Rodem Aquionics PureLine M Manual

P
Pu ur re eL Li
in ne e
M M
O
Op pe er ra at ti io on n & & M Ma ai in nt te en na an nc ce e
M
Ma an nu ua al l
Aquionics Inc.
1455 Jamike Avenue, Suite 100
Erlanger, KY 41018
United States of America
Tel [phone]
E-Mail [e-mail]
Web www.aquionics.com

190104-2001-02
Aquionics Contact Details
Should any problems be encountered during the installation, operation and maintenance of your
system, please do not hesitate to contact either our sales team or our service team using the
details below.
Telephone [phone]
Visit us on the web
www.aquionics.com
Email
[email protected]
[email protected]
To order further copies of this manual use the contact details above quoting Order Code
190104-2001.
Copyright © 2016.
All rights and subsequent amendments reserved.
No part of this publication may be reproduced, printed, photocopied stored on microfilm and / or
otherwise made public in any form whatsoever without obtaining the prior written permission of
Aquionics Inc.

PureLine M Operation and Maintenance Manual
Page 1 of 54
Table of Contents
1. INTRODUCTION ....................................................................................................3
1.1 GENERAL...................................................................................................................................3
1.2 SYSTEM OVERVIEW ................................................................................................................3
1.3 DOCUMENTS.............................................................................................................................3
1.4 TEXT CONVENTIONS...............................................................................................................4
2. SAFETY..................................................................................................................5
2.1 GENERAL...................................................................................................................................5
2.2 PICTOGRAMS AND GENERAL SAFETY INSTRUCTIONS.....................................................5
2.3 SYSTEM SAFETY FEATURES..................................................................................................6
2.4 BROKEN LAMPS OR QUARTZ SLEEVES ...............................................................................7
2.5 RECOMMENDED USE ..............................................................................................................7
2.6 NON-RECOMMENDED USE.....................................................................................................7
2.7 CE-MARKING.............................................................................................................................7
3. STORAGE AND TRANSPORT ..............................................................................8
3.1 ON RECEIPT..............................................................................................................................8
3.2 STORAGE..................................................................................................................................8
3.3 UNPACKING ..............................................................................................................................8
3.4 TRANSPORT..............................................................................................................................8
3.5 TAKING THE SYSTEM OUT OF USE TEMPORARILY............................................................8
4. GENERAL SYSTEM DESCRIPTION .....................................................................9
4.1 SYSTEM OVERVIEW ................................................................................................................9
4.2 DISINFECTION REACTOR........................................................................................................10
4.2.1 UV reactor...........................................................................................................................10
4.2.2 UV lamps.............................................................................................................................10
4.2.3 UV sensor ...........................................................................................................................11
4.2.4 Temperature sensor............................................................................................................11
4.2.5 Automatic wiping.................................................................................................................12
4.2.6 Water leak detector.............................................................................................................12
4.2.7 Relay for solenoid valve......................................................................................................12
4.3 CONTROL CABINETS...............................................................................................................13
4.3.1 Main configuration and display ...........................................................................................13
4.4 DIVERT VALVES .......................................................................................................................13
4.4.1 Single valve mode...............................................................................................................13
4.4.2 Multi-valve mode.................................................................................................................13
4.4.3 Divert valve location............................................................................................................14
4.5 ACCESSORIES..........................................................................................................................14
5. CONTROL SYSTEM DESCRIPTION AND OPERATION......................................15
5.1 FUNCTIONS OF THE CONTROL SYSTEM..............................................................................15
5.1.1 Access to the control software............................................................................................15
5.2 OVERVIEW SCREEN ................................................................................................................16
5.3 REACTOR SCREEN..................................................................................................................18

