bank
status (Table 3).
Table 3 System Overview Status Icons
Icon Definitions
A A faulted UV Bank or channel
� A UV Bank in warm-up mode
,�I A UV Bank in timing off mode
:.-Bank power is dampened
8.4.1.1 Flow Values
56
Note: The flow rate units are configured by the manufacturer in the system settings screens.
The Flow field shows the current total system flow value used for dose pacing. A selector above the flow
value will toggle the current flow signal source between the configured input instrument source, and a
manually entered value.
Enter a flow value manually
1.System Overview Screen ➔ Flow Source selector switch to set the system to Manual Flow
(Figure 18).
2.Use the keypad to enter the flow value.
3.Confirm the entry to exit the keypad.
Origin al Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Basic Operation
TROJANuv· SYSTEM OVERVIEW
3.75 NCO
Manual Flow UVT
3.00 70.00
Lead
Dose
mW.Siem' 64.73
No Gate I·(
3.00
®Q·
Heahhy MM4 100% Level OK Uh
�A e: 1st Lag Lead No Gate Healthy 100% level OK 17h 100% Jh
Help Channels Banks VoApef"• Settiogs
A
2SAJ1'100723153PM
USER: DEf AU. T
Next Rotation
Figure 18 System Overview Screen
8.4.1.2 Enter a UVT value manually
1.System Overview Screen ➔ Push the UVT source selector switch to set the system to Manual UVT
(Figure 18) .
2.Use the keypad to enter the UVT value .
3.Push ENTER to confirm .
8.4.1.3 Assign the Lead Bank or Channel
The lead and lag UV Banks or UV Channels can be rotated through the Priority Assignment screen
(Figure 19) .
1.System Overview Screen➔ Push NEXT ROTATION or PRIORITIES button .
Note: The command may vary with the software version .
2.Assign the UV Bank and UV Channel number for the lead, 1st lag and 2nd lag UV Banks and UV
Channels. UV Bank and UV Channel numbers can only be assigned once .
3.Push the ACCEPT PRIORITY CHANGES button to activate the changes .
Original Instructions
TROJANuv·@
O,annel #
Lead I
1st lag I
Cf 9 Hetp Channels Banks
PRIORITY ASSIGNMENT 25.01f2007, 1248 PM
USEI< OfM
Bank# I
Bank# I
ENTER1;JOR3FMBAM<A,BORC
lead 1st Lag
•
C � A @ Security Trends AJerms O.er-view
Figure 19 Priority Assignment
57
Basic Operation
8.4.2 Wiper Overview Screen
The control of wipers on the UV system is divided into UV Banks. The Wiper Overview screen
allows access to information and control of the wipers on a single UV Bank.
8.4.2.1 Initiate a Wipe Sequence for one Wiper Group
This screen shows the current status of the wipe sequence, the phase of the sequence and time
remaining until the next sequence.
1.Use the NEXT and PREV buttons to navigate to the HSC and wiper group (Figure 20).
2.Push the Initiate Wipe selector to start the sequence.
8.4.2.2 Enable or Disable a Wiper Group
1.Use the NEXT and PREV buttons to navigate to a wiper group (Figure 20).
2.Push ENABLE to activate the wiper group or DISABLE to deactivate the group. The currently selected
status will show on the screen.
8.4.2.3 Change the HSC Display
For wiping systems controlled by multiple HSCs, use the PREV HSC or NEXT HSC buttons to move to the
previous or next HSC status display.
Not available on systems with a single HSC.
8.4.2.4 Change the Wiper Group Display
If multiple wiper groups are configured for the system, use the PREV WIPER or NEXT WIPER buttons to
move to the previous or next wiper group status display.
q- ur ...
WIPER OVERVIEW
fl.OW UUff fOl w..G OI
WATOl:UVUOI
C�110NOIC
\'ftllll.•RlUOTt
PRUR.IEOI
UOTO.RWOC
WW'l.arumt.nno«
1t T C
2'00a.-11·t'.! OI 32 l�
U5'R QP1
Figure 20 Initiate Wiper Sequence
8.4.3 Bank Overview Screen
58
All UV Bank controls are accessed through the Bank Overview screen. From this screen, the
operation mode for each UV Bank is set to:
•REMOTE OFF
•REMOTE HAND
•REMOTE AUTO
•SCADA PERMISSIVE
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Basic Operation
Before a change is made to a UV Bank, make sure the information shown is for the correct UV Bank. Use
the NEXT BANK and PREV BANK buttons to access the correct UV Bank. Use the NEXT CHAN and PREV
CHAN buttons if operating a multi-channel system .
8.4.3.1 Select Bank Control Functions
Push the VIEW MODULE CONTROL button at the top right hand corner of the screen to toggle the control
button area of the screen from Module Control to Bank Control buttons .
8.4.3.2 Operate Bank in REMOTE OFF
Push the OFF button. The UV lamps in that UV Bank will be shut off .
8.4.3.3 Operate Bank in REMOTE HAND
•Push the HAND button. The selected UV Bank UV lamps will be energized at 100% power for a
warm-up period .
•To set power level for that UV Bank, select the MANUAL PWRentry field and enter the power setting.
Push ENTER to accept the new manual power value .
8.4.3.4 Operate Bank in REMOTE AUTO
Push the AUTO button. The controller will include that UV Bank in the dose pacing routine .
8.4.3.5 Change the Channel Display
Use the PREV CHANNEL or NEXT CHANNEL buttons to move to the previous or next channel display. For
single channel systems, only the existing channel status will show .
8.4.3.6 Change the Bank Display
Use the PREV BANK or NEXT BANK buttons to move to the previous or next UV Bank display .
8.4.3.7 Select Bank or Module Control
The screen will show different controls for UV Banks and modules
Bank Control
Table 4 shows the control options available in Bank Control mode .
Table 4 Bank Controls
Button Function
e> Changes the mode of operation to Remote Auto if the selected UV Bank is in the Remote mode .
(Q) Changes the mode of operation to Remote Off if the selected UV Bank is in the Remote mode .
Changes the mode of operation to Remote Hand if the selected UV Bank is in the Remote mode. When ® Remote Hand mode is selected, the manual power entry box shows next to the Hand mode selector. Use
the power entry box to adjust the power level. A UV Bank in Remote Hand mode must complete the
warm-up time before it will go to an entered power level other than 100% .
If the System is in SCADA Control mode, the SCADA Permissive run Indicator will be visible on the Bank
Overview beside the Auto PB. The Indicator will display the Enabled or Disabled Status of the SCADA
Permissive Run Signal.
Original Instructions 59
Basic Operation
Module Control
Table 5 shows the control options available in Module Control mode.
Table 5 Module Controls
Button Function
Changes the selected module for to the previous or next module in the UV Bank.
® Enables the selected module to operate as requested by the UV Bank. Holding this button will cause all
modules in the UV Bank to become enabled. This button is only available in Remote mode.
Disables the selected module so that it will remain off regardless of the operational status of the UV Bank.
This button is only available in Remote mode.
Initiates a reset function on the currently selected module. This function will cause the module to power
down and initiate a warm-up cycle. This may be used to try to restart UV lamps or lamp drivers on a module
that have extinguished, without the need to power cycle the entire UV Bank. This button is only available in
Remote mode.
8.4.3.8 Reset Buttons
When a failure condition exists, a RESET button shows beside the indic ator for the number of failed
components. Table 6 shows the faults and failures that can be reset from the Bank Overview screen. A
UV lamp or lamp driver that is off is shown in black, operating is light blue and failed is shown as red.
Table 6 Failure and Fault Resets
Failure or fault Corrective action
Shows next to the number of UV lamps that are out. Failed UV lamps stay latched in a
Failed UV lamp reset failed state until RESET is pushed. RESET will disappear if the UV Bank is off or if all
UV lamps in the UV Bank are currently on.
Shows next to the number of lamp drivers that are out. Failed lamp drivers stay
Failed lamp driver reset latched in a failed state until RESET is pushed. RESET will disappear if the UV Bank is
off or if all UV lamps in the UV Bank are currently on.
A multiple UV lamp fault condition occurs when the number of UV lamps that have
failed is equal to or greater than a configured value in the System Settings screens.
Multiple UV lamp fault reset When in Remote Auto, a UV Bank with a multiple UV lamp fault will be timed off and
another UV Bank run if one is av ailable. If there are not enough UV Banks available
for disinfection, a UV Bank with a multiple UV lamp fault will be run at full power. Push
RESET to clear this condition.
A multiple lamp driver fault condition occurs when the number of UV lamps that have
failed is equal to or greater than a configured value in the System Settings screens.
Multiple lamp driver fault reset When in Remote Auto, a UV Bank with a multiple lamp driver fault will be timed off
and another UV Bank run if one is available. If there are not enough UV Banks
available for disinfection, a UV Bank with a multiple lamp driver fault will be run at full
power. Push RESET to clear this condition.
