Pentair BIOSHIELD CLP41A6-XN User manual

IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
BIOSHIELD™
COMMERCIAL UV DISINFECTION SYSTEM
INSTALLATION AND
USER’S GUIDE

BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide
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P/N CLX-N-MN Rev. A 9/29/14
TABLE OF CONTENTS
Section 9: Commissioning ......................................
Start-Up
Section 10: Operation ..............................................
Microprocessor Control Power Supply Operation
Microprocessor Control Descriptions
Section 11: Maintenance .........................................
Routine Inspection
UV Lamp Replacement
UV Lamp Removal
UV Lamp Recycling
UV Lamp Installation
Quartz Sleeve Inspection/Replacement/Cleaning
Quartz Sleeve Removal
Quartz Sleeve Cleaning
Quartz Sleeve Installation
UV Vessel Cleaning
UV Vessel Disassembly
Cooling Fan and Filter Mat Replacement/Cleaning
Cooling Fan Filter Removal
Cooling Fan Filter Cleaning
Cooling Fan Filter Installation
Section 12: Replacement Parts ...............................
Quartz Sleeve and UV Lamp Matrix
Replacement Parts
Section 13: Troubleshooting ....................................
Section 1: Introduction .........................................
General Information
Glossary
Section 2: Health and Safety Precautions ...........
Safety Symbols
Safety Instructions
Hazardous Situations and Appropriate Actions
Section 3: UV Disinfection ....................................
What is Ultraviolet Light
Introduction to UV Disinfection
Factors Effecting UV Disinfection
Section 4: System Overview .................................
System Features
UV Vessel
Power Enclosure
Section 5: System Specifications .........................
Dimensions and Electrical Specifications
Water Flow Rates
Section 6: Installation ............................................
Pre-Installation Inspection
UV Vessel Installation
Quartz Sleeve Installation
Power Supply Installation
Temperature and UV Intensity Sensor
Installation
Section 7: Mandatory Water Test ...........................
Section 8: UV Lamp Installation ............................
UV Lamp Installation
Lamp Field Safety Cover Installation
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If you have questions about ordering Pentair Commercial Aquatics™ replacement parts and products, please use
the following contact information:
CUSTOMER SERVICE / TECHNICAL SUPPORT
Customer Service
8 AM to 7 PM — Eastern and Pacific Times
Phone: [phone]
Fax: [phone]
Web site
Visit www.pentaircommercial.com

1
General Information
In this manual you will find user information for your Bioshield™ UV Disinfection System. It is an important document for
safety guidance, installation, operation and maintenance. Read and understand all sections of this Manual before starting
the installation or operation of this UV system. Strictly follow this Manual and all safety notes, they are for your own
safety.
Custom-made, project specific modifications of the UV system and/or additionally integrated components may result in
non-conformity of the system and void the warranty.
The information contained in this manual represents our most recent experiences and technical knowledge. This
information does not hold a legally binding promise of certain characteristics or suitability for a specific application. The
user of the UV system will be required to perform his/her own verifications and safety measures.
Pentair Commercial Aquatics accepts no responsibility for any problems arising from incorrect installation, lack of routine
maintenance as specified in this manual or modifications of the UV system.
Glossary
Term Description
Disinfection The inactivation of harmful microorganisms
End of Useful Lamp Life Recommended time to replace a UV lamp
External On/Off Switch Manually operated switch to isolate the UV System
Fouling Build up of scale in the vessel, sensor or quartz sleeve
Isolation Valve Manually or automatically operated valve(s) used to isolate the UV vessel.
J/m2 Joule per square meter
A Unit of UV Dose 10 J/m2 = 1 mJ/cm2 = 1,000 uWs/cm2
Minimum UV Intensity Required value at end of lamp life (alarm threshold value) to maintain the minimum
UV dose at a given flow rate and a given UV transmission.
nm Nanometer – Light wavelength measurement
Personal Protective Equipment Hard Hat, Safety Glasses, Rubber Gloves, Safety Shoes
Power Supply Enclosure NEMA Type-12 cabinet housing electrical hardware, instruments and Microprocessor
Controller/Monitor
Text Display Screen used to view Microprocessor Controller/Monitor data
UV-C Specific UV area of the light spectrum (200 – 280 nm)
UV Dose Indicates amount of UV light
UV Intensity Indicates the strength of UV light
UV Output Amount of UV light emitted from a UV lamp
UVT Ultraviolet Transmissibility
UV Sensor Sensing-probe installed on the UV vessel to measure UV intensity-UV light
wavelength 254nm
UV System Entire UV System that includes the Power Supply Enclosure and UV Vessel
UV Vessel Wet portion of the UV System that generally consists of: quartz sleeve(s), UV lamp(s),
stainless steel or polymer vessel, and valve(s)
SECTION ONE
INTRODUCTION
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide

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DANGER: If the unit shows any sign of water leakage, immediately unplug it from the power source.
IMPORTANT: READ AND OBSERVE ALL IMPORTANT NOTICES AND LABELS ON THE UNIT.
REMOVAL OF PRODUCT LABEL WILL VOID WARRANTY!
DANGER: If the unit falls into the water, DO NOT REACH FOR IT! First unplug it and then retrieve
it. If the internal electrical components of the unit get wet, unplug the unit immediately.
IMPORTANT: For your safety the quartz sleeve and/or the UV lamp in this product may have been
broken or damaged during shipping. It is ESSENTIAL that the unit be CAREFULLY
INSPECTED BEFORE CONNECTING TO ELECTRIC POWER.
