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

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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.
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide

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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
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide

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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.
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide

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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
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide

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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
BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide BIOSHIELD™ Commercial UV Disinfection System Installation and User’s Guide