When two faulted UV lamps which are adjacent in a module, either beside, above or
Adjacent UV lamp fault reset diagonal to each other, the UV Bank will shut down on a major alarm. Failed UV
lamps stay latched in a failed state until RESET is pushed. RESET will disappear if the
UV Bank is off or if all UV lamps in the UV Bank are currently on.
When the UVI level drops below the low-low UVI setting, the default UVI value will be
Low-low UVI alarm reset used instead. Push RESET to clear this condition. RESET will only disappear if the UVI
returns to a value above the low-low UVI setpoint or if the UV Bank is off.
Shows when any of the UV modules in the UV Bank fails to communicate. Module
Module Communication Fault Reset communication fault status stay latched in a faulted state until RESET is pushed.
RESET will disappear when it is pushed and no module fails to communicate.
60 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
In-Op
Power% lM ll
�A�
Cycles�
lamp HoursQO
BankHoursQQ
lamp Out�
Doll-Out�
?QC Help Ch•nnels Binks
BANK OVERVIEW 26AJ112007113913.4.M
USffi OEM ·­-
Conlrol
12345678 00000000
"
Wipers Settings
� (A @
Security Trends Alarms �rwew
Figure 21 Bank Overview Screen
Basic Operation
8.4.4 Channel Overview Screen
Q The Channel Overview screen shows information about the selected UV channel and allows
control of channel functions. For a single channel system, this screen is display only and
summarizes the channels health status, lead priority, total system flow and flow through the
channel.
A RESET button will show if a Not Enough Healthy Channels alarm condition is present. To clear the alarm,
push RESET .
Important Note: Use caution when using gate alarm reset push-buttons. Gates may begin to move
immediately when the button is pushed and can cause physical damage to equipment if the cause of the
fault is not corrected first. Be sure that all personnel are clear of gates and gate control motors and gearing
before pushing these buttons .
8.4.4.1 Change the Channel Display
Use the PREV CHANNEL or NEXT CHANNEL buttons to move to the previous or next channel display. For
single channel systems, only the existing channel status will show .
8.4.4.2 Change the Gate Status
Use the GATE IS OPEN or GATE IS CLOSED buttons to set the status of the inlet slide gate for the selected
channel.
8.4.4.3 Open or Close the Slide Gate
Use Table 7 CLOSE SLIDE GATE or OPEN SLIDE GATE buttons to manually open or close the slide gate .
8.4.4.4 Inlet Gate Modes
Table 7 describes each mode. Push the AUTO or HAND button to select the mode .
Table 7 Inlet Gate Modes
Mode Description
Auto In Auto mode, the Dose Pacing routine will determine when to open and close
the slide gate. The slide gate must be in Remote mode to use Auto mode.
In Hand mode, use the manual command push buttons to determine when to
Hand open and close the slide gate. The slide gate must be in Remote mode to use
Hand mode .
Original Instructions 61
Basic Operation
TROJANUV"@
Health Status Healthy
PrtOrity
Dose
1Slla,g
:18.94
St11u•: No Command
CHANNEL OVERVIEW
lewel
Current 29.S
SetpOint-In
Channel
System
29101/20201!2U.P!.I
USER OU!
Flow
19.95 MGO 26.28
At Minimum Posit-,
(C E$ � IA Set1:n19s Info LogOu1 Trends Alarms
Figure 22 Channel Overview Screen
8.4.5 Trend Overview Screen
The Trend screen shows trend lines of data logged to an installed user interface compact flash
:..J card. Each line in the trending window represents the variables that are tracked, and shows the
7 current value for each at the right hand side of the screen. Each line is color-coded.
8.5 Level/Weir Monitoring
8.5.1 Channel Level
An analog level signal may be monitored for each channel. Alternately two analog level signals may be
monitored if the application is configured as a single Channel. The UV system will monitor one (or two)
4-20mA analog level signal(s) for each channel which can be calibrated to display a level in engineering
units selectable as inches or centimeters. Each level sensor configured may also monitor a sensor fail
discrete contact which will generate an alarm that is passed to the customer SCADA interface.
8.5.2 Level Device Monitoring
For all channel configurations, a channel level control modulating position or Valve position may also be
monitored. The UV system will monitor one 4-20mA analog channel level control modulating position or
valve position signal per channel which can be calibrated to display a position in engineering units
selectable as inches or centimeters. The Control Device position logic may also monitor a Control Device
fail discrete contact which will generate an alarm that is passed to the customer SCADA interface.
8.5.3 Level Monitoring & Level Device Monitoring Fault Conditions
Table 8 summarizes all of the available level/control device alarms. These alarms will be displayed based
on the Level control and Level monitoring options selected.
Table 8 Level/Control Device Alarms
Alarm Description Alarm Delay
Channel X Level Sensor Signal Channel analog level sensor is failed Minor Fault
Channel X Level Sensor Channel control device failed Minor Discrete Fault
Channel X Low Level Warning Channel Level is less than low level warning Set point 1 minute
Channel X High Level Warning Channel level is greater than high level warning Set point 1 minute
62 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ·•• • • • • •
• • • • • e • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Basic Operation
Table 8 Level/Control Device Alarms (continued)
Alarm Description
Influent Low Level Warning Channel 1 Influent Level is less than Influent Low Level Warning Set point
Influent High Level Warning Channel 1 Influent Level is greater than Influent High Level Warning Set point
Effluent Low Level Warning Channel 1 Effluent Level ,s less than Effluent Low Level Warning Set point
Effluent High Level Warning Channel 1 Effluent Level is greater than Effluent High Level Warning Set point
8.5.4 Level/Control Device HMI Interface
8.5.4.1 Operator Interface for Level/Control Device Monitoring
Alarm
Delay
1 minute
1 minute
1 minute
1 minute
•The operator interface will display the calibrated channel level/ Influent Level and Control Device
(WeirNalve) position/ Effluent Level in the engineering units selected, on the System Overview
screen
•These values will be indicated with red background if any low/high level warning occurs or 10
communication fails
Original Instructions 63
Basic Operation
8.5.4.2 Plant Interface Level/Control Device Configuration
The options and settings used for selecting Level/Control Device configuration will be available in a
selection of Protected Settings screens that are accessed with a password used by plant maintenance
personnel. The following items will be available on these screens:
•Device and Level Monitoring Enable/Disable selection
•Device and Level Monitoring 4mA scaled input
•Device and Level Monitoring 20mA scaled input
•Level Monitoring Low Level Warning Setpoint
•Level Monitoring High Level Warning Setpoint
•Control Device and Level Monitoring units
64 Originallnstructions
• • • • • • • • -• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
• • •• • • • • •• • • • •• • •• • • • • • • • • • • • • • • • • • •• • •• • • ••
Section 9 Advanced Operation
A DANGER
Obey all warning and caution statements. Refer to Section 2 .
Read and understand this Operation and Maintenance Manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment.
Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance .
9.1 Login
Use this screen to log into settings that have restricted access .
User Access Password
Default No password required
OP1 (plant maintenance) Password provided to trained personnel only
9.2 System Information
CD
The System Information screen shows information about the controller hardware and software. It is also
used to access the user interface clock setting and other internal maintenance functions .
To access the System Information settings, push the SECURITY button and the LOGIN button. Enter the
plant maintenance user name and password (Section 9.1 ) .
9.2.1 Set the System Clock
1.Set Time & Date button, enter the hour, minute or seconds .
2.Use the numeric keypad to enter the hour, minute or seconds .
Original Instructions 65
Advanced Operation
9.2.2 Set the User Interface Language
1.System Information Screen -Select language (Figure 23). A restart may be required to show the new
language selection.
1ll02n020S 1128 AN
USE� OP\ ,-----,-�=,........,--=------:--...-,!!I�� PL-C•nd Hf.II
-Firmware-­
PLC Revision: 32.11 I
®Q 0 Help Channel• Banks
Trojen Technolog.e5 www.TrojanUV.com
roject Number-
710000
ge{kBll Used 957
Free 2189
Total 3146
11 ►
®CDS�� Serungs Info Log Out Trench Alarms Overv,ew
Figure 23 System Information Screen -PLC and HMI Tab
9.2.3 Reset UV Lamp Life Hours
The running time of UV Bank UV lamps is maintained through counters for each UV Bank. When UV
lamps have been replaced, the UV lamp counter can be reset.
1.Push the SECURITY button and the LOGIN button. Enter the plant maintenance user name and
password.
2.In the Bank Overview screen, select Lamp Hours (Figure 24).
3.Select the box for the new Lamp Hours value and enter 0.
4.Confirm the new Lamp Hour value, then CLOSE.
9.2.4 Reset UV Lamp Cycles
66
When UV lamps have been replaced, the cycle counter can be reset.
1.Push the SECURITY button and the LOGIN button. Enter the plant maintenance user name and
password.
2.In the Bank Overview screen, select Cycles (Figure 24).
3.Select the box for the new Cycles value and enter 0.
4.Confirm the new Cycles value, then CLOSE.
