El Centro City Council
November 5, 2024

Section 13121

PRE-ENGINEERED BUILDING

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1.4 GUARANTEE
Twelve months from start-up not to exceed eighteen months from the ship date. This warranty is limited to the building construction only. Electrical apparatuses shall carry the manufacturersí pass-through warranty only. This warranty does not cover any acts of God, or damage cause by misuse, abuse, vandalism, or neglect.

PART 2 - PRODUCTS

2.1 GENERAL
All components for the pre-engineered metal buildings as herein specified shall, for the purpose of establishing the standard of quality, materials and general configuration desired be as manufactured by PROTECT CONTROLS INC, or approved equal. Other manufacturers will be considered provided they meet or exceed these specifications and are approved in advance by the Construction Manager.

2.2 DIMENSIONS
North Building Dimensions:

Length (inside dimensions) - 20 feet
Width (inside dimensions) - 7 feet
Height (floor to ceiling) - 10 feet
South Building Dimensions:

Length (inside dimensions) - 20 feet
Width (inside dimensions) - 8 feet
Height (floor to ceiling) - 10 feet

2.3 MATERIALS
Base - Skid-type; utilizing a channel perimeter framework and rigidly braced with channel cross-members. Lifting eyes will be provided to facilitate transportation and final installation. The lifting eyes are removable so as not to present a trip hazard.

Floor - 1/4î smooth; H.R. ASTM A-36 steel plate.

Exterior walls - 18-gauge galvanized steel interlocking panels.

Interior walls - 18-gauge galvanized steel overlapping sheet liner.

Exterior Roof - 18-gauge galvanized steel interlocking panels. The exterior roof slope will be 1/4î per linear foot from the high to the low side of the building.

Interior Ceiling - 18-gauge galvanized steel interlocking panels. The interior ceiling will be flat.

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2.4 PAINT
Surface Preparation - All surfaces shall be cleaned as necessary, SSPC-SP-1 (Solvent), SSPCSP-2 (Hand tool), or SSPC-SP-3 (Power tool) prior to application of primer.

Base - Primer - gray macropoxy 646-100 3-5 mils DFT.

Undercoat - emulsion, 25 mils DFT.

Floor - Primer - gray macropoxy 646-100 3-5 mils DFT.

Finish - gray high solids polyurethane 3-5 mils DFT non-skid.

Exterior - Primer ñ P60G2 industrial wash primer, 0.3-0.4 mils DFT.

Finish - white high solids polyurethane 3-5 mils DFT.

Interior - Primer - P60G2 industrial wash primer, 0.3-0.4 mils DFT.

Finish - white high solids polyurethane 2-3 mils DFT.

An exterior intermediate coat of gray epoxy, 3-6 mils DFT, is required. Exterior sealant, SikaflexlA, is to be applied on all exterior seams prior to paint.

2.5 INSULATION
North (20í x 7í) Building:

Walls - 3î RIB, composed of 1î foam board, R7.9, continuous and 3.5î un-faced fiberglass batt, R15, compressed to R11.332, cavity (4î nominal wall thickness) Roof - 3î RIB, composed of 1î foam board, R7.9, continuous and 3.5î un-faced fiberglass batt, R15, compressed to R11.332, cavity (4î nominal roof thickness) Floor ñ 3.5î polyurethane spray foam, R-24, continuous
Entry Doors - 1-1/2î foam board, R-9.75
South (20í x 8í) Building:

Walls - 3î RIB, composed of 1î foam board, R7.9, continuous and 3.5î un-faced fiberglass batt, R15, compressed to R11.332, cavity (4î nominal wall thickness) Roof - 3î RIB, composed of 2î foam board, R14.4, continuous and 3.5î un-faced fiberglass batt, R15, compressed to R11.332, cavity (5î nominal roof thickness) Floor ñ 3.5î polyurethane spray foam, R-24, continuous
Entry Doors - 1-1/2î foam board, R-9.75

2.6 ENTRY DOORS
One (1) per building: 4070 (48îx84î), 16-gauge galvanized steel with frame, Supplied with the following hardware:
• Panic with thumb latch - stainless steel, US32.
• Cylinder lock with two (2) keys
• Automatic closure with built-in hold open device
• Hinges - stainless steel, ball bearing type
• Gasket - neoprene, closed cell type
• Drip shields, frame and threshold - 14-gauge galvanized steel

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• Sign - ìDanger - High Voltage - Keep Outî
• Removable transom above door
• 11îx11îx1/4î laminated safety glass window

2.7 WINDOW
One (1) per building: 72îx48îx1/4î laminated safety glass window with commercial aluminum window frame with 3M Silver 15 exterior window tinting.

2.8 FLOOR CUTOUTS
Provide floor cutouts for pre-cast concrete trench access with 12-gauge galvanized steel cover plates with neoprene gaskets, top removable. Coordinate locations with pre-cast concrete trench layout (Specification Section 03490).

2.9 WALL BULKHEAD CUTOUTS
Provide framed wall cutouts for HVAC units and windows.

2.10 FASTENERS:

Exterior screws and miscellaneous hardware shall be Type 316 stainless steel.

2.11 ELECTRICAL PANELS
Provide electrical panels in buildings as shown on the plans.

2.12 INTERIOR LIGHT SWITCHES
Surface mounted, 3-way, 20A, 120V.

2.13 INTERIOR LIGHTING
Fluorescent surface mounted fixtures, 120V, with (2) T8-32w lamps, and electronic ballast, (3 per building)
Keystone LED light tube fixtures, with (2) T8 LED lights, 15W, (2 per building)

2.14 EXTERIOR LIGHTING
120-watt bulkhead fixture, 15,600 lumens, complete with photoelectric control, and 90-minute battery backup, (1 per building)

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2.15 COMBINATION EXIT SIGN/EMERGENCY LIGHTING
120VAC input, 6VDC output, 2-head with maintenance free rechargeable battery, solid-state charger and test switch. The unit will provide (90) ninety minutes of emergency lighting upon AC power failure. The exit signs remain illuminated at all times, but will only provide (90) ninety minutes of emergency lighting upon AC power failure, (1 per building)

2.16 RECEPTACLE (INDOOR)
20A, 125V, 5-20R, GFCI, surface mounted duplex, (2 per building)

2.17 RECEPTACLE (OUTDOOR)
20A, 125V, 5-20R, GFCI, surface mounted duplex in a weatherproof box with spring type hinged cover, (1 per building)

2.18 HVAC SYSTEM
Wall mounted low profile heat-pump unit, 3-tons cooling, 5kW electric heat, 240VAC, 1-phase, 41MCA, provided with grilles, high/low pressure controls, low ambient control, compressor anti-cycle relay, maintenance disconnect, and below listed accessories, (1 per building) • Auto change-over thermostat
• Economizer package

2.19 CONDUIT/WIREWAY
Interior: 4î x 4î NEMA-1 wireway, sized and located as necessary, with 3/4î EMT minimum, surface mounted conduit drops to the electrical devices.

Exterior: 3/4î RGS minimum, surface mounted.

2.20 WIRE
#12 AWG, ìTHWNî, (Black-White-Green) unless otherwise noted on the contract plans or specifications.

2.21 POWER INTERCONNECTS
Power Feeders: From the lighting transformer to the lighting panel From the lighting panel to the HVAC unit
House Feeders: From the lighting panel to basic building loads (lights, receptacles, etc.).

2.22 GROUND PADS
Stainless steel, 3îx4îx1/8î, NEMA 2-bolt pattern, mounted on the exterior, one (1) at each corner of the building, (4 per building)

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PART 3 - EXECUTION

3.1 INSPECTION
Prior to performing any work of this section, verify that all work of other trades, as applicable, is complete to the point where the installation may begin.

3.2 FABRICATION
A. The building shall be factory fabricated to the manufacturer's written standards, per the approved Shop Drawings and in accordance with the requirements of the UBC.

B. All material shall be completely fabricated and prepared for shipment, including any necessary crating or bundling. All parts of the building are to be accurately made and true to dimension so that all parts will easily fit together during building construction.

3.3 SITE CLEAN-UP
The Erector shall remove any temporary structure he used during construction, all debris and rubbish resulting from the erection work, all unused materials, and residue from the erection process from the building and building site.
**END OF SECTION**

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SECTION 16010

BASIC ELECTRICAL REQUIREMENTS
PART 1 - GENERAL

1.1 RELATED SECTIONS
A. Requirements specified within this Section apply to Division 16, Electrical. Work specified herein shall be performed as if specified in the individual sections.

1.2 SUBMITTALS
A. Action Submittals:

1. Provide manufacturers' data for the
following:
a. Electrical service components.
b. Nameplates, signs, and labels.
c. Contractor Phasing Plans

1.3 DEFINITIONS
A. Corrosive Area: Containment area or area exposed to delivery, storage, transfer, or use of chemicals.

B. Exterior Area: Location not protected from the weather by a building or other enclosed structure.

C. Interior Dry Area: Location inside building or structure where floor is not subject to liquid spills or wash down, nor where wall or roof slab is common to a water-holding or earth-retaining structure.

D. Interior Wet Area: Location inside building or structure where floor is sloped to floor drains or gutters and is subject to liquid spills or wash down, or where wall, floor, or roof slab is common to a water-holding or earth-retaining structure.

1.4 QUALITY ASSURANCE
A. Provide the Work in accordance with the latest version of NFPA 70, NFPA 820. Where required by Authority Having Jurisdiction (AHJ), material and equipment shall be labeled or listed by a nationally recognized testing laboratory or other organization acceptable to the AHJ, to provide a basis for approval under the NEC.

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B. Materials and equipment manufactured within the scope of standards published by Underwriters Laboratories Inc. shall conform to those standards and shall have an applied UL listing mark or label.

C. Provide materials and equipment acceptable to AHJ for Class, Division, and Group of hazardous areas indicated.

D. The company or individual providing electrical installations shall have a licensed journeyman electrician supervising the work.

E. Perform work following NFPA 70E requirements.

PART 2 - PRODUCTS

2.1 GENERAL
A. Where two or more units of the same class of material or equipment are required, provide products of a single manufacturer. Component parts of materials or equipment need not be products of the same manufacturer.

B. Material and equipment installed shall be capable of continuous operation at their specified ratings within an ambient temperature range of 32 degrees F to 122 degrees F.

C. Equip panels installed outdoors in direct sun with sun shields.

2.2 EQUIPMENT FINISH
A. Manufacturer's standard finish color, except where specific color is indicated. If manufacturer has no standard color, finish equipment with light gray color finish as approved by District.

2.3 NAMEPLATES
A. Material: Laminated plastic.

B. Attachment Screws: Stainless steel.

C. Color: Black, engraved to a white core.

D. Letter Height:

1. Pushbuttons/Selector Switches: 3/16 inch, block type.

2. Other electrical equipment: 3/8 inch.

2.4 SIGNS AND LABELS

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A. Sign size, lettering, and color shall be in accordance with NEMA Z535.4.

PART 3 - EXECUTION

3.1 GENERAL
A. Electrical Drawings show general locations of equipment, devices, and raceway, unless specifically dimensioned. Contractor shall be responsible for actual location of equipment and devices and for proper routing and support of raceways, subject to approval of Engineer.

B. Check approximate locations of light fixtures, switches, electrical outlets, equipment, and other electrical system components shown on Drawings for conflicts with openings, structural members, and components of other systems and equipment having fixed locations. In the event of conflicts, notify Engineer in writing.

