Trojan Technologies TROJANUVSIGNA Instruction Manual

Uv bank and hydraulic system center

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TROJANUVSIGNA

UV Bank and Hydraulic System Center Installation

Instruction Manual

Original Instructions

Edition 12

DC340601-005-12-03

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Page 1 ® TROJANUVSIGNA UV Bank and Hydraulic System Center Installation Instruction Manual Original Instructions Edition 12 © Trojan Technologies, 2025. All rights reserved. Printed in Canada. DC340601-005-12-03...
Page 2 If you require technical assistance, please contact the Technical Assistance Center (TAC) using the contact information below: North America: 1-866-388-0488 All other areas: 1-519-457-2318 E-mail: tac@trojantechnologies.com At the time of publishing, the information within this document is current. Due to continuous improvements, we may have future changes and recommendations which will be sent via product bulletins.
Page 3: Table Of Contents
Table of Contents Section 1 Specifications ........................5 Section 2 Safety Information ........................ 7 2.1 Use of Hazard Information ......................7 2.2 Precautionary Labels ........................7 2.3 Safety Precautions........................9 Section 3 General Information......................11 3.1 Acceptable Noise Levels......................11 3.2 Patents and Permissions ......................
Page 4 Table of Contents Original Instructions...
Page 5: Section 1 Specifications
Section 1 Specifications Specifications are subject to change without notice. Channel Frame and UV Bank UV Bank Channel Frame (Fully Assembled) # Lamps Weight Hydraulic System Center Voltage Refer to Component Label or Electrical Drawings Enclosure Rating Material Refer to Component Label or System Description Weight Hydraulic Fluid Type Refer to Label on HSC or System Description...
Page 6 Specifications Original Instructions...
Page 7: Section 2 Safety Information
Section 2 Safety Information Please read this entire manual before installing this equipment. Pay attention to all danger, warning and caution statements in this manual. Failure to do so could result in serious personal injury or damage to the equipment. Make sure that the protection provided by this equipment is not impaired.
Page 8 Safety Information This symbol indicates a trained and competent lift operator should be used to move the equipment. This symbol indicates a body crush hazard. People should stay clear from under overhead loads. This symbol indicates there is a potential fall from height hazard. This symbol indicates surfaces may be slippery and there is a potential fall hazard.
Page 9: Safety Precautions
Safety Information This symbol indicates a hard hat must be worn. This symbol indicates safety harness or fall protection equipment must be worn. This symbol indicates the operator must read all available documentation to perform the required procedures. 2.3 Safety Precautions Read the safety precautions in this section before doing installation.
Page 10 Safety Information C A U T I O N Slip and Fall Hazard. • Failure to follow these instructions may result in injuries from slip and fall. • ALWAYS ensure safe footing. • ALWAYS clean up spills promptly. • ALWAYS comply with site-specific safety protocols and procedures. N O T I C E Personal Protective Equipment Required.
Page 11: Section 3 General Information
3.2 Patents and Permissions The products described in this document may be protected by one or more patents in The United States of America, Canada and/or other countries. For a list of patents owned by Trojan Technologies, go to: www.trojantechnologies.com/patents.
Page 12: System Overview
General Information 3.4 System Overview The installation consists of the following components: Figure 1 System Overview Hydraulic System Center UV Bank 3.4.1 Hydraulic System Center (HSC) The HSC actuates the ActiClean Cleaning System (ACS). The HSC contains the pump, valves and additional equipment required to operate the cleaning system and lift/lower the UV Bank.
Page 13: Section 4 Lockout Tag Out
Section 4 Lockout Tag Out D A N G E R Obey all warning and caution statements. Refer to Section Read and understand this Operation and Maintenance Manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment.
Page 14: Lockout Tag Out Energy Sources
Lockout Tag Out 4.1.3 Lockout Tag Out Energy Sources 1. Use a multi-lock scissor adapter to lockout each energy source. 2. Attach a completed lockout tag. Include the required information: • Person and company applying the lockout • Reason for the lockout •...
