Pentair BIOSHIELD Installation And User Manual

®
BIOSHIELD
COMMERCIAL UV STERILIZER
INSTALLATION AND
USER'S GUIDE
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
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This document is subject to change without notice.
1620 HAWKINS AVE., SANFORD, NC 27330 • (919) 566-8000
10951 WEST LOS ANGELES AVE., MOORPARK, CA 93021 • (805) 553-5000
WWW.PENTAIR.COM
All Pentair trademarks and logos are owned by Pentair or one of its global aliates. Pentair Commercial Aquatics™
and Bioshield® are trademarks and/ or registered trademarks of Pentair Water Pool and Spa, Inc. and/or its aliated
companies in the United States and/ or other countries. Unless expressly noted, names and brands of third parties that may be used in this document are not used to indicate an aliation or endorsement between the owners of these names and brands and Pentair Water Pool and Spa, Inc. Those names and brands may be the trademarks or registered trademarks of those third parties. Because we are continuously improving our products and services, Pentair reserves the right to change specications without prior notice. Pentair is an equal opportunity employer.
P/N 960064 Rev. D 7/23/2019
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
TABLE OF CONTENTS
Section 1: Introduction ............................................. 4
General Information ............................................. 4
Glossary ............................................................... 4
Section 2: Health and Safety Precautions ............. 5
Safety Symbols .................................................... 5
Safety Instructions .............................................. 5
Hazardous Situations and
Appropriate Actions ............................................ 5
Section 3: Installation ............................................... 7
Pre-Installation Inspection .................................. 7
UV Vessel Installation .......................................... 8
Quartz Sleeve Installation ................................. 10
Power Supply Installation ................................. 12
Temperature and UV Intensity
Sensor Installation ............................................. 13
Section 4: Mandatory Water Test .......................... 14
Section 5: UV Lamp Installation ............................ 15
Lamp Field Safety Cover Installation ............... 17
Section 6: Commissioning ..................................... 18
Start-Up.............................................................. 18
Section 7: Operation ............................................... 19
Programmable Logic Control (PLC) .................19
PLC Enclosure ...................................................19
PLC Descriptions ............................................... 19
PLC Touch Screen Display ................................ 20
Section 8: Maintenance .........................................23
Routine Inspection ............................................ 23
UV Lamp Replacement ..................................... 23
UV Lamp Removal ............................................. 23
UV Lamp Recycling ...........................................24
UV Lamp Installation ......................................... 24
Quartz Sleeve .................................................... 24
Quartz Sleeve Removal ..................................... 24
Quartz Sleeve Cleaning ..................................... 25
Quartz Sleeve Installation ................................. 26
UV Vessel Cleaning ............................................26
UV Vessel Disassembly ..................................... 27
Cooling Fan and Filter Mat ................................ 29
Cooling Fan Filter Removal ............................... 29
Cooling Fan Filter Cleaning ............................... 29
Cooling Fan Filter Installation ........................... 29
Section 9: Replacement Parts ...............................30
Replacement Parts ............................................ 31
Section 10: Troubleshooting ..................................32
Section 11: System Specications ........................34
Vertical Series ....................................................34
CLP Series .........................................................36
Sizing Chart .......................................................39
Section 12: Product Warranty ...............................40
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 1: INTRODUCTION
General Information
In this manual you will nd user information for your Bioshield® Commercial UV Sterilizer. It is an important document for safety guidance, installation, operation and maintenance. Read and understand all sections of this Manual before starting the installation or operation of this UV system. Strictly follow this Manual and all safety notes, they are for your own
safety.
Custom-made, project specic modications of the UV system and/or additionally integrated components may result in non-conformity of the system and void
the warranty.
The information contained in this manual represents our most recent experiences and technical
knowledge. This information does not hold a
legally binding promise of certain characteristics or suitability for a specic application. The user of the UV system will be required to perform verications and safety measures.
Pentair Water Pool and Spa, Inc. (Pentair) accepts no responsibility for any problems arising from incorrect installation, lack of routine maintenance as specied in this manual or modications of the UV system.
