Trojan Technologies Aquafine TrojanUVLogic Series User manual

PLEASE KEEP FOR PERMANENT REFERENCE
Part Number 127 Rev E
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DISINFECTION • TOC REDUCTION • OZONE DESTRUCTION • CHLORINE/CHLORAMINE DESTRUCTION
TrojanUVLogic Series
Installation & Operation Manual
It is imperative that those responsible for the installation
of this equipment, as well as operating personnel, read this
manual and carefully follow all instructions and guidelines.
EQUIPMENT OPERATORS AND INSTALLERS MUST COM-
PLY WITH OPERATIONAL SAFETY REQUIREMENTS.
A TROJAN TECHNOLOGIES COMPANY
READ THIS MANUAL

TrojanUVLogic
TM
Revision:E
LastUpdate:07AU21
PlaceSystemLabel
Here.
Ifnolabelhasbeen
placedhere,referto
thelabelonthe
UVEquipment
fordetails.
Forfurtherclarificationoflabelinformation,pleaserefertoChapter2,page23,“SystemVerification
LabelDefinitions”.
Recordsystemsetpointsindicatedbelow:
UVIntensitySetPoint
TheTrojanUVLogic
TM inthismanualmaybecoveredbyoneormoreofthe
followingUnitedStates(US)Patents:
US6,342,188
US6,659,431
US6,564,157
US6,635,613
OTHERPATENTSMAYBEPENDING.
COPYRIGHT©2008byAQUAFINECORPORATION
ALLRIGHTSRESERVED

Volume Table of Contents
Trojan ogicTM Operations and Maintenance
UVL
PREFACE III
GENERAL INFORMATION.....................................................................................................................III
IMPORTANT CONTACTS...................................................................................................................... IV
WARNINGS AND PRECAUTIONS......................................................................................................... V
GENERAL LOCKOUT PROCEDURES ................................................................................................. XI
Lockout and Tag Procedure...............................................................................................................xi
LIST OF ACRONYMS/GLOSSARY...................................................................................................... XII
TROJANUVLOGIC MAINTENANCE REQUIREMENTS
TM .................................................................. XIII
Maintenance Schedule .................................................................................................................... xiv
Maintenance Checklist.....................................................................................................................xvi
Alarm Log........................................................................................................................................ xvii
System Operating Parameters.........................................................................................................xix
Maintenance Log ..............................................................................................................................xx
Lamp Log Table...............................................................................................................................xxi
1 INTRODUCTION TO UV THEORY 1-1
1.1 OVERVIEW OF TROJANUVLOGICTM ............................................................................................1-1
1.2 WHAT IS ULTRAVIOLET LIGHT?..................................................................................................1-1
1.3 DISINFECTION VS. STERILIZATION.............................................................................................1-2
1.4 APPLICATIONS OF UV LIGHT ......................................................................................................1-2
1.5 FACTORS AFFECTING UV DISINFECTION..................................................................................1-2
UV Transmittance:...............................................................................................................................................1-3
Suspended Solids:..............................................................................................................................................1-3
Level of Total Dissolved Solids:..........................................................................................................................1-3
Total Hardness:...................................................................................................................................................1-4
Sleeve Cleanliness:.............................................................................................................................................1-4
Treatment Process:.............................................................................................................................................1-4
Flow Rate:............................................................................................................................................................1-4
2 SYSTEM OVERVIEW 2-1
2.1 SYSTEM COMPONENTS ...............................................................................................................2-1
UV Reactor (UVR)............................................................................................................................................2-1
Control Panel (CP)...........................................................................................................................................2-1
UV Sensor........................................................................................................................................................2-2
Wiping Systems ...............................................................................................................................................2-2
Automatic Mechanical Wiping System (AMWS)....................................................................................................................2-2
Manual Mechanical Wiping System (MMWS)........................................................................................................................2-3
Power Pack.................................................................................................................................................................................2-3
2.2 OPERATIONS OVERVIEW.............................................................................................................2-3