Page 15: Section 5 Installation
Section 5 Installation D A N G E R Obey all warning and caution statements. Refer to Section Read and understand this Operation and Maintenance Manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment.
Page 16: Hydraulic System Center
Installation Symbols Description Symbols Description ® Power Drill with Bits Lint-free Cloth (Kimwipes 5.1.2 Hydraulic System Center Figure 2 HSC Assembly Mounting and Connections Mounting Holes (4x) Gland Plate Low Voltage (Left Side) High Voltage (Right Side) Lifting sling access Disconnect Handle (optional) Hydraulic Ports 5.1.2.1 Mounting the HSC...
Page 17 Installation Procedure: Note: Install lifting straps as required to safely lift and lower the HSC. Original Instructions...
Page 18: Bank Frame Assembly
Installation Note: Level the HSC in both directions (Top to bottom and front to back. 5.1.3 Bank Frame Assembly N O T I C E DO NOT remove the frame support located in the middle of the frame assembly. Remove only after the bank frame grouting is complete.
Page 19 Installation Materials: • Anchors (provided) • Concrete form work (by others) • Tape or protective film (by others) • Digital Level Procedure: Notes: 1) Make sure orientation of Frame Assembly aligns with Notes: 1) Level mounting frame assembly side to side and front to layout drawings.
Page 20 Installation Note: Make sure the bracket hardware is loose and able to move freely. Original Instructions...
Page 21 Installation Note: Apply anti-seize to fastening hardware. Note: Ensure the Bank Frame surface is free of debris prior to form work installation. Clean if required. Original Instructions...
Page 22 Installation Note: Place grout in between bank frame and channel wall. DO NOT allow grout to fill the inside slots of the bank frame. Original Instructions...
Page 23 Installation Note: Remove wood forms after grout has completely dried. Note: Repair concrete imperfections as required. Note: Repair concrete imperfections as required. Original Instructions...
Page 24: Uv Bank
Installation Note: The angle braces can be recycled where facilities exist. 5.1.4 UV Bank The Bank Frame Assembly supports two (2) UV Banks, one (1) A Bank and one (1) B Bank. All 'A Banks' are installed on the upstream side of the Bank Frame Assembly. All 'B Banks' are installed on the downstream side of the Bank Frame Assembly.
Page 25 Installation Figure 3 UV Bank Designations 'B Bank' Upstream Bank Frame Assembly Downstream 'A Bank' Flow Direction May also be referred to as Bank B, Bank D, Bank F or Bank H. May also be referred to as Bank A, Bank C, Bank E or Bank G. 5.1.4.1 Install UV Bank(s) Prerequisites: •...
Page 26 Installation Install: Note: Retain the lock pin and bushings for later use. Note: Once the UV Bank touches the frame, begin to lower the crane boom to allow the UV Bank to slide into the track. Original Instructions...
Page 27 Installation Notes: 1) Ensure that the guide rails line up with the slots in the channel mounting frame. 2) DO NOT damage the UV Bank seal during installation. Note: Retain the guide bracket and mounting hardware for later use. Original Instructions...
Page 28 Installation Note: Retain the lock pin and bushings for later use. Note: Once the UV Bank touches the frame, begin to lower the crane boom to allow the UV Bank to slide into the track. Original Instructions...
Page 29 Installation Notes: 1) Ensure that the guide rails line up with the slots in the channel mounting frame. 2) DO NOT damage the UV Bank seal during installation. Note: Install Bank Lift Cylinder Brackets. Original Instructions...
Page 30: Uv Bank Support Assembly
Installation 5.1.5 UV Bank Support Assembly Prerequisites: • Install UV Bank. Refer to Section 5.1.4.1. Tools: • Hoist Ring (x2) Materials: • Anchors (by others) Procedure: Original Instructions...