Safety Symbols
Caution High Voltage
Warning Chemical (Corrosive)
Protective Eye wear (UV Light) Sharp Object
Recycle
Safety Instructions
IMPORTANT SAFETY INSTRUCTIONS PLEASE READ PRIOR TO INSTALLATION AND OPERATION
Strictly follow the instructions within this manual to ensure the health and safety of both, yourself and the UV system. The
installation, operation and maintenance of the Bioshield™ UV Disinfection System can only be carried out after reading and
understanding the information contained in this manual.
The installation of the UV system must be carried out in accordance with local regulations and codes.
WARNING: Water and electricity can be a dangerous combination. Help us ensure your safety.
READ AND FOLLOW ALL SAFETY INSTRUCTIONS.
DANGER: UV lamps and quartz sleeves are fragile and if broken and handled incorrectly may
cause serious injury.
WARNING: DO NOT exceed 150 PSI during operation.
DANGER: To avoid possible electric shock special care should be taken since water is employed
in the use of the UV System. For each of the following situations, do not attempt repairs
yourself. Call Pentair Commercial Aquatics customer service department at
800-831-7133.
DANGER: DO NOT operate this unit if it has a damaged cord or plug, if it is malfunctioning, or if it
has been dropped or damaged in any manner.
SECTION TWO
HEALTH AND SAFETY PRECAUTIONS
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide

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IMPORTANT: Close supervision is necessary when any appliance is used by or near children, this UV
system is no exception.
IMPORTANT: Always unplug the unit from the electrical outlet when it’s not in use, before servicing,
cleaning or removing parts. Never yank the cord to pull the plug from the outlet. Grasp
the plug and pull to disconnect.
IMPORTANT: Each UV system is designed for a specific water-pressure. DO NOT use the UV system
for any application other than its intended use. The use of attachments not
recommended or sold by Pentair Commercial Aquatics may cause unsafe conditions and
possibly void any warranty.
IMPORTANT: Only (3) three wire grounded cables suitable for outdoor use should be used to connect
this unit. If joining cables for outdoor use, a suitable watertight cable connector must be
used. If an extension cord is necessary, a cord with a proper rating should be used. A
cord rated for less ampere or watts than the appliance’s rating may overheat. Care
should be taken to arrange the cord so that it will not be tripped over or pulled. If in
doubt consult a qualified electrician.
IMPORTANT: Only operate the UV system when it is properly maintained and in good working order.
IMPORTANT: DO NOT modify the UV system without authorization from Pentair.
DANGER: BLUE-LIGHT HAZARD Ultraviolet light will cause serious damage to your eyes and
skin! DO NOT handle or stare at an operating UV lamp. UV lamps become hot during
operation, DO NOT handle them during operation.
Hazardous Situations & Appropriate Actions
Situation Location Hazard Actions
Lamp or Quartz Sleeve UV Vessel Burn Isolate UV system from water source,
Removal shutdown system using external On/
Off switch and lock-out disconnect
from input power source.
Broken Quartz Sleeves/ UV Vessel Sharp Object Handle quartz sleeves and UV lamps
UV Lamps with extreme care, wear clean cotton
gloves.
UV Lamp UV Vessel Blue-Light Hazard DO NOT operate UV lamps outside the
Replacement UV vessel, wear protective eye wear
against ultraviolet light.
Drain UV Vessel UV Vessel Pressure Isolate UV system from water source
and shutdown system using external
On/Off switch and lock-out/disconnect
from input power source. Open valves
carefully to relieve pressure and drain
the UV Vessel.
Vessel Cleaning UV Vessel Corrosive/ Isolate the UV vessel and secure
Chemical against unauthorized operation. Wear
appropriate protection equipment.
No smoking or food allowed.
Electrical Work UV System Electrical Shock Shutdown system using the UV
system’s external On/Off switch and
lock-out/disconnect from input power
source. All electrical work should be
carried out by authorized and qualified
personnel only.
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What is Ultraviolet Light?
Ultraviolet light is a specific section of the Light Spectrum used primarily for germicidal disinfection. It is broken down into
four sections: Vacuum UV (100-200 nm), UV-C (200-280 nm), UV-B (280-315 nm) and UV-A (315-400 nm).
Introduction to UV Disinfection
Ultraviolet light, used in disinfection, is most effective
in the UV-C range, specifically between 240 and 280
nanometers. Input watts (voltage + current) are
supplied to the UV lamp creating an electrical arc
with the mercury inside the lamp’s glass envelope.
This reaction creates the specific range of UV-C light
(240-280 nm) required for germicidal disinfection.
Achieving successful UV disinfection requires the
UV-C light to penetrate a target microorganism’s cell
wall/membrane at a specific wavelength (UV Dose)
for a specific amount of time (flow-rate).
Ultraviolet disinfection is efficient, economical and
environmentally friendly.
Factors Affecting UV Disinfection
Target Microorganism
Microorganisms vary in type, size and life cycle. Selecting a target microorganism (Algae, Bacteria etc.) and identifying it’s
life cycle and established UV Dose are prerequisites for eliminating that particular microorganism.
UV Transmittance
The most critical UV performance factor is “UV Transmittance” (UVT). UV light that
is absorbed by substances in the water is unavailable to inactivate waterborne
microorganisms. The greater the amount of UV light absorbed by these substances
(i.e. low %UVT) the more UV capacity will be required. UV transmittance is not
turbidity but rather absorption by both visible particles and non-visible substances.
