Operation and Maintenance Manual Ultraviolet
Contents
1. 16 7 8 17 8 TROUBLESHOOTING UV HORIZONTAL CHANNEL SYSTEM 18 WARRANTY 20 WT O amp M Manual Version November 2006 LAMP CHANGE DATE TABLE Date System Installed LAMP CHANGE DATE COMMENTS Use the table to track maintenance and lamp replacement dates WT O amp M Manual Version November 2006 1 Important Information The equipment while sophisticated has been designed for simple and easy operation In keeping with this philosophy this user manual has been written to simplify all steps in the procedures that follow The UV equipment will need to be maintained and will require replacement parts We recommend that you only use Enchlor Inc factory parts Failure to use genuine parts may impact system performance and may void the warranty 2 About Ultraviolet UV Disinfection The inactivation of microorganisms by ultraviolet radiation is a physical process relying on the photochemical changes brought about when far UV radiation is absorbed by the genetic material of the cell deoxyribonucleic acid or DNA The wavelengths for optimum effectiveness correspond as expected to the maximum absorption2. Operation and Maintenance Manual Ultraviolet Disinfection System EC Series HORIZONTAL CHANNEL SYSTEMS PACKAGE PLANTS 130 West Main Street Silverdale PA 18962 215 453 2533 Fax 215 453 1101 www enchlor com Manufactured in the USA TABLE CONTENTS LAMP CHANGE DATE TABLE 2 cceccceeceeceeecceccecceecceceeeceeccecceneeeceeeseueeeseeneeuseeeseneneees 3 1 IMPORTANT INFORMATION 4 2 ABOUT ULTRAVIOLET UV DISINFECTION 4 3 PRE INSTALLATION GENERAL 5 LVVARNING rinra eee ot ee at ot 5 3 2 UV EFFECTIVENESS 5 2 3 5 6 3 4 6 3 5 ELECTRICAL REQUIREMENTS 1 0 0 6 3 6 INSPECTION seme anaes 6 22 2 DISPOSAL Sate E 6 4 SYSTEM 8 6
3. are housed in the PCC or PCE Circuit Breakers CBs are provided to protect a single channel Module or groups of channel Modules Some systems are wired with multiple CBs for example so neighboring Modules remain operating if one CB trips One CB handles Odd numbered Modules while one CB protects Even numbered Modules Your system will be clearly labeled inside The state of the CBs may be optionally detected for an Alarm system A is provided within the Power Center and is dedicated for each individual channel Module So a fault in any single Module does not effect the disinfection performance of any other Module trip may optionally be detected and fed to an Alarm system Testing the GFCI requires some understanding of the dynamics of the intelligent electronic ballasts cascaded with this device After tripping via Test button or actual Ground Fault wait 10 seconds to 2 minutes before pressing the Reset button If the immediately trips discontinue power to this section by turning the related Circuit Breaker Off for 2 minutes This breaker may control power to other Modules With power Off Reset the tripped GFCI Return power to the section by flipping the Circuit Breaker back On See the appendix on TROUBLESHOOTING if problems persist The functions of Over current and Ground Fault protection may be combined in a single device These are wired for dedicated individual Module protection like the
4. or leave empty and then power system Use a solution like Lime Away or a citric acid with a ScotchBrite pad Brush quartz until all sediment is removed You may want to use a cleaning rack or a washing tank to perform this duty If your unit did not come with a rack or tank you can order one This device can be made to your exact specifications After cleaning check compression nuts to make sure that the sleeves were not loosened during cleaning Lamps need to be changed on a yearly basis or if they become ineffective Even though a lamp is still glowing after a year it will have lost efficiency and will still need to be replaced Lamps can glow for up to three years or more and be completely ineffective EC O amp M Manual Version November 2006 14 6 Power Control Center PCC The plant electrician will need to bring protected power to the PCC Your UV system has been designed to work on a constant power supply The electronic ballasts are susceptible to power fluctuations Low voltage will cause ballast failures The ballasts have been labeled with the voltage and cycle It is imperative that the appropriate voltage range is maintained If you have questions call factory Failure to provide adequate power will void the warranty This configuration incorporates a remote modified NEMA style enclosure with window kit The enclosure will have been designed for indoor or outdoor use If used in an outdoor environment consult factory for