Page 31 Installation Note: Use a lifting device to raise the UV Bank. Note: Measure from base of Channel Frame. Mark a line on the channel wall. Notes: 1) Lift the UV Bank. Note: Adjust the width of the support beam mounting brackets to 2) DO NOT place anything under the lifted UV Bank.
Page 32 Installation Note: Push the Support Assembly flush to the lifted UV Bank. Make sure the bottom of the brackets are aligned with the marked line in step 2. Note: Adjust the tension hardware until the wear pads align with the UV Bank.
Page 33: Lift Cylinder
Installation Note: Tighten all UV Bank Support Assembly hardware. 5.1.6 Lift Cylinder 5.1.6.1 Install Bank Lift Cylinders Prerequisites: • Install UV Bank. Refer to Section 5.1.4.1. Tools: • Hoist Ring (x2) Materials: • Lift Cylinder (provided) • Guide bracket (provided) •...
Page 34 Installation Note: Use a lifting device to raise the UV Bank to gain access to the clevis pin bracket. Note: Make sure the bottom of the lift cylinder is properly seated in the bracket. Original Instructions...
Page 35 Installation Note: Lower the UV Bank down. Notes: 1) Make sure the cylinder follower is correctly seated in the Bank Frame Assembly. 2) Make sure the bottom of the lift cylinder is properly seated in the bracket. Original Instructions...
Page 36 Installation Original Instructions...
Page 37 Installation Note: Make sure the bottom of the lift cylinder is properly seated in the bracket. Original Instructions...
Page 38 Installation Note: Lower the UV Bank down. Notes: 1) Make sure the cylinder follower is correctly seated in the Bank Frame Assembly. 2) Make sure the bottom of the lift cylinder is properly seated in the bracket. Original Instructions...
Page 39: Cable Management
Installation 5.1.7 Cable Management The cable management brackets organize the Hydraulic Hoses, Lamp Cables, Bond Wire, UVI Sensor cable and Bank In Place Sensor cable. One cable management bracket per UV Bank is required. Cable management brackets may be supplied in left and/or right sided configurations. Refer to Figure 4 left and right handed UV Bank designations.
Page 40 Installation Figure 5 Cable Management - Assemblies Standard Channel Bracket (Right sided shown) Deep Channel Bracket (Left sided shown) [Used [Used for Channel Depths up to 233.7 cm (92 for Channel Depths greater than 233.7 cm (92 inches)] inches)] Figure 6 Lamp Cables and Hydraulic Hoses Routing Lamp Cables Field Wiring (i.e.
Page 41 Installation 5.1.7.1 Install Cable Management Assemblies on UV Bank Prerequisites: • Refer to the project layout drawings for installation location. • Install UV Bank. Refer to Section 5.1.4.1. Tools: Materials: • Bracket Mounting Hardware (provided) Procedure: Note: Follow the appropriate procedure for the Bracket Assembly type provided (i.e. Standard Channel or Deep Channel).
Page 42 Installation Note: Tighten Jam Nuts/Bolts to secure Cable Management Assembly. Deep Channel Bracket Assembly Note: Distance to be minimum 13mm (1/2 inch) below underside of * Staging Area (Wireway) grating. Original Instructions...
Page 43: Bank In Place Sensor
Follow the appropriate installation procedure for A-Bank and B-Bank below. N O T I C E Trojan Technologies personnel must install the UV Bank in Place Sensor during system commissioning. Protect Bank In Place Sensor connector from moisture prior to connection of the Bank In Place Sensor Cable (Section 5.2.4.2).
Page 44 Dielectric Silicone Grease Procedure: N O T I C E The Bank In Place Sensors and the spacers are shipped in the start-up crate. Trojan Technologies personnel must install the UV Bank in Place Sensor during system commissioning. Original Instructions...
Page 45 Installation A-Bank Installation Note: Adjust the vertical positioning of the Bank In Place Sensor Assembly by sliding along the slotted holes on the mounting bracket as shown. Note: Adjust the horizontal positioning of the Bank In Place Sensor Assembly by sliding along the slotted hole on the mounting bracket as shown.