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5.4 CONTROL CABINET CONNECTIONS......................................................................................19
5.5 INSTALLATION AND PREPARING FOR OPERATION............................................................21
5.5.1 General ...............................................................................................................................21
5.5.2 Mechanical installation........................................................................................................21
5.5.3 Electrical installation ...........................................................................................................21
5.5.4 Preparing for operation.......................................................................................................22
5.6 OPERATION...............................................................................................................................23
5.6.1 Switching on and off............................................................................................................23
5.6.2 Automatic cleaning system.................................................................................................23
5.7 REMOTE CONTROL EVENT SEQUENCES.............................................................................24
5.7.1 Single valve mode...............................................................................................................24
5.7.2 Multi-valve mode.................................................................................................................24
5.8 WARNINGS AND TRIPS............................................................................................................26
5.8.1 Alarms screen.....................................................................................................................26
5.8.2 Resetting the system ..........................................................................................................26
5.8.3 Alarm log.............................................................................................................................26
5.9 SETTINGS..................................................................................................................................27
5.10 TROUBLESHOOTING ...............................................................................................................31
5.10.1 Alarms.................................................................................................................................31
5.10.2 Malfunctions of the temperature sensor .............................................................................32
5.10.3 Other troubleshooting .........................................................................................................33
5.11 REPORTING DATA....................................................................................................................34
5.11.1 Database records................................................................................................................34
5.11.2 Backing-up data..................................................................................................................34
5.11.3 Replacing the memory card................................................................................................34
5.11.4 Generating reports..............................................................................................................35
5.11.5 Exporting reports.................................................................................................................35
6. MAINTENANCE OF THE REACTOR AND THE CONTROL CABINETS..............36
6.1 CLEANING THE QUARTZ SLEEVES........................................................................................36
6.1.1 General ...............................................................................................................................36
6.1.2 Chemical cleaning method..................................................................................................36
6.2 CLEANING THE UV SENSOR AND QUARTZ WINDOW .........................................................36
6.2.1 Cleaning procedure.............................................................................................................37
6.3 MAINTENANCE OF THE AUTOMATIC CLEANING MECHANISM..........................................39
6.3.1 Introduction and safety aspects..........................................................................................39
6.3.2 Wiper replacement procedure.............................................................................................39
6.4 VENTILATION OF THE CONTROL CABINET ..........................................................................41
6.5 EARTH LEAKAGE CIRCUIT BREAKER CHECK......................................................................41
6.6 CLEAN-IN-PLACE......................................................................................................................41
7. REPLACING LAMPS AND QUARTZ SLEEVES ...................................................42
7.1 SAFETY PRECAUTIONS...........................................................................................................42
7.2 MAIN REPLACEMENT PROCEDURE ......................................................................................43
7.2.1 Resetting the service history...............................................................................................48
7.3 REMOVING QUARTZ SLEEVES WITH THE JUPITO ..............................................................49
8. DISPOSAL..............................................................................................................51
8.1 GENERAL...................................................................................................................................51
8.2 RETURNING OLD LAMPS.........................................................................................................51

PureLine M Operation and Maintenance Manual
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1. INTRODUCTION
1.1 GENERAL
The objective of this manual is to explain clearly to
users the installation and operation of the PureLine M
water treatment system.
Users are advised to study this manual carefully –
chapter 2 in particular is important in helping to ensure
user safety.
The people that work with the systems are expected to
have sufficient in-depth knowledge of the applied
techniques and a thorough command of the operating
instructions and to be aware of the possible dangers
and risks.
1.2 SYSTEM OVERVIEW
The PureLine M water treatment system has been
developed to create ‘pasteurised equivalent water’ to
be used in the manufacture of dairy food and drink
products. The system is designed to comply with the
requirements of the Grade “A” Pasteurised Milk Ordi-
nance (PMO) issued by the United States Department
of Health and Human Services.
The system exposes the water to ultraviolet (UV) light
which deactivates germs, viruses, bacteria, spores,
fungi, algae and other micro-organisms quickly and
safely. For this purpose, a number of UV lamps are
placed in the liquid flow within a stainless steel reactor
to deliver a known UV dose within the normal process
ranges of flow rate and UV transmittance.
The system is powered and controlled via a separate
control panel. The control computer within this panel
continuously records the system’s status and operat-
ing parameters in a secure database which is stored in
the hard drive of the control computer, and backed-up
regularly to a separate memory card. A separate soft-
ware application (Crystal Reports v14) allows reports
to be generated from the stored system data. The
computer communicates using Ethernet with a
touchscreen display through which the user can con-
trol and monitor the system.
The control panel also sends a signal to operate a
divert valve if a PMO non-compliance occurs, to pre-
vent untreated water from entering the process. The
water is either run to drain or recirculated until the non-
compliance is resolved.
1.3 DOCUMENTS
In addition to this user manual, the following docu-
ments are included:
CE-declaration
Certificate of quality
Implementation card
Product specific technical user manual, including:
oElectrical circuit diagrams
oMechanical drawings
oDrawing of the lamp configuration
oSpare parts list
Unless stated otherwise, this user manual is valid for
the systems that are indicated on the front page.
Wherever system differences are relevant, this will be
mentioned additionally.
The manual is based on current developments in UV
technology. The supplier shall retain the right to make
amendments to the documentation without being
obliged to modify preceding versions.
Store this manual carefully for future use.
Attention
The pictures and drawings in this manual may deviate
in detail or may be a mirror image of the actual situa-
tion.
Most photographs are taken in laboratory circum-
stances or on work benches.