For example: metals in water, especially iron, absorb UV light.
These two graphs demonstrate how a lower %UVT parallels a diminished UV dose
when operating our model CLP6780A8 (3 – 260 Watt Amalgam UV lamps) at a flow
rate of 150 GPM.
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
%UVT
µWs/cm² at
End of Lamp Life
151,800
120,800
97,400
79,600
65,900
55,100
46,500
39,600
34,000
29,300
25,400
22,000
19,200
16,700
14,600
12,700
11,000
9,400
7,900
6,400
Total %
Loss
0%
-20.42%
-35.84%
-47.56%
-56.59%
-63.70%
-69.37%
-73.91%
-77.60%
-80.70%
-83.27%
-85.51%
-87.35%
-89.00%
-90.38%
-91.63%
-92.75%
-93.81%
-94.80%
-95.78%
160,000
140,000
120,000
100,000
80,000
60,000
40,000
20,000
0
100 80 60 40 20 0
%UVT
UV Dose: µWs/cm2
SECTION THREE
UV DISINFECTION
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Quartz Sleeve Condition
Materials (dirt, waste, bioflocculant, plant material and
scale) all absorb UV light. The more material on the quartz
sleeve the greater UV absorption. The result: reduced UV
performance. For quartz sleeve cleaning instructions See
Page 32.
UV Lamp Performance
A UV lamp degrades over its operating life thus explaining why Pentair
Commercial Aquatics suggests water flow-rates for our Bioshield™ UV
Disinfection System based on “end of useful lamp life” performance. Your
UV System is designed to utilize its lamp’s UV-C output to their maximum
potential and should not be modified. Lamps reaching the end of their
useful life should be changed-out. UV lamps that are operated past their
“end of useful lamp life” can reduce the ballasts operating efficiency.
Ballast Performance
The ballast/power supply must be sized appropriately to the specific “input watt” requirement of the UV lamp. Under-driving
the lamp will result in diminished UV-C output while over-driving the lamp will result in reduced “useful lamp life”.
Water Flow Rate
The “flow rate” must consider all critical operating criteria for the specific UV system combined with the intended
applications percent UV transmissibility (%UVT). Each model UV system and application is unique and therefore must be
calculated independently.
UV System Design
Your UV system is designed and manufactured to deliver many years of dependable operation. The UV system is unique
and designed to utilize its UV lamp’s output to their maximum potential. We combine critical performance criteria including:
UV lamp output, power supply performance and lamp array. We use the Bolton Photosciences “UV CALC Modeling
Program” to verify each UV system’s operating capacity. The Bolton Photosciences UV CALC Modeling Program is
recognized by the United States Environmental Protection Agency (EPA).
NOTE: Flange mating halves not supplied.
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System Features
• Corrosion-Resistant, Heavy-Wall Polymer UV Vessel Construction maximizes durability and operating performance.
• Watertight Design allows for safe operation in wet environments.
• “L Style” Vessel Design maximizes hydraulic efficiency.
• Single-End UV Lamp/Quartz Sleeve removal allows for quick and easy change-outs.
• UV Lamp array utilizes each lamp’s UV-C output to its maximum potential.
• T6 Amalgam “L Glass” (non-ozone emitting) UV Lamps produce a higher UV output than standard output
UV Lamps (>80% efficient after 12,000 hours of continual operation).
• Protective Quartz Sleeves thermally protect the UV Lamps, resulting in maximum UV output and safety.
• UL 508A listed Power Supply Enclosure.
• NEMA Type-12 High-Impact, Thermoplastic Enclosure with professionally assembled electrical hardware and
instrumentation.
• Microprocessor Controller Power Supply Enclosure.
UV Vessel
All Bioshield™ UV Disinfection System models are designed using the same design criteria, although individual model
dimensions and lamp numbers may differ. CLP Series models may be equipped with an optional integrated wiping system
(not shown).
The vessel (1) houses one or more UV lamps (2) that are arranged in an array that utilizes their UV output to their
maximum potential. Each lamp is thermally protected by its own quartz sleeve (3) made from transparent hard quartz
glass. The quartz sleeve is open on one end and allows for easy removal of the lamp. Quartz sleeves are held in place by
the Quartz Sleeve Module(s) located on the Quartz Sleeve Module Faceplate (4) and the Internal Quartz Sleeve Coupler
(5) located inside the UV vessel on the non-electrical end.
The vessel can have multiple sensor ports, usually a UV Intensity Sensor Port accompanied by a Water Temperature
Sensor Probe Port and a Vessel Drain Port that accepts a 0.5” PVC Ball Valve and an auxiliary service port (used for
chemical cleaning). The vessel Inlet Port (6) and Outlet Port (7) include flange fittings.
The vessel’s electrical end has a removable flanged Quartz Sleeve Module (QSM) Faceplate equipped with Quartz Sleeve
Modules (8). The quartz sleeve modules allow for single-end quartz sleeve and UV lamp removal/loading and are male
threaded to accept the Quartz Sleeve Retaining Nut (9), with a Lamp Field Safety Cover (10) to protect the cable wires. A
EDPM Rubber Gasket positioned inside the quartz sleeve retaining nut creates a watertight seal.
NOTE: Flange mating halves not supplied.
