Rodem Aquionics PureLine M Operation & Maintenance Manual

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Aquionics Inc.

1455 Jamike Avenue, Suite 100

Erlanger, KY 41018

United States of America

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+1 (859) 341 0710

sales@aquionics.com

www.aquionics.com

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Page 1 & & Aquionics Inc. 1455 Jamike Avenue, Suite 100 Erlanger, KY 41018 United States of America +1 (859) 341 0710 E-Mail sales@aquionics.com www.aquionics.com...
Page 2 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 +1 (859) 341 0710 Visit us on the web www.aquionics.com Email...
Page 3: Table Of Contents
PureLine M Operation and Maintenance Manual Table of Contents 1. INTRODUCTION ....................3 GENERAL ........................... 3 SYSTEM OVERVIEW ........................ 3 DOCUMENTS..........................3 TEXT CONVENTIONS ....................... 4 2. SAFETY ........................5 GENERAL ........................... 5 PICTOGRAMS AND GENERAL SAFETY INSTRUCTIONS ............. 5 SYSTEM SAFETY FEATURES ....................
Page 4 PureLine M Operation and Maintenance Manual CONTROL CABINET CONNECTIONS ..................19 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 OPERATION..........................23 5.6.1 Switching on and off ......................
Page 5: Introduction
PureLine M Operation and Maintenance Manual INTRODUCTION DOCUMENTS In addition to this user manual, the following docu- GENERAL ments are included: The objective of this manual is to explain clearly to  CE-declaration users the installation and operation of the PureLine M ...
Page 6: Text Conventions
PureLine M Operation and Maintenance Manual TEXT CONVENTIONS The following terms are used to draw additional atten- tion to specific sections of the text: 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.
Page 7: Safety
PureLine M Operation and Maintenance Manual SAFETY PICTOGRAMS AND GENERAL SAFETY INSTRUCTIONS GENERAL For using the UV system, the following pictograms and The UV system is built for easy and efficient operation. safety instructions are important: Users should nevertheless take proper note of the remarks accompanying the text in this manual and act accordingly.
Page 8: System Safety Features
PureLine M Operation and Maintenance Manual 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.
Page 9: Broken Lamps Or Quartz Sleeves
PureLine M Operation and Maintenance Manual BROKEN LAMPS OR QUARTZ RECOMMENDED USE SLEEVES  The system is designed for disinfecting UV per- meable liquids such as waste water, drinking wa- The UV lamps contain a small amount of mercury. If a ter and process water (see technical data sheet).
Page 10: Storage And Transport
PureLine M Operation and Maintenance Manual STORAGE AND TRANSPORT TAKING THE SYSTEM OUT OF USE TEMPORARILY ON RECEIPT If the system is taken out of use temporarily, it is im- Check the goods on receipt for signs of transport portant to flush the system with clean water so that no damage.
Page 11: General System Description
PureLine M Operation and Maintenance Manual GENERAL SYSTEM DESCRIP- TION SYSTEM OVERVIEW Figure 1 illustrates the main aspects of the construc- tion of the system. The diagram shows all possible applicable options. The actual situation can vary from the diagram depending on the application, the type of control system and the size of the reactor.
Page 12: Disinfection Reactor
PureLine M Operation and Maintenance Manual For detailed information, please see section 4.2 (Disin- 4.2.2 UV lamps fection reactor) and section 4.3 (Power supply and The number and type of UV lamps built into the sys- control). tem depend on the system size and the nature of the A number of tools are also available for manually test- liquid that has to be disinfected.
Page 13: Uv Sensor
PureLine M Operation and Maintenance Manual 4.2.3 UV sensor 4.2.4 Temperature sensor A UV sensor (see Figure 4) is fitted as standard on the The UV lamps produce a considerable amount of heat steel reactor and this measures the UV intensity of the that is removed if the flow rate of the liquid passing UV lamps at a fixed point.
Page 14: Automatic Wiping
PureLine M Operation and Maintenance Manual 4.2.5 Automatic wiping 4.2.6 Water leak detector An automatic cleaning system is used to keep the A water leak detector is fitted at each end of the UV quartz sleeve clean by wiping the surface with a rub- chamber, near the drain outlet (Figure 7).
Page 15: Control Cabinets