C. Install work in accordance with NECA Standard of Installation, unless otherwise specified.

D. Keep openings in boxes and equipment closed during construction. Protect all equipment from debris, dust, metal, shavings, etc.

E. Layout work carefully in advance. Do not cut or notch any structural member or building surface without specific approval of Engineer. Carefully perform cutting, channeling, chasing, or drilling of floors, walls, partitions, ceilings, paving, or other surfaces required for the installation, support, or anchorage of conduit, raceways, or other electrical materials and equipment. Following such work, restore surfaces to original condition

3.2 COMBINING CIRCUITS INTO COMMON RACEWAY
A. Homerun circuits shown on Drawings indicate functional wiring requirements for power and control circuits. Circuits may be combined into common raceways in accordance with the following requirements:

1. Analog control circuits from devices in same general area to same destination. a. No power or AC discrete control circuits shall be combined in same conduit with analog circuits.
b. No Class 2 or Class 3 circuits including, but not limited to, HVAC control circuits, fire alarm circuits, paging system circuits shall be combined with power or Class 1 circuits.
c. Analog circuits shall be continuous from source to destination. Do not add TJB, splice, or combine into a multi-pair cable without authorization of Engineer.

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d. Raceways shall be sized in accordance with the NEC and shall not exceed 40 percent fill.
e. Changes shall be documented on record drawings.

2. Discrete control circuits from devices in the same general area to the same destination.
a. No power or analog control circuits shall be combined in same conduit with discrete circuits.
b. No Class 2 or Class 3 circuits including, but not limited to, HVAC control circuits, fire alarm circuits, and paging system circuits shall be combined with power or Class 1 circuits.
c. Raceways shall be sized in accordance with the NEC and shall not exceed 40 percent fill.
d. Changes shall be documented on record drawings.

3. Power circuits from loads in same general area to same source location (such as:
panelboard, switchboard, low voltage motor control center). a. Lighting Circuits: Combine no more than three circuits to a single raceway. Contractor shall be responsible for increasing conduit and conductor size if derating is required by NEC.
b. Receptacle Circuits, 120-Volt Only: Combine no more than three circuits to a single raceway. Provide a separate neutral conductor for each circuit.

Contractor shall be responsible for increasing conduit and conductor size if derating is required by NEC.
c. All Other Power Circuits: Do not combine power circuits without authorization of Engineer.

3.3 NAMEPLATES, SIGNS, AND LABELS
A. Arc Flash Protection Warning Signs:

1. Field mark switchboards, motor control centers, panelboards, and other electrical equipment, to warn qualified persons of potential arc-flash hazards. Locate marking so to be clearly visible to persons before working on energized equipment.

2. Use arc flash hazard boundary, energy level, PPE level and description, shock hazard, bolted fault current, and equipment name from study required in Section 16055, Electrical Systems Analysis as basis for warning signs.

B. Equipment Nameplates:

1. Provide a nameplate to label electrical equipment including switchgear, switchboards, motor control centers, panelboards, motor starters, transformers,

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terminal junction boxes, disconnect switches, switches and control stations, outlets and lighting switches.

2. Switchgear, motor control center, transformer, and terminal junction box nameplates shall include equipment designation.

3. Disconnect switch, starter, and control station nameplates shall include name and number of equipment powered or controlled by that device.

4. Switchboard and panelboard nameplates shall include equipment designation, service voltage, and phases.

C. Entry Way Warning Signs:

1. Caution: Hearing protection shall be worn in the area.

2. Warning: High Voltage – Keep out

3. Provide warning signs: Caution – This equipment starts automatically by remote control.

4. Do not enter if light is flashing.

3.4 LOAD BALANCE
A. Drawings and Specifications indicate circuiting to electrical loads and distribution equipment.

B. Balance electrical load between phases as nearly as possible on switchboards, panelboards, motor control centers, and other equipment where balancing is required.

C. When loads must be reconnected to different circuits to balance phase loads, maintain accurate record of changes made, and provide circuit directory that lists final circuit arrangement.

3.5 CLEANING AND TOUCHUP PAINTING
A. Cleaning: Throughout the Work, clean interior and exterior of devices and equipment by removing debris and vacuuming.

B. Touchup Paint:

1. Touchup scratches, scrapes and chips on exterior and interior surfaces of devices and equipment with finish matching type, color, and consistency and type of surface of original finish.

2. If extensive damage is done to equipment paint surfaces, refinish entire equipment in a manner that provides a finish equal to or better than factory finish, that meets requirements of Specification, and is acceptable to Engineer.

3. Provide one gallon or equivalent spray cans of touch-up paint for each color of the provided equipment.

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3.6 PROTECTION FOLLOWING INSTALLATION
A. Protect materials and equipment from corrosion, physical damage, and effects of moisture on insulation and contact surfaces.

B. When equipment intended for indoor installation is stored at Contractor's convenience in areas where subject to dampness, moisture, dirt or other adverse atmosphere until completion of construction, ensure adequate protection from these atmospheres is provided and acceptable to Engineer.
**END OF SECTION**

Section 16050

BASIC ELECTRICAL MATERIALS AND METHODS

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SECTION 16050

BASIC ELECTRICAL MATERIALS AND METHODS
PART 1 - GENERAL

1.1 __ SUBMITTALS
A. Action Submittals:

1. Provide manufacturers’ data for the following:
a. Circuit breakers.
b. Fused and Non-fused switches.
c. Enclosures: Include enclosure data for products having enclosures.

PART 2 PRODUCTS

2.1 SUPPORT AND FRAMING CHANNELS
A. Carbon Steel Framing Channel:

1. Material: Rolled, mild strip steel, 12-gauge minimum, ASTM A1011/A1011M, Grade 33.

2. Finish: Hot-dip galvanized after fabrication.

B. PVC Coated Framing Channel: Carbon steel framing channel with 40-mil polyvinyl chloride coating.

C. Stainless Steel Framing Channel: Rolled, ASTM A167, Type 316 stainless steel, 12-gauge minimum.

D. Manufacturers:

1. B-Line Systems, Inc.

2. Unistrut Corp.

3. Aickinstrut.

2.2 ENCLOSURES
A. Finish: Sheet metal structural and enclosure parts shall be completely painted using an electrode position process so interior and exterior surfaces as well as bolted structural joints have a complete finish coat on and between them.

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B. Color: Manufacturer’s standard color (gray) baked-on enamel, unless otherwise shown.

C. Barriers: Provide metal barriers within enclosures to separate wiring of different systems and voltage.

D. Enclosure Selections: Except as shown otherwise, provide electrical enclosures according to the following table:

ENCLOSURES
Location Finish Environment NEMA 250 Type
Indoor Unfinished Industrial Use 12
Indoor and Outdoor Any Denoted “WP” 3R
Indoor and Outdoor Any Wet and
Corrosive
4X; 316 Stainless
Steel
PART 3 - EXECUTION
3 . 1 GENERA L
A. Install equipment in accordance with manufacturer’s recommendations.

B. Install enclosures with a 1/4 inch air gap from walls, unless otherwise noted.

3.2 SUPPORT AND FRAMING CHANNEL
A. Install where required for mounting and supporting electrical equipment, raceway, and cable tray systems.

B. Channel Type:

1. Interior, Wet or Dry (Noncorrosive) Locations:
a. PVC-Coated Conduit: PVC coated.
b. Steel Raceway and Other Systems Not Covered: Carbon steel.

2. Interior, Corrosive (Wet or Dry) Locations:
a. PVC-Coated Steel Conduit and Other Systems Not Covered:

Type 316 stainless steel, PVC-coated steel.

3. Outdoor Corrosive Locations:
a. PVC-Coated Steel Conduit and Other Systems Not Covered:

Type 316 stainless steel, or PVC coated steel.

C. Paint cut ends prior to installation with the following:

1. Carbon Steel Channel: Zinc-rich primer.

2. PVC-Coated Channel: PVC patch. PVC paint is not acceptable.

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**END OF SECTION**

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SECTION 16055

ELECTRICAL SYSTEMS ANALYSIS
PART 1 - GENERAL

1.1 SUBMITTALS
A. Action Submittals:

1. Short circuit study.

2. Protective Device Coordination Study: Submit within 90 days after approval of short circuit study.

3. Arc flash study.

4. Arc flash warning labels.

1.2 QUALITY ASSURANCE
A. Short circuit, protective device coordination, and arc flash studies shall be prepared by a professional electrical engineer registered in the State of California.

1.3 SEQUENCING AND SCHEDULING
A. Initial complete short circuit study shall be submitted and reviewed before Engineer will review Shop Drawings for equipment for incoming service.

B. Initial complete protective device coordination and arc flash studies shall be submitted within 90 days after approval of initial short circuit study.

C. Revised short circuit, protective device coordination, and arc flash studies, and arc flash labels shall be submitted 10 days before energizing electrical equipment.

D. Final short circuit, protective device coordination, and arc flash studies shall be completed prior to Project Substantial Completion. Final version of study shall include as-installed equipment, materials, and parameter data or settings entered into equipment based on study.

E. Submit final arc flash labels described herein and in compliance with NEMA Z535.4 prior to Project Substantial Completion.

1.4 GENERAL STUDY REQUIREMENTS
A. Equipment and component titles used in the studies shall be identical to equipment and component titles shown on Drawings.

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B. Perform studies using one of the following electrical engineering software packages:

1. SKM Power Tools for Windows.

2. ETAP.

3. EDSA.

4. Easy Power.

C. Perform complete fault calculations for each proposed source combination.

1. Source combination may include present and future power company supply circuits, large motors, or generators.

D. Utilize proposed and existing load data for study obtained from field investigation of system configuration, wiring information, and equipment.

E. Existing System and Equipment:

1. Extent of existing system to be included in study is limited to system elements that affect new system and equipment.

2. Include fault contribution of existing motors and equipment in study.

3. Include impedance elements that affect new system and equipment.

4. Include protective devices in series with new equipment.

F. Device coordination time-current curves for medium and low voltage distribution system; include individual protective device time-current characteristics.

1.5 SHORT CIRCUIT STUDY
A. General:

1. Prepare in accordance with IEEE 399.

2. Use cable impedances based on copper conductors, except where aluminum conductors are specified or shown.

3. Use bus impedances based on copper bus bars, except where aluminum bus bars are specified or shown.

4. Use cable and bus resistances calculated at 25 degrees C.

5. Use medium-voltage cable reactances based on use of typical dimensions of shielded cables with 133 percent insulation levels.

6. Use 600-volt cable reactances based on use of typical dimensions of THHN/THWN conductors.

7. Use transformer impedances 92.5 percent of "nominal" impedance based on tolerances specified in IEEE C57.12.00.

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B. Provide:

1. Calculation methods and assumptions.

2. Typical calculation.

3. Tabulations of calculated quantities.

4. Results, conclusions, and recommendations.

5. Selected base per unit quantities.

6. One-line diagrams.

7. Source impedance data, including electric utility system and motor fault contribution characteristics.

8. Impedance diagrams.

9. Zero-sequence impedance diagrams.

C. Calculate short circuit interrupting and momentary (when applicable) duties for an assumed three-phase bolted fault at each:

1. Electric utility's supply termination point.

2. Main switchboard.

3. Low-voltage switchgear and switchboards.

4. Motor control centers.

5. Standby generators.

6. Branch circuit panelboards.

7. Future load contributions as shown on one-line diagram.

D. Provide bolted line-to-ground fault current study for areas as defined for three-phase bolted fault short circuit study.