Original Instructions
e1 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ,. • • • • • • -
Advanced Operation
TROJANuv·@ BANK OVERVIEW
Mode
-Chi�
BkA�
Status
Power% 1M II
CQ �
aAIB(J ENTER PUSH TO
VM..W: NEW VALUE ACCEPT
Cycles QQ CC] IIIIDII
Lamp Hours� � IIIIDII
BankHou,s� 0 IIIIDII
LampoutCCJ
e.11-ou1CQ
25.01f2007 40152PM
USffi' OEM
View Module
Controt
® a; e g r. Settings Jnfo Security Trends Alarms Overvtew
Figure 24 Reset UV Lamp Hours
9.3 System Settings
The configuration settings for the UV system are accessed, reviewed or changed through the system
settings screens. To change system settings the user must be logged in with a sufficient security level. All
settings are organized by system function. Use the tabs at the top of each setting screen to navigate to the
Bank, Wiper, Flow, UVT, UVI, Dose, General and Channel screens. Online help is available for each of the
plant maintenance settings that can be accessed .
To change a value in any screen, push the numeric entry box, enter the value, then push ENTER to
confirm. Use the pop-up numeric touch pad to enter the value .
9.3.1 Change System Settings
1.Login with OP1 level access.(Sect1on 9.1)
9.3.2 Bank Settings
Table 9 describes each setting. Figure 25 shows the available settings with the Help screen descriptions .
Table 9 Bank settings
Setting Description
Set the value for the number of UV lamps that must fail in a UV Bank before it is
MULTIPLE UV LAMP FAILURE SP considered to have a major alarm condition and will trigger the Multiple UV lamp
Failure alarm. Banks with this condition will be timed off and another UV Bank will
be operated if there is an available healthy UV Bank .
MULTIPLE LAMP DRIVER FAILURE Set the value for the number of lamp driver failures in a UV Bank to signal a
SP Multiple Lamp Driver Failure alarm.
Set the value for the minimum number of UV Banks in a channel that will always
MINIMUM BANKS ON/CHANNEL be requested to run by the dose pacing routine, regardless of current process
conditions. If this value is set to 0, then all UV Banks in a channel may be shut off
if there is a Low Flow alarm condition.
Default value="ENABLED"
AUTOM ATIC BANK ROTATION Set the rotation condition for the lead UV Bank when the UV lamp life of the
current lead UV Bank reaches the End of UV lamp Life hours set point.
Original Instructions 67
Advanced Operation
Table 9 Bank settings
Setting Description
Default value="YES"
ROTATE LAST BANK IN CHANNEL Set the rotation condition for the last lag UV Bank in each channel when an
automatic rotation occurs. Permanently assigns a specific UV Bank to a lag or
standby position.
ADJACENT UV LAMP FAULT Default value="DISABLED"
DETECTION Set the fault detection condition for two or more adjacent UV lamps
SYSTEM SETTINGS
�,ou,-Lm 8.Jn� In Ch.>n1t1:I Yes:
Figure 25 Bank Settings
9.3.3 Wiper Settings
Table 10 describes each setting. Figure 26 show the available settings with the Help screen descriptions.
Setting
WIPER SEQUENCE CYCLE TIME
FLOW LIMIT FOR WIPING
Table 10 Wiper Settings
Description
Default value="24 hours"
Set the frequency for wiper cycles
Set the minimum channel flow condition to disable the wiper cycle
SETTINGS
Flow llnilr lot Wiping 9S �
Figure 26 Wiper Settings
Original Instructions
Advanced Operation
9.3.4 Flow Settings
Table 11 describes each setting. Figure 27 shows the available settings with the Help screen descriptions .
Table 11 Flow Settings
Setting Description
Determines the frequency at which the total flow on the flowmeter analog input is
FLOW SIG NAL SAMPLE RATE measured. This value should be increased if there is a noisy or erratic plant flow
signal that cannot be dampened by using the flow signal filter factor.
Portion of new flow signal averaged with old flow signal. For example, an entered
FLOW SIGNAL FILTER FACTOR value of 0.5 represents 50% of the current flow averaged with 50% of the stored
flow. To dampen a noisy plant flow signal, reduce this value in 0.1 increments.
LOW FLOW ALARM SET POINT Set the level to initiate a low flow alarm timer .
LOW FLOW ALARM DELAY Setpoint for the low flow alarm timer.
FLOW METER FULL SC ALE Full scale calibration value to measure the flow through the UV system
DEFAULT FLOW VALUE The flow value that is used for dose pacing if there is a flowmeter signal fault, or if
the source of signal input for flow is set to manual.
FLOW FACTOR SAFETY Measured Channel Flow Va lue (from Flow Source) x Flow Factor Safety
ADJUSTMENT Adjustment= The value used in the dose pacing calculation .
SYSTEM SETTINGS 09.'C!r.2-020 2 53 18 Pf.I
USf.R USSHSUU'l-5
9.3.5 UVT Settings
Flow Signal .Sample Rate ## s
Flow Signal Filter Factor #.#I
OOSf
-freQUency of Uff¥llnll of the analog flow signal (rtCfHU tnis val.la if 1M .IJonal II very noby)
-Prop,orlioncfnew flow S!QMl!l\11111,.era9&d wlttllhe old now sional (<lecrea� tnis va'-te 11 nOISV now}
Low Flow Alarm Setpoint ##ffl.1# m•Jday �w.:,-:bet:w WliCtl a Low flow4"'!llcono(D) wl
-rmeoeiay fora Low Flow alsrfflCDfldlJ:ln
Default Flow Value ##11#.## m'/day WIien tlo'N signal III kl� Al&o 111e now vabe
Flow Fector Safety Adjustment #.##
Figure 27 Flow Settings
Table 12 describes each setting. Figure 28 shows the available settings with the Help screen descriptions .
Table 12 UVT Settings
Setting Description
UVT SIGNAL SAMPLE RATE1 Sampling frequency of the analog signal. Increase the value if the signal is noisy
or erratic, or cannot be dampened by using the UVT Signal Filter Factor .
Portion of new UVT signal averaged with old UVT signal. For example, an entered
UVT SIGNAL FILTER FA CTOR value of 0.5 represents 50% of the current UVT averaged with 50% of the stored
UVT. To dampen a noisy plant UVT signal, reduce this value in 0.1 increments .
UVT LOW ALARM SET POINT Set the low UVT alarm timer level
UVT ALARM DELAY Set the low UVT alarm time delay
DEFAULT UVT VA LUE Full scale calibration value for the UVT signal used for dose pacing if there is a
UVT signal fault, or if the source of signal input for UVT is set to manual.
Setting is only available on systems which use an Online UVT system .
Original Instructions
Advanced Operation
9.3.6 UVI Settings
WT ShJn>I S.mpi.11.,,.
lM S;g,,./Fllr>rFa<lw
wr Low AL>rm Sell'Olnr
O.t>uh wr 65 •.
• frtqutr.cy of urnpl1ng of1hf -,ull)a uvr i.gnal fncrease thrs value 1f the 119nal 11 V'fry n<lniy)
• Proponion oil.he new vvr 1tgna1 lhat 1s �•aged
with l� ofd UYT ,ignal (decrun 1htJ vah.1t I no,1,y)
• 1M" vatue btlow wtwch a LoYri' LM 1l-1m tondi10n
...beg,nl"""'9
. I.WT ..-arut �-....Ch a Low low I.NT llarm condd.on 'flrllll � hm,ng
• imt dtio11y b • low LOilll UVT ai.,m cond1hon
• llvT 'fHHI ustd 'When the WT itgnil 1$ 1011 Also
ustd when !ht Low Low vYT iilarm 1s: Plt-itnl
Figure 28 UVT Settings
Table 13 describes each setting. Figure 29 shows the available settings with the Help screen descriptions.
Setting
70
Description
SYSTEM SETTINGS
lM
USfR OP1
UVI Low Alarm Setpoirit $0 "1. -Perce-nt crme.npea.eo .,.._.e h>r ll'IU$Ured W 1n1enuy bebw whet, a bw or bw.Cw W htensty liltm wl beOf'I
Measured UVI Display Units mW/cm
Cl\lroM-11 6ank'I W1pen semngs. Info Log0u1
Figure 29 UVI Settings
Advanced Operation
9.3. 7 Dose Settings
Table 14 describes each setting. Figure 30 shows the available settings with the Help screen descriptions .
Setting Description
UV LOW DOSE ALARM DELAY SP Determines the time delay for the UV Low Dose Alarm. The Value is in Seconds
Determines the percentage set point below which a Low Low UV Dose alarm will
LOW LOW UV DOSE ALARM OFFSE T be generated. The Currently Calculated Dose Value is compared against the
(ONLY NWRI SYSTEMS)
DOSE SAFETY FACTOR
DESIGN DOSE SETPOINT
DAMPEN TIMER PR ESET
BANK TIME OFF DELAY
9.3.8 General Settings
Setting
MINOR ALARM DELAY
MAJOR ALARM DELAY
CRIT ICAL ALARM DELAY
WINTERIZATION MODE
Configured Design Dose Set point to calculate a percentage value which is
compared against the alarm set point (Only NWRI Systems)
Determines the set point for the UV Dose Safety Factor. The Dose Safety Factor
is multiplied by the Design Dose Set point and the resulting value is used as the
target Dose for the System. The UV System will still use the Design Dose Set
point for alarm operations.