Important Note: This unit has demonstrated an ability to provide three log inactivation of Enterococcus Faecium [ATCC #6569] and Pseudomonas Aeruginosa [ATCC #27313]. This unit has not demonstrated an ability to provide three log kill or inactivation of Cryptosporidium. This product is designed for supplementary disinfection and is intended for use with appropriate residual levels of EPA registered disinfecting chemicals. Specic residual levels of EPA registered disinfecting chemicals may be required by the regulatory agency having authority.
Glossary
TERM DESCRIPTION
Disinfection The inactivation of harmful microorganisms
End of Useful Lamp Life Recommended time to replace a UV lamp
Fouling Buildup of scale in the vessel, sensor or quartz sleeve
J/m2 Joule per square meter A Unit of UV Dose 10 J/m2 = 1 mJ/cm2 = 1,000 uWs/cm
Minimum UV Intensity Required value at end of lamp life (alarm threshold value) to maintain the
minimum UV dose at a given ow rate and a given UV transmission.
nm Nanometer – Light wavelength measurement
Personal Protective Equipment
Power Supply Enclosure NEMA Type-12 cabinet housing electrical hardware, instruments and PLC
Text Display Screen used to view PLC Controller/Monitor data
UV-C Specic UV area of the light spectrum (200 – 280 nm) UV Dose Indicates amount
UV Intensity Indicates the strength of UV light
UV Output Amount of UV light emitted from a UV lamp
UVT Ultraviolet Transmissibility how far UV-C light travels through water
UV Sensor Sensing-probe installed on the UV vessel to measure UV intensity-UV light
UV System Entire UV System that includes the Power Supply Enclosure and UV Vessel
UV Vessel Wet portion of the UV System consists of: quartz sleeve(s), UV lamp(s), vessel,
Hard Hat, Safety Glasses, Rubber Gloves, Safety Shoes
control/monitor
of UV light
wavelength 254nm
and valve(s)
2
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 2: HEALTH AND SAFETY PRECAUTIONS
Safety Symbols
Caution
Warning
High Voltage
Chemical (Corrosive)
Sharp Object
Protective Eye wear (UV Light)
SAFETY INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS PLEASE READ PRIOR TO INSTALLATION AND OPERATION
Strictly follow the instructions within this manual to ensure the health and safety of both, yourself and the UV system. The installation, operation and maintenance of the Bioshield® Commercial UV Sterilizer can only be carried out after reading and understanding the information contained in this manual.
The installation of the UV system must be carried out in accordance with local regulations and codes.
WA RNING : Water and electricity can be a dangerous
combination. Help us ensure your safety. READ AND FOLLOW ALL
SAFETY INSTRUCTIONS.
DANG ER: UV lamps and quartz sleeves are fragile and if
broken and handled incorrectly may cause serious injury.
IMPORTANT: READ AND OBSERVE ALL IMPORTANT
NOTICES AND LABELS ON THE UNIT. REMOVAL OF PRODUCT LABEL W ILL VOID WARRANTY!
Recycle
DANGE R: If the unit shows any sign of water leakage,
immediately unplug it from the power source.
DANGER : DO NOT operate this unit if it has a damaged cord
or plug, if it is malfunctioning, or if it has been dropped or damaged in any manner.
IMPORTANT: Close supervision is necessary when any
appliance is used by or near children ; this UV system is no exception.
IMPORTANT: Always unplug the unit from the electrical
outlet when it’s not in use, before servicing, cleaning or removing parts. Never yank the cord to pull the plug from the outlet. Grasp the plug and pull to disconnect.
IMPORTANT: Each UV system is designed for a specific
water-pressure. DO NOT use the UV system for any application other than its intended use. The use of attachments not recommended or sold by Pentair Aquatic Eco-Systems may cause unsafe conditions and possibly void any warranty.
IMPORTANT: For your safety the quartz sleeve and /or
the UV lamp in this product may have been broken or damaged during shipping. It is ESSENTIAL that the unit be CAREFULLY
INSPECTED BEFORE CONNECTING TO ELECTRIC POWER.