E. Provide bolted line-to-line fault current study for areas as defined for three-phase bolted fault short circuit study.

F. Verify:

1. Equipment and protective devices are applied within their ratings.

2. Adequacy of switchgear switchboard and motor control centers bus bars to withstand short circuit stresses.

3. Adequacy of transformer windings to withstand short circuit stresses.

4. Cable and busway sizes for ability to withstand short circuit heating, in addition to normal load currents.

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G. Tabulations:

1. General Data:
a. Short circuit reactances of rotating machines.
b. Cable and conduit material data.
c. Bus data.
d. Transformer data.
e. Circuit resistance and reactance values.

2. Short Circuit Data (for each source combination):
a. Fault impedances.
b. X to R ratios.
c. Asymmetry factors.
d. Motor contributions.
e. Short circuit kVA.
f. Symmetrical and asymmetrical fault currents.

3. Equipment Evaluation:
a. Equipment bus bracing, equipment short circuit rating, transformer, cable, busway.
b. Maximum fault current available.

H. Written Summary:

1. Scope of studies performed.

2. Explanation of bus and branch numbering system.

3. Prevailing conditions.

4. Selected equipment deficiencies.

5. Results of short circuit study.

6. Comments or suggestions.

I. Suggest changes and additions to equipment rating and/or characteristics.

J. Notify Engineer in writing of existing circuit protective devices improperly rated for new fault conditions.

K. Revise data for "as-installed" condition.

L. Electronic Summary:

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1. Provide document in a PDF file or CD

2. Provide an electronic file in the Engineering Software project used in compiling the document.

1.6 PROTECTIVE DEVICE COORDINATION STUDY
A. General:

1. Prepare in accordance with IEEE 242.

2. Proposed protective device coordination time-current curves for distribution system, graphically displayed on conventional log-log curve sheets. a. Provide separate curve sheets for phase and ground fault coordination for each scenario.
b. Each curve sheet to have title and one-line diagram that applies to specific portion of system associated with time-current curves on that sheet. Limit number of devices shown to four to six.
c. Identify device associated with each curve by manufacturer type, function, and, if applicable, recommended tap, time delay, instantaneous and other settings recommended.
d. Terminate device characteristic curves at a point reflecting maximum symmetrical or asymmetrical fault current to which device is exposed. e. Apply motor protection methods that comply with NFPA 70.

B. Plot Characteristics on Curve Sheets (as applicable):

1. Electric utility's relays.

2. Electric utility's fuses including manufacturer's minimum melt, total clearing, tolerance, and damage bands.

3. Medium-voltage equipment relays.

4. Medium-voltage and low-voltage fuses including manufacturer's minimum melt, total clearing, tolerance, and damage bands.

5. Low-voltage equipment circuit breaker trip devices, including manufacturer's tolerance bands.

6. Pertinent transformer full-load currents at 100 percent.

7. Transformer magnetizing inrush currents.

8. Transformer damage curves; appropriate for system operation and location.

9. ANSI transformer withstand parameters.

10. Significant symmetrical and asymmetrical fault currents.

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11. Motor overload relay settings for motors greater than 40 horsepower.

12. Ground fault protective device settings.

13. Other system load protective devices for largest branch circuit and feeder circuit breaker in each motor control center.

C. Primary Protective Device Settings for Delta-Wye Connected Transformer:

1. Secondary Line-to-Ground Fault Protection: Primary protective device operating band within transformer's characteristics curve, including a point equal to 58 percent of IEEE C57.12.00 withstand point.

2. Secondary Line-To-Line Faults: 16 percent current margin between primary protective device and associated secondary device characteristic curves.

D. Separate medium voltage relay characteristics curves from curves for other devices by at least 0.4-second time margin.

E. Tabulate Recommended Protective Device Settings:

1. Relays:
a. Current tap.
b. Time dial.
c. Instantaneous pickup.
d. Electronic settings data file.

2. Circuit Breakers:
a. Adjustable pickups.
b. Adjustable time-current characteristics.
c. Adjustable time delays.
d. Adjustable instantaneous pickups.
e. I2
t In/Out.
f. Zone interlocking.
g. Electronic settings data file.

F. Written Summary:

1. Scope of studies performed.

2. Summary of protective device coordination methodology.

3. Prevailing conditions.

4. Selected equipment deficiencies.

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5. Results of coordination study.

6. Appendix of complete relay and circuit breaker electronic setting files, submit electronic data files from manufacturer's software.

7. Comments or suggestions.

1.7 ARC FLASH STUDY
A. Perform arc flash hazard study after short circuit and protective device coordination study has been completed, reviewed and accepted.

B. Perform arc flash study in accordance with NFPA 70E, OSHA 29 CFR, Part 1910 Subpart S, and IEEE 1584.

C. Base Calculation: For each major part of electrical power system, determine the following:

1. Flash hazard protection boundary.

2. Limited approach boundary.

3. Restricted approach boundary.

4. Prohibited approach boundary.

5. Incident energy level.

6. Personal protection equipment (PPE) hazard/risk category.

7. Type of PPE required.

D. Produce arc flash warning labels that list items in Paragraph Base Calculation and the following additional items.

1. Bus name.

2. Bus voltage.

E. Produce bus detail sheets that list items in Paragraph Base Calculation and the following additional items:

1. Bus name.

2. Upstream protective device name, type, and settings.

3. Bus line-to-line voltage.

F. Produce arc flash evaluation summary sheet listing the following additional items:

1. Bus name.

2. Upstream protective device name, type, settings.

3. Bus line-to-line voltage.

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4. Bus bolted fault.

5. Protective device bolted fault current.

6. Arcing fault current.

7. Protective device trip/delay time.

8. Breaker opening time.

9. Solidly grounded column.

10. Equipment type.

11. Gap.

12. Arc flash boundary.

13. Working distance.

14. Incident energy.

15. Required protective fire rated clothing type and class.

G. Analyze short circuit, protective device coordination, and arc flash calculations and highlight equipment that is determined to be underrated or causes incident energy values greater than 8 cal/cm2. Propose approaches to reduce energy levels.

H. Prepare report summarizing arc flash study with conclusions and recommendations which may affect integrity of electric power distribution system. As a minimum, include the following:

1. Equipment manufacturer's information used to prepare study.

2. Assumptions made during study.

3. Reduced copy of one-line drawing, with hazard category and incident energy displayed as data blocks; 11 inches by 17 inches.

4. Arc flash evaluations summary spreadsheet.

5. Bus detail sheets.

6. Arc flash warning labels printed in color on adhesive backed labels.

PART 2 - PRODUCTS

2.1 ARC FLASH WARNING LABELS
A. Printed in multicolor on adhesive backed labels. Refer to sample label at the end of this specification.

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PART3 - EXECUTION

3.1 GENERAL
A. Adjust relay and protective device settings according to values established by coordination study.

B. Make minor modifications to equipment as required to accomplish conformance with short circuit and protective device coordination studies.

C. Notify Engineer in writing of required major equipment modifications.

D. Provide laminated one-line diagrams (minimum size 11 inches by 17 inches) to post on interior of electrical room doors.

E. Provide arc flash warning labels on equipment as specified in this Section.

3.2 SAMPLE
A. The supplement listed below is a part of this Specification:

1. Figure 1: Example Arc Flash Label.

Arc Flash Label
**END OF SECTION**

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SECTION 16060

GROUNDING AND BONDING FOR ELECTRICAL SYSTEMS
PART 1 - GENERAL

1.1 SUBMITTALS
A. Action Submittals:

1. Shop Drawings: Product data for the following:
a. Exothermic weld connectors.
b. Mechanical connectors.
c. Compression connectors.
d. Ground Rods.

1.2 QUALITY ASSURANCE
A. Authority Having Jurisdiction (AHJ):

1. Provide the Work in accordance with NFPA 70, National Electrical Code (NEC).

Where required by the AHJ, material and equipment shall be labeled or listed by a nationally recognized testing laboratory or other organization acceptable to the AHJ to provide a basis for approval under NEC.

2. Materials and equipment manufactured within the scope of standards published by Underwriters Laboratories, Inc. shall conform to those standards and shall have an applied UL listing mark.

PART 2 - PRODUCTS

2.1 GROUND ROD
A. Material: Copper-clad. Steel.

B. Diameter: Minimum 5/8 inch.

C. Length: 10 feet.

2.2 GROUND CONDUCTORS
A. As specified in Section 16120, Conductors.

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2.3 CONNECTORS
A. Exothermic Weld Type:

1. Outdoor Weld: Suitable for exposure to elements or direct burial.

2. Indoor Weld: Utilize low-smoke, low-emission process.

3. Manufacturers:
a. Erico Products, Inc.; Cadweld and Cadweld Exolon.
b. Thermoweld.

B. Compression Type:

1. Compress-deforming type; wrought copper extrusion material.

2. Single indentation for conductors 6 AWG and smaller.

3. Double indentation with extended barrel for conductors 4 AWG and larger.

4. Barrels prefilled with oxide-inhibiting and antiseizing compound and sealed.

5. Manufacturers:
a. Burndy Corp.
b. Thomas and Betts Co.
c. ILSCO.

C. Mechanical Type: Split-bolt, saddle, or cone screw type; copper alloy material.

1. Manufacturers:
a. Burndy Corp.
b. Thomas and Betts Co.

PART 3 - EXECUTION

3.1 GENERAL
A. Grounding shall comply with NFPA 70 and IEEE C2.

B. Ground electrical service neutral at service entrance equipment to supplementary grounding electrodes.

C. Ground each separately derived system neutral to nearest effectively grounded building structural steel member or separate grounding electrode.

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D. Bond together system neutrals, service equipment enclosures, exposed noncurrentcarrying metal parts of electrical equipment, metal raceways, ground conductor in raceways and cables, receptacle ground connections, and metal piping systems.

E. Shielded Instrumentation Cables:

1. Ground shield to ground bus at power supply for analog signal.

2. Expose shield minimum 1 inch at termination to field instrument and apply heat shrink tube.

3. Do not ground instrumentation cable shield at more than one point.

3.2 WIRE CONNECTIONS
A. Ground Conductors: Install in conduit containing power conductors and control circuits above 50 volts.

B. Nonmetallic Raceways and Flexible Tubing: Install equipment grounding conductor connected at both ends to noncurrent-carrying grounding bus.

C. Connect ground conductors to raceway grounding bushings.

D. Extend and connect ground conductors to ground bus in all equipment containing a ground bus.

E. Connect enclosure of equipment containing ground bus to that bus.

F. Bolt connections to equipment ground bus.

G. Bond grounding conductors to metallic enclosures at each end, and to intermediate metallic enclosures.

H. Junction Boxes: Furnish materials and connect to equipment grounding system with grounding clips mounted directly on box, or with 3/8-inch machine screws.

I. Bond grounding conductors to metal enclosure hinged doors

3.3 GROUND RODS
A. Install full length with conductor connection at upper end.

B. Install with connection point below finished grade, unless otherwise shown.

C. Space multiple ground rods by one rod length.

3.4 CONNECTIONS
A. General:

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1. Above grade Connections: Install exothermic weld, mechanical, or compressiontype connectors; or brazing.