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Trojan ogicTM Operations and Maintenance
UVL
Main Menu Screen........................................................................................................................ 7-18
Active Alarms Screen.................................................................................................................... 7-18
Alarms List Screen Series............................................................................................................. 7-18
Alarm History Screen.................................................................................................................... 7-18
Alarm History Details Screen........................................................................................................ 7-18
Digital Input-Output Screen Series ............................................................................................... 7-19
Operator Access Level Screens..................................................................................................................7-19
Technician Level Access Screens..............................................................................................................7-19
Analog Input-Output Screen Series.............................................................................................. 7-20
Operator Access Level Screens..................................................................................................................7-20
Technician Level Access Screens..............................................................................................................7-20
System Settings Screens.............................................................................................................. 7-21
Operator Access Level Screens..................................................................................................................7-21
Technician Level Access Screens..............................................................................................................7-22
Trend Screens .............................................................................................................................. 7-23
Wiper Screen (AMWS)(For systems with a Wiper)...................................................................... 7-24
Wiper Sequence Timer (AMWS) (For systems with a Wiper)................................................................7-24
Wiper Auto Power Off (For systems with a Wiper)..................................................................................7-24
Analog Menu Screen .................................................................................................................... 7-25
Reactor Hi Temp (Reactor High Temperature) Configure Screen (Optional)............................... 7-25
Login Screen................................................................................................................................. 7-26
7.4 SYSTEM STATUS ALARM LIST..................................................................................................7-27
7.5 ALARM OVERVIEW......................................................................................................................7-27
Minor Alarms................................................................................................................................. 7-27
Major Alarms................................................................................................................................. 7-28
Critical Alarms............................................................................................................................... 7-29
7.6 INPUT AND OUTPUT OVERVIEW ...............................................................................................7-30
Standard Inputs and Outputs........................................................................................................ 7-30
Optional Inputs and Outputs......................................................................................................... 7-30
Additional Inputs and Outputs....................................................................................................... 7-31
7.7 DIGITAL OUTPUT WIRING DIAGRAMS......................................................................................7-31
8 ALARMS AND TROUBLESHOOTING 8-1
8.1 ALARM INDICATORS.....................................................................................................................8-1
8.2 GENERAL TROUBLESHOOTING..................................................................................................8-9
9 INSTALLATION INSTRUCTIONS 9-1
9.1 OVERVIEW .....................................................................................................................................9-1
9.2 SHIPPING CONTENTS...................................................................................................................9-1
9.3 SET-UP............................................................................................................................................9-1

Volume Table of Contents
Trojan ogicTM Operations and Maintenance
UVL
UV Sensor...........................................................................................................................................................7-3
External Interfaces............................................................................................................................................7-3
SCADA Communication (Optional)...............................................................................................................7-3
Alarms.................................................................................................................................................................7-3
Auto Home Position Reset (if Wiper is provided).......................................................................................7-4
Reactor Proximity Switch Input (Rev Counter)...........................................................................................7-4
Alarm Output Relays........................................................................................................................................7-4
7.2 CONTROL PANEL (CP) HARDWARE...........................................................................................7-5
Description...................................................................................................................................... 7-5
Specifications ....................................................................................................................................................7-5
Maintenance.......................................................................................................................................................7-6
Power Pack..................................................................................................................................... 7-6
Description.........................................................................................................................................................7-6
Specifications ....................................................................................................................................................7-6
Electronic Ballasts........................................................................................................................... 7-6
Description.........................................................................................................................................................7-6
Maintenance.......................................................................................................................................................7-0
AM Model –Ballast Removal & Replacement ............................................................................7-0
AS & AL Model –Ballast Removal & Replacement....................................................................7-8
System Controller – The Control Board........................................................................................ 7-10
Description.......................................................................................................................................................7-10
Board Power supply requirements – AM Models....................................................................................7-10
P40 Board Power supply requirements –AS and AL Models................................................................7-10
Board Diagram.................................................................................................................................................7-11
RS232 Com Port......................................................................................................................7-13
Ballast Communication Ports...................................................................................................7-13
Lamp Status (Midflow Models Only) ........................................................................................7-13
Board Fuse...............................................................................................................................7-13
Keypad Connector ...................................................................................................................7-13
VFD Communication Port ........................................................................................................7-13
Battery Replacement......................................................................................................................................7-13
Input / Output Features..................................................................................................................................7-13
Programmable Output Relays..................................................................................................7-13
Digital Output Relays (if Wiper is provided) .............................................................................7-14
Digital Inputs ............................................................................................................................7-14
Analog Inputs...........................................................................................................................7-14
Analog Outputs ........................................................................................................................7-14
Operator Interface......................................................................................................................... 7-15
Operation..........................................................................................................................................................7-15
Specifications ..................................................................................................................................................7-15
Maintenance.....................................................................................................................................................7-16
7.3 CONTROL PANEL (CP) SOFTWARE..........................................................................................7-16
Boot Menu Screen........................................................................................................................ 7-16
Main Display Screen..................................................................................................................... 7-16
UV Sensor..................................................................................................................................... 7-16
Reactor Temp Option (4 – 20 Analog Required): ......................................................................... 7-17