SECTION FOUR
SYSTEM OVERVIEW
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Model#:
No.of Lamps / Part #:
No.of Quartz Sleeves / Part #:
MaximumDesign Flow Rate:
UVSystem Serial #:
ModelDescription:
Max.Operating Pressure:
InputPower:
ShortCircuit Current Rating:
PowerSupply:
2KVA RMS277 VA CMAX
TYPE#2 ENCLOSURE
/
/
EmperorAquatics, Inc. - 2229 Sanatoga Station Road, Pottstown, PA. 19464
For Warranty, Repair and Replacement Part Requests: Please call 610–970–0440
or e-mail us at [email protected]
WARNING:DO NOT operate this equipment without
readingand understanding the Operator ’s Manual thoroughly.
WARNING:Protect eyes and skin from direct exposure to UV Light.
WARNING:Dangerous Voltage can cause severe or fatal injury. Install this equipment in accordance with all local electrical
codes.Disconnect power before attempting to service unit. See the Operator ’s Manual for proper procedures.
WARNING:Ensure that any trapped air is properly relieved from the unit, failure to do so will affect the unit’s performance.
DONOT operate unit in no-flow situations.
CAUTION:This equipment (UV Sterilizer) is designed for supplemental disinfection and should be used with registered or
approveddisinfection chemicals to impart residual concentrations.
NOTE:Replace UV lamps after 9,000 hours of continuous operation or as stated in the Operator ’s Manual. Replace the Quartz
SleeveSeals every 9,000 hours or when replacing the lamps. For reliable performance, use only genuine Emperor Aquatics, Inc.
UVlamps and replacement parts.
by
COOLING FAN
NOTE: CLEAN FILTER MATS REGULARLY
TO AVOID OVERHEATING AND DAMAGE.
WARNING:
HAZARDOUS VOLTAGE CAN CAUSE
SEVERE OR FATAL INJURY. MUST BE INSTALLED
ACCORDING WITH LOCAL ELECTRICAL CODES.
DISCONNECT POWER BEFORE ATTEMPTING TO
SERVICE UNIT.SEE INSTRUCTIONS FOR PROPER
PROCEDURES.
MAIN DISCONNECT AND BRANCH CIRCUIT
PROTECTION TO BE PROVIDED BY OTHERS
NOTE: THE TEMP.SENSOR CABLE MUST BE CONNECTED
FOR THE POWER ENCLOSURE TO OPERATE.
1
4
2
3
9
7 865
Power Enclosure
The Remote Power Enclosure houses all components used for operation, monitoring and control of the entire Bioshield™
UV Disinfection System (monitoring and control vary depending on model). The power enclosure is designed for remote
mounting from the vessel and is equipped with 12’ lamp cables and mounting hardware.
Microprocessor Controller Models
Features:
1. Microprocessor Controller Power Enclosure
2. Liquid Crystal Display Screen
3. Touch Pad Control
4. External On/Off Switch
5. Main Power Cable
6. Temperature Sensor
7. UV Intensity Sensor
8. Lamp Field Safety Cover Cable
9. Lamp/Power Cables
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Above: Bioshield™ UV Disinfection System polymer UV vessel, outfitted with raised flanges (available in all vessel diameters).
Model
2
Lamps/
Watts
UV-C
Spectrum
Output
Watts
Amps Max Load @
120/230 VAC
Max.
PSI
Max. Flow Rate
@ 90% UVT
40 mJ/cm2
(GPM)
Max. Flow Rate
@ 90% UVT
60 mJ/cm2
(GPM)
CLP41A6-XN1/130 40 2.1/1.0 150 49 33
CLP42A6-XN2/130 80 3.9/2.0 150 90 60
CLP43A6-XN3/130 120 5.8/2.9 150 125 83
CLP43A8-XN3/130 120 5.8/2.9 150 167 111
CLP44A8-XN4/130 160 7.5/3.7 150 227 151
CLP45A8-XN5/130 200 9.4/4.7 150 272 181
CLP46A10-XN6/130 240 11.2/5.6 120 365 244
CLP47A10-XN7/130 280 13.3/6.5 120 430 287
CLP47A12-XN7/130 280 13.3/6.5 90 492 328
CLP48A12-XN8/130 320 15.0/7.5 90 555 369
CLP61A6-XN1/320 98 3.2/1.6 150 113 75
CLP62A6-XN2/320 196 6.0/3.0 150 200 133
CLP63A6-XN3/320 294 9.0/4.5 150 279 186
CLP63A8-XN3/320 294 9.0/4.5 150 372 247
CLP64A8-XN4/320 392 12.0/6.0 150 505 336
CLP65A8-XN5/320 490 15.0/7.5 150 606 403
CLP66A10-XN6/320 588 18.0/9.0 120 814 542
CLP67A10-XN7/320 686
11.0
1
120 953 638
CLP67A12-XN7/320 686 11.0
1
90 1095 729
CLP68A12-XN8/320 784
13.0
1
90 1235 823
CLP69A14-XN9/320 882 14.0
1
50 1462 974
CLP610A16-XN10/320 980
16.0
1
50 1690 1127
CLP611A18-XN11/320 1,078 17.0
1
50 1963 1308
CLP612A20-XN12/320 1,176
19.0
1
50 2335 1555
Electrical and Flow Specifications
SECTION FIVE
SYSTEM SPECIFICATIONS
WATER TEMP. SENSOR PORT
B
WATER
OUTLET
PORT
WA
TER
INLET
PORT
WATER DRAIN PORT
REMOVABLE HEAD SECTION
CA
QUARTZ SLEEVE/
UV LAMP ACCESS
PORTS
UV INTENSITY SENSOR PORT
LAMP FIELD
SAFETY CO
VER
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Pre-Installation Inspection
Purpose
To familiarize the installer/operator with the Bioshield™
UV Disinfection System components, to assure proper
delivery of all the system’s components and to inspect
each component for shipping damages.