Determines the set point for UV dose control of the dose pacing routine. The dose
pacing routine will modulate UV Bank power level and bring UV Banks and
channel in and out of operation as required to maintain the dose a value just
above this set point.
Minimizes UV Bank power cycling. Determines the amount of time that the dose
pacing routine must call for a UV Bank power level to be reduced before a lower
power level will be used .
Minimizes UV Bank on/off cycling. Determines the amount of time that the dose
pacing routine must call for a UV Bank to turn off before it will de-energize. While
this timer is running, a UV Bank will typically be operated at minimum power .
SYSTEM SETTINGS I0/02/2020•09�PW
SANK WIPER. FLOW UVT 005£ GBERAL CHANNEL ..
UV Low Dose Alarm Oel;i 70 5
Dose Safiey Factor 1.25
• Low \JV Dose All!lrm C>t1ay SP Uld l.Dw Low .fJl!lm SP !NWR L1odeOnly)
• Oe119n Dose Softey factt.ir SP
Design Dose Se{pOinl 30.0 mW·s/cm . Taroei des� that wl be uno f« IIIJIOIMIIC dos.! paong
Dampen Timer Preset 2 min
Bank Time Off Delay 20 min
• CIUF\l\ell Sanl!s Wiper• Settings
. me �lsy oefore a �anl wl be alowe-o to bwer b te'QtJeSledoowerltve{
• nne oerey t>etw-e a ban., that IS no I0/10� reour-eo tor dQSI!! poct1g wlahUI off
Info
Figure 30 Dose Settings
Description
Time delay for minor alarms
Time delay for major alarms
Time delay for critical alarms
Enables or disables winterization mode. In the Enable mode, all alarm outputs are
disabled and all SCADA output is cleared. This option is used to mask nuisance
alarms during seasonal equipment shutdown periods .
71
Advanced Operation
Table 15 General Settings
Setting Description
Enables or disables password security. When enabled, the operator must log in to
be able to change any system modes or enter any values on the user interface.
OPERATOR CONTROL SECURITY After ½ hour of inactivity, the currently entered user name and password is cleared
and must be reentered to continue operating the system. This option is used to
prevent unauthorized changes to system operating parameters.
COMM FAILURE MODE During a comm failure, the UV Banks will either "Remain On" or "Turn On"
POWER FAILURE MODE During a power failure, the UV Banks will either "Remain On" or "Turn On"
SYSTEM SETTINGS -,..,,
9.3.9 Channel Settings
Mh,otAl.atmO.J.Jy l min
C1itJ.ul Abtnt 0.L,y 1" s
Wln,.rlz.,tion Mode OIJ.Jbfed
Op,tratot Conuol S.c.uthy Dis:Jbl•d
Comm F�lh,,. Modt R•�=fn
Po.'tt F:1lll,,. Mode Re�";:'"
• Twnt1 that fflUi.t uput btfort alarms art tmergtztd
Ddertnl �.,m, ,,. in d•rent calegonH
• En,b&wdts� b fHture 1hat dtsabaes .all alum
OtApolS and C't¥1 all SCA0A Odput �""�'°"
• EnMH/dtubtt b ft.a111tt lhii requ11H a uu, to
'°9-tn In onkr 10 �kt �y c.ontrol Chl09fl
(UHmam. ,.. 'OP' J)HfWrilOld c 1 l 111)
-Ow,ng .. comm !Mutt Of po,rtt fttluft tht banks Wit titter f'ffl'IH'l CM'\ or 1um on �ng on stu
Stitcl,on
Figure 31 General Settings
Table 16 describes each setting. Figure 32 shows the available settings with the Help screen descriptions.
Table 16 Channel Settings
Setting Description
The peak flow (in engineering units) that will trigger a peak flow alarm. This value
is also used to allow uneven flow splitting on multi-channel systems. The peak
PEAK FLOW flow value is set to the same value for each channel and the flow through each
open channel is assumed to be the total flow divided by the number of open
channels. These values may be set differently for uneven flow splitting.
The maximum time required for the inlet slide gate to complete its travel from a
INLET GATE TRAVEL TIME fully open or closed position. This set point is used to determine how long to wait
when a gate is commanded to move before checking for alarm conditions.
Time allowed for an empty channel to fill to the level switch before a Channel Low
CHANNEL FILL DELAY Level alarm is triggered. Channels that operate in the low level alarm condition are
not considered "healthy" and will not be available to the dose pacing routine.
MIN. NUMBER OF CHANNELS ON Number of channels that must always be open. Muse be equal to or greater than
one.
CHANNEL CLOSING DELAY Time delay before a channel that is no longer required is closed and taken out of
operation.
Time delay before the UV Banks in a closed channel will shut down. This allows
CHANNEL TIME OFF DELAY disinfection to continue in a channel that has been taken out of operation, until all
effluent has had a chance to drain past the UV Banks.
Maximum flow value before the next channel is requested. This value should be
CHANNEL FLOW LIMIT set to the minimum flow that a channel is able to disinfect at the lowest UVT value
that a plant will experience. The value is typically set to the plant design peak flow
divided by the total number of configured channels.
72 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
CHANNEL PEAK FLOW
Advanced Operation
The flow value that is used to determine the Hydraulic Maximum Exceeded Alarm
Ch;,ntH!I FIii O.� T20 s
SYSTE'M SE'IT/NGS
• Timt llowe-d for an f!mpty ChlMl!l 10 fiU onct the c.h.t.nnel tt runrung Low wattt tt¥e1 alarm delay
-NurT'INI' ot ch-isnne� 1h11 � a:Nl'iyt bl 1·1que1t8'd to bt oPfh
• Til'nt! d"lay befof!' a chamel will clos.t �pon not be-mg reqwed
• M111mvm low�lu• btfott nt•1 chtnne1 ,, requti1t:d
Figure 32 Channel Settings
Advanced Operation
Original Instructions
•••••••••••••••••••••••••••••••••••••••••• • •
Section 10 Maintenance
A DANGER
Obey all warning and caution statements. Refer to Section 2 .
Read and understand this Operation and Maintenance Manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment.
Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance .
10.1 Tools and Materials
Symbols Description Symbols Description r Allen Wrench ...... ActiClean ™ Gel (or approved cleaning
solution as per Table 20)
'--
IIJllllU �1 Dow Corning Lubricant 111® -�lsopropyl Alcohol """""' ·-
; � Lint free cloth (i.e. Kimwipes®) �, G Mild Soap and Water I/ 1 '
®
Sand Paper /}' Slot Screwdriver
; Socket Wrench j6 Spray Bottle
g ,_
Water ,, "Wire Side Cutter
-
� / 0) O-ring Open wrench
@ .. ,w
A Phillips Screwdriver � Nut Driver
07 -y� Drip Tray Funnel \
8 Shallow bowl tJ Bucket
Original Instructions 75
Maintenance
Symbols Description Symbols Description B Hydraulic Fluid
�
Pump Assembly
& J;;;;l. �
Loctite 222 Threadlocker -l Anti-seize C,
0 Pliers ' Torque Wrench ,,
�"
10.2 Torque Chart
Bolt Size Torque (N-m)
M4 1A
MS 2,6
M6 5,6
M8 11 ,3
M10 22
M12 50
M14 72
M16 108
M18 156
M20 217
M22 292
M24 362
M30 610
10.3 Preventive Maintenance Schedules
Table 17 shows required periodic maintenance,
Table 17 Required Preventive Maintenance Schedule
System Maintenance Requirement
Component iii > 0 >, >, :c Cl) :ii: Ck: 2!:;o -
Cl) C: C: C'II Cl) 0 0 0 � :ii:
Visual walk-about inspection (Table 18) X
UV system Clean the UV channel around the UV system,
Perform semi-annually for poor water quality
conditions,
76
Torque
12(in-lbs)
23(in-lbs)
50(in-lbs)
1 00(in-lbs)
195(in-lbs)
37(ft-lbs)
53(ft-lbs)
80(ft-lbs)
11 5(ft-lbs)
160(ft-lbs)
21 S(ft-lbs)
267(ft-lbs)
450(ft-lbs)
VI � .J:: VI C: C'II ... ...
0 ::J ::J C'II
Cl) :ii: C: 2!:;o 0 C: .J:: N N 1 � C'II 0 � ·e ::J 0
Cl) C: 0 Cl) > Cl) C: N-> w Cl) � ... w
X
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • -
Maintenance
Table 17 Required Preventive Maintenance Schedule (continued)
Maintenance Requirement 1/1 .?:-System .s:. I!! .... iii Component iii C: ..0 :s :s > 0 :E C: .?:-0 >, >, N C: .s:. N >, :E <F iii Q) :ii: � 0 � 0:: .?:-... ·e :s 0 Q) C: Q) C: 0 Q) C: "iii � 0 > Q) C: c-i > 0 C :E w Cl) c( .... w
Inspect HSC and Hydraulic System Components X (Section 10.5.2) .