Volume Table of Contents
Trojan ogicTM Operations and Maintenance
UVL
5 MECHANICAL WIPING SYSTEM (OPTIONAL) 5-1
5.1 INTRODUCTION .............................................................................................................................5-1
Description...................................................................................................................................... 5-1
5.2 MANUAL MECHANICAL WIPING SYSTEM (MMWS) (OPTIONAL).............................................5-1
Description...................................................................................................................................... 5-1
Maintenance ................................................................................................................................... 5-1
Manual Wiper Assembly Removal....................................................................................................................5-1
Push Retainer Replacement..............................................................................................................................5-2
Sleeve Wiper Replacement (MMWS)...............................................................................................................5-3
5.3 AUTOMATIC MECHANICAL WIPING SYSTEM (AMWS) (OPTIONAL) ....................................5-5
Description...................................................................................................................................... 5-5
Wiping System Drive...........................................................................................................................................5-5
Wiping System Operation...................................................................................................................................5-5
Specifications.................................................................................................................................. 5-5
Maintenance ................................................................................................................................... 5-5
Gear Motor Removal...........................................................................................................................................5-5
Stop Plate Bushing Replacement......................................................................................................................5-7
Drive Screw Roller Bearing, O-ring & Seal Replacement...............................................................................5-8
Sleeve Wiper Replacement (AMWS)................................................................................................................5-9
Drive Nut Removal /Replacement..................................................................................................................5-12
6UVSENSOR 6-1
6.1 INTRODUCTION .............................................................................................................................6-1
Description...................................................................................................................................... 6-1
Specifications.................................................................................................................................. 6-1
Maintenance ................................................................................................................................... 6-1
UV Sensor Removal and Cleaning................................................................................................................6-1
UV Sensor Replacement .................................................................................................................................6-2
7CONTROLPANEL(CP) 7-1
7.1 OPERATIONAL DETAILS ..............................................................................................................7-1
Controls Philosophy........................................................................................................................ 7-1
Control System Overview ...............................................................................................................................7-1
UV Reactor Control...........................................................................................................................................7-1
Normal Operation Start-up..............................................................................................................................7-1
Normal Operation..............................................................................................................................................7-1
Shutdown............................................................................................................................................................7-2
Lamp Control and Monitoring........................................................................................................................7-2
Wiping System (Optional) ...............................................................................................................................7-2

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Trojan ogicTM Operations and Maintenance
UVL
Control System Overview ............................................................................................................... 2-3
2.3 SYSTEM VERIFICATION LABEL DEFINITIONS...........................................................................2-4
3 START UPAND SHUT DOWN PROCEDURES 3-1
3.1 START UP UV SYSTEM.................................................................................................................3-1
3.2 SHUT DOWN UV SYSTEM.............................................................................................................3-1
4UVREACTOR(UVR) 4-1
4.1 INTRODUCTION .............................................................................................................................4-1
Description...................................................................................................................................... 4-1
Specifications.................................................................................................................................. 4-3
Maintenance ................................................................................................................................... 4-3
4.2 END CAPS ......................................................................................................................................4-3
Description...................................................................................................................................... 4-3
Specifications.................................................................................................................................. 4-3
Maintenance ................................................................................................................................... 4-3
End Cap Removal & Installation....................................................................................................................4-3
For Bolt-On Flange Style End Plates (20+cm Diameter Models)...............................................4-3
For Sanitary Clamp Style (Up to and including 20cm diameter chambers) ...............................4-4
4.3 UV LAMP ASSEMBLY....................................................................................................................4-4
Description...................................................................................................................................... 4-4
Specifications.................................................................................................................................. 4-4
Maintenance ................................................................................................................................... 4-4
Maintenance ................................................................................................................................... 4-5
Lamp Inspection/Replacement......................................................................................................................4-5
Elapsed Time Reset..........................................................................................................................................4-7
Lamp Number Configuration..........................................................................................................................4-7
4.4 QUARTZ SLEEVES ........................................................................................................................4-7
Description...................................................................................................................................... 4-7
Specifications.................................................................................................................................. 4-7
Maintenance ................................................................................................................................... 4-8
Sleeve Replacement.........................................................................................................................................4-8
Sleeve Cleaning...............................................................................................................................................4-11
Sleeve Cleaning Solutions.......................................................................................................4-11
Sleeve Cleaning Procedure .....................................................................................................4-11
Sleeve Holder / Wiper Assembly Removal................................................................................................4-11
Sleeve Bushing Replacement......................................................................................................................4-13
4.5 TEMPERATURE SWITCH ............................................................................................................4-15
Description.................................................................................................................................... 4-15
Specifications................................................................................................................................ 4-15