Page 46 Installation Notes: 1) Lift the UV Bank down. Refer to the Operation and Notes: 1) Ensure there is a 7mm gap between the sensors. Maintenance Manual. Additional spacer plates to be installed as needed, to 2) Carefully observe the lowering of UV Bank into the achieve the required spacing.
Page 47 Installation 8. If spacer plate(s): • need to be installed to achieve the required spacing, proceed to step 9. • are not needed, skip steps 9 to 12 and proceed to step 13. Notes: 1) Adjust the Bank In Place Sensor / Base Plate Assembly as needed to make space for the Spacer Plate(s).
Page 48 Installation Note: Apply a thin layer of dielectric silicone grease over the 5 pins of the male receptacle on the Bank In Place Sensor. 14. Refer to Section 5.2.4.2 for cable routing details. B-Bank Installation Note: Adjust the vertical positioning of the Bank In Place Sensor Assembly by sliding along the slotted holes on the mounting bracket as shown.
Page 49 Installation Note: Adjust the horizontal positioning of the Bank In Place Sensor Assembly by sliding along the slotted hole on the mounting bracket as shown. 4. Remove the HSC Lockout. Refer to Section 4. Restore power to the HSC. Original Instructions...
Page 50 Installation Notes: 1) Lift the UV Bank down. Refer to the Operation and Notes: 1) Ensure there is a 7mm gap between the sensors. Maintenance Manual. Additional spacer plates to be installed as needed, to 2) Carefully observe the lowering of UV Bank into the achieve the required spacing.
Page 51 Installation 8. If spacer plate(s): • need to be installed to achieve the required spacing, proceed to step 9. • are not needed, skip steps 9 to 12 and proceed to step 13. Notes: 1) Adjust the Bank In Place Sensor / Base Plate Assembly as needed to make space for the Spacer Plate(s).
Page 52: Wiring, Cables And Hoses
Installation Note: Apply a thin layer of dielectric silicone grease over the 5 pins of the male receptacle on the Bank In Place Sensor 14. Refer to Section 5.2.4.2 for cable routing details. 5.2 Wiring, Cables and Hoses 5.2.1 Tools and Materials Symbols Description Symbols...
Page 53: Hsc Electrical Installation
Installation 5.2.2 HSC Electrical Installation Prerequisites: • Mount the HSC. Refer to Section 5.1.2.1. • Use appropriately rated cable as per the Electrical and Layout Drawings provided by Trojan Technologies. • Apply Lockout Tag Out devices as required. Refer to Section •...
Page 54 Installation Figure 9 HSC - Gland Plate Assembly Gasket Flat Washer Gland Plate Splitlock Washer Plastic Washer Hex Nut Original Instructions...
Page 55: Hydraulic Hose - Cylinder Connections
Installation 5.2.3 Hydraulic Hose - Cylinder Connections 5.2.3.1 Connect the Hydraulic Hoses to the Lift and Wipe Cylinders Prerequisites: • Install HSC. Refer to Section 5.1.2.1. • Lockout Tag Out devices as required. Refer to Section • Install Cable Management Assemblies. Refer to Section 5.1.7.1.
Page 56 Installation Figure 12 Hydraulic Hose Connections (For UV Banks with 14 - 24 UV Lamps) Bank A or Bank C Wipe Cylinder Bank B or Bank D Lift Cylinder Bank A or Bank C Lift Cylinder Bank B or Bank D Wipe Cylinder * Hydraulic hoses can be routed to either the left or right side of the cylinders.
Page 57 Installation Procedure: 1. Route Hydraulic Hose from the UV Bank to the appropriate HSC. Refer to Layout Drawing. Refer to Table 2 for recommended hose installation order. Notes: 1) Make sure the pre-crimped end of the hydraulic hose is at the UV Bank side. 2) Refer to Section 5.1.7 for Hydraulic Hose Routing in Cable Management Assemblies.
