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Aquafine Logic AL20 Series Operation And Maintenance Manual

Automatic and non-wiping systems
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Aquafine Logic
AL20 Series
Automatic and Non-Wiping Systems
Operation and Maintenance
User Manual
Original Instructions
Edition 11
®
Aquafine Corporation
, 2024 All rights reserved. Printed in Canada.
DC660101-11-01

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  • Page 1 ® Aquafine Logic AL20 Series Automatic and Non-Wiping Systems Operation and Maintenance User Manual Original Instructions Edition 11 ® Aquafine Corporation , 2024 All rights reserved. Printed in Canada. DC660101-11-01...
  • Page 2 If you require technical assistance, please contact Aquafine Corporation Technical Support using the contact information below: Telephone: 1-661-257-4770 E-mail: techservice@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 ........................7 Section 2 Safety Information ......................... 9 2.1 Use of Hazard Information ......................9 2.2 Precautionary Labels ........................9 2.3 Safety Precautions........................11 2.4 Safety Features........................... 13 Section 3 General Information......................15 3.1 Acceptable Noise Levels......................15 3.2 Patents and Permissions ......................
  • Page 4 Table of Contents 8.4 Wiper Status Screen ........................36 8.5 Trend Screens..........................37 8.6 Alarm Screens..........................37 8.6.1 Active Alarm Screen ......................37 8.6.2 Alarm History Screen......................38 8.7 Information Screen ........................38 8.7.1 Data Logging ........................39 8.8 Settings Screens .........................39 8.8.1 Settings Menu........................40 8.8.2 General Settings Screen ....................40 8.8.3 Wiper Settings Screen......................41 8.8.4 Counter Settings Screen ....................41 8.8.5 Analog Input Settings Screen .....................42...
  • Page 5 Table of Contents 10.3.6 Replace the Wiper Seals and Wiper Seal Holders ............77 10.3.7 Replace the Bearing Housing and Bearing Housing O-ring* ........... 78 10.4 Repair ............................82 10.4.1 Replace the Stop Plate ....................82 10.4.2 Remove and Replace the Wiper Plate................84 10.4.3 Replace the Drive Shaft*....................
  • Page 6 Table of Contents Original Instructions...

  • Page 7: Section 1 Specifications

    Section 1 Specifications Specifications are subject to change without notice. UV Chamber Material 316L stainless steel Maximum Weight (dry) 52 kgs (115 lbs) Maximum Weight (wet) 105 kgs (230 lbs) I/O Connection Refer to Layout Drawing Ambient Relative Humidity 10% to 80% non-condensing Water Temperature 1°C to 40°C (34°F to 104°F) Ambient Operating Air...
  • Page 8 Specifications Original Instructions...

  • Page 9: Section 2 Safety Information

    Section 2 Safety Information Please read this entire manual before operating 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 10 Safety Information This symbol indicates a load lifting hazard. This symbol indicates a potential overhead crush hazard. This symbol indicates surfaces may be slippery and there is a potential fall hazard. This symbol indicates there is a potential UV hazard. Proper protection must be worn. This symbol indicates the marked item could be hot and should not be touched without care.

  • Page 11: Safety Precautions

    Safety Information 2.3 Safety Precautions Read the safety precautions in this section before doing maintenance, service or repair. Obey the instructions in the safety precautions. Failure to follow the instructions in the safety precautions can result in serious injury or death. D A N G E R Arc Flash and Shock Hazard - Live Electrical Circuit Present.
  • Page 12 • Thoroughly collect broken glass and trace amounts of mercury and place into a sealable bag or container. For further reference see the U.S. EPA guidelines. http://www.epa.gov/cfl/cleaning-broken-cfl. • If you have further questions about the safe clean-up of mercury containing lamps, contact the Aquafine service support group at techservice@trojantechnologies.com. Original Instructions...

  • Page 13: Safety Features

    Service Provider for assistance. N O T I C E ® The Aquafine Logic inactivates Escherichia coli (E. coli) and fecal coliform. WARNING: This product can expose you to chemicals including phthalates, which is known to the State of California to cause cancer, and mercury, which is known to the State of California to cause birth defects or other reproductive harm.
  • Page 14 Safety Information Original Instructions...