2. Below grade Connections: Install exothermic weld or compression type connectors.

3. Remove paint, dirt, or other surface coverings at connection points to allow good metal-to-metal contact.

4. Notify Engineer prior to backfilling ground connections.

B. Exothermic Weld Type:

1. Wire brush or file contact point to bare metal surface.

2. Use welding cartridges and molds in accordance with manufacturer's recommendations.

3. Avoid using badly worn molds.

4. Mold filled with metal when making welds.

5. After completed welds have cooled, brush slag from weld area and thoroughly clean joint.

C. Compression Type:

1. Install in accordance with connector manufacturer's recommendations.

2. Install connectors of proper size for grounding conductors and ground rods specified.

3. Install using connector manufacturer's compression tool having proper sized dies.

D. Mechanical Type:

1. Apply homogeneous blend of colloidal copper and rust and corrosion inhibitor before making connection.

2. Install in accordance with connector manufacturer's recommendations.

3. Do not conceal mechanical connections.

3.5 METAL STRUCTURE GROUNDING
A. Ground metal sheathing and exposed metal vertical structural elements to grounding system.

B. Bond electrical equipment supported by metal platforms to the platforms.

C. Provide electrical contact between metal frames and railings supporting pushbutton stations, receptacles, and instrument cabinets, enclosure doors, and raceways carrying circuits to these devices.

3.6 HANDHOLE GROUNDING

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A. Install one ground rod inside each.

B. Make connections of grounding conductors fully visible and accessible.

C. Connect all noncurrent-carrying metal parts, and any metallic raceway grounding bushings to ground rod with No. 6 AWG copper conductor. **END OF SECTION**

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SECTION 16120

CONDUCTORS
PART 1 - GENERAL

1.1 SUBMITTALS
A. Action Submittals:

1. Product Data:
a. Wire and cable.
b. Wire and cable accessories.
c. Cable fault detection system.

B. Informational Submittals:

1. Journeyman lineman or electrician splicing credentials.

2. Factory Test Report for conductors 600 volts and below.

3. Factory Test Report in accordance with AEIC CS 8, including AEIC qualification report for conductors above 600 volts.

1.2 QUALITY ASSURANCE
A. Authority Having Jurisdiction (AHJ):

1. Provide the Work in accordance with NFPA 820 and NFPA 70. Where required by the AHJ, material and equipment shall be labeled or listed by a nationally recognized testing laboratory or other organization acceptable to the AHJ in order to provide a basis for approval under NEC.

2. Materials and equipment manufactured within the scope of standards published by Underwriters Laboratories Inc. shall conform to those standards and shall have an applied UL listing mark.

PART 2 - PRODUCTS

2.1 CONDUCTORS 600 VOLTS AND BELOW
A. Conform to applicable requirements of NEMA WC 70.

B. Conductor Type: Soft drawn stranded copper, 98 percent minimum conductivity.

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C. Insulation: Type THHN/THWN-2.

D. Flexible Cords and Cables:

1. Type SOW-A/50 with ethylene propylene rubber insulation in accordance with UL 62.

2. Conform to physical and minimum thickness requirements of NEMA WC 70.

E. Manufacturers:

1. Anaconda.

2. Brand-Rex.

3. General Electric.

4. Okonite.

5. Or equal.

2.2 600-VOLT RATED CABLE
A. General:

1. Type TC, meeting requirements of UL 1277, including Vertical Tray Flame Test at 70,000 Btu per hour, and NFPA 70, Article 340, or UL 13 meeting requirements of NFPA 70, Article 725.

2. Permanently and legibly marked with manufacturer's name, maximum working voltage for which cable was tested, type of cable, and UL listing mark.

3. Suitable for installation in open air, in cable trays, or conduit.

4. Minimum Temperature Rating: 90 degrees C dry locations, 75 degrees C wet locations.

5. Overall Outer Jacket: PVC, flame-retardant, sunlight- and oil-resistant.

B. Type 1, Multi-conductor Control Cable:

1. Conductors:
a. 14 AWG, seven-strand copper.
b. Insulation: 15-mil PVC with 4-mil nylon.
c. UL 1581 listed as Type THHN/THWN-2 rated VW-1.
d. Conductor group bound with spiral wrap of barrier tape. e. Color Code: In accordance with ICEA S-58-679, Method 1, Table 2.

2. Cable: Passes the ICEA T-29-520, 210,000 Btu per hour Vertical Tray Flame Test.

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3. Cable Sizes:

No. of Conductors
Max. Outside Diameter
(Inches)
Jacket Thickness
(Mils)
3 0.41 45
5 0.48 45
7 0.52 45
12 0.72 60
19 0.83 60
25 1.00 60
37 1.15 80

4. Manufacturers:
a. Okonite Co.
b. Southwire.
c. Or equal
C. Type 3, 16 AWG, Twisted, Shielded Pair, Instrumentation Cable: Single pair, designed for noise rejection for process control, computer, or data log applications meeting NEMA WC 57 requirements.

1. Outer Jacket: 45-mil nominal thickness.

2. Individual Pair Shield: 1.35-mil, double-faced aluminum/synthetic polymer overlapped to provide 100 percent coverage.

3. Dimension: 0.31-inch nominal OD.

4. Conductors:
a. Bare soft annealed copper, Class B, seven-strand concentric, meeting requirements of ASTM B8.
b. 18 AWG, seven-strand tinned copper drain wire.
c. Insulation: 15-mil nominal PVC.
d. Jacket: 4-mil nominal nylon.
e. Color Code: Pair conductors, black and clear.

5. Manufacturers:
a. Okonite Co.
b. Alpha Wire Corp.
c. Belden.

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D. Type 4, 16 AWG, Twisted, Shielded Triad Instrumentation Cable: Single triad, designed for noise rejection for process control, computer, or data log applications meeting NEMA WC 57 requirements.

1. Outer Jacket: 45-mil nominal.

2. Individual Pair Shield: 1.35-mil, double-faced aluminum/synthetic polymer, overlapped to provide 100 percent coverage.

3. Dimension: 0.32-inch nominal OD.

4. Conductors:
a. Bare soft annealed copper, Class B, seven-strand concentric, meeting requirements of ASTM B8.
b. 18 AWG, seven-strand, tinned copper drain wire.
c. Insulation: 15-mil nominal PVC.
d. Jacket: 4-mil nylon.
e. Color Code: Triad conductors black, red, and clear.

5. Manufacturers:
a. Okonite Co.
b. Alpha Wire Corp.
c. Belden.

2.3 SPECIAL CABLES
A. Type 30, Unshielded Twisted Pair (UTP) Telephone and Data Cable, 300V:

1. Category 6 UTP, UL listed, and third party verified to comply with TIA/EIA 568- C Category 6 requirements.

2. Suitable for high speed network applications including gigabit Ethernet and video.

Cable shall be interoperable with other standards compliant products and shall be backward compatible with Category 5 and Category 5e.

3. Provide four each individually twisted pair, 23 AWG conductors, with FEP insulation and blue PVC jacket.

4. NFPA 70 Plenum (CMP) rated; comply with flammability plenum requirements of NFPA 70 and NFPA 262.

5. Cable shall withstand a bend radius of 1-inch minimum at a temperature of minus 20 degrees C maximum without jacket or insulation cracking.

6. Manufacturer and Product: Belden; 7852A.

2.4 GROUNDING CONDUCTORS

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A. Underground grounding conductors: Bare Copper.

B. Branch circuit and feeder equipment grounding conductors: Bare Copper.

2.5 ACCESSORIES FOR CONDUCTORS 600 VOLTS AND BELOW
A. Tape:

1. General Purpose, Flame Retardant: 7-mil, vinyl plastic, Scotch Brand 33+, rated for 90 degrees C minimum, meeting requirements of UL 510.

2. Flame Retardant, Cold and Weather Resistant: 8.5-mil, vinyl plastic, Scotch Brand 88.

3. Arc and Fireproofing:
a. 30-mil elastomer.
b. Manufacturers and Products:
(1) 3M; Scotch Brand 77, with Scotch brand 69 glass cloth tape binder.
(2) Plymouth; 53 Plyarc, with 77 Plyglas glass tape binder.

B. Wire Markers:

1. Wire markers shall be provided to identify all conductors and cables at equipment terminals, and in pull boxes, handholes, and manholes. The wire markers shall be one uniform standardized marking system. Heat shrinking of the wire markers and clear tubing shall be in accordance with manufacturer's specifications. The field installed conductor wire number shall be labeled with the same number as the terminal number it is connected to.

2. The marking system shall consist of heat shrinkable flame retarded identification sleeves that fit tightly over the wire to be insulated. Wire tags shall be made of a seamless cross-linked polyolefin with a 3 to 1 shrink ratio.

3. Wire marker system shall be UL recognized to Standard 224, MIL-M-81531.

Wire markers shall be smear resistant prior to shrinking and achieve mark permanent when shrunk, without the need for permatizing equipment. Markers shall be seamless. Markers shall be resistant to common industrial fluids including Freon TF, Osopropyl Alcohol and Ethylene Glycol. Markers shall have a temperature range of minus 30 degrees C to 105 degrees C and a dielectric strength of 500V/mil minute. Marks shall be legible after 20 eraser rubs and 30 solvent brush strokes. The markers shall be suitable for indoor or outdoor use. A Kroy Tube Marker Model No. K4100 or Tyco #LM2020Plus thermal labeler complete with a case, serial cable and an AC power adapter shall be purchased for tagging wires/cables and shall be supplied as part of the MCC. The system describe as manufactured by Raychem/Kroy Cable Marking, or BradyPage 466 of 1513 Section 16120

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Permasleeve White Polyolefin (B-342), or equal. Heat shrinkable thermoplastic tags are not acceptable.

C. Clear Tubing:

1. Adhesive type wire markers are not acceptable by themselves. Due to higher ambient temperatures as witnessed in the desert, a translucent (clear) shrink tube must be placed over each adhesive wire marker (extending past both edges of adhesive wire marker) and heat shrunk. The clear tube shall be suitable for high temperature performance that meets or exceeds military industrial standards:

MIL1-23053, Test C, with UL VW-1 ratings. Operating temperature range shall be minus 55 degrees C to 175 degrees C. Product shall be Kynar as manufactured by Raychem or approved equal.

D. Wire Connectors:

1. Connectors shall be provided for splices and terminal connections of all copper conductors and cables. The connector shall fit the conductor to which it shall be connected, and the assembly shall have pressure contact surfaces of not less than 50 percent. Cutting strands of the conductor or cables to fit within a wire or cable terminal shall not be permitted.
a. Compression connectors for No. 8 AWG and larger shall be copper lugs for terminal connections and cables, and two-way copper sleeves and taps for splice connections. A crimping tool shall be provided to make a tight and neat compression connection. The connectors and crimping tool shall be Burndy "Hylug", Thomas and Betts "Shure Sta-kon", or approved equal.
b. Tapered spring connectors shall have a live spring attached to the inner steel housing and enclosed with winged nylon or plastic insulators. Vinyl insulated spring type wire nuts are not approved. Connectors shall be provided for No. 10 AWG conductors and smaller, and shall be Buchanan type B-cap, Ideal type Twister or wing nut, 3M type Hyflex and Ranger, Gardner-Bender type wing nut or approved equal.
c. Ground clamps shall be provided for cable connections to ground rods and metal pipes as shown on the Drawings. Clamp shall be copper alloy, heavy duty, corrosion resistant and consist of U-bolts, acorns and saddles with bolted cable connections. The ground clamps shall be O-Z/Gedney, Thomas and Betts, Burndy or approved equal. All connectors shall be UL approved for the purpose and shall be accessible.
d. Terminal block termination shall be the practice when any conductors and spare conductors are installed inside a motor control center, or unit control panel, or local control panel, or free standing panel. Provide future and 25 percent spare terminals for future use.

