UV Superstore LEOPARD UV Series User manual

Ultraviolet Water Treatment System
Installation, Operation and Maintenance Manual
One Source for All Your UV Needs!

               




-

            


                



               
               


      -       




One Source for All Your UV Needs!

Table of Contents
Safety Instructions ............................................................................................................. 1
1) Information .................................................................................................................... 2
2) About Ultraviolet (UV) Disinfection ........................................................................... 2
3) Major Components ........................................................................................................ 3
a) Disinfection Chamber .................................................................................................................................................... 3
b) Lamp and Quartz Sleeve Inspection .......................................................................................................................... 3
c) Electronic Control Center (ECC) ................................................................................................................................... 4
4) Preparation For Installing UV System ........................................................................ 6
a) Water Quality................................................................................................................................................................. 6
b) Important Safety Information ....................................................................................................................................... 6
c) Optimizing System Performance .................................................................................................................................. 7
d) Environmental Issues Relating To UV Lamps ............................................................................................................. 7
e) Receiving UV Equipment And Spare Parts.................................................................................................................. 7
f) Electrical Configuration And Maintenance .................................................................................................................. 7
5) Installation ...................................................................................................................... 8
a) ECC Wiring ..................................................................................................................................................................... 8
b) Hands Off Auto (HOA) Switch Wiring ...................................................................................................................... 10
c) Lamp Out Alert (Optional) .......................................................................................................................................... 11
d) Chamber ....................................................................................................................................................................... 11
e) Sensor Probe (For Models with Optional Standard or WatchDog Monitoring System) .................................... 12
f) Quartz Sleeve Installation ............................................................................................................................................ 13
g) Lamp & Lamp Harness Bracket Installation ............................................................................................................ 15
6) Operation and Monitoring .......................................................................................... 17
a) Electronic Control Center (ECC ) ............................................................................................................................... 17
1. On/Off Switch and Hands Off Auto (HOA) Switch ...................................................................................................... 18
2. Lamp Status ............................................................................................................................................................................... 19
3. Runtime Monitoring ................................................................................................................................................................ 19
b) Viewport ........................................................................................................................................................................ 19
c) Lamp Out Alert ............................................................................................................................................................. 19
7) UV Monitoring System Options ................................................................................. 20
a) Standard UV Meter Board Monitor .......................................................................................................................... 20
b) Standard High Heat Sensor ...................................................................................................................................... 23
Refer to the Options Manual for Operational Instructions for Standard and WatchDog UV Monitoring System
8) Maintenance ................................................................................................................. 24
a) Lamp Maintenance ..................................................................................................................................................... 24
b) Quartz sleeve Maintenance ....................................................................................................................................... 24
c) ECC Maintenance ........................................................................................................................................................ 25
d) Viewport Maintenance ................................................................................................................................................ 25
e) High Heat Maintenance for Standard High Heat Option...................................................................................... 25
f) Sensor Probe Maintenance for Standard and WatchDog Monitoring System Option ........................................ 26
g) Chamber Maintenance................................................................................................................................................ 27
Chamber Break Down—Removal of Heads ............................................................................................................. 27

9) Water Sampling (Flange Models) .............................................................................. 28
a) Sampling Valves .......................................................................................................................................................... 28
b) Sampling Procedure .................................................................................................................................................... 28
FDA Statement ........................................................................................................................................ 30
Heat Sanitization .................................................................................................................................... 31
Replacement Parts List ....................................................................................................................... 32
Maintenance Log ..................................................................................................................................... 36
Troubleshooting ...................................................................................................................................... 38
Warranty Information .......................................................................................................................... 39
Wiring Diagram Pullout
Refer to the Options Manual for Operational Instructions for Standard and WatchDog UV Monitoring System


In order to protect end users and operators from injury, safety precautions must
be followed. This installation, operation and maintenance manual outlines
important safety issues. The following WARNING SYMBOLS will be found
throughout the manual to alert the end users to take important precautions:
SAFETY INSTRUCTIONS
EYE PROTECTION
This symbol indicates that eye protection must be worn to protect
from UV light as well as debris.
HAND PROTECTION
This symbol signifies that hand protection must be worn to
protect the lamps from skin oils as well as protect the operator
from UV light and sharp materials caused by a broken lamp/quartz.
ELECTRIC SHOCK
This symbol signifies electrical shock possibility.
CAUTION
This symbol indicates a potentially dangerous situation. Failure to
adhere to this warning may lead to serious injury and/or death.
INFORMATION
This symbol signifies helpful information.