  • Page 15: Section 3 General Information

    Section 3 General Information The information in this manual has been carefully checked and is believed to be accurate. However, the manufacturer assumes no responsibility for any inaccuracies that may be contained in this manual. In no event will the manufacturer be liable for direct, indirect, special, incidental or consequential damages resulting from any defect or omission in this manual, even if advised of the possibility of such damages.

  • Page 16: System Overview

    General Information 3.4 System Overview The system is a pressurized UV Chamber that uses high-output amalgam UV Lamps. Figure 1 shows the UV Chamber components. One Control Power Panel (CPP) provides the power distribution for one UV Chamber and controls the UV Chamber through a microprocessor user interface.

  • Page 17: 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 manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment. Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual.

  • Page 18: Lockout Tag Out Energy Sources

    Lockout Tag Out 4.1.3 Lockout Tag Out Energy Sources 1. Use a multi-lock scissor adaptor 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 19: Section 5 Shipment And Storage

    Section 5 Shipment and Storage 5.1 Shipping Contents The system consists of two major components, the UV Chamber and the CPP. Some components may be disconnected at the UV Chamber for shipment. 5.2 How the equipment is shipped The system is delivered to the site by truck. System components are packed in wooden crates labeled with the component name.
  • Page 20 Shipment and Storage Original Instructions...

  • Page 21: Section 6 Installation

    Section 6 Installation D A N G E R Obey all warning and caution statements. Refer to Section Read and understand the Operation and Maintenance Manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment.

  • Page 22: Cpp

    Installation • Protect the equipment from the environment. Do not expose the equipment to direct water spray. • The UV System does not introduce any chemical residue within the water, it is desirable to install the UV Chamber as close as possible to the point-of-use to avoid potential recontamination by discharge pipes, fitting, etc.

  • Page 23: Electrical Connections

    Installation Procedure: 1. Position a lifting strap around each of the UV Chamber mounting brackets (between the flange and the bracket). Center the lifting straps around the UV Chamber. Bring the two lifting straps above the UV Chamber and connect as required to a crane. Use a crane to lift the UV Chamber into position. The UV Chamber can be installed in either a horizontal or a vertical position.

  • Page 24: Hydrostatic Test

    Installation Tools: Materials: • Electrical Drawings (supplied with the system) Procedure: 1. Connect the CPP to the UV Chamber. The individual lamp connectors are numbered with wire tags for convenient connection; match these numbers to their corresponding number on the UV Chamber end plate.

  • Page 25: Acceptable Uv Chamber Installation Orientations

    Installation 2. If leaks are found: a. Depressurize and drain the UV Chamber. Refer to Section 9.4. b. Fix the leaks. c. Fill the UV Chamber and do a pressure test. Check for leaks. 3. If there are no leaks, depressurize the UV Chamber. Refer to Section 9.4.
  • Page 26 Installation Original Instructions...

  • Page 27: Section 7 System Startup And Shutdown

    Section 7 System Startup and Shutdown D A N G E R Obey all warning and caution statements. Refer to Section Read and understand this manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment. Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual.

  • Page 28: Startup The Uv System From Local

    System Startup and Shutdown 3. When warming is complete, and no major or critical alarms are present, the UV System: • Sets the UV System Online bit. • Clears the UV System Warming bit. 4. The plant: • Resolves any active alarms. •...

  • Page 29: Shutdown The Uv System From Scada

    System Startup and Shutdown 2. The UV System control logic (Microprocessor Board): • Sets the UV Chamber to the Warming state. • Energizes the UV System Warming digital output signal (configuration optional). • Sets the power level at 100%. • Does not register any alarm until a 20-second startup timer has expired.

  • Page 30: Shutdown The Uv System From Remote

    System Startup and Shutdown 7.7 Shutdown the UV System from Remote Prerequisite: Pre-start Checklist. Refer to Section 7.1. Shutdown procedure: 1. The plant: • Stops process flow through the UV Chamber • De-energizes the Remote On/Off digital input signal. 2. The UV System: •...

  • Page 31: Section 8 Operation From The Cpp

    Section 8 Operation from the CPP D A N G E R Obey all warning and caution statements. Refer to Section Read and understand this manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment. Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual.

  • Page 32: Home Screen

    Operation from the CPP 8.2 Home Screen The Home Screen is the main system overview screen and is designed to provide all necessary information. Figure 5 Home Screen 8.2.1 Navigation Bar Figure 6 Navigation Bar The navigation bar allows the user to navigate between the different sections of the HMI application and is available on most screens.