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E. Cable Ties:

1. Nylon, adjustable, self-locking, and reusable.

2. Manufacturer and Product: Thomas & Betts; TY-RAP.

F. Heat Shrinkable Insulation:

1. Thermally stabilized cross-linked polyolefin.

2. Single wall for insulation and strain relief.

3. Dual wall, adhesive sealant lined, for sealing and corrosion resistance.

4. Manufacturers and Products:
a. Thomas & Betts; SHRINK-KON.
b. Raychem; RNF-100 and ES-2000.

2.6 PULLING COMPOUND
A. Nontoxic, noncorrosive, noncombustible, nonflammable, water-based lubricant; UL listed.

B. Suitable for rubber, neoprene, PVC, polyethylene, hypalon, CPE, and leadcovered wire and cable.

C. Approved for intended use by cable manufacturer.

D. Suitable for zinc-coated steel, aluminum, PVC, bituminized fiber, and fiberglass raceways.

E. Manufacturers:

1. Ideal Co.

2. Polywater, Inc., Lubricant J

3. Cable Grip Co.

4. Gardner-Bender; Poly Gel

2.7 SOURCE QUALITY CONTROL
A. Conductors 600 Volts and Below: Test in accordance with UL 44 and UL 854.

PART 3 - EXECUTION

3.1 GENERAL
A. Conductor installation shall be in accordance with manufacturer's recommendations.

B. Conductor and cable sizing shown is based on copper conductors, unless noted otherwise.

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C. Do not exceed cable manufacturer's recommendations for maximum pulling tensions and minimum bending radii.

D. Terminate conductors and cables, unless otherwise indicated.

E. Tighten screws and terminal bolts in accordance with UL 486A-486B for copper conductors.

F. Cable Lugs: Provide with correct number of holes, bolt size, and center-to-center spacing as required by equipment terminals.

G. Bundling: Where single conductors and cables in manholes, handholes, vaults, cable trays, and other indicated locations are not wrapped together by some other means, bundle conductors from each conduit throughout their exposed length with cable ties placed at intervals not exceeding 12 inches on center.

H. Ream, remove burrs, and clear interior of installed conduit before pulling wires or cables.

Clean installed ducts by pulling a flexible steel mandrel, followed by a wire brush and swab, through each duct. Mandrel shall be 1/4-inch less in diameter than the duct diameter. Spare ducts shall have a 200-pound strength nylon cord installed with at least 36 inches of slack at each end.

3.2 CONDUCTOR MATERIAL APPLICATIONS
A. Feeders: Copper; stranded for No. 14 AWG and larger.

B. Branch Circuits: Copper. stranded for No. 12 AWG and larger.

C. Grounding conductors; solid for No. 12 AWG and smaller; stranded for No. 10 AWG and larger.

3.3 CONDUCTOR INSULATION AND MULTICONDUCTOR CABLE APPLICATIONS

AND WIRING METHODS
A. Branch Circuits: Type THHN/THWN-2, single conductors in raceway.

B. Calculations for Determining Tension:

When conductors are installed with pulling eyes attached, maximum tension should not exceed 0.008 cmil. Therefore : T = 0.008 x N x cmil
Where T (tension) is determined in pounds, N is the number of conductors being pulled in, and cmil is the circular-mil.

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C. The cable pulling lubricant shall be compatible with all cable jackets. The lubricant shall be clear, contain no greases, silicones, or polyalkylene glycol oils or waxes. Complete cleanup possible with water. The lubricant shall be UL or CSA listed or equal.

3.4 INSTALLATION OF CONDUCTORS AND CABLES
A. Conceal cables in finished walls, ceilings, and floors unless otherwise indicated.

B. Complete raceway installation between conductor and cable termination points according to Section 16130 "Raceways and Boxes" prior to pulling conductors and cables.

C. Use manufacturer-approved pulling compound or lubricant where necessary; compound used must not deteriorate conductor or insulation. Do not exceed manufacturer's recommended maximum pulling tensions and sidewall pressure values.

D. Use pulling means, including fish tape, cable, rope, and basket-weave wire/cable grips, that will not damage cables or raceway.

E. Install exposed cables parallel and perpendicular to surfaces of exposed structural members, and follow surface contours where possible.

3.5 CONNECTIONS
A. Tighten electrical connectors and terminals according to manufacturer's published torquetightening values. If manufacturer's torque values are not indicated, use those specified in UL 486A-486B.

B. Make splices, terminations, and taps that are compatible with conductor material and that possess equivalent or better mechanical strength and insulation ratings than unspliced conductors.

C. Wiring at Outlets: Install conductor at each outlet, with at least 6 inches of slack.

Extending past the outer edge of the box and/or ring adapter.

3.6 POWER CONDUCTOR COLOR CODING
A. Conductors 600 Volts and Below:

1. 6 AWG and Larger: Apply general purpose, flame retardant tape at each end, and at accessible locations wrapped at least six full overlapping turns, covering area 1- 1/2 inches to 2 inches wide.

2. 8 AWG and Smaller: Provide colored conductors.

3. Colors:

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System Conductor Color
All Systems Equipment
Grounding
Bare
240/120 Volts, SinglePhase, Three-WireGrounded Neutral One Hot Leg
Other Hot Leg
White
Black
Red
208Y/120 Volts,
Three-Phase, FourWire
Grounded Neutral Phase
A Phase B Phase C
White Black Red
Blue
240/120 Volts, ThreePhase, Four-Wire,
Delta, Center Tap,
Ground on SinglePhase
Grounded Neutral
Phase A
High (wild) Leg
Phase C
White Black Orange
Blue
480Y/277 Volts,
Three-Phase, FourWire
Grounded Neutral Phase
A Phase B Phase C
White Brown Orange
Yellow
Note: Phase A, B, C implies direction of positive phase rotation.

Color Service
Black L1 of 120V
Brown Main coil (usually to start P.B.)
Red 480 volt wiring in MCC for phase fail relay
Orange Trip coil
Yellow Pump start after time delay (part wound) and interlock control circuit from external source
Bare Equipment Grounding conductor
Violet Telemetry Call to start pump
Gray Common return
White L2 of 120V (current carrying ground)
Pink Hot lead (usually to stop P.B.) and Reset Control

4. Tracer: Outer covering of white with identifiable colored strip, other than green, in accordance with NFPA 70.

3.7 CIRCUIT IDENTIFICATION
A. Identify power, instrumentation, and control conductor circuits at each termination, and in accessible locations such as manholes, handholes, panels, switchboards, motor control centers, pull boxes, and terminal boxes.

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B. Identify conductors in accordance with the Circuit and Raceway Schedule.

C. Method:

1. Heat shrink wire markers with heat shrink tubing.

2. Taped-on markers or tags relying on adhesives not permitted.

3.8 CONDUCTORS 600 VOLTS AND BELOW
A. Install 10 AWG or 12 AWG conductors for branch circuit power wiring in lighting and receptacle circuits.

B. Do not splice incoming service conductors and branch power distribution conductors 6 AWG and larger, unless specifically indicated or approved by Engineer.

C. Connections and Terminations:

1. Install nylon self-insulated crimp connectors and terminators for instrumentation and control, circuit conductors.

2. Install self-insulated, set screw wire connectors for two-way connection of power circuit conductors 12 AWG and smaller.

3. Install uninsulated crimp connectors and terminators for instrumentation, control, and power circuit conductors 4 AWG through 2/0 AWG.

4. Install uninsulated, bolted, two-way connectors and terminators for power circuit conductors 3/0 AWG and larger.

5. Install uninsulated terminators bolted together on motor circuit conductors 10 AWG and larger.

6. Place no more than one conductor in any single-barrel pressure connection.

7. Install crimp connectors with tools approved by connector manufacturer.

8. Install terminals and connectors acceptable for type of material used.

9. Compression Lugs:
a. Attach with a tool specifically designed for purpose. Tool shall provide complete, controlled crimp and shall not release until crimp is complete. b. Do not use plier type crimpers.

D. Do not use soldered mechanical joints.

E. Splices and Terminations:

1. Insulate uninsulated connections.

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2. Indoor and Outdoor Dry Locations: Use flame retardant, cold- and weatherresistant tape or single wall heat shrink.

3. Below Grade and Wet or Damp Locations: Use dual wall heat shrink.

F. Cap spare conductors with UL listed end caps.

G. Cabinets, Panels, and Motor Control Centers:

1. Remove surplus wire, bridle and secure.

2. Where conductors pass through openings or over edges in sheet metal, remove burrs, chamfer edges, and install bushings and protective strips of insulating material to protect the conductors.

H. Control and Instrumentation Wiring:

1. Where terminals provided will accept such lugs, terminate control and instrumentation wiring, except solid thermocouple leads, with insulated, lockingfork compression lugs.

2. Terminate with methods consistent with terminals provided, and in accordance with terminal manufacturer's instructions.

3. Locate splices in readily accessible cabinets or junction boxes using terminal strips.

4. Where connections of cables installed under this Section are to be made under sections of these specification, leave pigtails of adequate length for bundled connections.

5. Cable Protection:
a. Under Infinite Access Floors: May install without bundling. b. All Other Areas: Install individual wires, pairs, or triads in flex conduit under floor or grouped into bundles at least 1/2 inch in diameter. c. Maintain integrity of shielding of instrumentation cables. d. Ensure grounds do not occur because of damage to jacket over shield.

I. Extra Conductor Length: For conductors to be connected by others, install minimum 6 feet of extra conductor in freestanding panels and minimum 2 feet in other assemblies. **END OF SECTION**

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SECTION 16130

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PART 1 - GENERAL

1.1 SUBMITTALS
A. Action Submittals:

1. Manufacturer's Literature:
a. PVC Schedule 40 conduit.
b. PVC-coated rigid galvanized steel conduit.
c. Flexible metal, liquid-tight conduit.
d. Conduit fittings.
e. Device boxes for use in hazardous areas.
f. Junction and pull boxes used at or below grade.
g. Large junction and pull boxes.
h. Terminal junction boxes.

2. Precast Handholes:
a. Dimensional drawings and descriptive literature.
b. Traffic loading calculations.
c. Accessory information.

3. Equipment and machinery proposed for bending metal conduit.

4. Method for bending PVC conduit less than 30 degrees.

1.2 QUALITY ASSURANCE
A. Authority Having Jurisdiction (AHJ):

1. Provide the Work in accordance with NFPA 820 and NFPA 70, National Electrical Code (NEC). Where required by the AHJ, material and equipment shall be labeled or listed by a nationally recognized testing laboratory or other organization acceptable to the AHJ to provide a basis for approval under NEC.

2. Materials and equipment manufactured within the scope of standards published by Underwriters Laboratories, Inc. shall conform to those standards and shall have an applied UL listing mark.

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PART 2 - PRODUCTS

2.1 CONDUIT AND TUBING
A. PVC Schedule 40 Conduit:

1. Meet requirements of NEMA TC 2 and UL 651.

2. UL listed for concrete encasement, underground direct burial, concealed or direct sunlight exposure, and 90 degrees C insulated conductors.

B. PVC-Coated Rigid Galvanized Steel Conduit:

1. Meet requirements of NEMA RN 1.

2. Material:
a. Meet requirements of NEMA C80.1 and UL 6.
b. Exterior Finish: PVC coating, 40 mils nominal thickness, bond to metal shall have tensile strength greater than PVC.
c. Interior finish: Urethane coating, 2 mils nominal thickness.