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Trojan ogicTM Operations and Maintenance
UVL
9.4 AUTOMATIC MECHANICAL WIPING SYSTEM (AMWS) INSTALLATION..................................9-4
9.5 SYSTEM START-UP.......................................................................................................................9-4
Appendices................................................................................................. ..
APPENDIX A........................................................................................................................ WARRANTY
........................................................................................................................ Certificate of Equipment Warranty
APPENDIX B.............................................................................................REPLACEMENT PARTS LIST
APPENDIX C............................................................................................................................LAYOUT DRAWINGS
.................................... LG0001D01 - STD., UVLOGIC SHORT LAMP 40 SERIES (AMWS AND NO WIPING)
.......................................LG0004D01 - STD., UVLOGIC LONG LAMP 50 SERIES (AMWS AND NO WIPING)
............................................................LG0005D01 - STD., UVLOGIC LONG LAMP 30 SERIES (NO WIPING)
....................................................................LG0006D01 - STD., UVLOGIC LONG LAMP 30 SERIES (MMWS)
....................................................................LG0007D01 - STD., UVLOGIC LONG LAMP 30 SERIES (AMWS)
..............................................LG0008D01 - STD., UVLOGIC SHORT/LONG LAMP 20 SERIES (NO WIPING)
.....................................LG0009D01 - STD., UVLOGIC SHORT/LONG LAMP 20 SERIES (NO WIPING) ANSI
......................................................LG0010D01 - STD., UVLOGIC SHORT/LONG LAMP 20 SERIES (MMWS)
........................... LG0011D01 - STD., UVLOGIC SHORT/LONG LAMP 20 SERIES (MMWS) ANSI
..................................................... LG0012D01 - STD., UVLOGIC SHORT/LONG LAMP 20 SERIES, (AMWS)
............................................. LG0013D01 - STD., UVLOGIC SHORT/LONG LAMP 20 SERIES (AMWS) ANSI
.................................................................... LG0014D01 - STD., UVLOGIC MIDFLOW SERIES, (NO WIPING)
.......................................................... LG0015D01 - STD., UVLOGIC MIDFLOW SERIES, (NO WIPING) ANSI
........................................................................... LG0016D01 - STD., UVLOGIC MIDFLOW SERIES, (MMWS)
...................................................................LG0017D01 - STD., UVLOGIC MIDFLOW SERIES, (MMWS)ANSI
APPENDIX D..................................................................................................ELECTRICAL DRAWINGS
..............................................LG0002D01 – STD., UVLOGIC SINGLE LINE DIAGRAM – MIDFLOW MODELS
..........................LG0003D01 – STD., UVLOGIC SINGLE LINE DIAGRAM – SHORT / LONG LAMP MODELS
.............................................................................LG0018D01 – STD., UVLOGIC INTERCONNECT DIAGRAM
APPENDIX E...................................................................................SCADA COUMMICATION MODULE
E.1 P40 MODBUS ACTIONS AT POWER UP...................................................................................................V
E.2 MODBUS COMMANDS...............................................................................................................................VI
E.3 LOGIC/SWIFTSC CCB RECEIVE PROTOCOL (FROM PLANT PLC)....................................................... IX
E.4 LOGIC/SWIFTSC CCB TRANSMIT PROTOCOL (FROM P40 TO PLC)....................................................X
E.5 REVISION HISTORY................................................................................................................................XXII

PREFACE
TrojanUVLogic
TM Operations&Maintenance
i
Preface ....................................................................................................iii
GENERALINFORMATION ................................................................................................................................ III
IMPORTANTCONTACTS..................................................................................................................................IV
WARNINGSANDPRECAUTIONS......................................................................................................................V
GENERALLOCKOUTPROCEDURES ..............................................................................................................XI
LockoutandTagProcedure...........................................................................................................................xi
LISTOFACRONYMS/GLOSSARY...................................................................................................................XII
TROJANUVLOGIC
TM MAINTENANCEREQUIREMENTS................................................................................XIII
MaintenanceSchedule ................................................................................................................................xiv
MaintenanceChecklist.................................................................................................................................xvi
AlarmLog.................................................................................................................................................. xviii
SystemOperatingParameters.....................................................................................................................xix
MaintenanceLog..........................................................................................................................................xx
LampLogTable ..........................................................................................................................................xxi

PREFACE
TrojanUVLogic
TM Operations&Maintenance
ii

PREFACE
TrojanUVLogic
TM Operations&Maintenance
iii
PREFACE
GeneralInformation
Congratulationsonyourpurchaseofthe
TrojanUVLogic
TM
ThisOperationsandMaintenance(O&M)
Manualprovidesinstructionsonhowtooperate
thesystemandcarryoutroutinemaintenance.
Theobjectiveofthismanualistoprovide
simple,clearandcompleteinstructions.Itis
backedbyAquafineCorporationscommitment
tooffersuperiorcustomersupport.Everyeffort
hasbeentakentoensuretheaccuracyand
completenessofinformationinthismanual.
Ifyoudonotunderstandanyofthe
informationorprocedureexplanationsin
thismanual,callyourAquafineService
Providerforassistance.
Donotundertakeoperation,repairsor
servicingofequipmentunlessyouarefamiliar
withtheoperationandservicingoftechnical
equipmentandaretrainedinelectricaland
mechanicalsafety.
Ifyourleveloftraining,skillorcomprehension
ofthemanual’sinstructionscouldpossibly
resultininjuryordamagetotheequipment,
havetheworkdonebyaqualifiedoperatorora
Aquafinerepresentative.Yourcommonsense
andgoodjudgmentarecrucialtothesafeand
successfuloperationandmaintenanceofthe
TrojanUVLogic™.
1. ReadtheWarningsandPrecautions and
GeneralLockoutProcedure inthissection
beforeoperatingorperformingany
maintenanceonthisequipment.
2. Readprocedures thoroughlybeforestarting.
3. Reviewallwarningsandcautionsthat
accompanyanyprocedureandreviewthe
WarningsandPrecautions sectioneachtime
youpreparetoperformmaintenanceonthe
TrojanUVLogic
TM
Threetypesofnoticesareusedinthismanual.
WARNING
CONTAINSINFORMATIONTHATIF
NOTHEEDED,MAYRESULTIN
INJURYTOPERSONNELOR
EQUIPMENTDAMAGE.
CAUTION
TELLSREADERSWHENCAREIS
NEEDEDTOPREVENTEQUIPMENT
DAMAGE.
Note:PROVIDESCOMMENTSWHICHCLARIFY
INFORMATION.
ThissectionoftheO&MManualcontains
ImportantContacts,WarningsandPrecautions,
GeneralLockoutProcedures,andaListof
AcronymsandGlossaryofTerms.
Chapter1providesanintroductionintothe
theoryofultravioletlightdisinfection.
Chapter2  isanoverviewofthe
TrojanUVLogic™ComponentsandOperation
anddescribesregularMaintenance
Procedures.
Chapter3  providesinstructionsforthestartup
andshutdownoftheTrojanUVLogic
TM
Chapters4 7  providesdetailsforthe
operation,maintenanceandspecificationsfor
themajorcomponentsoftheTrojanUVLogic
TM
includingtheUVReactor(UVR),Lampsand
Sleeves,UVSensor(s),ControlPanel,and
optionalManualorAutomaticMechanical
WipingSystems.
Chapter8  providesinformationonAlarmsand
Troubleshooting.
Chapter9 – providesInstallationInstructionsfor
theTrojanUVLogic
TM