  • Page 33: System Status

    Operation from the CPP 8.2.2 System Status The System Status indicator tells the operator what system conditions are currently present and is available on most screens. The different System Status are: • OK - Lamps are ON, warm-up is complete, no Major or Critical alarms are present. Will display as grey.

  • Page 34: Login Button

    Operation from the CPP 8.2.5 LOGIN Button The LOGIN button allows the user to change the user access level and is available on most screens. Touching the button will bring up the login dialog pop-up where users can select the desired user access level and enter the required password for that level.
  • Page 35 Operation from the CPP 8.2.7.2 Current Lamp Hours The current system lamp hours. If the current lamp hours exceed the End Of Lamp Life Hours set point, the indicator will show yellow. In this case, touching the indicator will navigate to the Counters Settings screen where the hours can be reset once new UV Lamps have been installed.

  • Page 36: Analog Graphs Screen

    Operation from the CPP 8.3 Analog Graphs Screen The Analog Graphs Screen shows the current values of all input signals. This includes signals from Analog Inputs, signals from SCADA and entered signals. Only the signals that are configured for the system will be shown.

  • Page 37: Trend Screens

    Operation from the CPP Shows the current status of the wiper. • IDLE – Wiper is stationary at home position. Wiper Status • EXTENDING – Wiper is currently traveling away from home position. • RETRACTING – Wiper is currently traveling towards home position. •...

  • Page 38: Alarm History Screen

    Operation from the CPP 8.6.2 Alarm History Screen The Alarm History screen shows the last 100 alarms that are no longer active in the order they were cleared. Figure 15 Alarm History Screen 8.7 Information Screen The Information Screen shows the information about the system and application version that Trojan’s Technical Assistance Center (TAC) will need in order to help troubleshoot issues.

  • Page 39: Data Logging

    Operation from the CPP 8.7.1 Data Logging Materials: • USB Stick Procedure: 1. Install USB stick into HMI. 2. Navigate to the Information Screen. 3. Select “Copy Data to USB” to show the “Select Data to Export” screen.Refer to Section 8.7.1.1.

  • Page 40: Settings Menu

    Operation from the CPP 8.8.1 Settings Menu The settings menu allows access to the various settings screens. Depending on the level of access some screens may not be available. Settings Menu with General Access Settings Menu with Technician Access Figure 18 Settings Menu 8.8.2 General Settings Screen The General Settings screen has settings and buttons that do not fall under one of the other settings categories.

  • Page 41: Wiper Settings Screen

    Operation from the CPP Resets the microprocessor user interface settings back to the original factory settings. Reset Factory Defaults Note: DO NOT reset without authorization from Trojan Technologies. Sets the High Temperature Off alarm delay—0 to 15 minutes. If set to 0, the UV Lamps High Temperature Off Delay turn off immediately when a Hi Temp Critical alarm occurs.

  • Page 42: Analog Input Settings Screen

    Operation from the CPP The counter for the number of times the power to the board has transitioned from OFF to ON. Board OFF-ON Cycles RESET - Resets this counter to zero. The counter for the number of times power to the UV Lamps in the UV Chamber has transitioned Lamp OFF-ON Cycles from OFF to ON.

  • Page 43: Analog Flow Settings Screen

    Operation from the CPP Figure 23 Analog Output Settings Screen Available Analog Output Signals • UV Intensity 1 • UV Chamber Temperature • UV Transmittance • Valve Position • Dose Achieved - DoseDP Systems Only • UV Intensity Lowest 8.8.7 Analog Flow Settings Screen The Analog Flow Settings screen allows users with Technician access to customize the Flow signal used for pacing and control of the UV System.

  • Page 44: Analog Uvt Settings Screen

    Operation from the CPP The static Flow value to be used when Signal Source is configured for Entered. Entered Value Note: This value has no effect when Signal Source is other than “Entered”. High Flow Major Alarm The Flow value at which the system will trigger a High Flow Major Alarm. The 20 mA scaling value to be used when the Signal Source is configured for Live 4-20 mA.

  • Page 45: Uv Chamber Analog Temperature Settings Screen

    Operation from the CPP 8.8.9 UV Chamber Analog Temperature Settings Screen The Analog Temperature Settings screen allows users with Technician access to customize the UV Chamber Analog Temperature signal used for control of the UV System. Figure 26 UV Chamber Analog Temperature Settings Screen Enable Analog Temp.