1) Information
Please read this manual prior to installing, starting up and operating the equipment. The
equipment uses the latest in UV technology, but has been designed to make operation and
maintenance easy.
The quality of the liquid entering the UV system needs to be monitored. Based on your water quality, the
UV system will need to be cleaned on a periodic basis. Maintenance of the UV system will require
replacement parts. It is suggested that key spare and replacement parts be kept on hand. For best operation,
it is recommended to use the correct replacement parts. Incorrect replacement parts could result in
damage to the system and void the warranty.
2) About Ultraviolet (UV) Disinfection
The technology uses UV light to target and disable disease-causing microorganisms (pathogens).
Over 100 years ago, scientists discovered that if you exposed pathogens to UV light, their
reproduction was limited. The UV light source that they used, resided in the UVC range of the light
spectrum. Specifically, they discovered that light in the 254 nanometer (NM) range was the most effective
wavelength for this process.
When many pathogens are exposed to UV light, their cells become damaged and this damage inhibits
reproduction. The UV light, produced by a special UV lamp, damages the cell’s DNA and RNA and once
damaged, they are unable to replicate. This physical process renders them harmless. The amount of damage
is a result of the intensity of the UVC output multiplied by the time the pathogens are exposed to the light.
The applied dosage is commonly referred to as microwatt seconds per square centimeter or millijoule per
square centimeter and is often expressed as µWs/cm² or mJ/cm². Most industrial applications require a
dosage of 30,000 µWs/cm² or 30mJ/cm².
Why are plants and operators selecting UV technology?
a) UV is considered a green technology
b) No chemicals are added, so there is no need for chemical removal
c) No chemical storage
d) UV works instantly without requiring a residence time
e) Easy maintenance


3) Major Components
The UV disinfection system will come with a number of components.
The following list highlights the main ones:
a) Disinfection Chamber (aka vessel)
b) Ultraviolet Lamps and Quartz Sleeves
c) Electronic Control Center (ECC)
a) Disinfection Chamber
The chamber is manufactured from high-grade 316L stainless steel. The chamber has been electropolished
and passivated to protect against aggressive high purity water.
The chamber has an inlet/outlet connection, drain, sampling (with flange models only), and monitoring
ports.
b) Lamp and Quartz Sleeve Inspection
Use cotton gloves when handling lamps and quartz sleeves to prevent them from becoming
dirty. If you break the lamps or quartz sleeves, take extra care to prevent yourself from
becoming injured.
If damage has occurred during shipment, please put to the side in the original packaging and contact
manufacturer. A claim will have to be made immediately to the shipping company.


c) Electronic Control Center (ECC)—
for Polycarbonate Enclosures
The ECC is designed to be remote mounted within 4-6 feet of the chamber. Prior to final placement, ensure
that the supplied cable lengths (8 ft.) are adequate to reach between the ECC and the chamber.
The ECC requires clean power. Information on voltage and cycle is found on the wiring diagram located in
the back of this manual. Equipment should be kept off lines where there are surges or brownouts. Always
disconnect power before servicing the system.
The ECC will contain the ballasts and other electrical controls. For models equipped with the standard UV
Meter Board Monitor option and/or standard High Heat option, the ECC will display operation status such as
individual Lamp Indicator, Elapsed Runtime Meter (ERTM), optional UV Monitor Intensity, optional Low UV
Indicator, and optional High Heat indicator.
For models equipped with the optional Standard UV Meter Board Monitor, the ECC displays operation
status such as individual Lamp Indicator, Elapsed Runtime Meter (ERTM) , lamp runtime hours and relative
UV lamp intensity. For models equipped with the WatchDog Monitoring System, the ECC will display
operation status such as individual Lamp Indicator, and is capable of monitoring total runtime hours, lamp
runtime hours, lamp intensity, relative UV percentage, temperature and in some models, real-time dosage.
The ECC is equipped with a manual on/off switch for standard models. The optional HOA (Hands Off Auto)
switch enables you to remotely power on/off your UV system.





