PREFACE
TrojanUVLogic
TM Operations&Maintenance
iv
Appendicesincludeavarietyofmaterialsuch
asElectricalDrawings,LayoutDrawingsand
theEquipmentWarranty.
ImportantContacts
AQUAFINECORPORATION
HeadOffice(Canada)
29010AvenuePaine
Valencia,CA91355
TollFree:18004233015
(outsideCA,withinUSA&Canadaonly)
Phone:6612574770
Fax:6612572489
Internet:www.aquafineuv.con
Europe†
AquafineGmbH
Ramskamp7785
D25337Elmshorn
Germany
Phone:+49(4121)5780613
Fax:+49(4121)5780630
†ForprojectsinContinentalEurope
LocalRepresentative

PREFACE
TrojanUVLogic
TM Operations&Maintenance
v
WarningsandPrecautions
Pleasereadwarningsandprecautionsbeforeproceedingwithoperation,maintenanceorrepairofthe
equipment.Alwaysfollowlocalsafetycodesandensuretoolsandpersonalprotectiveequipmentarein
goodconditionandproperlyfittedandtested.
WARNING
WearUVResistantFaceShield!
UNPROTECTEDEXPOSURETOULTRAVIOLETLIGHTCANCAUSESEVERE BURNSTOTHEEYESAND
SKIN. FACESHIELDSHOULDBEWORNASTHEPRIMARYPROTECTIONAGAINSTSUCHEXPOSURE.
NEVERLOOKDIRECTLYATTHEENERGIZEDLAMPSUNLESSYOUAREWEARINGULTRAVIOLET
RESISTANTFACESHIELDORGLASSES(FORSHORTTERMEXPOSURE)
EyeProtectionMustbeWorn!
ASADDEDPROTECTION,ORASAMINIMUMPROTECTIONFORSHORTTERMEXPOSURES,TIGHT
FITTINGGLASSESWITHSIDESHIELDSPROTECTIONWHERESUCHSHIELDSARECONTIGUOUSMUST
BEWORNATALLTIMESWHENTHEREISAPOTENTIALEXPOSURETOULTRAVIOLETLIGHT. GLASSES
SUCHASWRAPAROUNDSTYLEAREMOSTEFFECTIVE.
WearProtectiveGloves!
ALWAYSWEARPROTECTIVEGLOVESWHENWORKINGONEQUIPMENT.
WearSafetyBoots!
ALWAYSWEARPROTECTIVEFOOTWEARWHENWORKINGONEQUIPMENT.
WearEarProtection!
THETROJANUVLOGIC™DOESNOTPRODUCEAHARMFULLEVELOFNOISE,BUTUSERSARE
CAUTIONEDTHATTHEYSHOULDWEARHEARINGPROTECTIONASAPPROPRIATETOPROTECT
AGAINSTOTHERNOISETHATMAYBEPRESENTATAWASTEWATERORWATERTREATMENTPLANT.