5. recommendations Enchlor Inc recommends protecting the enclosure from high heat and extreme environmental conditions If this information was not taken into consideration during the design phase the PCC may need to be modified EXHAUST RUN TME METER i SIE i LEDS ANALOG UV MONITOR ON OFF The PCC is generally provided with analog displays Lamp on off indicators LEDs running time meter and optional UV intensity meter The PCC will have an On Off or HOA switch The PCC may optionally be provided with a front panel HMI Human Machine Interface when a PLC is used for automated controls and monitoring The PCC contains ballasts The ballasts drive the UV lamps In order to keep the ballasts running at optimum performance it is necessary to cool the ballasts As ballasts heat up they become exponentially less efficient The PCC will come with a fan cooling system Insure that the fans are operational and filters are cleaned EC O amp M Manual Version November 2006 15 PCC Displays 6 1 1 Lamp out Indicators The Power Centers display lamp status indicators LEDs LED indictors show green light when the lamp is on This provides the operator with a quick overview of system status As noted before lamps can operate for years without producing any UV light This is why it is essential to track lamp replacements If the LED goes off then it may mean that a lamp is no longer functioning However it m
6. system over the arc length of the UV lamp The cleaning system is comprised of a stainless steel fitting housing an EPDM ring The quick stroke squeegee approach prevents build up and also prevents dragging of material over the sleeve The horizontal channel system has come equipped with an automatic quartz cleaning system The system can be set to clean on a periodic basis field adjustable The timing mechanism is located in the main Power Control Center Individual solenoid valves are located in the junction box on the end of each module An air hose has been incorporated into the underside of the module The plant will have to run air from the compressor to the air distribution piping PLENUM From this pipe individual lines will be run to the back of each module Each module has two interchangeable ports to receive the tubing Insert the tubing into either quick connect and leave one open as an exhaust EC O amp M Manual Version November 2006 13 5 4 4 Removal of Module for Cleaning a Disconnect power to the module that will be cleaned To do this disconnect power to the Power Control Center Remove the yellow cable from the receptacle by unscrewing cap and pulling the cord from the connection Use safety glasses or a face shield that is UV resistant Even though you are removing one module the system can still operate and UV light may come from the channel Remove the module from the channel Install spare module
7. 5 STAINLESS STEEL CHANNEL OR MODULAR SUPPORT 7 9 52 dene ate eed 9 5 3 LAMPS AND QUARTZ SLEEVES INSPECTION AND 5 0 11 5 4 QUARTZ SLEEVE MAINTENANCE 0 ccccccecceccecceccecuccuccuccecuecuecueceeaeeuecuecueaesaeeneeueaeeatens 12 5 4 1 Manual Cleaning 12 5 4 2 Automated Cleaning Optional 12 5 4 3 Automatic Cleaning Optional 12 5 4 4 Removal of Module for Cleaning 2 22 0000000000000 0066 13 6 255 14 WSO ASE 15 6 1 1 Lamp Oul Indicator Snine narn 15 6 1 2 Running Time 0 0000022 22 000 6000001000000200000 15 6 1 3 Ultraviolet 202222 9 010 15 6 2 16 6 2 1 Over Current and Ground Fault 22 2 220042 74 900 16
8. V light is extremely harmful to eyes and skin Do not look directly at the light or expose your skin for any prolonged time Use protective clothing and eyewear UV resistant when servicing equipment Always disconnect power to your unit or module before servicing If accidentally exposed to UV light for an extended period immediately seek medical attention When handling lamps and quartz use gloves to prevent them from becoming dirty If they do wipe them with denatured alcohol Oils dirt and scratches will block UV light When installing the quartz sleeves and O rings be careful not to crack the quartz The broken glass like material is sharp and can cause serious injuries In addition do not use tools to tighten the compression nuts only hand tighten 3 2 UV Effectiveness Your disinfection system needs to be maintained We recommend that you change the lamp yearly 9 000 12 000 hours O rings when brittle or every lamp change and change the quartz every three to five years We also recommend a quartz cleaning schedule to maintain system effectiveness Operators can use cleaning agents such as Lime Away or a citric acid to remove build up on the quartz sleeve Fouled or scratched quartz sleeves will lead to higher fecal counts Failure to do periodic maintenance will impact your unit s effectiveness WT O amp M Manual Version November 2006 3 3 System Design Your UV system has been designed based on certain informatio