  • Page 46: Digital Output Settings Screens (1 - 4 And 5 - 7)

    Operation from the CPP 8.8.11 Digital Output Settings Screens (1 – 4 and 5 – 7) The two Digital Output settings screens allow users with Technician access to configure which digital signals are configured for the 7 available digital output connections. Digital Outputs 1 - 4 Settings Digital Outputs 5 - 7 Settings Figure 28 Digital Output Settings Screens...

  • Page 47: Section 9 Maintenance

    Section 9 Maintenance D A N G E R Obey all warning and caution statements. Refer to Section Read and understand this manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment. Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual.

  • Page 48: System Component

    Maintenance Table 2 Preventive Maintenance Schedule System Maintenance requirement component Inspect a representative sample (i.e. 10%) of lamp sleeves (Section 9.8.1). • Check the Lamp Sleeve O-Rings for UV decay and brittle parts. Replace the Lamp Sleeve O-Rings as needed. •...

  • Page 49: Depressurize And Drain A Uv Chamber

    Maintenance 9.4 Depressurize and Drain a UV Chamber The manufacturer recommends that the UV Chamber be depressurized and drained before any maintenance, service or repair task is done. Failure to depressurize and drain the UV Chamber can result in serious injury or death. Always follow all site-specific safety protocols and procedures. Refer to Section Prerequisites: •...

  • Page 50: Remove And Install The Service End Cap

    Maintenance Procedure: 1. Slowly fill the UV Chamber with water. a. Stand off to the side of the end plate and make sure the area is clear of all plant personnel. b. Pressurize the UV Chamber. c. Check for leaks. d.
  • Page 51 Maintenance Remove: Original Instructions...

  • Page 52: Uv Lamps

    Maintenance 3. To install a service end cap, do the illustrated steps in the opposite direction. 4. When service is complete, assembly the prerequisites in the reverse order of disassembly. 9.7 UV Lamps UV lamps contain mercury (Section 9.7.1 Storage Requirements for Used UV lamps Put used UV lamps into the replacement UV lamp shipping container, or a similar container.
  • Page 53 Maintenance Procedure: Remove: Note: Ensure that the spring remains inside the Lamp Sleeve. 3. Inspect the UV Lamp pins for: • Evidence of overheating • Moisture • Displaced or bent pins 4. Inspect the UV Lamp for: • Cracks or breaks, loose ceramic ends. 5.

  • Page 54: Lamp Sleeves

    Maintenance Install: Notes: 1) Always support the UV Lamp with clean, cotton gloved hands. Note: Hand tighten the cap compression nut. 2) Align the UV Lamp so that the amalgam spot is on the bottom. 3. Dispose of the old UV lamp, as per local regulations. 4.
  • Page 55 Maintenance • Remove a UV Lamp. Refer to Section 9.7.2. Tools: • Lamp Sleeve Removal Tool • Sleeve Bolt Socket • -in. drive torque wrench, 10.1 N.m (90 lbf.in) Materials: • Lamp Sleeve - if required • Lamp Sleeve O-Ring(s) •...
  • Page 56 Maintenance Remove: Note: Inspect the Lamp Sleeve, Lamp Sleeve O-Ring (Section 9.8.2). Original Instructions...
  • Page 57 Maintenance Install: Original Instructions...

  • Page 58: Inspect The Lamp Sleeves And Lamp Sleeve O-Rings

    Maintenance 9.8.2 Inspect the Lamp Sleeves and Lamp Sleeve O-rings Inspect the Lamp Sleeves and Lamp Sleeve O-Rings as a part of scheduled maintenance, when a UV Intensity Low alarm occurs or a Dose/RED Low alarm occurs. Prerequisites: • Remove Lamp Sleeves and Lamp Sleeve O-Rings. Refer to Section 9.8.1.

  • Page 59: Clean The Lamp Sleeves Manually

    Maintenance 9.8.3 Clean the Lamp Sleeves Manually N O T I C E Do not use abrasive materials to clean a Lamp Sleeve. Abrasive materials will scratch and cause damage to the Lamp Sleeve. Keep water and debris out of the Lamp Sleeves. Moisture can cause build-up in the Lamp Sleeves and corrosion of the lamp shunt and pins, which results in shorter UV Lamp life.