WARNING: DO NOT exceed listed pressure rating for unit.
DANGER : To avoid possible electric shock special care
should be taken since water is emp loyed in the use of the UV System. For each of the following situations, do not attempt repairs yourself. Call Pentair customer service department at ( 800) 831-7133.
DANGER: If the unit falls into the water, DO NOT REACH
FOR IT ! First unplug it and then retrieve it. If the internal electrical
components of the unit get wet, unplug the unit immediately.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
IMPORTANT: Only (3) three wire grounded cables suitable
for outdoor use should be used to connect this unit. If joining cables for outdoor use, a suitable watertight cable connector must be used. Care should be taken to arrange the cord so that it will not be tripped over or pulled. If in doubt consult a qualified electrician.
IMPORTANT: Only operate the UV system when it is
properly maintained and in good working order.
IMPORTANT: DO NOT modify the UV system without
authorization from Pentair Aquatic Eco-Systems.
DANGER : BLUE-LIGHT HAZARD Ultraviolet light will
cause serious damage to your eyes an d skin! DO NOT handle or stare at an operating UV lamp. UV lamps become hot during operation, DO NOT handle them during operation.
SECTION 2: HEALTH AND SAFETY PRECAUTIONS
HAZARDOUS SITUATIONS & APPROPRIATE ACTIONS
SITUATION LOCATION HAZARD ACTIONS
Lamp or Quartz
Sleeve Removal
Broken Quartz
Sleeves/ UV Lamps
UV Lamp
Replacement
Drain UV Vessel UV Vessel Pressure
Vessel Cleaning UV Vessel
Electrical Work UV System
UV Vessel Burn
UV Vessel Sharp Object
UV Vessel
Blue-Light
Hazard
Corrosive/
Chemical
Electrical
Shock
Isolate UV system from water source, shutdown system using external On/ O switch and lock-out disconnect from input power source.
Handle quartz sleeves and UV lamps with extreme care, wear clean cotton gloves.
DO NOT operate UV lamps outside the UV vessel, wear protective eye wear against ultraviolet light.
Isolate UV system from water source and shutdown system using external On/O switch and lock-out/ disconnect from input power source. Open valves carefully to relieve pressure and drain the UV Vessel.
Isolate the UV vessel and secure against unauthorized operation. Wear appropriate protection equipment. No
smoking or food allowed.
Shutdown system using the UV system’s external On/ O switch and lock-out/disconnect from input power source. All electrical work should be carried out by authorized and qualied personnel only.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 3: INSTALLATION
Pre-Installation Inspection
Purpose
To familiarize the installer/operator with the UV
Systems™ Commercial Lines’ components, to assure
proper delivery of all the system’s components and to inspect each component for shipping damages.
Frequency
To be conducted prior to installation.
Parts and Required Equipment
• Adjustable Wrench or 1.5” Socket
• Box Cutter
• Hammer/Nail Remover
• Flashlight
During pre-installation there is a general risk
due to load.
The UV System consists of:
• Quartz Sleeve Module (QSM) Faceplate (assembled
on Vessel)
• QSM Faceplate Gasket (assembled on Vessel)
• UV Intensity Sensor (PLC models only)
• Temperature Sensor
• Quartz Sleeve Retainer Nut (one for each quartz sleeve)
• Quartz Sleeve Gasket (one for each quartz sleeve retainer nut)
• Drain Valve Assembly
• Quartz Sleeve (one for each UV Lamp)
• UV Lamp(s)
• Vessel
• Bolt(s) (assembled on Vessel)
• Nut(s) (assembled on Vessel)
Quartz Sleeves and UV Lamps are fragile and
potentially dangerous if broken. Handle with care.
Procedure
NOTE: Vessel diameters up to 8” are shipped with
their quartz sleeves assembled. Vessel diameters 10” and larger are shipped with their quartz sleeves packaged separately.
NOTE: UV Lamp(s) are shipped in a separate package
either inside the vessel crate or separately.