PREFACE
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WARNING
ElectricalHazard!
BECAUSEOFTHEPOTENTIALHAZARDFROMTHISPOWERSOURCE,ITISPRUDENTTOUSELOCK
OUTPROCEDURESANDTAGALLSOURCESOFPOWERBEFOREPERFORMINGANYMAINTENANCE,
CLEANINGORREPAIRSONANYPIECEOFEQUIPMENT. THEPOWERSOURCESMAYINCLUDE
ELECTRICALORSTOREDENERGY. REFERTOTHEGENERALLOCKOUTANDTAGPROCEDURESIN
THISMANUAL.
WearHardHat!
WEARANAPPROVEDHARDHATANDOTHERPERSONALPROTECTIVEEQUIPMENTTHATISREQUIRED
ACCORDINGTOCONSTRUCTIONSITE,WASTEWATERORWATERTREATMENTPLANTSAFETY
REGULATIONS.
TripHazard!
STAYALERTANDBEAWAREOFPOTENTIALTRIPHAZARDSBEFOREWORKINGONEQUIPMENT.
HotSurface!
ALLOWELECTRONICBALLASTANDLAMPSTOCOOLBEFOREHANDLING.
ULTRAVIOLETLAMPSBECOMEHOTDURINGOPERATION. HOTLAMPSCANCAUSESERIOUS BURNS.
ALLOWTHELAMPSTOCOOLBEFORESERVICING.
3~THREEPHASEALTERNATINGCURRENT!
~SINGLEPHASEALTERNATINGCURRENT!

PREFACE
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WARNING
|ON(SUPPLY)
OFF(SUPPLY)
PROTECTIVEEARTHTERMINAL!
PINCHHAZARD!
CONSULTYOURTECHNICALMANUALBEFORESERVICING!

PREFACE
TrojanUVLogic
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viii
CAUTION
THELAMPSINTHISSYSTEMEMITULTRAVIOLETLIGHT. EXPOSURETOULTRAVIOLETLIGHTCANCAUSE
SERIOUSBURNSTOUNPROTECTEDEYESANDSKIN. NEVERVIEWULTRAVIOLETLIGHTDIRECTLYWITH
THENAKEDEYE. ALWAYSUSETHEPROPERPROTECTIVEEYEWEARORAUVRATEDVIEWPORT.
ALWAYSWEARPROTECTIVECLOTHINGWHENEXPOSEDTOULTRAVIOLETLIGHT. ENSUREALLLAMPS
AREPROPERLYSECUREDWITHINTHEUVRCHAMBERBEFORETURNINGTHESYSTEMON. TURNTHE
SYSTEMOFFBEFORESERVICING.
TOPREVENTELECTRICALSHOCK,TURNTHESYSTEMOFFBEFOREREMOVINGANYOFTHECOVERSON
THEUVRCHAMBEROROPENINGTHECONTROLPANEL.
TOAVOIDPERSONALINJURY,TURNOFFPOWERBEFOREREMOVINGREACTORENDCAP.
ULTRAVIOLETLAMPS,ANDTHESLEEVESTHEYAREHOUSEDIN,ARECONSTRUCTEDOFQUARTZ
TUBING. QUARTZTUBINGISVERYFRAGILEANDEASILYFRACTURED. DONOTSTRIKE,BENDORAPPLY
PRESSURETOTHISMATERIALORITWILLBREAK. BROKENLAMPSORSLEEVESCANCAUSESERIOUS
CUTS.
DISCARDLAMPSANDSLEEVESACCORDINGTOTHEREQUIREMENTSOFYOURJURISDICTION.
ACIDSUSEDFORCLEANINGTHESLEEVESMAYCAUSEBURNS. WEARPROTECTIVECLOTHINGAND
PROTECTIVEEYEWEARWHENUSINGTHESEMATERIALS. AFTERCLEANING,RINSETHESYSTEM
COMPONENTSTHOROUGHLYWITHDISTILLEDWATER. ALWAYSFOLLOWTHESAFETYPRECAUTIONS
RECOMMENDEDBYTHEMANUFACTUREROFTHECLEANINGSOLUTION.
ACIDSUSEDTOCLEANTHESENSORCANCAUSEBURNS. WEARPROTECTIVECLOTHINGANDEYEWEAR
WHENHANDLINGTHESEMATERIALS. AFTERCLEANING,RINSETHESYSTEMCOMPONENTS
THOROUGHLYWITHDISTILLEDWATER. ALWAYSFOLLOWTHESAFETYPRECAUTIONSRECOMMENDEDBY
THEMANUFACTUREROFTHECLEANINGSOLUTION.
THISSYSTEMUSESULTRAVIOLETLIGHTTOREDUCETHECONCENTRATIONOFPATHOGENSTOANON
INFECTIOUSLEVEL. NONOBSERVANCEOFTHEMAINTENANCEINSTRUCTIONSORTHEALARM
MESSAGESWILLDIMINISHTHEEFFECTIVENESSOFTHISSYSTEM. REQUIREDDISINFECTION
EFFECTIVENESSISNOLONGERGUARANTEEDANDTHATTHEREQUIREMENTSOFTHEWATERSUPPLY
REGULATIONSARENOLONGERBEINGMET. AHEALTHRISKEXISTS.
THISSYSTEMISDESIGNEDTOWORKOPTIMALLYUNDERTHEREQUIREMENTSDESCRIBEDBYTHE
CUSTOMER. ANYMODIFICATIONTOTHESEFACTORSMAYREDUCETHEEFFECTIVENESSOFTHE
DISINFECTIONOFTHESYSTEM. THEFACTORSTHATAFFECTOPERATIONMAYBEFOUNDINTHE
INTRODUCTIONTOUV THEORY. SEECHAPTER1.
REMOVETHEENDCAPCOMPLETELY. DONOTALLOWTHEENDCAPTOHANGONTHEWIPERHANDLE
WHILECONDUCTINGWORK.
THESLEEVESMAYBELEFTINTHEWIPERASSEMBLYWHENTHESTOPPLATEISREMOVED;HOWEVER,
IFTHESLEEVESARENOTREMOVED,YOUMUSTENSURETHEYAREPROPERLYSUPPORTEDWHENTHE
STOPPLATEISNOTTHERETOAVOIDDAMAGE.
ITISESSENTIALTHATTHECOMPONENTSOFTHESTOPPLATEASSEMBLYBEPROPERLYINSTALLEDON
TOTHEENDOFTHEDRIVESCREWFORCONSISTENTWIPEROPERATION.
FAILURETODOSOMAYRESULTINIMPROPERWIPEROPERATION.
LONGLAMPSYSTEMS(ALMODELS)HAVETWOSEPARATEWIPERASSEMBLIESMOUNTEDONTOTHE
DRIVESCREW. MAINTAINTHEDISTANCEOF28” CENTERTOCENTERBETWEENTHETWOWIPER