PureLine M Operation and Maintenance Manual CONTROL CABINETS DIVERT VALVES 4.3.1 Main configuration and display 4.4.1 Single valve mode The UV disinfection system is connected to a power To ensure compliance with the requirements of the supply cabinet and a control unit. Depending on the PMO, a divert valve must be installed downstream size of the system and specific customer requirements, from the UV reactor and be controlled by the plant’s...
Page 16: Divert Valve Location
PureLine M Operation and Maintenance Manual 4.4.3 Divert valve location ACCESSORIES The divert valve must be supplied by the customer and The following additional accessories are available: should be installed at a point downstream that gives sufficient time for the valve to operate before any wa- Lamp tester: ter that was in the reactor when the fault occurred The lamp tester gives a high-voltage pulse that can be...
Page 17: Control System Description And Operation
PureLine M Operation and Maintenance Manual  Operator: this user level allows the lamps to be CONTROL SYSTEM DESCRIP- switched on and off, alarms to be acknowledged TION AND OPERATION and wipe cycles to be performed.  Secure: this user level allows alarms to be reset, FUNCTIONS OF THE CONTROL usage data to be cleared, and a limited range of SYSTEM...
Page 18: Overview Screen
PureLine M Operation and Maintenance Manual OVERVIEW SCREEN Figure 12: Overview screen (single valve mode) The Overview screen displays the status of the water treatment process stream, comprising the UV reactor and the divert valve. The functions of the Overview screen features and buttons are: Element Description The picture of the reactor on the screen is coloured depending on whether the system is operat-...
Page 19 PureLine M Operation and Maintenance Manual Element Description ALARM Resets the system from a trip after the cause has been resolved. Only Secure and Maintenance RESET users can operate this button. OPERATOR Used to record any comments required. These are saved in the system database and will ap- COMMENTS pear as a sub-report in the footer of the main report.
Page 20: Reactor Screen
PureLine M Operation and Maintenance Manual REACTOR SCREEN Figure 14: Reactor screen The Reactor screen gives more information about the UV system and allows the lamps and wiper to be controlled (if the software is operating under the Secure or Maintenance user). The functions of the screen features and buttons (ignoring those which are also shown on the Overview screen) are: Element Description...
Page 21: Control Cabinet Connections
PureLine M Operation and Maintenance Manual CONTROL CABINET CONNECTIONS The tables below describe all the inputs and outputs that are available to the user. Refer to the drawings provided with your system for further details. Digital Inputs All digital inputs are 0–24 V dc signals. Signal Description REMOTE...
Page 22 PureLine M Operation and Maintenance Manual Signal Description WATER TEMP A High signal indicates that the water temperature has exceeded the warning level. This WARNING output can also be used to operate the bleed valve on the reactor if one is installed. WATER/ CABINET A Low signal indicates that either the water or cabinet temperature has exceeded the trip TEMP ALARM...
Page 23: Installation And Preparing For Operation
PureLine M Operation and Maintenance Manual INSTALLATION AND PREPARING 5.5.3 Electrical installation FOR OPERATION Attention 5.5.1 General Installation work may only be carried out When installing the system, the following guidelines by qualified personnel. must be adhered to:  The surroundings must be free of corrosive va- pours, steam, excessive condensation, dripping Connect the power supply and control cabinet accord- liquids, explosive mixtures and gasses, salt air...
Page 24: Preparing For Operation
PureLine M Operation and Maintenance Manual 5.5.4 Preparing for operation Warning After the mechanical and electrical installation work has been completed, the following precautionary Only switch the unit on if the end plates measures should be taken before operating the sys- are fitted or wear safety glasses.
Page 25: Operation
PureLine M Operation and Maintenance Manual OPERATION 5.6.1 Switching on and off Make sure that the pipework system is completely filled with liquid and that the flow rate is at normal operating levels to ensure cooling of the reactor. Switch on the cabinet power switch. Log in to the software (section 5.1.1).
Page 26: Remote Control Event Sequences
PureLine M Operation and Maintenance Manual REMOTE CONTROL EVENT UV system switches off recirculation pump. UV system opens drain valve (to purge untreated SEQUENCES water). 5.7.1 Single valve mode When recirculation pump has stopped, recircula- tion valve closed. Event sequence for switching on the system: Plant control system switches on flow through UV Plant control system sends signal to Remote chamber.