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1.4 TEXT CONVENTIONS
The following terms are used to draw additional atten-
tion to specific sections of the text:
Tip
Suggestions and advice for carrying out specific tasks
more easily or practically.
Attention
This remark is placed next to the text to draw the us-
er’s attention to possible problems.
Caution
If procedures are not carried out with due care and
attention, the system can be damaged.
Warning
If procedures are not carried out carefully, the user or
other persons could be injured or the system could be
seriously damaged.
The following symbols are used in this manual:
Summary of a number of options:
Option 1
Option 2
...
Action to be carried out:
Step 1
Step 2
...

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2. SAFETY
2.1 GENERAL
The UV system is built for easy and efficient operation.
Users should nevertheless take proper note of the
remarks accompanying the text in this manual and act
accordingly.
Persons working on or in the direct vicinity of the sys-
tem must be familiar with these instructions.
In addition to the instructions in this manual, generally
applicable safety rules and regulations must be ob-
served at all times.
2.2 PICTOGRAMS AND GENERAL
SAFETY INSTRUCTIONS
For using the UV system, the following pictograms and
safety instructions are important:
Wear safety glasses to prevent eye
injuries from ultraviolet light.
Do not look directly into a UV lamp that
is switched on.
Do not unnecessarily expose your skin
to UV radiation.
Wear clean gloves free of talc powder
and grease when handling the lamps.
If you do have to hold the lamps, do so
by the connectors.
Remember UV lamps remain hot for a
considerable time after they have been
turned off.
Allow the lamps to cool off after use for
at least 15 minutes.
The disinfection reactor and the control
unit have to be wired to an earth leak-
age circuit breaker with sufficient ca-
pacity.
Switch the power supply off before car-
rying out repair work and maintenance.
Take account of the fact that there is
inadequate disinfection if the lamps are
not up to temperature or if the lamps
have been switched off
Also: general safety symbol.
The UV lamps contain mercury.
Take defective lamps to a depot for
chemical waste.
See section 2.4 for details of what to do
if a lamp breaks.
Do not dispose of old lamps as unsort-
ed municipal waste.
The following points of attention should also be taken
into account:
Keep your work area clean and tidy and make
sure it is properly illuminated.
Keep control cabinets closed during normal use.
Only use original Hanovia parts.
Carry out proper maintenance on a regular basis.
Read the maintenance instructions in chapter 6
and 7.

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2.3 SYSTEM SAFETY FEATURES
The UV system is fitted with the following safety fea-
tures:
Effective protection against the UV radiation pro-
duced by the lamps.
Safeguards to prevent the lamps and the power
supply cabinet from overheating.
Quality control of the UV lamps in order to monitor
the liquid disinfection process.
The following safety stickers have been placed on the
system:
Location:
End closure of the UV reactor
Location:
Outside the control cabinet(s)
Warning
Replace stickers if they are damaged or lost.