9. al EPA guidelines for disposal protocol 4 System Components You will have received the following a UV module support structures two available types 1 Stainless steel channel A packaged channel may have been sent It will have connections in the form of a U bolt pattern flange or a pipe The channel may have been sent with transition boxes to help make the connection The stainless steel channel may have also been supplied with a fixed serpentine weir that will be located at the discharge end of the channel WT O amp M Manual Version November 2006 7 2 Modular Support System MSS This is used when a stainless steel channel is not required because of an existing structure or newly poured concrete If this is provided it will come with all hardware except concrete anchorages b Stainless steel disinfection modules completely wired and provided with compression fittings O rings lamp holders and watertight cabling c Power Control Center PCC d Ultraviolet lamps e Quartz sleeves f UV sensor probe with monitor optional g System Monitoring Center PLC optional h Level control optional i Optional equipment j Spare parts optional k Safety and cleaning supplies optional 1 Warranty information 5 Stainless Steel Channel or Modular Support System You will have received a stainless steel channel or modular support system This should be installed according to the engineering specifications and
10. associated drawings The stainless steel channel will have been shipped ready to be installed The Modular Support System MSS will need to be bolted into place using stainless steel anchorages as shown in the following drawings EC O amp M Manual Version November 2006 STAINLESS STEEL HARDWARE SUPPLIED BY OTHERS SPLIT LOCK WASHER WALL BRACKET Pe THREADED ROD N NOt s g AZ SPLIT LOCK WASHER A Ne NUT Ne ix MODULE PIN CHANNEL WALL TRUSS THREADED ROD Ex SPLIT LOCK WASHER WALL BRACKET R NUT SPLIT LOCK WASHER TR TRUSS NUT EC O amp M Manual Version November 2006 5 1 Weir Your system may have come with a fixed serpentine weir standalone serpentine weir or a more sophisticated automatic level control ALC system These devices are meant to keep the ultraviolet lamps submerged to insure optimum operating temperatures and maximum disinfection The weir is designed to keep the lamps submerged during no low average and peak flows If your unit came with a fixed weir you do not have to worry about any installation If your unit came with a standalone weir it should be installed no less than 2 5 from the end of the last bank of UV lamps If your channel ca
11. ay indicate a problem with the LED the lamp s corresponding ballast or a problem located within the lamp holder SEE TROUBLE SHOOTING SECTION 6 1 2 Running Time Meters This non resettable time meter will allow you to see how long the system or bank has been running It will also be instrumental in establishing a cleaning schedule As noted lamps need to be replaced after 9 000 hours 6 1 3 Ultraviolet Monitor After 100 hour burn in the UV display is procedurally set to Full Scale 100 This is done during nominal operating and water quality conditions This UV reading is not NIST calibrated to absolute mW cm2 intensity It cannot be used directly in calculating dosages It is simply a relative of its nominal specified operating performance Initial setup is obviously 100 of nominal performance since everything is brand new Subsequently any decline in UV Relative Intensity is likely any combination of fouling quartz sleeves fouling UV probe face lamp aging water quality UV Transmission UV detector aging f eroding electrical connections a b we a NS A low UV Relative Intensity Threshold setting may optionally be used to activate a Common Alarm EC O amp M Manual Version November 2006 16 6 2 PCC Electrical 6 2 1 Over Current and Ground Fault Protection The system features Over current protection via Circuit Breakers as well as Ground Fault Protection via devices These