Initiate wipe sequence and check the HSC pressure X Is within range (180-200 psi) (Section 10.5.3)
Check the hydraulic fluid level (Section 10 5 4) X Hydraulic System Replace the filter (Section 10 5 3) X Center
Inspect the hydraulic hoses for wear. Replace hoses
if bulges, splits, cracks or nicks are apparent. X X Perform when recharging the ActiClean TM Gel
(Section 10 5 5)
Replace hydraulic fluid (Section 10.5.3) X
Check Level Sensor for debris, algae or damage. Clean the sensor rods as needed with a wire brush .
Level Sensor(s) Replace if worn. X
Perform once every two weeks for poor water quality conditions .
Inspect for debris and remove as needed .
Perform once every two weeks for poor water X Water Level quality conditions . Control Inspect grouting/seals and repair/replace if any X signs of cracking or damage
Inspect and if required remove debris from module . Use low pressure washer (e.g. a garden hose). X X Perform once every two months for poor water
quality conditions .
UV Module Remove the module. Replace UV lamps and lamp X sleeve O-ring seals (Section 10.4 ) .
Check the module power cable strain relief for X tightness .
Replace end cap seal (Section 10 4 6 2). X
Remove module debris and fill the wiper collars with X X ActiClean ™ Gel (Section 10.6.1)
Apply grease to the wiper cylinder-done at same X time as filling theActiClean ™ Gel (Section 10.7.1 2)
ActiClean ™ Flush and clean entire cleaning system and replace Cleaning System ActiClean TM Gel (perform at the same time as
replacing UV lamps at EOLL) or every 18 months. X (Section 10 6. 1)
Perform annually for poor water quality conditions .
Replace Wiper Seals (Section 1 0 6.2.1) X
Table 18 Daily Visual Walk-about Inspection Checklist
System component Inspection activity
sec Check Alarm Status screen for new faults and record new alarms sec Check the Alarm History screen to get an overview of past faults
sec Check the Overview screen(s) on the user interface to make sure that all the UV Banks are in REMOTE AUTO and that all Modules are enabled
ActiClean TM Cleaning Check the Wiper Control screen(s) on the user interface to make sure that all the wiper groups System are in REMOTE AUTO and that all wiper groups are enabled.
Original Instructions 77
Maintenance
Table 18 Daily Visual Walk-about Inspection Checklist
System component Inspection activity
Level sensor Visually inspect water level sensor for debris build up. Clean as needed.
Hydraulic System Center Visually inspect Manifold and HSC for Hydraulic fluid leaks.
10.4 UV Modules
The Lamp Driver enclosure is tested and certified to UL50 performance requirements to provide a degree of protection
against hose-directed water, the entry of water during temporary submersion at a limited depth and damage from external ice
formation. Because the rating is dependent upon how the system is handled, operated and maintained, the manufacturer
only guarantees the rating for one year from system commissioning. If the enclosure is stored, handled, operated and
maintained according to the instructions in this user manual, environmental protection may last for the life of the product.
When a module is removed from the UV channel for maintenance, perform the inspection actions listed in
Table 19.
Table 19 Recom mended UV Module Inspection
Component Action
Check to make sure that there is no visual fouling or hazing on the exterior of the lamp sleeve.
If any signs of fouling are present, make sure the ActiClean ™ Gel in the wiper collars is full.
Manually clean sleeves as required.
Lamp sleeves Make sure that the lamp sleeve nuts are hand tight to prevent moisture leaks into the lamp
sleeve.
Over-tightening may damage the seal and allow moisture to enter the lamp sleeve.
Visually inspect the lamp sleeves for internal moisture. If more than a few pin-head type
droplets are present, clean and dry the affected lamp sleeves and UV lamps.
Support Rack Inspect the module support rack spacer clips for broken clips. Replace clips as needed.
Hydraulics Inspect hydraulic hoses for cracks, leaks, etc. Replace hoses as needed.
Check to make sure that there are no bent pins. If any pins are bent, immediately remove the
module from service and replace the Module Power Cable.
Check pins for corrosion (observed as a white discoloration or patina on the surface of the
Module Power Cable pin). Manually cleaned using a soft metal wire brush, such as brass, or emery cloth with a 90
or finer grade. Ensure all debris is removed. Once the pins are clean, Trojan recommends
applying a corrosion preventative compound to prevent future occurrences of corrosion.
'Corrosion Zero' is known to be compatible with all components of the power cord connector
and is approved by Trojan for this purpose.
10.4.1 Right-Left Module Configuration
78
Each UV Bank of modules consists of two types of module configurations. Figure 33 and Figure 34 show
the module configurations:
•Left module
•Right module
Modules alternate left then right in the UV Bank, with the first module (1) always being left.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • -
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
One module per UV Bank will have the UV sensor. This module must be located in the middle of the UV
Bank, close to the center of the UV channel. When there are two or three modules per UV Bank, the
sensor module will be adjacent to the UV channel wall. All UV sensor modules are left modules . I
Figure 33 UV Module Right-Left Configuration
1 Left module 4 Power cord
2 Right module 5 Hydraulic lines (black)1
3 Hydraulic lines (blue)1
1 Systems with ActiClean TM Cleaning System only
I
0--I
3
2
1 .. I
Figure 34 UV Module Installation-Top View
1 Left module 3 Module number order
2 Right module 4 PDC
10.4.2 Remove the UV Module from the UV Channel
Prerequisites: £6
•Shutdown the system. Refer to Section 7.2 .
•Lockout tag out the system components. Refer to Section 4 .
Tools:
�
Original Instructions
I
-0 I
79
Maintenance
1
2
80
Materials:
Procedure: ��filffi8
1.Determine the UV Bank and module number that needs service from the labels on PDC.
2.Bank Overview Screen (Figure 21)-+ disable the module to be serviced (Table 4).
3.At the HSC, set the applicable wiper mode selector switch -+ OFF position.
4.Depressurize the Hydraulic System (Section 10.5.1 ).
5.Loosen and unplug the power cord attached to the module at the PDC. Loosen and unplug the UVI
power cord at the PDC (Figure 35).
6.Disconnect Hydraulic Hoses, install protective covers, clean up spills.
7.Carefully lift the module from the UV channel. Put the module on a clean, dry work surface or a
maintenance rack.
8. Remove debris from the module with low pressure potable water, such as a garden hose.
Figure 35 UV Module Power and Sensor Connections
UV sensor connector 3 Module power cable
Power cord connec tor 4 UV sensor cable
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
Figure 36 UV Module Hydraulic Connections
1 Hydraulic couplers 3 Protective cap
2 Hydraulics manifold
10.4.3 Install the UV Module in the UV Channel
Prerequisites: £6
•Shutdown the system. Refer to Section 7.2 .
•Lockout tag out the system components. Refer to Section 4 .
Materials:
Procedure:
1.Put the module into the UV channel. Make sure to maintain the alternate right-left configuration
(Section 10.4.1 ). Make sure that hydraulic hoses are not pinched under aluminum enclosure .
2.Connect the module coupler to the PDC manifold. Align the locking ball on female coupler .
3.Attach the module power cord. Attach the UV sensor power cord (labeled UVI) into the PDC
(Figure 35) .
4.Set the HSC wiper mode selector switch to REM (Remote) .
5.Enable the module at the sec .
Original Instructions 81
Maintenance
10.4.4 Replace Module Rack Spacer Clips
Prerequisites:
•Remove the UV module. Refer to Section 10.4.2.
Tools: GD
Materials: (860e =i
Procedure:
Remove: Install:
Note: Turn the screw until it is flush with the top surface of the clip.
82 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
10.4.5 UV Sensor
10.4.5.1 Remove and Install UV Sensor
Prerequisites:
•Remove the UV module. Refer to Section 10.4.2 .
Tools: ® I
Materials: oc,o
•Dielectric grease
•New sensor sleeve O-ring
•New sensor sleeve washer
Procedure:
Remove:
I1 r
A ,1:--��
Note: DO NOT completely remove the retaining screw.
Original Instructions
Note: Swing the sensor assembly out a little .
Maintenance
83
Maintenance
©
Note: Hold the Sensor and Sleeve by the sleeve cup nut. Pull
straight back. Some resistance will be felt.
84
7.Inspect the UV Sensor (Section 10.4.5.2).
f
Note: Thread the sensor cable connector from the sensor and set
aside both the sensor cable connector and sensor mount.