3. Threads: Hot-dipped galvanized and factory coated with urethane.

4. Bendable without damage to either interior or exterior coating.

C. Flexible Metal, Liquid-Tight Conduit:

1. UL 360 listed for 105 degrees C insulated conductors.

2. Material: Galvanized steel, with an extruded PVC jacket.

3. Conduits less than 1-1/4” shall have an internal copper bonding conductors wound spirally in the space between each convolution.

2.2 FITTINGS
A. PVC Conduit and Tubing:

1. Meet requirements of NEMA TC-3.

2. Type: PVC, slip-on.

B. PVC-Coated Rigid Galvanized Steel Conduit:

1. Meet requirements of UL 514B.

2. Fittings: Rigid galvanized steel type, PVC coated by conduit manufacturer.

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3. Conduit Bodies: Cast metal hot-dipped galvanized or urethane finish.

Cover shall be of same material as conduit body. PVC coated by conduit manufacturer.

4. Finish: 40-mil PVC exterior, 2-mil urethane interior.

5. Overlapping pressure-sealing sleeves.

6. Conduit Hangers, Attachments, and Accessories: PVC-coated.

7. Manufacturers:
a. Robroy Industries.
b. Ocal.

8. Expansion Fitting Manufacturer and Product: Ocal; OCAL-BLUE XJG.

C. Flexible Metal, Liquid-Tight Conduit:

1. Metal insulated throat connectors with integral nylon or plastic bushing rated for 105 degrees C.

2. Insulated throat and sealing O-rings.

3. Manufacturers and Products:
a. Thomas & Betts; Series 5331.
b. O-Z/Gedney; Series 4Q.

D. Flexible Coupling, Hazardous Locations:

1. Approved for use in the atmosphere involved.

2. Rating: Watertight and UL listed for use in Class I, Division 1 and 2 areas.

3. Outer bronze braid and an insulating liner.

4. Conductivity equal to a similar length of rigid metal conduit.

5. Manufacturers and Products:
a. Crouse-Hinds; Type ECGJH or ECLK.
b. Appleton; EXGJH or EXLK.

E. Watertight Entrance Seal Device:

1. New Construction:
a. Material: Oversized sleeve, malleable iron body with sealing ring, pressure ring, grommet seal, and pressure clamp.
b. Manufacturer and Product: O-Z/Gedney; Type FSK or WSK, as required.

2. Cored-Hole Application:

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a. Material: Assembled dual pressure disks, neoprene sealing ring, and membrane clamp.
b. Manufacturer and Product: O-Z/Gedney; Series CSM.

2.3 OUTLET AND DEVICE BOXES
A. Cast Metal:

1. Box: Malleable iron.

2. Cover: Gasketed, weatherproof, malleable iron, with stainless steel screws.

3. Hubs: Threaded.

4. Lugs: Cast Mounting.

5. Manufacturers and Products, Nonhazardous Locations:
a. Crouse-Hinds; Type FD.
b. Appleton; Type FD.
c. Killark.

6. Manufacturers and Products, Hazardous Locations:
a. Crouse-Hinds; Type GUA or EAJ.
b. Appleton; Type GR.

B. PVC-Coated Cast Metal:

1. Type: One-piece.

2. Material: Malleable iron, cast ferrous metal, or cast aluminum.

3. Coating:
a. Exterior Surfaces: 40-mil PVC.
b. Interior Surfaces: 2-mil urethane.

4. Manufacturers:
a. Robroy Industries.
b. Ocal.

2.4 TERMINAL JUNCTION BOX
A. Cover: Hinged, unless otherwise shown.

B. Interior Finish: Paint with white enamel or lacquer.

C. Terminal Blocks:

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1. Separate connection point for each conductor entering or leaving box.

2. Spare Terminal Points: 20 percent, minimum.

2.5 TERMINAL BLOCKS
A. Provide terminal blocks as needed per the amount required for all the connections with 20 percent additional spare terminals for future connections. The terminal blocks shall be din rail mounted, 600V ac, 30-amp minimum, capable of accommodating multiple wire terminations of two No. 2 AWG minimum. Terminal blocks used in pull out starter buckets shall be latched pull apart type without disconnecting the wire from the terminal blocks. Wire termination shall accommodate at least one No. 18 to one No. 10 AWG conductors. Provide spacers and end stops where necessary. Terminal numbers shall not be duplicated anywhere within the motor control center (MCC) unless the terminal point is the same potential and function throughout the MCC, i.e. L1 or L2 or N.

B. Blown fuse indicators and fuse pullers shall be a part of terminal blocks used for holding fuses within the circuitry. Minimum current rating of the fuse holder shall be 30-amperes.

The terminal blocks shall be UL recognized as a minimum.

2.6 PRECAST HANDHOLES
A. Concrete Strength: Minimum, 3,000 psi compressive, in 28 days.

B. Loading: AASHTO, H-20 in accordance with ASTM C857.

C. Access: Provide cast concrete 6- or 12-inch risers between top of box and finished grade at required elevations.

D. Drainage:

1. Slope floors toward drain points, leaving no pockets or other nondraining areas.

2. Provide drainage outlet or sump at low point of floor constructed with a heavy, cast iron, slotted or perforated hinged cover, and a minimum 4-inch outlet and outlet pipe.

E. Raceway Entrances:

1. Provide on all four sides.

2. For raceways to be installed under this Contract, provide knockout panels or precast individual raceway openings.

3. At entrances where raceways are to be installed by others, provide minimum 12- inch high by 24-inch wide knockout panels for future raceway installation.

F. Embedded Pulling Iron:

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1. Material: 3/4-inch diameter stock, fastened to overall steel reinforcement before concrete is placed.

2. Location:
a. Wall: Opposite each raceway entrance and knockout panel for future raceway entrance.
b. Floor: Centered below manhole or handhole cover.

G. Cable Racks:

1. Arms and Insulators: Adjustable, of sufficient number to accommodate cables for each raceway entering or leaving, including spares.

2. Wall Attachment:
a. Adjustable inserts in concrete walls. Bolts or embedded studs not permitted.
b. Insert Spacing: Maximum 3 feet on center for entire inside perimeter. c. Arrange so that spare raceway ends are clear for future cable installation.

H. Handhole Frames and Covers:

1. Frame Material: Steel, hot-dipped galvanized.

2. Cover Type: Solid aluminum, bolt-on, hinged, torsion spring, of nonskid design.

3. Cover Loading: AASHTO H-20.

4. Cover Designation: Burn by welder, on upper side in integral letters, minimum 2 inches in height, appropriate titles:
a. 600 Volts and Below: ELECTRICAL POWER.
b. SIGNAL.
c. CONTROL.

I. Hardware: Steel, hot-dip galvanized.

J. Furnish knockout for ground rod in each handhole.

K. Manufacturers:

1. Utility Vault Co.

2. Penn-Cast Products, Inc.

3. Concrete Conduit Co.

4. Associated Concrete Products, Inc.

5. Pipe, Inc.

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2.7 ACCESSORIES
A. Duct Bank Spacers:

1. Type: Nonmetallic, interlocking, for multiple conduit sizes.

2. Suitable for all types of conduit.

3. Manufacturers:
a. Underground Device, Inc.
b. Carlon.

B. Identification Devices:

1. Raceway Tags:
a. Material: Brass.
b. Shape: Round, 1-inch diameter, or larger oval, if necessary to fit designation.
c. Raceway Designation: Pressure stamped, embossed, or engraved. d. Tags relying on adhesives or taped-on markers not permitted. e. Attached to conduits with stainless steel 0.02 dia or 14 gauge bailing wire.

2. Warning Tape:
a. Material: Polyethylene, 4-mil gauge with detectable strip. b. Color: Red.
c. Width: Minimum 3 inches.
d. Designation: "CAUTION, BURIED ELECTRICAL LINE BELOW". e. Identifying Letters: Minimum 1-inch high permanent black lettering imprinted continuously over entire length.
f. Manufacturers and Products:
(1) Panduit; Type HTDU.
(2) Reef Industries; Terra Tape.

C. Heat Shrinkable Tubing:

1. Material: Heat-shrinkable, cross-linked polyolefin.

2. Semi-flexible with meltable adhesive inner liner.

3. Color: Black.

4. Manufacturers:

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a. Raychem.
b. 3M.

D. Wraparound Duct Band:

1. Material: Heat-shrinkable, cross-linked polyolefin, precoated with hot-melt adhesive.

2. Width: 50 mm minimum.

3. Manufacturer and Product: Raychem; Type TWDB.

PART 3 - EXECUTION

3.1 GENERAL
A. Conduit and Tubing sizes shown are based on the use of copper conductors. Aluminum conductors are not acceptable.

B. All installed Work shall comply with NECA Installation Standards.

C. Crushed or deformed raceways not permitted.

D. Maintain raceway entirely free of obstructions and moisture.

E. Immediately after installation, plug or cap raceway ends with watertight and dust-tight seals until time for pulling in conductors.

F. Sealing Fittings: Provide drain seal in vertical raceways where condensate may collect above sealing fitting.

G. Avoid moisture traps where possible. When unavoidable in exposed conduit runs, provide junction box and drain fitting at conduit low point.

H. Group raceways installed in same area.

I. Proximity to Heated Piping: Install raceways minimum 12 inches from parallel runs.

J. Follow structural surface contours when installing exposed raceways. Avoid obstruction of passageways.

K. Run exposed raceways parallel or perpendicular to walls, structural members, or intersections of vertical planes.

L. Block Walls: Do not install raceways in same horizontal course or vertical cell with reinforcing steel.

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M. Install watertight fittings in outdoor, underground, or wet locations.

N. Paint threads and cut ends, before assembly of fittings, galvanized conduit, PVC-coated galvanized conduit, or IMC installed in exposed or damp locations with zinc-rich paint or liquid galvanizing compound.

O. Metal conduit shall be reamed, burrs removed, and cleaned before installation of conductors, wires, or cables.

P. Do not install raceways in concrete equipment pads, foundations, or beams.

Q. Horizontal raceways installed under floor slabs shall lie completely under slab, with no part embedded within slab.

R. Install concealed, embedded, and buried raceways so that they emerge at right angles to surface and have no curved portion exposed.

S. Install conduits for fiber optic cables, telephone cables, and Category 6 data cables in strict conformance with the requirements of EIA/TIA 569-A.

T. Innerducts, where installed, shall be used for fiber optic installation, and inside PVC or metal conduit only.

3.2 REUSE OF EXISTING CONDUITS
A. Where Drawings indicate, existing conduits may be reused, they may be reused only where they meet the following criteria.

1. Conduit is in useable condition with no deformation, corrosion, or damage to the exterior surface.

2. Conduit is sized in accordance with the NEC.

3. Conduit is of the type specified in Contract Documents.

4. Conduit is supported as specified in Contract Documents.

B. Conduit shall be reamed with wire brush, then with a mandrel approximately 1/4 inch smaller than raceway inside diameter then cleaned prior to pulling new conductors.