12. discussion above when used 6 2 2 Electronic Ballast The Enchlor Inc provided electronic ballast is specially designed for germicidal performance in challenging water treatment conditions The ballast controls the start up and maintenance of the conductive arc in the mercury vapor lamp under conditions of varying temperature The ballasts will need to be replaced if found defective To replace the ballast simply disconnect the wires loosen holding screws and insert new ballast Send defective ballast back to Enchlor Inc for warranty work or out of warranty service EC O amp M Manual Version November 2006 17 BALLASTS BREAKERS EXTERNAL p men ON OFF SWITCH 7 Attachments If your unit came with optional equipment instructions will be attached to this manual This includes informational material on the following UV Monitoring System Automatic Cleaning System Replacement Parts Wiring Diagrams EC O amp M Manual Version November 2006 18 8 Troubleshooting UV Horizontal Channel System This guide provides information and recommendations on how to correct basic operational problems When performing any of these tasks be sure to wear protective clothing and eyewear In addition protect yourself from shock hazards Symptom Check Power Center UV lamp LED s Off Power Off wait power On observe LED s The intelligent ballasts will keep a lamp Off for various causes in s
13. eet Silverdale PA 18962 215 453 2533 Fax 215 453 1101 EC O amp M Manual Version November 2006
14. follow directions above 5 4 Quartz Sleeve Maintenance In order to insure proper disinfection the quartz sleeves need to be maintained Since the lamps produce heat and since the effluent has solids the quartz sleeves can become fouled This necessitates a cleaning regime that will be determined by plant operating conditions There are three methods for cleaning the quartz sleeves 5 4 1 5 4 2 5 4 3 Manual Cleaning Plant operators can remove a module and clean by hand A mild citric acid or a lime removal product and a ScotchBrite pad should be used to hand clean the sleeves If this is the method of choice a cleaning rack can be provided This can be a wall mounted or free standing stainless steel support Automated Cleaning Optional Equipment Plant operators can remove the module and place it in a stainless steel tank for cleaning The tank would hold a mild citric acid that would be agitated by a pump The tanks come with wheels a pump and a drain In cases where this is the preferred method an additional spare module should be kept on site to replace the removed module to insure continual disinfection Automatic Cleaning Optional Equipment To automate the cleaning process an air driven cleaning system can be incorporated Note that in many cases a system may not be upgradeable The system would operate using plant compressed air or via a dedicated air compressor An air driven piston will push the quartz wiping
15. ge when it leaves the system Advantages There are many advantages to this type of disinfection no need for toxic and expensive chemicals fast treatment low maintenance and simple and extremely low cost operation 1 EPA Ultraviolet Disinfection Technology Assessment EPA 832 R 92 004 September 1992 WT O amp M Manual Version November 2006 Applications While UV disinfection is well suited for wastewater treatment it is important to monitor the water quality and system performance One must look for situations that inhibit UV light from penetrating the water Turbidity the state of water when it is cloudy from having sediment stirred up will interfere with the transmission of UV energy and decrease the disinfection efficiency Total Suspended Solids TSS will also impact UV effectiveness TSS numbers should be lower than 30 mg liter In cases where the water has high iron or manganese content is cloudy or has other organic or chemical impurities it may be necessary to improve the pre treatment process or increase the UV dosage Once this has been addressed UV disinfection will be effective in destroying microorganisms 3 Pre Installation General Information Your Ultraviolet UV wastewater disinfection system has been tested at Enchlor Inc manufacturing facility In order to insure that the system works at optimum performance please follow the instructions and recommendations outlined in this manual 3 1 Warning U