Page 58 Installation Example - Lift Cylinder Circuit Note: Extend = Red Color and Retract = Yellow Color Example - Wipe Cylinder Circuit (For UV Banks with 8 - 12 UV Lamps) Note: Extend = Green Color and Retract = Blue Color Original Instructions...
Page 59 Installation Example A - Wipe Cylinder Circuit (For UV Banks with 14 - 24 UV Lamps) Note: For sites that require cables and hydraulic hoses to be routed towards cable troughs located on the side of the UV Channel opposite from default side, skip this procedure and proceed to Example B - Wipe Cylinder Circuit (For UV Banks with 14 - 24 UV Lamps).
Page 60 Installation Repeat steps 3 to 7 for the Wiper Extend hydraulic hose assembly. Original Instructions...
Page 61 Installation Note: Extend = Green Color and Retract = Blue Color Repeat steps 3 to 10 for remaining Wipe Hydraulic Cylinders. Original Instructions...
Page 62: Cable And Wire Routing
Installation 5.2.4 Cable and Wire Routing Prerequisites: • Install PDC. Refer to Operation and Maintenance Manual. • Lockout Tag Out devices as required. Refer to Section 5.2.4.1 Bond Wire(s) Procedure: 1. Install a bond wire onto the UV Bank and route the bond wire to corresponding PDC. Refer to Layout Drawing and Figure Note: Each UV Bank is required to have a dedicated bond wire.
Page 63: Install Cables, Wires And Hydraulic Hoses In Bracket Assemblies
Installation Procedure: 1. Route field wires from Bank A to corresponding PDC. Refer to TrojanUVSigna Electrical Interconnect, System Wiring drawing (i.e. 341146G) and the Project Layout Drawing for additional field wiring details. Note: Protect Bank In Place Sensor Cable connector from moisture prior to connection to the Bank In Place Sensor.
Page 64 Installation If Spiral Wrap is supplied, wrap around the following: • Lamp Cables • Hydraulic Hoses • Bank in Place Sensor Cable • UV Intensity Sensor Cable • Bond Wire N O T I C E A maximum of twelve (12) Lamp Cable per spiral wrap bundle allowed. Where there is greater than twelve (12) UV Lamps per UV Bank, split the Lamp Cables into two (2) separate spiral wrap bundles.
Page 65 Installation Cable Routing through Deep Channel Bracket Assemblies - Spiral Wrap Figure 15 Cable Routing through Deep Channel Bracket Assemblies - Spiral Wrap Top of UV Channel Wall Cable Trough* Bank A Bank B Upstream Downstream Cable Ties Cable Spiral Wrap Hydraulic Hose** * One (1) cable trough per UV Channel is required.
Page 66: Cable Trough Cable Management - Cable Track
Installation 5.2.6 Cable Trough Cable Management - Cable Track The Cable Track can be installed on one side of the UV Channel or both sides of the UV Channel. Refer to project layout drawing for Cable Track installation location. Figure 16 Cable Track Installation on One Side of UV Channel Figure 17 Cable Track Installation on Both Sides of UV Channel - Method A Figure 18 Cable Track Installation on Both Sides of UV Channel - Method B Original Instructions...
Page 67 Installation Cable Routing through Cable Track Figure 19 Cable Routing through Cable Track Top of UV Channel Wall Cable Trough* Bank A Bank B Upstream Downstream Cable Ties Cable Track Hydraulic Hose** * One (1) cable trough per UV Channel is required. Cable trough is recommended to be located on the same side of the UV Channel as the PDC’s.
Page 68 Installation Procedure: Install: Note: Install Cable Track mounting bracket to the cable Note: Position the cable track in the cable trough as per the project management assembly. layout drawings. Original Instructions...
Page 69 Installation Note: Position the chain links as shown. Note: Pry open the cross bars using a screwdriver as shown. Note: Retain the cross bars for later use. Note: Press the side plates together to join the chain links. Original Instructions...