1. Unpack and inspect vessel for shipping damage. A box cutter or hammer/nail remover may be needed to unpack the UV System.
2. Conduct an internal, visual inspection of models shipped with their quartz sleeves assembled. A ashlight will help with the internal inspection.
• Washer(s) (assembled on Vessel)
• 4-Pin Connector(s) (attached to lamp cables)
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 3: INSTALLATION
UV Vessel Installation
Purpose
Proper installation of the UV Vessel achieves expected results and ensures safe operation.
Frequency
Required with new construction, retro-t or replacement of outdated equipment.
Parts and Required Equipment
• Socket Wrenches
• Adjustable Wrenches
• Set of Slotted and Phillips Head Screwdrivers
• Lifting Equipment with Slings
• Vessel Mounting Brackets
• Required Isolation Valves
• Plumbing Components
3. Install UV vessel mounting brackets if required (to be supplied by others).
NOTE: A 46” clearance for both Vertical Series and
CLP4 Series models is required for lamp and quartz sleeve removal.
A 76” clearance for CLP6 Series models is required for lamp and quartz sleeve removal.
Horizontal Installation
Horizontal installation requires the vessel outlet port to face upwards, allowing trapped air to escape. If installed on a “by-pass lter loop” or isolated using valves, an automatic air bleed system is required.
Failure to remove trapped air can result in rupture or heat damage to the vessel.
• Personal Safety Equipment
General risk due to load.
General risk due to pressurized piping or UV
Vessel.
Quartz Sleeves are fragile and potentially
dangerous if broken. Handle with care.
Procedure
IMPORTANT: The installation of the UV system must
be carried out in accordance with local regulations and codes.
1. Install the UV system after the mechanical ltration. This eliminates debris from entering the vessel and diminishing the unit’s eectiveness, as well as potentially damaging the quartz sleeves and UV
lamps.
2. Install inlet and outlet isolation valves (to be supplied by others).
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 3: INSTALLATION
Vertical Installation
Vertical installation requires the bottom port to be used as the vessel’s inlet and the port closest to the electrical end to be used as the outlet; allowing trapped air to escape. If installed on a “by-pass lter loop” or isolated using valves, an automatic air bleed system is required. Failure to remove trapped air
can result in rupture or heat damage to the vessel.
5. The UV System (models w/ diameters of 10” and larger) may have been shipped without their quartz sleeves installed in the vessel, please install now.
6. The vessel is equipped with a 0.5” female threaded drain port for installation of the Drain Valve Assembly. Use thread tape on the threads when installing the drain valve assembly.
7. The vessel is equipped with various sensor ports (UV Intensity and Water Temperature Sensors); additional sensor ports may be included depending on the model or options purchased with the UV
System. All sensor ports will be labeled on the
vessel based on their respective function. Use thread tape on the threads to create a reliable seal with all sensors. Sensors must be threaded into their respective vessel ports prior to connection to the power supply enclosure to avoid sensor damage from cable twisting.
4. Isolation Valves are necessary for vessel removal and chemical cleaning procedure. It is recommended to install the isolation valves in conjunction with a separate set of, matching size & type, water port connections to the inlet/outlet ports of the vessel. Adding the “double connection” will enable the UV sterilizer to be removed from the ltration loop without shutting the total ltration system down.
If this installation arrangement is not possible,
install the unit in a way that chemical cleaners or freshwater rinse can be drained completely from the vessel without contaminating the process
water.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
10
SECTION 3: INSTALLATION
Quartz Sleeve Installation
Purpose
To thermally protect the UV lamp and isolate it from
water.
Frequency
Quartz Sleeve(s) are installed after being inspected/ cleaned or damaged. Water quality conditions may warrant more frequent inspection/cleaning. Fouled quartz sleeves absorb UV light and therefore may reduce the UV intensity.
Replace broken quartz sleeve(s).