Frequency
To be conducted prior to installation.
Parts and Required Equipment
• Adjustable Wrench or 1.5” Socket
• Box Cutter
• Hammer/Nail Remover
• Flashlight
Procedure
Note: Vessel diameters up to 8” are shipped with their quartz sleeves assembled. Vessel diameters 10” and larger are
shipped with their quartz sleeves packaged separately.
Note: UV Lamp(s) are shipped in a separate package either inside the vessel crate or separately.
1. Unpack and inspect vessel for shipping damage. A box cutter or hammer/nail remover may be needed to unpack the
UV System.
2. Conduct an internal, visual inspection of models shipped with their quartz sleeves assembled. A flashlight will help with
the internal inspection.
The UV System consists of:
• Quartz Sleeve Module (QSM) Faceplate (assembled on Vessel)
• QSM Faceplate Gasket (assembled on Vessel)
• UV Intensity Sensor
• Temperature Sensor
• Quartz Sleeve Retainer Nut (one for each quartz sleeve)
• Quartz Sleeve Gasket (one for each quartz sleeve retainer nut)
• Drain Valve Assembly
• Quartz Sleeve (one for each UV Lamp)
• UV Lamp(s)
• Vessel
• Bolt(s) (assembled on Vessel)
• Nut(s) (assembled on Vessel)
• Washer(s) (assembled on Vessel)
• 4-Pin Connector(s) (attached to lamp cables)
• Lamp Field Safety Cover and Cable
During pre-installation there is a general risk due to load.
Quartz Sleeves and UV Lamps are fragile and potentially dangerous if broken. Handle with care.
NOTE: Flange mating halves not
supplied.
SECTION SIX
INSTALLATION
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General risk due to load.
General risk due to pressurized piping or UV Vessel.
Quartz Sleeves are fragile and potentially dangerous if broken. Handle with care.
UV Vessel Installation
Purpose
Proper installation of the UV Vessel achieves expected results and ensures safe operation.
Frequency
Required with new construction, retro-fit or replacement of outdated equipment.
Parts and Required Equipment
• Socket Wrenches
• Adjustable Wrenches
• Set of Slotted and Phillips Head Screwdrivers
• Lifting Equipment with Slings
• Vessel Mounting Brackets
• Required Isolation Valves
• Plumbing Components
• Personal Safety Equipment
Procedure
Important: The installation of the UV system must be carried out in accordance with local regulations and codes.
1. Install the UV system after the mechanical filtration. This eliminates debris from entering the vessel and diminishing
the unit’s effectiveness, as well as potentially damaging the quartz sleeves and UV lamps.
2. Install inlet and outlet isolation valves (to be supplied by others).
3. Install UV vessel mounting brackets if required (to be supplied by others).
Note: A 46” clearance for CLP4 Series models and a 76” clearance for CLP6 Series models is required for lamp and
quartz sleeve removal.
Horizontal Installation
Horizontal installation requires the vessel outlet port to face upwards, allowing
trapped air to escape. If installed on a “by-pass filter loop” or isolated using
valves, an automatic air bleed system is required. Failure to remove trapped
air can result in rupture or heat damage to the vessel.
Vertical Installation
Vertical installation requires the bottom port to be used as the vessel’s inlet and the port
closest to the electrical end to be used as the outlet; allowing trapped air to escape. If installed
on a “by-pass filter loop” or isolated using valves, an automatic air bleed system is required.
Failure to remove trapped air can result in rupture or heat damage to the vessel.
LAMP#1
LAMP#2
LAMP#3
LAMP#4
LAMP#5
LAMP#6
LAMPHOURMETER
RESETBUTTON
MAINPOWER
LAMP#1
LAMP#2
LAMP#
3
LAMP#4
LAMP#
5
LAMP#6
L
AMPHOURMETE
R
R
E
S
ETB
U
TT
O
N
M
AINP
O
WE
R
LAMP#1
LAMP#2
LAMP#3
LAMP#4
LAMP#5
LAMP#6
LAMPHOURMETER
RESETBUTTON
MAINPOWER
LAMP#1
LAMP#2
LAMP#
3
LAMP#4
LAMP#
5
LAMP#6
L
AMPHOURMETE
R
R
E
S
ETB
U
TT
O
N
M
AINP
O
WE
R
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4. Models equipped with inlet/outlet raised flanges require mating pipe flanges (not included). Depending on port type
ordered, further fabrication may be required by the installer.
5. Isolation Valves are necessary for vessel removal and chemical cleaning procedure. It is recommended to install the
isolation valves in conjunction with a separate set of, matching size & type, water port connections to the inlet/outlet
ports of the vessel. Adding the “double connection” will enable the UV sterilizer to be removed from the filtration loop
without shutting the total filtration system down. If this installation arrangement is not possible, install the unit in a
way that chemical cleaners or freshwater rinse can be drained completely from the vessel without contaminating the
process water.
6. The UV System (models w/ diameters of 10” and larger) may have been shipped without their quartz sleeves installed
in the vessel, please install now. See “Quartz Sleeve Installation” below for details.
7. The vessel is equipped with a 0.5” female threaded drain port for installation of the Drain Valve Assembly. Use thread
tape on the threads when installing the drain valve assembly.