  • Page 60: Uv Sensor

    Maintenance 9.9 UV Sensor 9.9.1 Remove and Replace the UV Sensor and Sensor Window Replace a UV Sensor when the UV Sensor is damaged or when UVI alarms occur that are not caused by UV lamp failure . Clean the UV Sensor as part of scheduled monthly maintenance or when a low UV alarm occurs.
  • Page 61 Maintenance Remove and Clean the UV Sensor: Note: If water is draining at a high rate from the sensor port the UV Chamber is not fully drained. Drain UV Chamber completely before continuing. 4. When service is complete, assemble the prerequisites in the reverse order of disassembly. Original Instructions...

  • Page 62: Automatic Mechanical Wiper System (Amws)

    Maintenance 9.10 Automatic Mechanical Wiper System (AMWS) Note: Applies to Automatic Wiping Systems only. 9.10.1 Remove the Gear Motor Assembly Remove the gear motor assembly as necessary to access UV lamps and lamp sleeves that are located behind the gear motor assembly. Prerequisites: •...

  • Page 63: Replace The Gear Motor

    Maintenance Install: Post-requisites: • When service is complete, assemble the prerequisites in the reverse order of disassembly. 9.10.2 Replace the Gear Motor Replace the gear motor when it can no longer turn the drive shaft to move the wiper plates. Prerequisites: •...
  • Page 64 Maintenance Remove: Install: • Turn the drive shaft coupler so that the wiper revolution proximity UV Sensor has enough clearance to rotate freely (approximately 0.050" or 1.25mm). • When service is complete, assemble the prerequisites in the reverse order of the disassembly. Original Instructions...

  • Page 65: Replace The Wiper Revolution Proximity Sensor

    Maintenance 9.10.3 Replace the Wiper Revolution Proximity Sensor Replace the wiper revolution proximity sensor when a wiper home alarm occurs and the wiper revolution proximity sensor has failed. Prerequisites: • Remove the gear motor assembly. Refer to Section 9.10.1. Tools: 17 mm Materials: •...

  • Page 66: Control Power Panel (Cpp)

    Maintenance 9.11 Control Power Panel (CPP) 9.11.1 Open the CPP Enclosure Open the CPP enclosure to replace lamp drivers or the air filter. Prerequisites: • Shutdown the UV System. Refer to Section 7.5 Section 7.6 as needed. • Apply lockout tag out devices as necessary. Refer to Section 4.1.
  • Page 67 Maintenance Remove: Original Instructions...
  • Page 68 Maintenance Replace: 1. Set the DIP switches on the new lamp driver to match the settings on the old lamp driver. Original Instructions...

  • Page 69: Replace The Cpp Air Filter

    Maintenance 9.11.3 Replace the CPP Air Filter Replace the air filter as part of regular maintenance or when the air filter is dirty. Prerequisites: • Open the CPP enclosure. Refer to Section 9.11.1. Materials: • New air filter Procedure: 1. Slide the old air filter out and replace with the new one. Follow all local regulations for filter disposal. Original Instructions...
  • Page 70 Maintenance Original Instructions...

  • Page 71: Section 10 Service And Repair

    Section 10 Service and Repair 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 72: Legend

    Service and Repair 10.2 Legend The symbols in the following table will be used in this Section to define the wiping option provided. Follow the instructions that correspond to the supplied system. Symbol Description Symbol Description Automatic Wiping Option Non-wiping Option 10.3 Service 10.3.1 Service Schedule Inspect all system components during disassembly to determine whether repair is needed.

  • Page 73: Open The Uv Chamber

    Service and Repair 10.3.2 Open the UV Chamber The UV Chamber must be open with the UV lamp holder assembly removed to do service tasks. Prerequisites: • Shutdown the UV system. Refer to Section • Apply Lockout Tag Out devices as necessary. Refer to Section 4.1.

  • Page 74: Assemble The Uv Chamber

    Service and Repair Note: Guide rod is not applicable on systems with sanitary flanges. The UV Chamber and internal components are now accessible for cleaning and service. 10.3.3 Assemble the UV Chamber Tools: 17 mm 90in-lbf 240in-lbf Materials: Original Instructions...
  • Page 75 Service and Repair Procedure: Note: The End Cap Limit Switch is not shown for clarity in the following procedure Note: Guide rod is not applicable on systems with sanitary flanges. Original Instructions...