Page 27 PureLine M Operation and Maintenance Manual Exception data logging starts (section 5.10.4). Plant control system switches off flow through UV chamber, switches off Process Water signal to UV system, and closes divert valve. UV system opens recirculation valve. When valve open, UV system switches on recir- culation pump.
Page 28: Warnings And Trips
PureLine M Operation and Maintenance Manual WARNINGS AND TRIPS 5.8.2 Resetting the system Malfunctions result in WARNING or TRIP alarms. After a trip has occurred, perform the following actions Events can be defined as trips (T) or warnings (W) in to restart the system: the Settings screens (see section 5.8).
Page 29: Settings
PureLine M Operation and Maintenance Manual SETTINGS There are two Settings screens in the software, accessible through the Overview and Reactor screens. The Over- view Settings screen allows the most critical settings to be configured, with the remainder being available on the Reactor Settings screen.
Page 30 PureLine M Operation and Maintenance Manual Setting Description PMO APPLICATION This should be set to Yes permanently, as it controls the signal to operate the flow valve(s) (section 4.4). PMO REPORTS Select the format of reports to be generated by the system. Standard reports display all events, Exception reports only display events when the system is non-compliant with the PMO.
Page 31 PureLine M Operation and Maintenance Manual Setting Description NUMBER OF Set the number of analogue outputs to be used for electronic ballasts. Not to be changed by ANALOG OUTPUTS users. BALLAST TYPE Choose between Electronic (EL) or Conventional (Conv.). Not to be changed by users. MINIMUM POWER Set the minimum power setting for electronic ballasts (0–50%).
Page 32 PureLine M Operation and Maintenance Manual Figure 19: UV dose control Page 30 of 54...
Page 33: Troubleshooting
PureLine M Operation and Maintenance Manual 5.10 TROUBLESHOOTING 5.10.1 Alarms The table below describes appropriate actions to be taken if a particular system alarm occurs. Alarm Description and Action EARTH LEAKAGE Check quartz sleeves and UV lamps for excessive moisture. Check wiring and load. POWER CAB TEMP Cabinet temperature has exceeded 50ºC.
Page 34: Malfunctions Of The Temperature Sensor
PureLine M Operation and Maintenance Manual Alarm Description and Action VALVE ERROR The divert valve has not moved into the correct position. VALVE TIMEOUT A control valve has not responded within the required time period (10 seconds by default). 5.10.2 Malfunctions of the temperature sen- Temp [°C] Current [mA] 4.00...
Page 35: Other Troubleshooting
PureLine M Operation and Maintenance Manual 5.10.3 Other troubleshooting  The UV Alarm is active, but the lamps and quartz sleeves are working properly:  Check the liquid.  The UV lamps do not switch on:  Check whether the lamps are not cooling down.
Page 36: Reporting Data
PureLine M Operation and Maintenance Manual 5.11 REPORTING DATA 5.11.2 Backing-up data The operating data of the system is stored in a secure The database is stored on a solid-state hard drive SQL database which cannot be accessed by users. within the system control cabinet.
Page 37: Generating Reports
PureLine M Operation and Maintenance Manual 5.11.4 Generating reports 5.11.5 Exporting reports On the Overview screen, press Overview Set- Press the Export icon on the main toolbar in tings. the Report screen. Press Page Down to view the PMO Reports set- The Export dialog is displayed.
Page 38: Maintenance Of The Reactor And The Control Cabinets
PureLine M Operation and Maintenance Manual MAINTENANCE OF THE REACTOR AND THE CONTROL CLEANING THE UV SENSOR AND CABINETS QUARTZ WINDOW CLEANING THE QUARTZ SLEEVES The UV sensor measures the efficiency of the UV lamps in combination with the level of contamination of 6.1.1 General the water.
Page 39: Cleaning Procedure
PureLine M Operation and Maintenance Manual 6.2.1 Cleaning procedure Warning  Turn off the main switch and the circuit breakers in the power supply cabinet.  Turn off the flow and drain the liquid in the disinfection reactor. Step Instruction ...
Page 40 PureLine M Operation and Maintenance Manual Step Instruction  Clean the quartz holder with a soft cloth and a small amount of alcohol.  Fit all parts in reverse order.  Switch the system on again. Page 38 of 54...
Page 41: Maintenance Of The Automatic Cleaning Mechanism
PureLine M Operation and Maintenance Manual MAINTENANCE OF THE AUTOMATIC CLEANING Warning MECHANISM  Remember that the lamps can be 6.3.1 Introduction and safety aspects hot. Several parts have to be replaced after approximately 7,000 wiper movements or at least once per year. Caution Warning ...