Electronic Control Center (ECC)
For Stainless Steel Enclosures
The ECC is designed to be remote mounted within 4-6 feet of the chamber. Prior to final
placement, ensure that the supplied cable lengths (8 ft.) are adequate to reach between the
ECC and the chamber.
The ECC requires clean power. Information on voltage and cycle will be on the wiring
diagram inside the ECC cover. Equipment should be kept off lines where there are surges or
brownouts. Always disconnect power before servicing the system.
The ECC will contain the ballasts and other electrical controls. For models equipped with the standard UV
Monitor option and/or standard High Heat option, the ECC will display operation status such as individual
Lamp Indicator, Elapsed Runtime Meter (ERTM), optional UV Monitor Intensity, optional Low UV Indicator,
and optional High Heat indicator. For models equipped with the optional WatchDog Monitoring System, the
ECC will display operation status such as individual Lamp Indicator, and the WatchDog Monitoring
System display is capable of monitoring total runtime hours, lamp runtime hours, lamp intensity, relative UV
percentage, temperature and in some models, real-time dosage.
The ECC is equipped with a manual on/off switch for standard models. The optional HOA (Hands Off Auto)
switch enables you to remotely power on/off your UV system.
Display Plate with
WatchDog Monitoring System
Option
Manual
On/Off
Switch
or
Optional
HOA
Switch
Elapsed
Run Time
Meter
Low
UV Indicator
High Heat
Shut Off
Indicator
Lamp Status
Indicator
Photo shown is display plate for
the standard UV Monitor Option
and standard High Heat Option
UV
Monitor
Option


4) Preparation for Installing UV System
The following information is meant to be used by engineers, contractors, operators and owners to
help better understand the technology, its’ benefits and potential hazards.
a) Water Quality
For optimum performance of your UV system, water quality is extremely important. Proper pretreatment is
essential for the UV disinfection system to operate as intended.
UV disinfection dosages are dependent upon the quality and clarity of incoming water. Impurities in water can
interfere with UV intensity and cause dosage to fall to unsafe levels. Have your water tested to determine it meets
the standards in the below table. If any of the elements exceed the maximum levels shown in the table, contact your
water professional for recommendations for proper pretreatment.
The following table shows levels that are recommended for installation:
b) Important Safety Information
UV lamps and their quartz sleeves can become razor sharp if broken. Take care when installing and
removing the quartz sleeves. Only hand-tighten compression fittings. Do not use wrenches or other
tools.
UV light is extremely harmful to eyes and skin and will cause burns. Do not look directly or indirectly
at the UV light. Do not expose your skin for any prolonged time. Use protective clothing and
eyewear (make sure it is UV resistant) when servicing equipment. If accidentally exposed to UV light
for an extended period, immediately seek medical attention. Symptoms for eye exposure include
burning, itching and redness. Symptoms for skin exposure are similar to sun burn.
Use cotton gloves when handling lamps and quartz sleeves. Skin oils will adhere to the lamps and
sleeves and prevent UV light from properly emanating. If the sleeves become dirty, wipe them with a
lint free cloth with denatured alcohol.
 



 
 
 
 
 
 
 


c) Optimizing System Performance
The UV lamps and their corresponding quartz sleeves need to be maintained. As a general rule, the lamps
need to be changed after a year of usage (10,000 hours). Quartz sleeves should be changed every three (3)
to five (5) years or sooner if damaged.
Quartz sleeves also need to be cleaned on a periodic basis based on real world plant conditions. The
factory recommends using denatured alcohol or a commercially available non-abrasive cleaning product. In
addition to cleaning, please remember to wear gloves when handling lamps and sleeves. It is important that
the cleaning product you select leaves no residue.
d) Environmental Issues Relating to UV Lamps
UV lamps need to be recycled like fluorescent lamps because they contain mercury. Please
follow your local recycling laws. Please visit www.lamprecycle.org for help finding a recycling
center in your area. In the event that you are unable to find a disposal location, please
contact manufacturer’s representative.
e) Receiving UV Equipment and Spare Parts
Inspection of the UV equipment must be made immediately upon receipt for damage and verification of
contents. It is important to compare the contents of your shipment to the actual packing list. Any
deviations must be brought to the factory’s attention. Additionally, lamps and quartz sleeves need to be
inspected for damage. If shipment or parts are damaged, immediately contact factory and hold broken
contents and their containers for inspection by shipping company. Failure to make a damage claim within 2
business days of receipt of product can result in loss of claim.
f) Electrical Configuration
The UV disinfection system uses sophisticated electronics and specialty lamps. The UV system’s electronics
requires clean power. The system has been designed to use a certain specified voltage. UV equipment must
be protected from surges. If the plant is susceptible to brownouts, please contact factory.
Do not exceed 3 ON/OFF cycles per 24-hour operation. Excessive cycling of the UV system will cause the
UV lamps to age prematurely.