Parts and Required Equipment
• Quartz Sleeve(s)
• Quartz Sleeve Retaining Nut Gasket
• Adjustable Wrench
• Cotton or Silicon Gloves
• Personal Safety Equipment
2. Carefully slide the quartz sleeve(s) into the Quartz Sleeve Faceplate’s “Quartz Sleeve Module” (QSM) allowing approximately 12” of the quartz sleeve to remain outside the UV vessel.
3. With 12” of the quartz sleeve exposed outside the vessel, carefully place the Quartz Sleeve Rubber Gasket Seal onto the open-end of the quartz sleeve.
Apply water or a small amount of water soluble lubricant onto the end of the quartz sleeve, this will act as a lubricant and will allow you to easily slide the Rubber Gasket onto the quartz sleeve.
The rubber gasket should be ush with the end of the quartz sleeve.
General risk due to electricity.
General risk due to pressurized piping or UV
Vessel.
Quartz Sleeves are fragile and potentially
dangerous if broken. Handle with care.
Procedure
NOTE: Use clean cotton or silicon gloves when
handling the quartz sleeve(s). Skin oils absorb ultraviolet light and reduce UV intensity.
1. Apply water (wet) or a small amount of water soluble lubricant to the domed-end of the quartz sleeve. Lubricating will aid in inserting the domed­end of the quartz sleeve into the vessel’s internal quartz sleeve coupler.
4. As you push the quartz sleeve into the vessel (through the Quartz Sleeve Module) elevate the domed-end of the quartz sleeve by gently pushing down on the open-end approximately 1/2”. This will help guide the domed-end of the quartz sleeve into its correct Internal Quartz Sleeve Coupler “Port”.
5. Finish sliding the remainder of the quartz sleeve into the vessel until the gasket makes contact with the Quartz Sleeve Module.
As you thread and tighten the Quartz Sleeve Retaining Nut onto the Quartz Sleeve Module the Quartz Sleeve Retaining Nut’s internal lip will automatically set the quartz sleeve in its proper
position.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 3: INSTALLATION
6. Using the white retaining nut tightening tool included with the UV system or a 1.5” socket or an adjustable wrench, tighten the Quartz Sleeve Retaining Nut until snug (5 ft. • lb.). Over-tightening can break the Quartz Sleeve Module on the faceplate or the quartz sleeve inside the UV vessel.
7. The quartz sleeve is now properly assembled; you
are now ready to perform a Water Test See Page
14.
11
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
12
SECTION 3: INSTALLATION
Power Supply Installation
Purpose
Power Supply Enclosure is part of the complete Bioshield UV Systems™ Series.
Frequency
Required with new construction, retro-t or replacement of outdated equipment.
Parts and Required Equipment
• Set of Slot and Phillips Head Screwdrivers
• Adjustable Wrench
• Pliers
• Wall Struts or Braces
• Supplied Enclosure Mounting Hardware
• Personal Safety Equipment
4. The Power Supply Enclosure should be located in a place that provides sucient weather protection, in the case of outdoor installation. Sucient space near the cooling fan’s intake and exhaust must be provided.
5. The Power Supply Enclosure must be supplied with the correct operating voltage (120/230 VAC). Failure to supply the UV System with the correct operating voltage can damage the ballasts and other electrical hardware. Use only a well- ground electrical circuit.
6. The UV System is equipped with an equipment­grounding conductor and a grounding plug. The grounding plug must be installed and grounded in accordance with all local codes and ordinances. Improper connection of the equipment- grounding conductor can result in electrocution. Check with a qualied electrician or service personnel if you question whether the equipment is properly grounded.
7. Input power to the Power Supply Enclosure is switched on and o using the enclosure’s External On/O switch or Remote On/O control.
General risk due to suspended load.
General risk due to electricity.
General risk due to pressurized piping or UV
Vessel.
Procedure
1. Use the supplied enclosure mounting feet if the Power Supply Enclosure is going to be mounted
on a wall.
2. Mount the Power Supply Enclosure close to the UV Vessel so that the lamp cables reach between the Power Supply Enclosure and the UV Vessel. The power supply lamp and sensor cables are approximately 20’ long to provide an adequate routing length from the power supply enclosure to the UV vessel.