PREFACE
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TM Operations&Maintenance
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CAUTION
ASSEMBLIES. THISISTOMAINTAINFULLWIPINGCOVERAGEOFTHESLEEVESANDPREVENTJAMMING
OFTHEWIPERASSEMBLYONTHEOUTLETENDOFTHECHAMBER.
IFYOUHEARORSUSPECTSLEEVEBREAKAGE,DONOTWIPEBYRESETTINGTHEPOWER. YOUWILL
BREAKMORESLEEVESORLAMPS.
INSTALLATIONANDMAINTENANCETOBEPERFORMEDBYQUALIFIEDPERSONNELONLY.
THISSYSTEMISDESIGNEDONLYFORINDOORUSE.
THISSYSTEMCANDISINFECTONLYWATER.
NEVEROPERATETHEUNITWHILEEMPTYORWITHOUTFLOWFORANEXTENDEDPERIOD.
OPERATETHESYSTEMONLYIFTHECHAMBERISCOMPLETELYFILLEDWITHFLOWINGWATER.
INTERMITTENTOPERATIONOFTHESYSTEMREQUIRESTHATAMINIMUMAMOUNTOFWATERFLOWS
THROUGHTHESYSTEMINORDERTOCOOLTHELAMPS.
CONNECTTHISSYSTEMONLYTOACPOWERTHATCONFORMSTOTHEINFORMATIONINTHERATING
PLATEASREGARDSVOLTAGEANDVOLTAGESPECIFICATION.
IFYOURSYSTEMRUNSWITHPULSECOMPRESSION,ABUFFERTANKOROTHERREMEDIALMEASURE
MUSTBEPROVIDED.
THEULTRAVIOLETEMISSIONOFTHESELAMPSDECREASESOVERTIME. THEUV LAMPSINTHISSYSTEM
MUSTBEREPLACEDEVERY9000HOURSOFOPERATIONINORDERTOENSUREPROPEROPERATION,
SEECHAPTER4.
REGULARTESTINGOFSYSTEMPERFORMANCEUSINGSTANDARDIZEDMETHODS(E.G.,WATERSUPPLY
REGULATIONSOFVARIOUSCOUNTRIES)ISRECOMMENDED. WHENINSTALLINGTHE
TROJANUVLOGIC
TMSYSTEM,ALLOWENOUGHROOMFORSAMPLINGPOINTS.
ALLREPAIRSARETOBEDONEBYAQUAFINECORPORATION’SSERVICEORBYQUALIFIEDSPECIALISTS.
DEPRESSURIZE& DRAINTHEUVR.
PRESSUREMUSTBERELIEVEDFROMTHESYSTEMPRIORTOANYMAINTENANCE,TOPREVENTDAMAGE
TOTHEEQUIPMENTORPERSONALINJURY.
TOAVOIDPERSONALINJURY,TURNOFFPOWERBEFOREREMOVINGUVR ENDCAP.
FORCORRECTINSTALLATION,FOLLOWTHEINSTALLATIONINSTRUCTIONSINCHAPTER9. REFERTO
THEAPPROPRIATEELECTRICALDIAGRAMINAPPENDIXD,WHICHSHOWSHOWTOSETUPTHEPROPER
SYSTEMCONNECTIONSBETWEENTHECONTROLPANELANDTHEREACTORCHAMBER.