8. The vessel is equipped with various sensor ports (UV Intensity and Water Temperature Sensors), additional sensor
ports may be included depending on the model or options purchased with the UV System. All sensor ports will be
labeled on the vessel based on their respective function. Use thread tape on the threads to create a reliable seal
with all sensors. Sensors must be threaded into their respective vessel ports prior to connection to the power supply
enclosure to avoid sensor damage from cable twisting.
Quartz Sleeve Installation
Purpose
To thermally protect the UV lamp and isolate it from water.
Frequency
Quartz Sleeve(s) are installed after being inspected/cleaned or damaged. Water quality conditions may warrant more fre-
quent inspection/cleaning. Fouled quartz sleeves absorb UV light and therefore may reduce the UV intensity.
Replace broken quartz sleeve(s).
Parts and Required Equipment
• Quartz Sleeve(s)
• Quartz Sleeve Retaining Nut Gasket
• Adjustable Wrench
• Cotton or Silicon Gloves
• Personal Safety Equipment
General risk due to electricity.
General risk due to pressurized piping or UV Vessel.
Quartz Sleeves are fragile and potentially dangerous if broken. Handle with care.
Procedure
Note: Use clean cotton or silicon gloves when handling the quartz sleeve(s). Skin oils absorb ultraviolet light and reduce
UV intensity.
1. Apply water (wet) or a small amount of water soluble lubricant such as Ideal Industries Clear Glide to the domed-end
of the quartz sleeve. Lubricating will aid in inserting the domed-end of the quartz sleeve into the vessel’s internal
quartz sleeve coupler.
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2. Carefully slide the quartz sleeve(s) into the Quartz Sleeve Faceplate’s “Quartz Sleeve
Module” (QSM) allowing approximately 12” of the quartz sleeve to remain outside the
UV vessel.
3. With 12” of the quartz sleeve exposed outside the vessel, carefully place the Quartz
Sleeve Rubber Gasket Seal onto the open-end of the quartz sleeve. Apply water or a
small amount of water soluble lubricant onto the end of the quartz sleeve, this will act as a
lubricant and will allow you to easily slide the Rubber Gasket onto the quartz sleeve.
4. Push the Rubber Gasket onto the quartz sleeve. Position the Gasket approximately 1/2”
from the sleeve’s open end.
5. As you push the quartz sleeve into the vessel (through the Quartz Sleeve Module) elevate the domed-end of the
quartz sleeve by gently pushing down on the open-end approximately 1/2”. This will help guide the domed-end of the
quartz sleeve into its correct Internal Quartz Sleeve Coupler “Port”.
6. Finish sliding the remainder of the quartz sleeve into the vessel until the gasket makes
contact with the Quartz Sleeve Module.
As you thread and tighten the Quartz Sleeve Retaining Nut onto the Quartz Sleeve
Module the Quartz Sleeve Retaining Nut’s internal lip will automatically set the quartz
sleeve in its proper position.
7. Using a 1.5” socket or adjustable wrench, tighten the Quartz Sleeve Retaining Nut until
snug (5 ft. • lb.). Over-tightening can break the Quartz Sleeve Module on the faceplate or
the quartz sleeve inside the UV vessel.
8. The quartz sleeve is now properly assembled, you are now ready to perform a Water Test See Page 16.
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Procedure
1. Use the supplied enclosure mounting feet if the Power Supply Enclosure is going to be mounted on a wall.
2. Mount the Power Supply Enclosure close to the UV Vessel so that the lamp cables reach between the Power Supply
Enclosure and the UV Vessel. The power supply lamp cables are approximately 10 - 20’ long to provide an adequate
routing length from the power supply enclosure to the UV vessel. Keep in mind that the temperature & UV sensors
have approximately 12’ long cables, so the power supply should be placed within this length constraint to avoid the
additional requirement of sensor extension cables.
3. The Power Supply Enclosure should be mounted so that the controls are visible to the operator. The location used for
mounting the Power Supply Enclosure should be as dry and cool as possible.
4. The Power Supply Enclosure should be located in a place that provides sufficient weather protection, in the case of
outdoor installation. Sufficient space near the cooling fan’s intake and exhaust must be provided.
5. The Power Supply Enclosure must be supplied with the correct operating voltage (120/230 VAC). Electrical requirement
information is located on the Power Supply Enclosure labeling and can be found on Page 8 (Dimensions and Electrical
Specifications) of this manual. Failure to supply the UV System with the correct operating voltage can damage the
ballasts and other electrical hardware. Use only a well-ground electrical circuit.
6. The UV System is equipped with an equipment-grounding conductor and a grounding plug. The grounding plug must
be installed and grounded in accordance with all local codes and ordinances. Improper connection of the equipment-
grounding conductor can result in electrocution. Check with a qualified electrician or service personnel if you question
whether the equipment is properly grounded.
7. Input power to the Power Supply Enclosure is switched on and off using the enclosure’s
External On/Off switch or optional Remote On/Off control.
Power Supply Installation
Purpose
Power Supply Enclosure is part of the complete Bioshield™ UV Disinfection System.
Frequency
Required with new construction, retro-fit or replacement of outdated equipment.
Parts and Required Equipment
• Set of Slot and Phillips Head Screwdrivers
• Adjustable Wrench
• Pliers
• Wall Struts or Braces
• Supplied Enclosure Mounting Hardware
• Personal Safety Equipment
General risk due to suspended load.
General risk due to electricity.
General risk due to pressurized piping or UV Vessel.