16. ken Sleeve Broken Gland Broken Quartz Broken Glass Carefully Loosen and dismantle effected parts compression nut O ring Remove broken shards and debris Dry the area including lamp base connector May use a water displacement spray for electrical parts eg WD 40 or petroleum distillate with silicone lubricant Do NOT contaminate any Quartz Sleeve or Lamp with this spray Complete the installation with a fresh O ring and Quartz Sleeve Hand tighten the compression nut EC O amp M Manual Version November 2006 20 ENCILOR WARRANTY REGISTRATION MODEL NUMBER SERIAL NUMBER REPRESENTATIVE NAME INSTALLATION DATE NAME ADDRESS CITY STATE POSTAL CODE COUNTRY PHONE EMAIL Please fill out the above information and forward it to Enchlor Inc This will provide the WWTP with a five 5 year warranty on the stainless steel components and a one 1 year warranty on the electrical components UV lamps are warranted for one year This warranty applies to equipment that has been installed and maintained according to the instructions in this manual Enchlor Inc is not responsible for damage due to improper use operation or installation Enchlor Inc is not responsible for improper plant design or changes to the effluent The warranty applies to replacing defective equipment Enchlor Inc shall have no liability hereunder either direct or contingent for any consequential damages 130 West Main Str
17. me with another type of ALC then the installation directions and O amp M manual will be attached 5 2 Lamp Modules The lamp modules will have come completely wired and ready to be installed You will need to install the lamps and quartz sleeves as well as to connect the module to the Power Control Center The lamp module is constructed from stainless steel and comes with a UL approved cable that connects to the Power Center The lamp module will come with lamp holders that are pre wired The lamp holder bolts directly to the effluent module s legs It is an independent component that comes with a wire harness socket compression nut and O ring The lamp holder is designed to isolate damage in the event that a sleeve breaks or if some other event causes water infiltration p a BE INTERNAL LAMP ORING SEAL MODULE KNURLED LEG COMPRESSION EC O amp M Manual Version November 2006 To connect or remove the module cable to the Power Center simply plug the cable into the receptacle and hand tighten the retaining collar RETAINING COLLAR MODULE CABLE SENSOR PORT RECEPTACLE Jf RECEPTACLE MODULE 1 MOOULE 2 A 2 POWER CORD S MODULE CABLE EC O amp M Manual Version November 2006 11 Quartz holder Lamp holder MODULE REMOVED FROM CHANNEL 5 3 Lamps and Quartz Sleeves Inspection and Installation Insure that lamps and quartz have not been broken We recom
18. mend that you use gloves when handling lamps and quartz sleeves to prevent them from becoming dirty If lamps or quartz have broken take extra care to prevent yourself from becoming injured Take the module and place it on a clean work surface You will need to install a lamp and quartz sleeve into each lamp holder There are 2 ways to accomplish this task 1 Loosen the compression nut but do not remove it from the lamp holder nipple Check to see if the O ring is inside Once loosened take the lamp and slide the end into the quartz sleeve Make sure that the 4 pin connection remains outside Moisten the domed end closed end of the quartz sleeve as well as the rubber grommet in the quartz holder with water Slide the dome end through the quartz holder grommet Connect the lamp to the socket Push the open end of the quartz sleeve into the compression nut Gently push in feel the sleeve stop and then withdraw the sleeve 1 8 You need to leave some room because when you tighten the nut it will push the quartz further in Hand tighten the compression nut Once you have hand tightened the nut gently pull the quartz sleeve to see if it disengages from the nut If it does not then you have a secure fit OR EC O amp M Manual Version November 2006 2 12 Completely remove the compression nut and O ring Slide compression nut oring over the open end of the quartz Take the lamp and slide the end into the quartz sleeve and
19. n regarding plant operating conditions All changes in plant conditions will impact the UV system Since plant operating conditions are subject to change please insure that all significant changes to flow rates minimum average and maximum transmission or total suspended solids are brought to your representative s or Enchlor s attention 3 4 Flow Rate Your unit has been designed to accommodate a certain flow rate Increases to flow will impact the UV dosing 3 5 Electrical Requirements The electronics have been designed to work with a variety of power supplies Since the unit is susceptible to power fluctuations we recommend that the system be kept off any lines where there are surges This includes pumps or motors If there are fluctuations please use a surge suppressor All ballasts will be labeled indicating the required power Unlike pumps or motors your UV disinfection system is sensitive to spikes 3 6 Inspection Insure that lamps and quartz have not been broken It is recommended that you use gloves when handling lamps and quartz sleeves to prevent them from becoming dirty A warranty sheet has been included Please fill out the warranty and send back to manufacturer or dealer This warrantees the chamber for 5 years and electrical components for 1 year It also provides a mechanism to allow your dealer to remind you when it is time for lamp replacement 3 7 Disposal The UV lamps contain mercury Please follow your loc