3.3 CONDUIT APPLICATION
A. Diameter: Minimum 3/4 inch.

B. Exterior, Exposed:

1. PVC-coated rigid galvanized steel.

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C. Interior, Exposed:

1. PVC-coated rigid galvanized steel.

D. Direct Earth Burial:

1. PVC Schedule 40. All bends 45 degrees and larger shall be PVC-coated rigid steel.

E. Concrete-Encased Raceways:

1. PVC Schedule 40. All bends 45 degrees and larger shall be PVC-coated rigid steel.

F. Transition from Underground or Concrete Embedded to Exposed: PVC-coated rigid steel conduit.

G. Exterior Light Pole Foundations: PVC-coated rigid steel conduit.

H. Corrosive Areas: PVC-coated rigid galvanized steel.

I. Hazardous Gas Areas: PVC-coated rigid galvanized steel.

3.4 FLEXIBLE CONNECTIONS
A. For motors, wall or ceiling mounted fans and unit heaters, dry type transformers, electrically operated valves, instrumentation, and other locations approved by Engineer where flexible connection is required to minimize vibration:

1. Conduit Size 4 Inches or Less: Flexible, metal, liquid-tight conduit.

2. Hazardous Areas: Flexible coupling suitable for Class I, Division 1 and 2 areas.

3. Length: 18-inch minimum, 60-inch maximum, sufficient to allow movement or adjustment of equipment.

3.5 PENETRATIONS
A. Make at right angles, unless otherwise shown.

B. Notching or penetration of structural members, including footings and beams, not permitted.

C. Entering Structures:

1. General: Seal raceway at the first box or outlet with oakum or expandable plastic compound to prevent the entrance of gases or liquids from one area to another.

2. Concrete Roof or Membrane Waterproofed Wall or Floor:
a. Provide a watertight seal.

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b. Without Concrete Encasement: Install watertight entrance seal device on each side.
c. With Concrete Encasement: Install watertight entrance seal device on the accessible side.
d. Securely anchor malleable iron body of watertight entrance seal device into construction with one or more integral flanges.
e. Secure membrane waterproofing to watertight entrance seal device in a permanent, watertight manner.

3. Heating, Ventilating, and Air Conditioning Equipment:
a. Penetrate equipment in area established by manufacturer. b. Terminate conduit with flexible metal, liquid-tight conduit at junction box or condulet attached to exterior surface of equipment prior to penetrating equipment.
c. Seal penetration with Type 5 sealant.

4. Corrosive-Sensitive Areas:
a. Seal all conduit passing through room walls.
b. Seal conduit entering equipment panel boards and field panels containing electronic equipment.

5. Existing or Precast Wall (Underground): Core drill wall and install a watertight entrance seal device.

6. Nonwaterproofed Wall or Floor (Underground, without Concrete Encasement):
a. Provide Schedule 40 galvanized pipe sleeve, or watertight entrance seal device.
b. Fill space between raceway and sleeve with expandable plastic compound or oakum and lead joint, on each side.

7. Handholes:
a. Metallic Raceways: Provide insulated grounding bushings. b. Nonmetallic Raceways: Provide bell ends flush with wall. c. Install such that raceways enter as near as possible to one end of wall, unless otherwise shown.

3.6 SUPPORT
A. Support from structural members only, at intervals not exceeding NFPA 70 requirements, and in any case not exceeding 6 feet. Do not support from piping, pipe supports, or other

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raceways. A support shall be located within 3 feet of any termination or change of direction.

B. Multiple Adjacent Raceways: Provide ceiling trapeze. For trapeze-supported conduit, allow 20 percent extra space for future conduit.

C. Application/Type of Conduit Strap:

1. PVC-Coated Rigid Steel Conduit: PVC-coated metal.

D. Provide and attach wall brackets, strap hangers, or ceiling trapeze as follows:

1. Wood: Wood screws.

2. Hollow Masonry Units: Toggle bolts.

3. Concrete or Brick: Expansion shields, or threaded studs driven in by powder charge, with lock washers and nuts.

4. Steelwork: Machine screws.

5. Location/Type of Hardware:
a. Dry, Noncorrosive Areas: Galvanized.
b. All Others: Stainless steel.

E. Nails or wooden plugs inserted in concrete or masonry for attaching raceway not permitted. Do not weld raceways or pipe straps to steel structures. Do not use wire in lieu of straps or hangers.

3.7 BENDS
A. Install concealed raceways with a minimum of bends in the shortest practical distance.

B. Make bends and offsets of longest practical radius. Bends in conduits and ducts being installed for fiber optic cables shall be not less than 20 times cable diameter, 15 inches minimum.

C. Install with symmetrical bends or cast metal fittings.

D. Field-made bends and offsets, where necessary, shall be made with an acceptable hickey or bending machine. Do not heat metal raceways to facilitate bending.

E. Make bends in parallel or banked runs from same center or centerline with same radius so that bends are parallel.

F. Factory elbows may be installed in parallel or banked raceways if there is change in plane of run, and raceways are same size.

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G. PVC Conduit:

1. Bends 45 Degrees and Larger: Provide PVC-coated rigid steel elbows.

2. Use manufacturer's recommended method for forming smaller bends.

H. Flexible Conduit: Do not make bends that exceed allowable conductor bending radius of cable to be installed or that significantly restricts conduit flexibility.

3.8 EXPANSION/DEFLECTION FITTINGS
A. Provide on all raceways at all structural expansion joints, and in long tangential runs.

B. Provide expansion/deflection joints for 50 degrees F maximum temperature variation.

C. Install in accordance with manufacturer's instructions.

3.9 PVC CONDUIT
A. Solvent Welding:

1. Provide manufacturer recommended solvent; apply to all joints.

2. Install such that joint is watertight.

B. Adapters:

1. PVC to Metallic Fittings: PVC terminal type.

2. PVC to Rigid Metal Conduit or IMC: PVC female adapter.

C. Belled-End Conduit: Bevel the unbelled end of the joint prior to joining.

3.10 PVC-COATED RIGID STEEL CONDUIT
A. Install in accordance with manufacturer's instructions.

B. Tools and equipment used in cutting, bending, threading and installation of PVC-coated rigid conduit shall be designed to limit damage to PVC coating.

C. Provide PVC boot to cover all exposed threading.

D. Touch up with manufacturer's recommended methods to repair damage and nicked PVC coatings. PVC paint will not be accepted. A PVC patch is the method required to keep the 40-mil thickness.

3.11 TERMINATION AT ENCLOSURES

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A. Cast Metal Enclosure: Provide manufacturer's premolded insulating sleeve inside metallic conduit terminating in threaded hubs.

B. Sheet Metal Boxes, Cabinets, and Enclosures:

1. General:
a. Install insulated bushing on ends of conduit where grounding is not required.
b. Provide insulated throat when conduit terminates in sheet metal boxes having threaded hubs.
c. Utilize sealing locknuts or threaded hubs on sides and bottom of NEMA 3R and NEMA 12 enclosures.
d. Terminate conduits at threaded hubs at the tops of NEMA 3R and NEMA 12 boxes and enclosures.
e. Terminate conduits at threaded conduit hubs at NEMA 4 and NEMA 4X boxes and enclosures.

2. PVC-Coated Rigid Galvanized Steel Conduit:
a. Provide PVC-coated, liquid-tight, metallic connector. b. Install grounding bushing.
c. Provide bonding jumper from grounding bushing to equipment ground bus or ground pad.

3.12 UNDERGROUND RACEWAYS
A. Grade: Maintain minimum grade of 4 inches in 100 feet, either from one handhole, or pull box to the next, or from a high point between them, depending on surface contour.

B. Cover: Maintain minimum 2-foot cover above conduit and concrete encasement, unless otherwise shown.

C. Make routing changes as necessary to avoid obstructions or conflicts.

D. Couplings: In multiple conduit runs, stagger so couplings in adjacent runs are not in same transverse line.

E. Union type fittings not permitted.

F. Spacers:

1. Provide preformed, nonmetallic spacers, designed for such purpose, to secure and separate parallel conduit runs in a trench or concrete encasement.

2. Install at intervals not greater than 5 feet.

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G. Support conduit to prevent bending or displacement during backfilling or concrete placement.

H. Transition from Underground or Concrete Embedded to Exposed: All exposed conduit stub-ups or risers shall be PVC-RGS.

I. Installation with Other Piping Systems:

1. Crossings: Maintain minimum 12-inch vertical separation.

2. Parallel Runs: Maintain minimum 12-inch separation.

3. Installation over valves or couplings not permitted.

J. Provide expansion fittings that allow minimum of 4 inches of movement in vertical conduit runs from underground where exposed conduit will be fastened to or will enter building or structure.

K. Provide deflectional/expansion fittings in conduit runs that exit building or structure belowgrade. Conduit from building wall to fitting shall be PVC-coated rigid steel.

L. Concrete Encasement:

1. Concrete Color: Red iron oxide pigment, in the proportion of 2 pounds per sack of cement.

2. Concrete shall be 2 sack mix, Class C (500PSI minimum).

M. Backfill:

1. Controlled low strength fill is an acceptable bedding and pipe zone material.

2. Do not backfill until inspected by Engineer.

3.13 OUTLET AND DEVICE BOXES
A. Install suitable for conditions encountered at each outlet or device in wiring or raceway system, consistent with the raceway system, and sized to meet NFPA 70 and NFPA 820 requirements.

B. Size:

1. Depth: Minimum 2 inches, unless otherwise required by structural conditions.

Box extensions not permitted.
a. Hollow Masonry Construction: Install with sufficient depth such that conduit knockouts or hubs are in masonry void space.

2. Ceiling Outlet: Minimum 4-inch octagonal device box, unless otherwise required for installed fixture.

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3. Switch and Receptacle: Minimum 2-inch by 4-inch device box.

C. Locations:

1. Drawing locations are approximate.

2. To avoid interference with mechanical equipment or structural features, relocate outlets as directed by Engineer.

3. Light Switch: Install on lock side of doors. In case of double doors, install on side with door knob.

4. Light Fixture: Install in symmetrical pattern according to room layout, unless otherwise shown.

D. Mounting Height:

1. General:
a. Dimensions given to centerline of box.
b. Where specified heights do not suit building construction or finish, adjust up or down to avoid interference. Do not straddle CMU block or other construction joints.

2. Light Switch: 48 inches above floor.

3. Thermostat: 54 inches above floor.

4. Convenience Receptacle:
a. General Interior Areas: 15 inches above floor.
b. Industrial Areas, Workshops: 48 inches above floor.
c. Outdoor, All Areas: 24 inches above finished grade.

5. Switch, Motor Starting: 48 inches above floor, unless otherwise indicated on Drawings.

E. Install plumb and level.

F. Flush Mounted:

1. Install with concealed conduit.

2. Install proper type extension rings or plaster covers to make edges of boxes flush with finished surface.

3. Holes in surrounding surface shall be no larger than required to receive box.

G. Support boxes independently of conduit by attachment to building structure or structural member.

H. Install bar hangers in frame construction or fasten boxes directly as follows:

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1. Wood: Wood screws.

2. Concrete or Brick: Bolts and expansion shields.

3. Hollow Masonry Units: Toggle bolts.

4. Steelwork: Machine screws.

I. Threaded studs driven in by powder charge and provided with lock washers and nuts are acceptable in lieu of expansion shields.

J. Boxes embedded in concrete or masonry need not be additionally supported.

K. Install galvanized mounting hardware in industrial areas.

L. Install separate junction boxes for flush or recessed lighting fixtures where required by fixture terminal temperature.

M. Boxes Supporting Fixtures: Provide means of attachment with adequate strength to support fixture.

N. Open no more knockouts in sheet steel device boxes than are required; seal unused openings.

3.14 JUNCTION AND PULL BOXES
A. Install where shown and where necessary to terminate, tap-off, or redirect multiple conduit runs.