  • Page 76: Clean The Uv Chamber Interior

    Service and Repair Post-requisites: • Install the Lamp Sleeves. Refer to Section 9.8.1. • Install the UV Lamps. Refer to Section 9.7.2. • Install the Gear Motor assembly (Automatic Wiping Systems Only). Refer to Section 9.10.1. • Install the Service End Cap. Refer to Section 9.6.

  • Page 77: Replace The Sleeve Holder Bushings And Wear Pads

    Service and Repair 2. When service and repair is complete, assemble the UV Chamber. Refer to Section 10.3.3. 10.3.5 Replace the Sleeve Holder Bushings and Wear Pads Prerequisites: • Open the UV Chamber. Refer to Section 10.3.2. Tools: Materials: • Lamp Sleeve Holder Bushings •...

  • Page 78: Replace The Bearing Housing And Bearing Housing O-Ring

    Service and Repair Tools: Materials: • Lamp Sleeve Wiper Seals • Lamp Sleeve Wiper Seal Holders Procedure: Remove: Install: When service and repair is complete, assemble the UV Chamber. Refer to Section 10.3.3. 10.3.7 Replace the Bearing Housing and Bearing Housing O-ring* Note: Applies to Automatic Wiping Systems only.
  • Page 79 Service and Repair Materials: • Bearing Housing Kit • Bearing Housing O-ring Procedure: Original Instructions...
  • Page 80 Service and Repair Note: Apply liquid soap on end of the drive shaft. Note: Remove and dispose of the tape. Original Instructions...
  • Page 81 Service and Repair Illustration showing Type 04AL20. Original Instructions...

  • Page 82: Repair

    Service and Repair 10.4 Repair Do repair tasks when: • Service inspection shows wear • There is damage to the interior components of the UV Chamber 10.4.1 Replace the Stop Plate Prerequisites: • Remove the Lamp Sleeve Holder Bushings and Wear Pads. Refer to Section 10.3.5.
  • Page 83 Service and Repair Remove: Note: Remove the Cotter Pin using pliers. Install: Illustration showing Type 04AL20 Post-requisites: • Install the Lamp Sleeve Holder Bushings and Wear Pads. Refer to Section 10.3.5. • Assemble the UV Chamber. Refer to Section 10.3.3. Original Instructions...

  • Page 84: Remove And Replace The Wiper Plate

    Service and Repair 10.4.2 Remove and Replace the Wiper Plate Note: Applies to AutomaticWiping Systems only. Prerequisites: • Open the UV Chamber. Refer to Section 10.3.2. • Remove the Stop Plate. Refer to Section 10.4.1. Tools: 7/16-in Materials: • New Wiper Plate •...

  • Page 85: Replace The Drive Shaft

    Service and Repair Notes: 1) Ensure the drive shaft turns freely by hand after the drive nuts are tightened. Do not tighten the drive nut hardware. 2) Install the new wiper plate on the drive shaft in original orientation. Illustrations showing Type 04AL20. 10.4.3 Replace the Drive Shaft* Note: Applies to Automatic Wiping Systems only.
  • Page 86 Service and Repair Original Instructions...

  • Page 87: Section 11 Troubleshooting

    Section 11 Troubleshooting D A N G E R Obey all warning and caution statements. Refer to Section Read and understand this manual before operating this equipment. Read all user documentation before performing operations, inspections, repair, or maintenance on this equipment. Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual.

  • Page 88: Minor Alarms

    Troubleshooting 11.2.1 Minor Alarms When a minor alarm occurs, the UV Chamber remains on-line. Minor alarms show on the CPP and the alarm relays are deactivated. When a minor alarm occurs, take action to correct the problem soon after the alarm occurs.

  • Page 89: Major Alarms

    Troubleshooting 11.2.2 Major Alarms When a major alarm occurs, take immediate action to correct the problem. Make sure that system performance is not compromised. Alarm relays are deactivated. Refer to Table 8 for alarm definitions. Table 8 Major Alarms Definition Major Alarm name Active when Alarm delay...

  • Page 90: Critical Alarms

    Troubleshooting 11.2.3 Critical Alarms When a critical fault occurs, the UV Chamber is set to shutdown. On a critical alarm, the system CPP takes immediate action to prevent damage to the equipment. Take immediate action to make sure that system performance is not compromised.