5) Installation
Qualified professionals (contractors, plumbers and electricians) should install the mechanical and electrical
components as per code as per the engineering documents.
a) ECC Wiring —
The ECC is supplied with either a power cord or conduit opening depending on the model.
The ECC is designed to be remote mounted within 4-6 feet of the chamber. Prior to final
placement, ensure the supplied cable lengths (8 ft. / 15 ft.) are adequate to reach between the
ECC and the chamber. Make sure power to the equipment matches the voltage requirements
of the system. Make sure the system is properly grounded. For complete wiring instructions,
see wiring diagram inside the electrical enclosure or the pullout in the back of this manual.
a.1 Polycarbonate Enclosures
The ECC is supplied with a power cord. Make sure power to the equipment matches the voltage
requirements of the system. Make sure the system is properly grounded. Plug the power cord into the
appropriate outlet.
a.2 Stainless Steel Enclosure with Power Cord
To provide power to the Electrical Enclosure for 120V:
Make sure power to the equipment matches the voltage requirements of the system. Make sure the system
is properly grounded. Plug the power cord into the appropriate outlet.
To provide power to the Electrical Enclosure for 220V:
1. To make installation easy, first remove the wire duct cover and unscrew the display plate (this does not
need to be removed completely) to access the circuit breaker to install incoming power wires.
2. Locate the power connection point and install your incoming 220V power wires through the strain relief
on the bottom of the enclosure to the breaker.
3. Connect ground wire to the ground bar.
4. Turn the breaker on.
5. Mount the display panel back onto standoffs and reapply the wire duct covers.


a.3 Stainless Steel Enclosure
The ECC is designed to be remote mounted within 4-6 feet of the chamber. Prior to final
placement, ensure the supplied cable lengths (8 ft. / 15 ft.) are adequate to reach between the
ECC and the chamber. Make sure power to the equipment matches the voltage requirements
of the system. Make sure the system is properly grounded. For complete wiring instructions,
see wiring diagram inside the electrical enclosure or the pullout in the back of this manual.
To provide power to the Electrical Enclosure for 120V:
1. To make installation easy, first remove the wire duct cover to install incoming power wires.
2. Locate the power connection point and install your incoming 120V “hot” wire to the breaker.
3. Install the “neutral” wire to # 3 on the switch.
4. Connect ground wire to the ground bar.
To provide power to the Electrical Enclosure for 220V:
1. To make installation easy, first remove the wire duct cover and unscrew the display plate (this does not
need to be removed completely) to access the circuit breaker to install incoming power wires.
2. Locate the power connection point and install your incoming 220V power wires through the strain relief
on the bottom of the enclosure to the breaker.
3. Connect ground wire to the ground bar.
4. Turn the breaker on.
5. Mount the display panel back onto standoffs and reapply the wire duct covers.
“Neutral”
Wire
“Hot”
Wire


b) Hands Off Auto Switch Wiring
b.1 Polycarbonate and Stainless Steel Enclosure with Power Cord
To wire the HOA Switch for remote access:
1. Remove the display/cover plate to access the HOA relay connection points for the remote switch.
2. Locate strain relief supplied at bottom of ECC for wiring to the HOA connection points.
3. Run 120V hot and neutral leads through the strain relief to the A1 and A2 on the HOA relay.
4. Re-assemble display/cover plate.
5. Turn switch on enclosure to “Auto”
b.2 Stainless Steel Enclosures
To wire the HOA Switch for remote access:
1. Remove the display plate to access the HOA switch relay connection points for the remote switch.
2. Locate the strain relief supplied at bottom of ECC for wiring to the HOA connection points.
3. Run 120V hot and neutral leads through the strain relief to the A1 and A2 on the HOA switch relay.
4. Re-assemble display plate.
5. Turn switch on enclosure to “Position 2”
  