20. ome cases this may be a false trip If the LED s come On and then flicker Off it means that the ballast is good and that the problem is past the ballast If problem recurs see LED stays Off UV lamp LED s stays Power Off and remove yellow cable from Power Control Center Off receptacle Remove cable from a known good module and connect known bad module into the receptacle If the problem is fixed then it is most likely bad ballast If the problem follows it is most likely associated with module If suspected to be the module lift module out Examine for damage water infiltration and really blackened lamp ends If none power On and observe through your UV face shield at safe distance if lamp actually lights If Lamp lights and LED is On suspect loose electrical connection If Lamp lights and LED is still Off call Authorized Service for Power Control Center repair If lamps are still Off suspect bad ballast and replace Breaker Off Ground Fault occurred May be a false trip Power the effected All lamp LEDs for a module Off if not already powered by GFCI On Off Breaker module off combination Examine cable connectors for tightness If suspicious loosen disconnect clean dry and re connect Lift module out of channel and examine for water infiltration If so see Water Infiltration Reset GFCI and Power On or Power On and reset If problem recurs refer to Authorized Service for Power Cont
21. rol Center repair UV Monitor Alarm Check Panel LED to see if lamp is extinguished UV Monitor Warn Check the age of the Lamp Refer to Lamp replacement records UV Monitor Low Check the physical positioning of the UV Sensor Probe The sensor element inside may not be looking in the same direction as the probe tube is pointing The probe may have shifted within the retaining compression nut Sometimes this is pulled by the weight of the cable Check for debris or film on the UV probe window Clean and rough position with Lamp powered Off Check for debris or film on Quartz Sleeve and clean Install module then fine position while watching for high reading on UV Monitor Cleaning may be accomplished with detergent and green scouring pad LimeAway or Citric acid to remove scale Alcohol for final rinse and dry Hydraulic EC O amp M Manual Version November 2006 19 Water Sleeve Water in Gland Water in Quartz Water Infiltration Check compression nut for tightness Notice how tight it is It may simply need to be tighter when reassembled later Disassemble and dry related parts Sleeve O ring Lamp The inside of a Sleeve may be cleaned with Citric acid if a mild detergent fails to remove all scale The inside of a Sleeve may be rinsed with Alcohol It may be dried by poking a dry lint free cloth tethered on a string for retrieval to the end with a thin dowel stick Mechanical Bro
22. spectrum for nucleic acids between 250 and 265 nanometers How it works Wastewater enters the vessel channel or chamber Once inside it is exposed to UV light The UV lamp used for germicidal disinfection produces a portion of its light in the 254 nm wavelength At this wavelength UV light destroys bacteria protozoa viruses molds algae and other microbes This includes fecal coliform and such waterborne diseases as E coli hepatitis cholera dysentery typhoid fever as well as many others The actual lamps are housed in quartz sleeves These sleeves not only help maintain maximum operating temperature but also prevent the lamps from coming in contact with the water While in the vessel the wastewater is exposed to doses of UV energy Simply put UV dose lamp intensity multiplied by residence time It is usually represented in microwatt seconds per square centimeter mWs cm2 Time is calculated as the hydraulic residence time in the UV system The intensity is a function of the lamp type the arrangement of lamps and the energy absorbing elements in the water that absorb or interfere with light before it reaches the targeted microorganism The measurement of absorbing material is referred to as UV transmission UVT This is expressed as Most plants average 65 Since the UV disinfection process does not add chemicals or change the physical or chemical properties of the effluent the wastewater is ready for dischar
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