Page 70 Installation Note: Install the cross bars. Note: Route the cables and hoses though the Cable Track as shown. Notes: 1) Disconnect the hoses from the Hydraulic Cylinders. Note: Use a lifting device to raise the UV Bank. 2) A small amount of hydraulic fluid may drain from the cylinder fittings, take precautions to avoid spills.
Page 71 Installation Notes: 1) Connect the hoses to the Hydraulic Cylinders. Note: Mark the position of the cable track mounting bracket. 2) Inspect the hydraulic hose and hose connections to ensure there is enough hose slack to allow movement. Original Instructions...
Page 72 Installation Note: Install and anchor the mounting plate on the concrete. Note: Install Cable Track mounting bracket to the mounting plate. Notes: 1) Disconnect the hoses from the Hydraulic Cylinders. 2) A small amount of hydraulic fluid may drain from the cylinder fittings, take precautions to avoid spills.
Page 73: Cable Trough Cable Management - Spiral Wrap
Installation 5.2.7 Cable Trough Cable Management - Spiral Wrap Note: If Cable Track is supplied, skip this section and proceed to Section 5.2.8. Prerequisites: • Install Cable Management Assemblies. Refer to Section 5.1.7.1. • Install Hydraulic Hoses. Refer to Section 5.2.3.
Page 74 Installation With a Standard Channel Bracket Assembly: Figure 20 Section View UV Bank B UV Bank A - Trough Bracket UV Bank A Flow Direction Cable Management Assembly Cable Trough UV Bank B - Trough Bracket Trough Height, from floor (Table Table 3 Standard Channel Bracket Installation Location Dimension A...
Page 75 Installation With a Deep Channel Bracket Assembly: Figure 21 Section View UV Bank B UV Bank A - Trough Bracket UV Bank A Flow Direction Cable Management Assembly Cable Trough UV Bank B - Trough Bracket Trough Height, from floor (Table Table 4 Deep Channel Bracket Installation Location Dimension A...
Page 76 Installation Table 4 Deep Channel Bracket Installation Location (continued) Dimension A Dimension B Inches feet Inches feet 8'-10" 2692 5'-5" 1651 8'-11" 2718 5'-4" 1626 9'-0" 2743 5'-3" 1600 9'-1" 2769 5'-2" 1575 9'-2" 2794 5'-1" 1549 9'-3" 2819 5'-0" 1524 9'-4"...
Page 77 Installation Note: Lamp Cables, Bond Wire, UV Intensity Sensor Cable, Bank In Place Sensor Cable, and Hydraulic Hoses are not shown in some illustrations for clarity. Original Instructions...
Page 78 Installation Standard Cable Management Arm Deep Channel Cable Management Arm Notes: 1) Repeat steps for remaining cable bundles. 2) Install Cable Tie as shown to tie down the cable and hose bundle to the bracket. Original Instructions...
Page 79: Hydraulic Hose - Hsc Connections
Installation 5.2.8 Hydraulic Hose - HSC Connections 5.2.8.1 Hydraulic Hose Fittings and Connections Each HSC is able to provide lift and wipe functions for up to four (4) UV Banks. Refer to the site layout drawings and electrical drawings provided to determine the number of UV Banks that the HSC will provide lift and wipe functions for.
Page 80 Installation Figure 23 Hydraulic Hose Connections at HSC Bank A Lift Extend = Red color Bank B Lift Retract = Yellow color Bank C Wiper Extend = Green Color Bank D 10 Wiper Retract = Blue Color Lift Circuits 11 Front of HSC Wiper Circuits Refer to Table 5...
Page 81 Installation 1. Install Field Connect Hose Fittings onto the first hose. Refer to DC000601-019. Note: Fully thread the elbow fitting into the hole. Note: Orientate fitting so that the hoses will not interfere with each other. Tighten the lock nut while maintaining elbow orientation. Original Instructions...
Page 82 Installation 7. Repeat steps 1 to 6 for remaining hydraulic hoses until complete. Refer to the Installation section in the Operation and Maintenance Manual for next steps. Original Instructions...