Note: Remove the sensor from the sensor sleeve.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • Install: • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ·•• • • • • • •
1.·�.. ,-,. --,J -• oi))� 1-::J�-
\��
Note: Replace
i!.JT © _\_
and O-ring. sensor sleeve washer
( c-= , -
A �.... .. ,�iii---� -C
' -�I /J 'ill l I
B
h. layer of dielectric grease . Note: Apply a t m
Original Instructions
Maintenance
I
. L� -=-1.!3 =-I � .�\BL �--,·:i--
'. --
I l' L �E
=·-� m1:[ 1(
85
Maintenance
10.4.5.2 Inspect the UV Sensor
Prerequisites:
86
•Remove the UV sensor. Refer to Section 10.4.5.1.
Materials:
Procedure:
1.Make sure all parts are clean, dry and undamaged.
•Body O-ring
•Rubber washer
•Sensor Sleeve Washer
•Inner sensor sleeve-Clean, if necessary, with a lint-free cloth (Kimwipes®) and lsopropyl
alcohol only.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
10.4.6 Lamp Driver
10.4.6.1 Remove the Lamp Driver Tray
Prerequisites:
•Remove the UV module. Refer to Section 104.2 .
Tools: �©·77
Materials:
Procedure:
-�
-�
�-
Note: Brush or wipe away any large debris from the end cap using a
soft bristled brush or rag .
Original Instructions
Maintenance
87
Maintenance
�' A-
l�-
� 1
Notes: 1) Pull the lamp driver tray toward the cable end. Disconnect UV lamp connections.
2)Push the lamp driver tray through other end of enclosure until removed.
4.Put the tray on a clean workbench for maintenance and service.
10.4.6.2 Install the Lamp Driver Tray
The enclosure must be securely sealed to keep the Module Control Board dry and free of debris.
Prerequisites:
Remove the lamp driver tray. Refer to Section 10.4.6.1.
Tools: ��-77
Materials:
•Household cleaner
•End Cap Seal
•Desiccant Pack
Procedure:
l!JJI!ll
1.Identify whether the UV Module is left sided or right sided (Section 10 4.1 ). Install Lamp Driver tray in
correct orientation.
88 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Note: Match the corresponding numbered lamp connectors. (i.e. 112
connected to 112) .
Notes: 1) If the groove is damaged, replace the end cap.
2) If the groove is free of damage, clean with household cleaner
and a lint-free cloth .
Original Instructions
Maintenance
Note: Align the pressure cone with the indentation inside the
enclosure. Turn the pressure cone until it is touching the wall
of the enclosure. Turn an additional half turn to seat the
pressure cone .
89
Maintenance
Note: Replace the seal. Keep new seals in sealed bags until
they are needed for installation.
,/ >,. _..,..,..._/
\_
ef,eA �;9;,_g"/�/\ �/_,,/) I>'/ _.,, I � � ..,..,,, I '. II•• ,..,.. /,II, D I
�,,. "-"
Notes: 1) Clean first 51mm (2in.) of lamp driver enclosure interior with Notes: 1) Insert seal slowly to prevent the seal comers from being
90
isopropyl alcohol. Inspect for deep gouges. Use 220 grit pinched. Push in until end cap makes full contact with
sandpaper to remove rough surfaces. Repeat cleaning. enclosure body.
2) Insert a new desiccant pack.2)Tighten screws an additional 114 turn after end caps is
3)The power cord strain relief must be installed toward the top installed. Make sure the power cord is tight.
of the enclosure.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
9.Make sure that the power cord strain relief is tight.
Maintenance
10.To do the optional air pressure test, refer to Instruction DC050601-017, provided in the Air PressureTest Kit (907631). Otherwise, return the module to service (Section 10.4.3) .
10.4.6.3 Remove and Replace the Lamp Driver
Always carry lamp driver trays in an upright position .
Prerequisites:
•Remove the lamp driver tray. Refer to Section 10 4.6.1.
Note: Put the lamp driver on a workbench so the module control board is on the left .
•Identify the Lamp Driver needs to be replaced .
Tools:
Materials: 0(7)0
•Cable Ties provided
Procedure:
Remove:
Note: Carefully cut cable tie and remove. Note: Disconnect lamp cables on left side of lamp driver.
Original Instructions 91
Maintenance
Note: Lift the lamp driver slightly up and off the tray and disconnect
the ground wire.
�. !oom,ffiii,m,ffi !oom,•ffi !oom,iJ
@] @] � [TI
Note: Set the DIP switches on the replacement lamp driver to the same positions.
92 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Install:
A
-l -lB
Original Instructions
Maintenance
Note: Align lamp driver tray along a straight edge. Verify all lamp
drivers are aligned .
93
Maintenance
* Install cable ties on the straight section of the ribbon cable, close to the connector.
Note: Inspect all other lamp drivers to ensure ribbon cables are
correctly tied. Re-tie if required.
When service is complete, assemble prerequisites in reverse order of disassembly.
10.4.6.4 Replace the Module Control Board (MCB)
Prerequisites:
94
•Remove the lamp driver tray. Refer to Section 10.4.6.1.
Tools: ®
Materials:
•ESD Wrist Strap
Procedure:
�
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • r; • • • • • • • • •
Maintenance
Note: Disconnect communication and power lines from MCB .
4.Install new MCB. Assemble in reverse order of disassembly .
5.When service is complete, assemble prerequisites in reverse order of disassembly .
Original Instructions 95
Maintenance
10.4.7 UV Lamps and Lamp Sleeves
UV lamps contain mercury (Section 2).
10.4.7.1 Storage Requirements for Used UV lamps
Put used UV lamps into the replacement UV lamp shipping container, or a similar container. It is
preferable that the original packing materials be used where possible, or materials adequate to prevent
breakage during storage and transportation.
Boxes of used UV lamps should be labeled as such and stored in a location where the potential for
accidental breakage is minimized.
A UV lamp re-cycler may have specific procedures and UV lamp storage requirements. Consult with a
UV lamp re-cycler to determine all applicable policies .
10.4.7.2 Inspect the Lamp Sleeves
Make sure that lamp sleeves are clean internally and externally. Fouling will block UV and compromise
disinfection. Fouling can also result in higher UV lamp operating temperatures and reduce UV lamp
efficiency.
Excessive moisture in the lamp sleeve can cause corrosion of the UV lamp shunt and pins, which results
in shorter UV lamp life.
UV lamp failure due to corrosion is not covered by warranty.
Replace expired UV lamps. The frequency of UV lamp replacement varies due to:
•The temperature of the effluent
The power level of the UV lamps (60-100%)
•The frequency of cycling UV lamps on and off (up to 4 cycles per day). The UV Bank timer specified
in the control strategy will control the frequency of on/off cycles and preserve UV lamp life.
UV lamps cycled on and off more than 4 times in a 24-hour period will void the warranty.
10.4.7.3 Cleanliness Inspection
Coating on the lamp sleeves may have several causes:
Mechanical failure-Trapped debris may prevent completion of the wiper stroke, scratch the lamp
sleeve, or create leakage of the cleaning agent.
Hydraulic failure-The wiper stroke does not extend over the full length of the UV lamp. The stroke
time may not be long enough or a hydraulic problem may exist (e.g., low fluid, clogged filter, clogged
pressure relief valve).
Chemical failure-Diluted or weak cleaning agent or the absence of cleaning agent in the wiping
canister will cause the mechanical action to leave a track over the length of the wiper stroke.
Prerequisites:
•Shutdown the system. Refer to Section 7.2.
•Lockout tag out the system components. Refer to Section 4.
96 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
•Complete a manual wipe sequence on the module .
•Remove the module from the UV channel. Refer to Section 10.4.2 .
Materials: 060 IIJll:-C]
Procedure:
1.Let the lamp sleeves dry for 10 minutes. Coating may not be visible while the lamp sleeve is wet.
2.Inspect the outside of the dry lamp sleeves for coating. Coating may appear as uniform or streaked,
heavy or light. The color may be white, brown or yellow, depending on the wastewater quality and the
chemicals used in treatment.
3.Clean the lamp sleeves as needed (Section 10 4 7 4) .
4.Return the module to the UV channel (Section 10.4.3) .
10.4.7.4 Clean the Sleeves Manually
TVJ, "'-.-lrJr...;:)1.....,
Do not use abrasive materials to clean the lamp sleeves. Abrasive materials will scratch and damage the lamp sleeves .
If the cleaning solution comes in contact with the lamp driver enclosure, immediately flush and clean the enclosure with potable water to prevent permanent damage. Damage due to cleaning solution will void the warranty .
Only use Trojan Technologies approved cleaning solutions in the wiper canisters. Use of unapproved chemicals may result in damage to the equipment. For a list of approved cleaning solutions refer to Table 20 .
Prerequisites:
•Remove the UV module. Refer to Section 10 4.2 .
Materials:
•Sponge or non abrasive plastic scrub pad
Procedure: A�
Original Instructions 97
Maintenance
Solution
1.Refer to Table 20 for dilution ratio's.
•Mix the solution thoroughly. Use pH indicator strips to make sure that pH is between 1.0 - 1.5.
The solution is effective in cleaning UV modules when the pH is less than 3.0. Above pH 3.0, the
cleaning solution should be recharged with acid or replaced.