A2 A1


c) Lamp Out Alert (Optional)
For models equipped with Lamp Out Alert ballast(s), connect your external control (PLC or SCADA) to the
bottom of the enclosure via the auxiliary connection.
Warning! Control signal may not exceed 32V AC, 50V DC, 50mA current
d) Chamber
Minimum Clearance
Ensure that you have adequate space on the lamp side of the treatment chamber to insert and
remove the quartz sleeve and UV lamp(s).
· 40” or more is preferred for short chambers
· 70” or more is preferred for long chambers
If thought is not given to this aspect, the lamps and quartz sleeves will be impossible to install.

—

—



e) Sensor Probe Installation—For Models Standard UV Monitoring System or
WatchDog Monitoring System
P/N SNSR0007 Wetted Sensor
For models equipped with the Standard UV Monitoring System, a sensor probe and sensor cable will need to
be installed on the UV chamber. The sensor probe contains an O-ring to ensure a watertight seal. To install,
first attach the sensor probe to the sensor port on the UV chamber and secure. Then attach the sensor
cable to the sensor probe.
P/N SNSR0004 Wetted Sensor
For models equipped with the WatchDog monitoring system, a sensor probe, sensor port fitting and sensor
cable (not shown) will need to be installed on the UV chamber. The sensor fitting and sensor probe contains
an O-ring to ensure a watertight seal. To install, first attach the sensor fitting to the sensor port on the UV
chamber. Slide the sensor probe through the fitting and secure. Then attach the sensor cable to the sensor
probe.
P/N SNSR0005 Non-Wetted Sensor and Viewing Window
For models equipped with the WatchDog monitoring system, a sensor probe, sensor viewing window and
sensor cable (not shown) will need to be installed on the UV chamber. The viewing window and sensor
probe contains an O-ring to ensure a watertight seal. To install, first attach the sensor viewing window to
the sensor port on the UV Chamber. Slide the sensor probe through the viewing window and secure. Then
attach the sensor cable to the sensor probe.











f) Quartz Sleeve Installation for Open Ended Sleeves
When working on this task a single operator is appropriate..
The quartz sleeves seal by using a compression nut, a stainless steel washer and an O-Ring. This task
requires no tools. Use cloth gloves to handle quartz sleeves and UV lamps to avoid putting fingerprints on
the sleeves and lamps.
First, the quartz sleeve needs to be inserted into the lamp head plate gradually and securely through to the
other end. As the quartz sleeve approaches the opposite end, make sure you guide the sleeve all the way
through. It is suggested that a finger or a dowel may be used to catch the end of the quartz.


Once through, make sure that each end of the quartz sleeve protrudes the same amount on both sides.
Before sliding the O-Ring on, it is suggested to lubricate both the O-Ring and the sleeve making it slippery.
Then slide an O-Ring over each end of the sleeve. Once the O-Rings are on then place the stainless steel
washers on each end. See Figure 1.
The compression fittings should first be hand tightened and the process needs to be
completed for each quartz sleeve. Do NOT install the UV lamp at this time.
Do not use a wrench to tighten the compression nuts. Doing so can crack the quartz
sleeves and cause leakage. A compression nut tool has been provided with the system to
further tighten the compression nuts. See Figure 2.
Once secure and once all other ports are closed, it is time to pressurize the system to look for any leaks at
the compression seals. Slowly fill the vessel with water. Prevent any onrush of water or water hammer as
this may damage the sleeves. Also ensure that the UV lamps have not been placed in the vessel. In the
event of a water hammer, the quartz sleeve(s) may break and if the lamps are already installed, they too
could break.
Once pressurized, let stand for 10 minutes and inspect the seals. If any are found to be leaking, stop
water, release pressure, drain system and then redo the leaking seals. Once redone, run the pressurization
test and ensure that all seals are not leaking.