PREFACE
TrojanUVLogic
TM Operations&Maintenance
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CAUTION
ATTENTION
OBSERVE PRECAUTIUONS
FOR HANDLING
ELECTROSTATIC
SENSITIVE
DEVICES

PREFACE
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GeneralLockoutProcedures
Thefollowinglockoutprocedureistheminimum
requirement.Additionalprecautionsshouldbe
takendependingonsitespecificprotocols.
Alwayscheckwiththeplantmanagerand
seniorelectricianforadditionalprecautions.
WARNING
EYEPROTECTION! WEARUV
RESISTANTFACESHIELDWHEN
LOOKINGATLAMPSORREACTION
CHAMBER.
WARNING
HANDPROTECTION! WEARPROPER
GLOVESANDCLOTHINGWHEN
SERVICINGEQUIPMENT.
WARNING
FOOTPROTECTION! WEARPROPER
FOOTPROTECTIONBEFORE
ENTERINGAWATERTREATMENT
PLANT.
LockoutandTagProcedure
1. Locateandidentifyelectricalsupplyto
equipment.Identifyspecificbreakersor
disconnectsthatservice AquafineCorporation
equipment.Ifyouareunsure,contacttheplant
electricianormaintenancepersonneltolocate
thecorrectelectricalsupply.
WARNING
BEAWARETHATTHEPANELMAYBE
FEDFROMMULTIPLESOURCES!
2. WhilestandingtothesideoftheElectrical
Panel,useyourclosestarmtomovethe
RotaryDisconnectSwitchtotheOFFposition.
3. AttachyourLockandSafetyTagtotheRotary
DisconnectSwitch.Includeyourname,date
andtime,andtheworktobeperformedonthe
tag.
4. ReturntotheControlPanel(CP)andverify
correctpowersourcehasbeenlockedout.
WARNING
THEEQUIPMENTMAYHAVE
STOREDENERGY! ENSURETHAT
ALLPARTSHAVESTOPPED
MOVINGANDANYSTORED
CAPACITANCEHASBEEN
EFFECTIVELYDRAINED.
5. Proceedtotheworkareaandvisuallycheckto
ensurethattheequipmentisOFF.
6. DoublecheckwithaMultimeteratthe
equipmentServiceEntrancetoensurethatthe
systemhasbeendeenergized.
7. Wait fiveminutes oncesystemisturned
OFF,toallowforCapacitiveDischarge.
8. Itisnowsafetoworkonthesystem.
9. Completeallrequiredmaintenance.
AfterServiceWorkIsComplete
10.EnsureCPdoorisclosed.
11.EnsurealloftheequipmentisintheOFF
position.
12.Clearanytoolsordebrisfromworkarea.
13.RemoveallLockoutDevicesandTags.
14.WhilestandingtothesideoftheElectrical
Panel,useyourclosestarmtomovethe
RotaryDisconnectSwitchtotheONposition.
15.Notifytheplantmanagerorsiteelectricianthat
workiscompleteandthatthesystemhas
beenrestarted.

PREFACE
TrojanUVLogic
TM Operations&Maintenance
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ListofAcronyms/Glossary
Thisglossarydefinesalistofacronymsthatwill
befoundthroughoutthismanual.
o
C–DegreesCelsius
AC–AlternatingCurrent
_LLongLampLogicModel
AMWSAutomaticMechanicalWipingSystemis
anoptionalcomponentthatprovidesautomated
wipingoftheLampSleevesduringnormal
operation.
ANSI–AmericanNationalStandardsInstitute
_SShortLampLogicModel
BarBarometricPressure
BSP–BritishStandardPipe
CCB–CommunicationControlBoard
cmCentimeter
CPControlPanel
DC–DirectCurrent
DINDeutscheIndustrieNorm(German
EquivalentofANSI)
DNADeoxyribonucleicAcid
EOLEndofLife
GNDGround
GPMUSGallonsperMinute
Hp–Horsepower
Hrs–Hours
in
.
lb–Inchpound
Lb
.
ft–PoundFoot
L/s–Literspersecond
LEDLightEmittingDiode
mA–Milliamps
MAXMaximum
MGDMillionsofGallonsperDay
mg/l–Milligramsperliter
MIN–Minimum
mJ/cm
2Millijoulespersquarecentimeter
MLDMillionsofLitersperDay
mmMillimeters
MMWSManualMechanicalWipingSystemis
anoptionalcomponentthatprovidesthe
operatortheabilitytowipetheLampSleeves
duringnormaloperation.
MPaMegapascals
mW/cm
2Milliwattspersquarecentimeter
N
.
m–Newtonmeter
nm–Nanometers
NPT–NationalPipeThread
O&MOperationsandMaintenance
OH–HydroxylFreeRadicals
phPhase
ppm–PartsperMillion
psi–PoundsperSquareInch
sec–Second
SST–StainlessSteel
TOC–TotalOrganicCarbon
UVUltraviolet
UVRUVReactor
VAC–VoltageAlternatingCurrent
VDC–VoltageDirectCurrent
VFD–VacuumFluorescentDisplay
w–Wire
W/m
2–Wattspermetersquared