3. The Power Supply Enclosure should be mounted so that the PLC is visible to the operator. The location used for mounting the Power Supply Enclosure should be as dry and cool as possible.
NOTE: All UV control enclosures that utilize our PLC
should be mounted with considerations to other devices that emit, or are suspected of emitting, any EMI & RFI noise and that any sensors used in conjunction with our PLC should use industry standard procedures to avoid EMI & RFI noise issues.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
SECTION 3: INSTALLATION
13
Temperature & UV Intensity Sensor Installation
Purpose
To instruct the operator how to properly install the Temperature and UV Intensity Sensors.
Frequency
Required with new installation or when servicing the unit during general maintenance.
Parts and Required Equipment
• Flare-Nut Wrenches
• Thread Tape
• Personal Safety Equipment
General risk due to electricity.
3. Once the sensors have been installed into the vessel you can attach cables to their respective connection points located on the bottom of the Power Supply Enclosure.
WARNING: Sensor-cables should be isolated from
other electrical devices, preventing electrical interference. UV intensity sensor-cables must also be separated from UV lamp cables to minimize electrical interference.
NOTE: The Temperature Sensor must be installed
in the vessel with its water tight connector properly connected to its respective port located on the power supply enclosure.
A Temperature Sensor Cable connection interruption will automatically shut down the system.
General risk due to pressurized piping and UV
vessel.
General risk due to suspended load.
Procedure
1. Install the Temperature and UV Intensity Sensors into their respective port locations as labeled on the vessel using Thread Tape to properly seal the sensor threads in the vessel. To avoid possible sensor damage from cable twisting, DO NOT connect the sensor cables to the power supply until after they are installed into the vessel. Leave the sensor cables coiled up close to the sensor during the installation process to allow the cable to rotate as the sensor is being screwed into the vessel. If the cable becomes twisted during the installation process, untwist it before proceeding.
2. Use a are-nut wrench to carefully tighten the UV sensor and temperature sensor. These components are made of soft polytetrauoroethylene (PTFE) and can be easily damaged. Leave the sensor cables coiled up close to the sensor during the
installation.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
14
SECTION 4: MANDATORY WATER TEST
Mandatory Water Test
Purpose
The Mandatory Water Test identies a potential quartz sleeve assembly seal failure. During normal UV system operation, a quartz sleeve assembly failure can result in extensive damage to the UV lamp, quartz sleeve and ballast.
Frequency
The Mandatory Water Test must be performed after a quartz sleeve/retaining nut gasket inspection/ replacement. Quartz
Sleeve inspection/retaining nut gasket replacement must be carried out annually, at minimum.
Parts and Required Equipment
• Paper Towels
• Personal Safety Equipment
General risk due
UV Lamps are fragile and potentially dangerous
if broken. Handle with care.
Procedure
IMPORTANT: Failure to perform a water test could
lead to unsafe conditions and may void your product’s warranties.
3. Place rolled-up paper towels into the Quartz Sleeve Retaining Nuts. During the water test, the paper towels may absorb moisture. The presence of any moisture identies that a quartz sleeve seal failure (leak) has occurred.
4. Inspect all piping connections to the UV Vessel and conrm that valves are in their correct position prior to start-up.
5. With satisfactory piping and valve inspection, operate the UV system. Allow water to ow through the UV Vessel for no less then fteen minutes.
6. After fteen minutes of owing water through the UV vessel, remove the paper towel from each Quartz Sleeve Retaining Nut and inspect closely for ANY sign of moisture. If leaks are detected, shut the system down and re-install any quartz sleeve with an inadequate seal. For quartz sleeve removal/installation See Page 24 and 7.
7. If no leaks were detected you are now ready to install the UV Lamp(s). See Page 15.
1. With the quartz sleeves installed inside the UV vessel, before installation of the UV lamps, perform a water test as explained below. For quartz sleeve removal See Page 24. For installation See Page 7.
2. Thread all sensors into their respective ports on the UV vessel.
BIOSHIELD® Commercial UV Sterilizer Installation and User's Guide
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