Note: All UV control enclosures that utilize our microprocessor controls should be mounted with considerations to
other devices that emit, or are suspected of emitting, any EMI & RFI noise and that any sensors used in conjunc-
tion with our microprocessor controls should use industry standard procedures to avoid EMI & RFI noise issues.
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Remote Main System On/Off Capability (Optional)
A discrete input circuit is provided to allow for Remote On/Off control of the control system. Located inside the main control
enclosure there are two terminal blocks (brown). For remote on/off capability these terminals would be wired to an external
switch capable of handling your unit’s voltage; for example, 230-volt AC @ 1-amp.
Note: The system is supplied with these terminals jumped together as the default ON setting, to use this option the jumper
must be removed and replaced by the user’s own external switch. WARNING: DO NOT SUPPLY ADDITIONAL POWER
TO TERMINALS!
Note: Options below MUST be purchased with original equipment.
Main Power Run Confirm Output Signal (Optional)
The system’s main power contactor circuit is equipped with a Main Power Run Confirm Output Voltage Signal Relay (see
image for terminal locations and identification) that triggers when the lamp field has been energized.
Note: This Run Confirm relay circuit is intended to be used as a status indicator only, and is NOT currently wired for a load
bearing circuit. Please contact Pentair Commercial Aquatics prior to using this relay circuit as anything other than a status
indicator. The three terminal block connections (Gray, White, and Orange) for this output feature are located in the inside of
the power enclosure.
Gray= Normally-Closed
Orange= Normally-Open
White= Common
Gray and White = (Open) when the lamp field has been energized
Orange and White = (Closed) when the lamp field has been energized
4-20 Milliamp Output Connection (Optional)
The Red (+) and Black (-) terminal blocks are the 4-20 milliamp contact connections. Use a digital
multimeter (set on mA) to view the current output (Red probe to the Red terminal, Black probe to
the Black terminal). WARNING: DO NOT SUPPLY ADDITIONAL POWER TO TERMINALS!
Note: The Microprocessor Control system’s analog signal must be specified with original purchase.
Typically this option is used for UV intensity, but it can also monitor the temperature or flow circuit (if
equipped).
Alarm Relays
A discrete output relay circuit (24-VAC/DC 200 milliamp maximum current, normally open
“Form A” contact) is provided to allow for alarm enunciation of any of the following monitored
conditions: lamp failure, low UV intensity, vessel water over-temperature, enclosure over-
temperature, end of lamp life, under/over input voltage alarm and lamp field safety cover. These
two yellow terminal blocks are located inside the main control enclosure. The relay will close when
any alarm is triggered.
Individual Output Alarm Relay (Optional)
(7) Discrete output relay circuits (200 milliamp, 24VAC/DC MAX, normally Open contact)
are provided to allow for alarm enunciation of the following monitored conditions:
Yellow Failsafe that sets on any alarm
Black Lamp status
White End of lamp life
Gray UV intensity low
Green Enclosure over-temp
Orange Vessel water over-temp / Sensor Not attached
Blue Input voltage Low or High
These terminal blocks are located inside the main control enclosure. The relay will close when alarm is triggered.
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Individual Output Alarm Relay (Optional)
(7) Discrete output relay circuits (200 milliamp, 24VAC/DC MAX, normally Open contact)
are provided to allow for alarm enunciation of the following monitored conditions:
Yellow Failsafe that sets on any alarm
Black Lamp status
White End of lamp life
Gray UV intensity low
Green Enclosure over-temp
Orange Vessel water over-temp / Sensor Not attached
Blue Input voltage Low or High
These terminal blocks are located inside the main control enclosure. The relay will close when alarm is triggered.
Temperature & UV Intensity Sensor Installation
Purpose
To instruct the operator how to properly install the Temperature and UV Intensity Sensors.
Frequency
Required with new installation or when servicing the unit during general maintenance.
Parts and Required Equipment
• Flare-Nut Wrenches
• Thread Tape
• Personal Safety Equipment
General risk due to electricity. General risk due to pressurized piping and UV vessel.
General risk due to suspended load.
Note: The sensor cables are approximately 12’ long, if you find that
you require a greater length you can purchase 12’ cable extensions
using the following part numbers:
• Optional UV Intensity Sensor Extension Cable: #20214-EXTCABLE
• Optional Temperature Sensor Extension Cable: #20217-EXTCABLE
• Not Shown = Lamp Field Safety Extension Cable:
#20252-EXTCABLE
Note: The Temperature Sensor must be installed in the vessel with its water tight connector properly connected to
its respective port located on the power supply enclosure. A Temperature Sensor Cable connection interruption will
automatically shut down the system.
2. Use a flare-nut wrench to carefully
tighten the UV sensor and temperature
sensor. These components are made
of soft Polytetrafluoroethylene (PTFE)
and can be easily damaged. Leave the
sensor cables coiled up close to the
sensor during the installation.
3. Once the sensors have been installed
into the vessel you can attach cables
to their respective connection points
located on the bottom of the Power
Supply Enclosure.
Input Connection
Microprocessor Controllers
Temperature Sensor
UV Sensor
UV Sensor
#20217-EXTCABLE#20214-EXTCABLE
WARNING: Sensor-cables should be isolated from other electrical devices, preventing electrical interference.
UV intensity sensor-cables must also be separated from UV lamp cables to minimize electrical interference.
Procedure
1. Install the Temperature and UV Intensity Sensors into their respective port locations as
labeled on the vessel using thread tape to properly seal the sensor threads in the vessel.