  • Page 91: Optional Inputs And Outputs

    Troubleshooting 11.2.5 Optional Inputs and Outputs Note: Optional inputs and outputs cannot typically override standard provided inputs and outputs. Analog (4) Output Analog 4-20 mA System I/O Remote ON/OFF Input Digital Voltage sensing input Customer I/O Wiper Alarms - Applies to Automatic Wiping Systems only. Wiper Option –...

  • Page 92: Communication Control Board (Ccb) - Automatic Wiping Systems

    Troubleshooting 11.3.1 Communication Control Board (CCB) - Automatic Wiping Systems Figure 21 Microprocessor Communication Control Board (CCB) RS232 Communication Port Fuse - Slow Blow 1 A SCADA Communication Module Location 10 Power Indicator LED Battery, 3 V Lithium CR1220 11 Wiper Control Relay Sockets Temperature Switch 12 Relay Outputs for Wiper Control Wiper Revolution Sensor...

  • Page 93: Communication Control Board (Ccb) - Non Wiping Systems

    Troubleshooting 11.3.2 Communication Control Board (CCB) - Non Wiping Systems Figure 22 Microprocessor Communication Control Board (CCB) RS232 Communication Port Fuse - Slow Blow 1 A SCADA Communication Module Location Power indicator LED Battery, 3 V Lithium CR1220 10 End Cap attached Temperature Switch 11 Remote ON/OFF 24 VDC Analog Inputs (5x)
  • Page 94 Troubleshooting Original Instructions...

  • Page 95: Section 12 Replacement Parts And Accessories

    Section 12 Replacement Parts and Accessories Contact your Service Provider with the listed information to order replacement parts. Provide the: • Product name and model number (refer to the front of this manual) • Part number and description of the replacement part or accessory If a replacement part is not listed, contact your Service Provider.

  • Page 96: Uv Sensor

    Replacement Parts and Accessories 12.2 UV Sensor Figure 24 UV Sensor components Component Description Part Number Package Qty UV Sensor 793200-014 1 pcs Adapter, Sensor 794287 1 pcs Gasket, Sanitary 2 in. 002285-020 1 pcs Clamp, Sanitary BLT 2 in. 013213-200 1 pcs Original Instructions...

  • Page 97: Non Wipe Kit

    Replacement Parts and Accessories 12.3 Non Wipe Kit Note: For Non-Wiping Systems only. Figure 25 Non Wipe Kit Component Description Part Number Package Qty Plug, 1/4in Thread Hex 316 SST 794225-001 1 pcs O-Ring, 1-3/16 x 3/32 002333-123 1 pcs Rod, Lamp Holder 793299-001 1 pcs...

  • Page 98: Gear Motor Drive

    Replacement Parts and Accessories 12.4 Gear Motor Drive Note: For Automatic Wiping Systems only. Figure 26 Gear Motor Drive components Component Description Part Number Package Qty Cotter pin, 3/8-in SST 013207P 10 pcs Washer, 3/8" Flat 316 SST 010026P 100 pcs Flange Bushing 798123-001 1 pcs...

  • Page 99: Lamp Sleeve Wiping System

    Replacement Parts and Accessories Component Description Part Number Package Qty Wiper Motor Power Connector 916774-1521326 1 pcs Gear Motor, 3:1 gear ratio 792949 1 pcs 12.5 Lamp Sleeve Wiping System Note: For Automatic Wiping Systems only. Figure 27 Automatic Wipe Components Component Description Part Number...

  • Page 100: Stop Plate

    Replacement Parts and Accessories 12.6 Stop Plate Figure 28 Stop Plate components System Model Component Description Part Number Package Qty Stop Plate 1 pcs Lamp Sleeve 792942P 10 pcs Holder Bushing Wear Pad 792916P 10 pcs Illustration showing Type 04AL20. *AW = Automatic Wipe *NW = Non Wipe Original Instructions...

  • Page 101: Uv Chamber

    Replacement Parts and Accessories 12.7 UV Chamber Automatic Wiping Non-Wiping Figure 29 UV Chamber Original Instructions...

  • Page 102: Cpp Components

    Replacement Parts and Accessories Component Description Part Number Package Qty Service End Cap Non Wipe - Horizontal Install Orientation 700222-005 1 pcs Non Wipe - Vertical Install Orientation 700222-006 1 pcs Automatic Wipe - Horizontal Install Orientation 700222-002 1 pcs Automatic Wipe - Vertical Install Orientation 700222-004 1 pcs...

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