Table 20 Approved Cleaning Solutions and Dilution Ratios
Dilution
ActiClean TM Gel Not required
20% Phosphoric Acid 2 parts ActiClean TM Gel to 1 part acid
40% Phosphoric Acid 5 parts ActiClean TM Gel to 1 part acid
75% Phosphoric Acid 10 parts ActiClean TM Gel to 1 part acid
80% Phosphoric Acid 12 parts ActiClean TM Gel to 1 part acid
Note: When mixing the solution, always add the acid to the tank filled with water.
2.Remove debris from the module with low pressure potable water, such as a garden hose.
3.Apply a manufacturer approved cleaning agent (ActiClean ™ Gel or diluted phosphoric acid, refer to
Table 20 for dilution ratios) to a sponge, paper towel or plastic scrub pad. Rub the outside of the lamp
sleeve until all deposits are gone.
Note: Clean up spills to avoid slipping and dispose of cleaning solution as per site and country
protocols.
•If heavy internal fouling is present, replace the lamp sleeve.
•Clean all visible moisture inside of the lamp sleeve with a clean, dry paper towel or Kimwipe®.
4.Let the lamp sleeves dry for minimum 10 minutes and reinspect, repeat manual cleaning as required.
Note: A completely clean lamp sleeve will have the clarity of a new, unused lamp sleeve.
5.Make sure the ActiClean TM Cleaning Sy stem is parked at the dome end of the lamp sleeve.
6.Install the UV Module into the UV Channel (Section 10.4.3).
10.4.7.5 Remove and Replace a UV Lamp and Lamp Sleeve
Prerequisites:
98
•Remove the UV Module. Refer to Section 10.4.2.
Materials:
•New UV Lamp (if required)
•New Lamp Sleeve (if required)
•New compression spring (if required)
Procedure:
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
A
It ---------\
Remove/replace the lamp sleeve:
Note: Pull UV Lamp straight out to avoid bending the connector pins .
Original Instructions
Maintenance
Note: Wet the lamp sleeve and slide it along with UV lamp through the bottom wiper canister and out of the module leg .
Remove/replace UV lamp:
A
99
Maintenance
Remove/replace the lamp sleeve o-ring: Remove/Replace the lamp compression spring:
B ... oo= .... ---------
Note: Transfer sleeve nut and compression spring from old sleeve to Note: Replace with new compression spring if required.
new sleeve. Replace 0-ring.
7.To install a new UV lamp or lamp sleeve, assemble in reverse order of disassembly.
Note: Hand tighten sleeve nut. DO NOT over-tighten.
8.Return the module to the UV channel (Section 10.4.3).
9.Reset Lamp Hours if a new UV lamp was installed. (Section 9.2 3).
10.5 Hydraulic System Center (HSC)
10.5.1 Depressurize the Hydraulic System
100
Prerequisites: £6
•Shutdown the system. Refer to Section 7.2.
•Apply lockout tag out devices as necessary. Refer to Section 4.
•Open HSC lower door.
Materials:
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ·•• •• •• •
• • • • • • • • • •· • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Procedure:
Before Service:
Notes: 1) Open the Extend, the Retract override knobs for each UV
Bank requiring service .
2)Manual Override Knobs to remain pulled out until
service is complete
After Service:
10.5.2 Inspect the HSC and Hydraulic System Components
Inspect the HSC during scheduled maintenance .
Prerequisites: ££�6
•Depressurize the Hydraulic System. Refer to Section 10.5.1.
•Open HSC lower door .
Materials:
Procedure:
Maintenance
1.Inspect the HSC, hoses and fittings for hydraulic fluid leaks. Ensure to inspect below the HSC
enclosure for leaks. To avoid hydraulic fluid injection injury, never use hand to inspect a leak. Instead ,
put a piece of paper or card board on the leaking area to determine the location of leaking .
Original Instructions 101
Maintenance
2.If a leak is seen at a hydraulic fitting, tighten the hydraulic fitting with a wrench to stop the leak
(Section 10.5.5). Do not over tighten the fittings.
3.If a hydraulic hose has a leak, replace the hose (Section 10.5 .5).
4.If a leak is seen at the hydraulic fluid filter, turn the filter to tighten. If the leak is still present:
a.Remove the filter (Section 10.5.3).
b.Remove debris from the sealing surfaces of the filter and filter housing using a clean, dry cloth.
c.Inspect the sealing surfaces of the filter for damage. Ensure that the O-Ring is positioned on the
filter correctly.
d.Replace the filter if the sealing surface of the filter or O-Ring is damaged.
e.Install the filter.
5.Inspect the hydraulic hoses for damage (bulges, splits, cracks and nicks). Replace hydraulic hoses
that are damaged (Section 10.5.5).
6.Ensure that the hydraulic fluid reservoir is full. If the reservoir is not full, add hydraulic fluid until full
(Section 10.5.4).
7.Remove debris and hydraulic fluid from the HSC surfaces. Use a mild soap and water solution and a
damp sponge or soft cloth.
8.Close HSC lower door.
10.5.3 Replace the Hydraulic Fluid Filter
102
Replace the hydraulic fluid filter during scheduled maintenance or when damaged.
Prerequisites: �Li�@
Depressurize the Hydraulic System. Refer to Section 10.5.1.
•Open HSC lower door.
Materials:
•Hydraulic fluid filter
Procedure:
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • a • • • • • • • • •
Maintenance
103
Maintenance
+
When replacement procedure is completed run system, check for leaks. Fill the Hydraulic Fluid Reservoir if
required (Section 10.5.4).
10.5.4 Drain and Fill the Hydraulic Fluid Reservoir
Drain the hydraulic fluid reservoir during schedule maintenance. During the first two months of operation,
air works its way out of the UV system. Hydraulic fluid must be monitored to make sure the fluid level is
adequate.
Use only a manufacturer-approved hydraulic fluid. Refer to the reservoir label for more information.
Fill the hydraulic fluid reservoir when the level is less than full.
Table 21 Approved Hydraulic Fluids
Fluid type Description and use . A low viscosity mineral-based oil
Mineral Hydraulic Oil . Use where wide variations in ambient temperatures
occur. . Use all year. No seasonal oil change necessary .
Prerequisites: £6
•Lockout Tag Out HSC. Refer to Section 4.1.
•Open HSC lower door.
Operating
temperature
-35 to 49 °C
(-32 to 120.2 °F)
104 Original Instructions
• • •
� • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • a • • • • • • • • •
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
Tools: 7Y
•Siphon container
Materials:
Procedure:
Drain: Fill:
Note: Dispose the waste oil according to local regulations .
When service is complete, assemble the prerequisites in the reverse order of disassembly .
10.5.5 Replace the UV Module Hydraulic Hoses
Prerequisites: Lt��ffi&6
•Remove the UV module. Refer to Section 10.4.2 .
•Position a shallow pan below the hydraulic fittings .
Original Instructions 105
Maintenance
Tools:
1/2-in ( 9/16-in !'
Materials: (8()0�□
•New Hydraulic Hose(s)
Procedure:
Remove:
A
Note: Gently pull the hoses down from the underside of the entire length of the lamp driver enclosure.
106
Note: 1) Remove old hose from UV Module. Make sure there is no pressure trapped in the hose.
2)The oil will drain into the pan. Clean up spills.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
Replace:
Notes: 1) Ensure replacement hose has the same specification and type of hose fitting as the original. Replace one hose at a time.
2)Turn swivel nut to finger tight. Wiggle hose to checkalignment. Tighten until it seats.
3)Tighten addition 1/4 turn .
x4
x4
Notes: 1) Press-fit the hose into the slot on the bottom of the enclosure before installing the T-Clamps .
2) Clean up hydraulic fluid residue.
3.Repeat procedure for remaining hoses (if required) .
Notes: 1) Make sure that the connections are tight and that the hose is securely clamped to the
bottom of the module. The hose must be seated completely in the grooves to reduce the
risk of pinching the hose .
2)Make sure that the hoses are not kinked, twisted or bent and that there is adequate slack
while the hoses are in use .
4.Install UV Module in UV Channel (Section 10.4.3) .
The wiper system will require constant filling during the recharging of the hose or the reservoir will become too low and damage to the pump may occur .
5.Inspect hydraulic fluid level with fluid level stick on hydraulic oil reservoir cap and add if required
(Section 10.5.4 ) .
6.Re-engage the manual override valve (Section 10 5.1 ) .
7.Initiate a wipe sequence on the wiper that is connected to the new hydraulic hose (Section 8.4.2.1 ) .
8.When the wiping cycle is complete, add hydraulic fluid to the reservoir until full (Section 10.5.4 ) .
Repeat as required .
9.Inspect the new hydraulic hose and fittings for leaks. If a leak is seen at a hydraulic fitting, tighten the
hydraulic fitting .
10.When service is complete, assemble the prerequisites in the reverse order of disassembly .