Page 42 PureLine M Operation and Maintenance Manual Step Instruction  Unscrew the wiping blade of the spindle.  Replace the wiper rings.  If necessary, replace the wiper flap for the sen- sor window. See item 4 in Figure 23.  Replace the seal of the threaded spindle (item 1 in Figure 23) and the plastic threaded nut (item 2) as necessary but at least once a year.
Page 43: Ventilation Of The Control Cabinet
PureLine M Operation and Maintenance Manual VENTILATION OF THE CONTROL CABINET  Regularly check and, if necessary, replace the dust filters in the cabinet ventilators. EARTH LEAKAGE CIRCUIT BREAKER CHECK  Every month, check the earth leakage circuit breaker to make sure it is working properly by pressing the test button.
Page 44: Replacing Lamps And Quartz Sleeves
REPLACING LAMPS AND QUARTZ SLEEVES REPLACING LAMPS AND QUARTZ SLEEVES This procedure describes the actions needed to initial- ly fit or replace UV lamps and to clean or replace quartz sleeves. SAFETY PRECAUTIONS Attention Warning  Outworn lamps and lamp groups must be replaced as Turn off the main switch and the soon as their UV intensity (after cleaning) is 5% or circuit breakers in the power supply...
Page 45: Main Replacement Procedure
PureLine M Operation and Maintenance Manual MAIN REPLACEMENT PROCEDURE  Steps 1 to 3 and 12 to 21 are sufficient when fitting the lamps for putting into use the first time.  Steps 1 to 5 and 12 to 21 are sufficient for the replacement of a worn or defective lamp (without cleaning the quartz sleeve).
Page 46 PureLine M Operation and Maintenance Manual Step Instruction  Loosen the lamp wire on the connector block (both sides).  Take the old lamp out of the quartz sleeve, to- gether with the two glass tubes (make sure that the two glass tubes do not get mixed up as there may be a difference in length).
Page 47 PureLine M Operation and Maintenance Manual Step Instruction  Clean the tube using alcohol. Never touch the tube with bare hands.  If necessary: replace the wipe-rings (see section 6.3.2).  Refit the quartz tube in the UV body.  Moisten the black O-rings using clean water and slide these over the quartz tube on both sides.
Page 48 PureLine M Operation and Maintenance Manual Step Instruction  New UV lamps are supplied in cardboard pack- aging, including instructions.  Never touch the glass of the lamp with bare hands.  Do not hold the lamp by one end. ...
Page 49 PureLine M Operation and Maintenance Manual Step Instruction  If necessary clean the lamp with a cotton cloth and a little alcohol, but never touch it with bare hands.  Slide the lamp carefully into the quartz sleeve. Keep the lamp horizontal. ...
Page 50: Resetting The Service History
PureLine M Operation and Maintenance Manual Step Instruction  If necessary: fit the wipe motor.  Fit the black cover plate on both sides. Press the Lamp/Wiper button to display the 7.2.1 Resetting the service history Lamp/Wiper screen. After replacing the lamp and servicing the wiper Press the Clear button for the wiper and for each mechanism, the service history of the components lamp that has been replaced, as appropriate.
Page 51: Removing Quartz Sleeves With The Jupito
PureLine M Operation and Maintenance Manual REMOVING QUARTZ SLEEVES WITH THE JUPITO Quartz sleeves that have become stuck due to water pollution may be removed easily using the Jupito. The use of a hammer is not necessary. Caution If a quartz sleeve is really stuck, there is always the risk that it will break.
Page 52 PureLine M Operation and Maintenance Manual Step Instruction  Screw the holder into the lamp flange of the UV reactor.  Do not tighten the holder so that the O rings of the quartz sleeves are not clamped extra tight. ...
Page 53: Disposal
PureLine M Operation and Maintenance Manual DISPOSAL GENERAL RETURNING OLD LAMPS If the UV system is no longer used and has to be dis- Used lamps can be returned to the system supplier. assembled, the following steps should be carried out To do this, ask for the required “RMA number”...
Page 54 PureLine M Operation and Maintenance Manual APPENDIX A CE DECLARATION (EXAMPLE) EC Declaration of conformity In accordance with Machine guideline 2006/42/EG – Appendix II.1.A Declares that the product Product : UV system Type Serial number is in conformity with the European directives: ...
Page 55 PureLine M Operation and Maintenance Manual APPENDIX B QUALITY CERTIFICATE (EXAMPLE) Quality certificate Warranty certificate Product : UV system Type Serial number Hanovia order no. : Hanovia hereby certifies that this Ultraviolet System was designed, manufactured and tested according to applicable Hanovia procedures. These procedures are ISO 9001 and ISO 14001 controlled, and are designed to assure that the installation meets the agreed specifications and that environmental guidelines are maintained.