To avoid possible sensor damage from cable twisting, DO NOT connect the sensor cables
to the power supply until after they are installed into the vessel. Leave the sensor cables
coiled up close to the sensor during the installation process to allow the cable to rotate
as the sensor is being screwed into the vessel. If the cable becomes twisted during the
installation process, untwist it before proceeding.
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Mandatory Water Test
Purpose
The Mandatory Water Test identifies a potential quartz sleeve assembly seal failure. During normal UV system operation,
a quartz sleeve assembly failure can result in extensive damage to the UV lamp, quartz sleeve and ballast.
Frequency
The Mandatory Water Test must be performed after a quartz sleeve/retaining nut gasket inspection/replacement. Quartz
Sleeve inspection/retaining nut gasket replacement must be carried out annually, at minimum.
Parts and Required Equipment
• Paper Towels
• Personal Safety Equipment
General risk due
UV Lamps are fragile and potentially dangerous if broken. Handle with care.
Procedure
Important: Failure to perform a water test could lead to unsafe conditions and may void your product’s warranties.
1. With the quartz sleeves installed inside the UV vessel, before installation of the UV lamps,
perform a water test as explained below. For quartz sleeve removal See Page 30. For
installation See Page 11.
2. Thread all sensors into their respective ports on the UV vessel.
3. Place rolled-up paper towels into the Quartz Sleeve Retaining Nuts. During the water test,
the paper towels may absorb moisture. The presence of any moisture identifies that a
quartz sleeve seal failure (leak) has occurred.
4. Inspect all piping connections to the UV Vessel and confirm that valves are in their correct position prior to start-up.
5. With satisfactory piping and valve inspection, operate the UV system. Allow water to flow through the UV Vessel for no
less then fifteen minutes.
6. After fifteen minutes of flowing water through the UV vessel, remove the paper towel from each Quartz Sleeve
Retaining Nut and inspect closely for ANY sign of moisture. If leaks are detected, shut the system down and re-install
any quartz sleeve with an inadequate seal. For quartz sleeve removal/installation See Page 30-32.
7. If no leaks were detected you are now ready to install the UV Lamp(s). See Page 17.
SECTION SEVEN
MANDATORY WATER TEST
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1. Remove the white Polytetrafluoroethylene (PTFE) “wire keeping” rings from the UV lamp by
carefully cutting it off with wire cutters.
Note: Be careful not to cut the lamp wires!
2. Gently slide the UV Lamp into the Quartz Sleeve Retaining Nut leaving 6” of the UV lamp
exposed.
IMPORTANT: INSTALL LAMPS WITH AMALGAM SPOT IN DOWN POSITION!
Note: Lower wattage amalgam lamps contain a single mass of amalgam while higher wattage
amalgam lamps contain multiple masses of amalgam.
Procedure
Important: Before installing the UV Lamp(s) a MANDATORY WATER TEST must be performed. See Page 16.
Note: Use clean cotton or silicon gloves when handling the UV lamp(s). Skin oils absorb ultraviolet light and reduce
UV intensity. Skin oils may also lead to premature lamp failure.
UV Lamp Installation
Purpose
To instruct the operator how to properly install the UV lamp(s).
Frequency
Lamp installation in new unit or lamp replacement change-out (after every 12,000 hours of continual operation).
Parts and Required Equipment
• UV Lamp(s)
• Wire Cutters
• Adjustable Wrenches
• Cotton or Silicon Gloves
• Personal Safety Equipment
General risk due to electricity.
UV Lamps are fragile and potentially dangerous if broken. Handle with care.
UV SENSOR
LAMP WIRES
UV LAMP
QUARTZ SLEEVE
UV VESSEL
Note: When installing the lamp into the quartz sleeve position that is
monitored by the UV Intensity Sensor, it is important to make sure the lamp
wires that run the length of the lamp are not facing the sensor. See diagram, at
right for the proper lamp placement.
SECTION EIGHT
UV LAMP INSTALLATION
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Note: Each Lamp cable (1) is equipped with a Water Tight Connector (2). This
cable adapter is made up of three components: Nut (3), Rubber Gasket (4)
and Male-Threaded Body (5).
3. Loosen (not remove) the lamp Water Tight Connector nut (3) to release tension on the lamp cable allowing the cable to
slide freely through the adapter. This will allow the male-threaded body (5) portion of the lamp Water Tight Connector to
be threaded into the white quartz sleeve retaining nut without twisting the lamp cable (after lamp installation).
4. With the UV lamp installed inside the quartz sleeve and six inches exposed,
attached the lamp cable’s stepped 4-Pin Connector on to the four pins of the
UV lamp.
5. With the lamp cable/lamp connection complete gently slide the remainder of the lamp w/ cable through the Quartz
Sleeve Retaining Nut and into the quartz sleeve. With the lamp now inside the quartz sleeve, gently continue to push
the lamp (w/ connected lamp cable) into the quartz sleeve until it stops, then pull out 1/2” of the lamp cable. This will
position the lamp properly inside the quartz sleeve avoiding heat damage to the Quartz Sleeve Module Faceplate and
Quartz Sleeve Module.
6. With the UV lamp in its correct position inside the quartz sleeve, thread the water tight
connector into the Quartz Sleeve Retaining Nut.
7. With the “black” Water Tight Connector threaded into the Quartz Sleeve Retaining Nut,
tighten the Cable Adapter Nut (3) to create a watertight seal on the lamp’s cable. Take
care not to bend or damage the Water Tight Connector’s “gasket prongs” during this
process.
8. The UV lamp is now properly installed.
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