Original Instructions 107
Maintenance
10.6 ActiClean rM Cleaning System
Inspect the wipers and lamp sleeves regularly to avoid cleaning problems. Dirty lamp sleeves will inhibit the
amount of UV light that can enter the wastewater and possibly compromise disinfection.
In remote mode, the ActiClean ™ Cleaning System (ACS) is controlled by the sec, which implements the
cleaning cycle to all connected UV Banks and then repeats the cycle at regular time intervals pre-selected
by the operator. The ACS wiping sequence can be manually initiated from the SCC.
The ACS can also be manually controlled by moving the wiper mode selector switch on the HSC to LOC
(local) mode. Placing the wiper control switch in the SEQ (sequence) position will initiate the cleaning cycle
one UV Bank at a time. The RET (retract) and EXT (extend) positions are used primarily for performing
maintenance checks on the wiper system.
10.6.1 Wiper Canister
10.6.1.1 Drain/Flush the Wiper Canisters
For cold wint er storage (i.e. wi nterization) each cani ster needs to be drained and flushed to remove all debris and ActiClean ™ Gel Failure to fully clean could lead to damage of plastic parts.
108
Drain the Wiper Canisters for long term storage (i.e. 4 - 6 months).
Prerequisites: £��£&6
•Initiate a manual wipe sequence for wiper group. Refer to Section 8.4.2.1
•Remove the UV module. Refer to Section 10.4.2.
Tools:
Materials: tiOOQ lllll:i::l
•Lamp Sleeve O-ring
Procedure:
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
Original Instructions
Maintenance
109
Maintenance
7.Repeat the procedure for the remaining canisters down the UV Module.
Notes: 1) Ensure all water is drained from the wiper system if winterizing UV Module.
2)If additional cleaning is required to remove debris, wiper canister may need to be removed
and rinsed completely in warm water
10.6.1.2 Fill the Wiper Canisters
Systems with more than 50 UV Modules located in North America and China only.
The system will be supplied with the drill pump for wiper canister filling. Refer to Instruction Document
Number DC050601-030.
Systems with 50 or less UV Modules and systems located outside of North America and China.
The system will be supplied with a hand pump for wiper canister filling. Follow the procedure below.
Prerequisites: Lh£�Ltffi6
•Initiate a manual wipe sequence for the wiper group. Refer to Section 8.4.2 1.
•At the SCC, Bank Overview Screen, disable the UV Module.
•At the HSC, set the applicable wiper mode selector switch to the OFF position.
•Depressurize the Hydraulic System. Refer to the Section 10.5.1.
•Remove the UV Module. Refer to Section 10.4.2.
110 Originallnstructions
• • • ••• • •• • •• • • • • • • • • • • • •• • • • • • • • • •• • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
I
Tools:
��
Materials: (1>80 □
Procedure:
1.Turn top pump handle to the left to unlock
2.Pump the pump handle up / down until resistance is felt.
Maintenance
Note: Using a bucket, test the flow rate of the gel. Ensure it is sufficient but not excessively ejecting
from the nozzle. Excessive gel may splash or spatter. To relieve pressure, turn the handle on
the injector assembly to the left. Repeat steps 1-2 .
3.Push handle in and turn to the right to lock .
B
I D
Original Instructions
Notes: 1) Fill the canister until the gel overflows out of the top filler plug hole into the reclaim bottle and air bubbles are gone .
2) Remove the top hose slowly, wait a few minutes before disconnecting
3) Wipe excess gel from around top and bottom plug holesafter removing overflow hose and pressure injector nozzle .
111
Maintenance
10.6.2 Wiper Canister Maintenance
10.6.2.1 Remove and Install the Wiper Canister
Prerequisites:
•Drain the Wiper Canisters. Refer to Section 10.6.1.1.
•Remove the Lamp Sleeve. Refer to Section 10.4.7.5.
Tools:
«J)
�
Materials: OOO'D
Procedure:
Remove:
For top or bottom canisters only:
- \'"
( !OIT ;111
r,
A
;,,. ,
,�11 { �o · 1 r ll
' -i / es(�
B
Notes: 1) Loosen the hardware. Note: Note the angle and shape of the tubing connections.
2) Remove the top and bottom brackets.Disconnect hoses.
112 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
For top and bottom canisters only:
Note: Ensure wiper canister is installed in correct location and orientation
Maintenance
Note: Connect all removed hoses.
113
Maintenance
Note: Tighten the nuts at a torque of 35 in/lbs (3.9 N-m).
114
4.Install UV Lamp and Lamp Sleeve (Section 10.4.7.5), ensure drive lug seats into the slot on the drive
bar. Repeat for all removed lamp sleeves.
5.Fill ActiClean ™ Gel (Section 10.6.1.2).
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
Remove:
Original Instructions
Maintenance
115
Maintenance
Install:
116
are
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
4.Repeat steps for remaining wiper canisters as required .
5.Fill the Wiper Canisters. Refer to DC050601-022 .
6.When service is complete, assemble prerequisites in reverse order of disassembly .
10.7.0.1 Remove and Replace Wiper Seals and O-Rings
Prerequisites:
•Remove the wiper canister. Refer to Section 10.6.21 .
Tools:
i? ® 3/16-r
•Cap removal tool
Materials: OtJOQo�_�t �& llN,C] �-
•Fittings (if required)
•End Caps (if required)
•Wiper Seals
Procedure:
A
Note: Repeat on the other side and replace end cap if broken .
Original Instructions
Maintenance
117
Maintenance
'\\\'.�
�<;_�{. \��r�1 l ----
fill
Note: Ensure O-Rings are not rolled or twisted
118
Note: Ensure inside is free of debris.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • -
"' • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Note: Lubricate only the seal ends .
Note: Do not over tighten .
0 '
0�
10.Install Wiper Canister (Section 10.6.2.1) .
11.Fill ActiClean ™ Gel (Section 10.6.1.2) .
Original Instructions
Maintenance
119
Maintenance
10.7.1 Hydraulic Cylinder
10.7.1.1 Replace the Hydraulic Cylinder
Prerequisites: £��£&@
•Remove the UV Module. Refer to Section 10 4.2.
Tools:
Materials: 060 □�,,_�� =i::J
•Hydraulic cylinder
Procedure:
Note: Hydraulic lines and power cables are not shown for clarity.
Remove:
120 Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
Note: Remove the hose at the hydraulic cylinder.
A
Note: Hold the cylinder while removing the bolt .
Original Instructions
Maintenance
121
Maintenance
Install: c;
B1 B2
A
B
122
t
A
�
Note: Torque bolts to 150in//bs (16.9 N-m).
J rn tr �Cr:l
~.r -..I
B
Original Instructions
• • • • • • • • •• • •• • •••• •• • •• • •• • ••••••• • •• ••• • ••••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
A
x2
B
Notes: 1) Center align all the middle canister lugs to drive bar slots.
7.Fill the wiper system if required (Section 10.6.1 2) .
2)Tighten the drive bar locking plate screws at a torque of
45 in/lbs (5. O N-m).
3) Tighten bracket mounting nuts at a torque of 35 in/lbs (3.9
N-m).
8.Clean all hydraulic residue and ActiClean TM Gel from the lamp sleeves, wiper canisters and module
legs.
9.Add hydraulic fluid to the HSC if required (Section 10.5.4) .
10.Return the module to the UV channel. (Section 10.4.3) .
10.7.1.2 Apply Grease to the Hydraulic Cylinder
Prerequisites: £���&6
•Remove the UV module. Refer to Section 10.4.2 .
Tools:
•Grease gun with grease
•Loctite 243 threadlocker
Original Instructions 123
Maintenance
Materials: 000
Procedure:
B
124
(9 0
Notes: 1) Inject until clear clean grease comes out of the vent hole.
Continue for 3 or 4 additional injections.
2)Do not allow grease to contact the lamp or sensor sleeves.
Orig in al Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Maintenance
A
B
Note: 1) Apply Loctite 243 thread locking adhesive to the screw .
2) Wipe off excess grease.
4.Ensure there is no grease on the lamp sleeves, clean or replace sleeve if required .
5.Return the UV module to the UV channel (Section 10.4.3) .
10.8 System Control Center (SCC)
10.s.1 Clean the sec
Prerequisites: Lh6
•Shutdown the system. Refer to Section 7.2 .
•Lockout tag out the system components. Refer to Section 4 .
Materials:
Procedure:
1.Use a mild soap and water solution and a damp sponge or soft cloth. Gently wipe the controller
exterior to remove debris .
2.Do NOT use any corrosive cleansers on the SCC cabinet or operator interface .
Original Instructions 125
Maintenance
10.9 Power Distribution Center (PDC)
10.9.1 Clean the PDC
126
Prerequisites: £6
•Shutdown the system. Refer to Section 7.2.
•Lockout tag out the system components. Refer to Section 4.
Materials:
Procedure:
1.Use a mild soap and water solution and a damp sponge or soft cloth. Gently wipe the controller
exterior to remove debris.
Original Instructions
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••