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2.4 BROKEN LAMPS OR QUARTZ
SLEEVES
The UV lamps contain a small amount of mercury. If a
lamp breaks, the mercury has to be collected by bind-
ing it with sulphur powder. Carefully remove the mer-
cury after collecting it.
If necessary, defective or burnt-out lamps can be sent
back to the system supplier.
Warning
Avoid contact with the skin and eyes, do not breathe
in any vapours and make sure there is sufficient ven-
tilation.
Warning
Take the mercury to a depot for chemi-
cal waste in accordance with local regu-
lations.
If one of the quartz sleeves breaks:
Shut off the liquid supply pipes immediately and
switch the system off (if this is not done automati-
cally).
Open the UV reactor as described in chapter 6
and 7. Remove all fragments and other lamp
parts (wear suitable protective clothing and use
any protective means necessary.).
Carefully rinse the reactor with clean water and
make sure that no dirt or cleansing agent residue
gets into the water.
Replace any defective components.
Only switch on the system after the reactor has
been completely filled with water again (consult
the start-up procedure in section 5.6.1).
2.5 RECOMMENDED USE
The system is designed for disinfecting UV per-
meable liquids such as waste water, drinking wa-
ter and process water (see technical data sheet).
For other applications it is advisable to contact
your supplier’s representative.
There are restrictions when using liquids, which
have high concentrations of dissolved minerals or
salts. High concentrations of these substances
can cause corrosion of metal components. Con-
tact your supplier for further information.
A high concentration of particulates in the medium
can cause excess wear. Contact your supplier for
further information.
The system may only be used in the configuration
described in this document.
2.6 NON-RECOMMENDED USE
The system should never, under any circum-
stances whatsoever, be switched on if it is not
completely built into the adjoining pipework. The
UV lamps must be shielded at all times to prevent
harmful UV radiation.
Do not remove plugs or other components which
allow any UV radiation to be emitted to the out-
side.
Consult your supplier representative before using
transparent pipework systems.
Mechanical modifications to the system, such as
drilling holes or welding on parts can damage the
system.
2.7 CE-MARKING
The system complies with the EU Directive for ma-
chine safety. The respective CE declaration is sup-
plied separately with the system. An example is shown
in the appendix at the back of this manual.

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3. STORAGE AND TRANSPORT
3.1 ON RECEIPT
Check the goods on receipt for signs of transport
damage. Report any such cases directly to the carrier
and your supplier. Take photographs of any damage
and store the packaging for inspection.
3.2 STORAGE
If you do not intend to install the system immediately, it
is advisable to store the components in their original
packaging. Avoid jolts and excessive vibrations.
UV lamps must always be stored in the original pack-
aging.
The storage area must meet the following require-
ments:
Atmospheric humidity : 10 – 80% RH
Temperature : 10 – 30°C
3.3 UNPACKING
Read any instructions and warning messages that
may be attached to the packaging. Even though they
are packed separately, please bear in mind that the
lamps are fragile and should be handled with care.
Keep the lamps in their individual original packaging
until they are to be installed in the reactor.
Check that your delivery is complete from the packer’s
receipt. Report any parts that are missing directly to
the carrier and your supplier.
When the system is shipped, the UV lamps are
packed separately from the UV reactor. The lamps
should only be fitted after the installation has been
completed mechanically and electrically and connect-
ed up. The procedure for fitting the lamps is described
in chapter 7.
3.4 TRANSPORT
If internal transport of the system is necessary, make
sure that:
the UV lamps have been removed and that they
are stored in their original packaging;
the system has been completely disconnected
from the electricity mains;
the system is clean and dry;
all the components are suitably protected against
external contaminants and damage.
3.5 TAKING THE SYSTEM OUT OF USE
TEMPORARILY
If the system is taken out of use temporarily, it is im-
portant to flush the system with clean water so that no
sand, salts or other corrosive materials remain behind
in the system. Leave the system in a dry state.
Dissolved and non-dissolved particulates (such as
minerals) may affect the high-grade stainless steel if
the medium is stagnant.