B. Install pull boxes where necessary in raceway system to facilitate conductor installation.

C. Install in conduit runs at least every 150 feet or after the equivalent of three (90 degree) right-angle bends.

D. Use outlet boxes as junction and pull boxes wherever possible and allowed by applicable codes.

E. Use conduit bodies as junction and pull boxes where no splices are required and their use is allowed by applicable codes.

F. Installed boxes shall be accessible with 42 inches minimum clearance in front.

G. Do not install on finished surfaces.

H. Install plumb and level.

I. Support boxes independently of conduit by attachment to building structure or structural member.

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J. Install bar hangers in frame construction or fasten boxes directly as follows:

1. Wood: Wood screws.

2. Concrete or Brick: Bolts and expansion shields.

3. Hollow Masonry Units: Toggle bolts.

4. Steelwork: Machine screws.

K. Threaded studs driven in by powder charge and provided with lock washers and nuts are acceptable in lieu of expansion shields.

L. Boxes embedded in concrete or masonry need not be additionally supported.

M. At or Below grade:

1. Install boxes for below grade conduit flush with finished grade in locations outside of paved areas, roadways, or walkways.

2. If adjacent structure is available, box may be mounted on structure surface just above finished grade in accessible but unobtrusive location.

3. Obtain Engineer's written acceptance prior to installation in paved areas, roadways, or walkways.

4. Use boxes and covers suitable to support anticipated weights.

N. Flush Mounted:

1. Install with concealed conduit.

2. Holes in surrounding surface shall be no larger than required to receive box.

3. Make edges of boxes flush with final surface.

O. Mounting Hardware:

1. Noncorrosive Dry Areas: Galvanized.

2. Noncorrosive Wet Areas: Type 304 stainless steel.

3. Corrosive Areas: Type 316 stainless steel.

P. Install Drain/breather fittings in NEMA 250 Type 4 and Type 4X enclosures.

3.15 HANDHOLES
A. Excavate, shore, brace, backfill, and final grade.

B. Do not install until final raceway grading has been determined.

C. Install such that raceways enter at nearly right angles and as near as possible to one end of wall, unless otherwise shown.

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D. Identification: Field stamp covers with manhole or handhole number as shown.

Stamped numbers to be 1-inch minimum height.

3.16 IDENTIFICATION DEVICES
A. Raceway Tags:

1. Identify in accordance with the Circuit and Raceway Schedule.

2. For exposed raceways, install tags at each terminus, near midpoint, and at minimum intervals of every 50 feet, whether in ceiling space or surface mounted.

3. The Contractor is required to label all conduits and affix the 1 inch brass tag to the conduit within the motor control center and on conduits before they enter a junction box or unit control panel.

4. Provide stainless steel mechanic wire for attachment only.

B. Nameplates shall be permanently affixed to the junction box cover in accordance with the manufacturer's approved methods, to not jeopardize the NEMA rating, and labeled with the nomenclature as illustrated on the construction drawings.

C. Warning Tape: Install approximately 12 inches above underground or concrete-encased raceways. Align parallel to, and within 12 inches of, centerline of runs.

3.17 PROTECTION OF INSTALLED WORK
A. Protect products from effects of moisture, corrosion, and physical damage during construction.

B. Provide and maintain manufactured watertight and dust-tight seals over all conduit openings during construction.

C. Touch up painted conduit threads after assembly to cover nicks or scars.

D. Touch up coating damage to PVC-coated conduit, fittings, and supports with patching compound approved by manufacturer. PVC paint is not acceptable. Compound shall be kept refrigerated according to manufacturers' instructions until time of use. **END OF SECTION**

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SECTION 16140

WIRING DEVICES
PART 1 - GENERAL

1.1 SUBMITTALS
A. Action Submittals: Manufacturer's product data for wiring devices.

PART 2 - PRODUCTS

2.1 SWITCHES
A. Switch, General Purpose:

1. NEMA WD 1 and FS W-S-896F.

2. Totally enclosed, ac type, with quiet tumbler switch and screw terminal.

3. Rivetless one-piece brass or copper alloy contact arm with silver alloy contact.

4. Capable of controlling 100 percent tungsten filament and fluorescent lamp loads.

5. Rating: 20 amps, 120/277 volts.

6. Automatic grounding clip and integral grounding terminal on mounting strap.

7. Color: Ivory.

8. Manufacturers and Products, Industrial Grade:
a. Cooper Arrow Hart; AH1220 Series.
b. Bryant; 4901 Series.
c. Hubbell; 1221Series.
d. Leviton; 1221 Series.

B. Switch, Motor Rated:

1. Type: Two-pole or three-pole, manual motor starting/disconnect switch without overload protection.

2. UL 508 listed.

3. Totally enclosed snap-action switch. Quick-make, slow-break design with silver alloy contacts.

4. Minimum General Purpose Rating: 30 amperes, 600V ac.

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5. Minimum Motor Ratings:
a. 2 horsepower for 120V ac, single-phase, two-pole.
b. 3 horsepower for 240V ac, single-phase, two-pole.
c. 10 horsepower for 480V ac, three-phase, three-pole.

6. Screw-type terminal.

7. Manufacturers and Products:
a. Cooper Arrow Hart.
b. Hubbell Bryant: HBL78 Series.
c. Leviton.

C. Heavy Duty Safety Switch:

1. Type: Three-pole, manual disconnect switch

2. UL 98 listed.

3. Totally enclosed snap-action switch. Quick-make, quick-break design with silver alloy contacts.

2.2 RECEPTACLES
A. Receptacle, General Purpose:

1. NEMA WD 1 and FS W-C-596G.

2. Duplex, two-pole, three-wire grounding type with screw type wire terminals.

3. Impact resistant nylon cover and body, with finder grooves in face, unless otherwise indicated.

4. One-piece mounting strap with integral ground contact (Rivetless construction).

5. Contact Arrangement: Contact to be made on two sides of each inserted blade without detent.

6. Rating: 125 volts, NEMA WD 1, Configuration 5-20R, 20 amps, unless otherwise indicated.

7. Size: For 2-inch by 4-inch outlet box.

8. Industrial Grade Manufacturers and Products:
a. Cooper Arrow Hart; 5362 Series.
b. Hubbell Bryant; HBL5362 Series.
c. Leviton; 5362 Series.

B. Receptacle, Ground Fault Circuit Interrupter:

1. Meet requirements of general-purpose receptacle.

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2. Listed Class A to UL 943, tripping at 5 mA.

3. Rectangular smooth face with push-to-test and reset buttons.

4. Listed weather-resistant in accordance with NEC 406.8.

5. Feed-through Capability: 20 amps.

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6. Manufacturers and Products:
a. Hubbell Bryant; GFTR20 Series.
b. Cooper Arrow Hart; WRVGF20 Series.
c. Leviton; 7899 Series.

2.3 HAZARDOUS (CLASSIFIED) LOCATION DEVICES
A. Wiring devices for hazardous (classified) locations shall comply with NEMA FB 11 and UL 1010.

B. Switch:

1. Industrial grade, totally enclosed, ac type, with tumbler switch.

2. Capable of three-way or four-way operation where indicated on Drawings.

3. Rating: 20 amps at 120/277 volts.

4. Material: Cast aluminum backbody and cover.

5. Hazardous Area Ratings: NEMA 7D, suitable for Class I, Group C and Group D locations.

6. Manufacturers and Products:
a. Killark: XS Series.
b. Appleton: EDS Series.

C. Switch, Motor Rated:

1. Enclosed manual motor starter-type, three-pole, nonreversing without overloads.

2. Minimum Motor Rating: 10 horsepower, 480V ac, three-phase, three-pole.

3. Enclosure: NEMA 250, Type 7.

4. Operator: External handle with padlocking provisions.

5. Manufacturer and Product: Eaton, Type B101.

D. Receptacles, General:

1. Contain integral switch which must be closed to energize circuit.

2. Design shall permit only an approved plug to be energized. a. Actuation of switch shall require plug be inserted and rotated approximately 45 degrees.
b. Plug shall lock into this position preventing unintended disengagement. c. To remove, plug shall be turned opposite direction as engagement and pulled straight out.

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E. General Purpose Receptacle, Explosion Proof, 125 Volts, 20 Amps:

1. Dead front, interlocked, circuit breaking.

2. Receptacle Cover: Spring loaded closes when plug is removed.

3. Enclosure: Corrosion-resistant, aluminum alloy with less than 0.4 percent copper.

4. Finish: Electrostatically applied and baked powder epoxy/polyester.

5. External Hardware: Type 316 stainless steel.

6. Switch Chamber: Factory sealed to contain switch's arcing components

7. Hazardous Area Ratings: Suitable for Class I, Division 2 NEMA7D.

8. Manufacturers and Products:
a. Cooper Crouse-Hinds; Ark Guard 2, Series ENR.
b. EGS/Appleton Electric; U-Line.
c. Killark, a division of Hubbell Inc.; UGR/UGP.

F. Ground Fault Circuit Interrupter (GFCI), Explosion-Proof:

1. Meet requirements of general-purpose receptacle, except as otherwise indicated.

2. Hazardous Area Ratings: NEMA 7D, suitable for Class I, Group C and Group D, locations.

3. Provide matching plug with each receptacle.

4. Manufacturers and Products:
a. Killark; Acceptor series UGFI.
b. Appleton; EFSXXX-2023GFI.

2.4 DEVICE PLATES
A. Sectional type plate not permitted.

B. Metal:

1. Material: Specification grade, one-piece, 0.040-inch nominal thickness stainless steel.

2. Finish: ASTM A167, Type 302/304, satin.

3. Mounting Screw: Oval-head, finish matched to plate.

C. Cast Metal:

1. Material: Malleable ferrous metal, with gaskets.

2. Screw: Oval-head stainless steel.

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D. Sheet Steel:

1. Finish: Zinc electroplate.

2. Screws: Oval-head stainless steel.

3. Manufacturers:
a. Appleton.
b. Crouse-Hinds.

E. Weatherproof:

1. Receptacle, Weatherproof Type 1:
a. Gasketed, cast-aluminum, with individual cap over each receptacle opening.
b. Mounting Screw and Cap Spring: Stainless steel.
c. Manufacturers and Products:
(1) Crouse-Hinds; Type WLRD-1.
(2) Appleton; Type FSK-WRD.

2. Receptacle, Cover Weatherproof while in use Type 2:
a. UL listed for wet location while in use.
b. Die cast metal cover.
c. Depth: 3.5 inch
d. Manufacturer and Product: TayMac; Type Multi-Mac or Thomas & Betts

3. Switch:
a. Gasketed, cast-metal or cast-aluminum, incorporating external operator for internal switch.
b. Mounting Screw: Stainless steel.
c. Manufacturers and Products:
(1) Crouse-Hinds; DS-181 or DS-185.
(2) Appleton; FSK-1VTS or FSK-1VS.

F. Raised Sheet Metal: 1/2-inch high zinc- or cadmium-plated steel designed for one-piece drawn type sheet steel box.

G. Sheet Steel: Formed sheet steel or Feraloy designed for installation on cast-metal box.

2.5 FINISHES

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A. Wiring device catalog numbers specified in this Section do not designate device color.

Unless otherwise indicated, or required by code, provide colors as specified below.

B. Wiring Device:

1. Office Areas: Ivory.

2. Other Areas: Gray.

C. Special purpose and hazardous location devices may be manufacturer's standard color (black).

D. Label: Panel board and circuit number, after load balancing has been completed, shall be engraved on a phanolie nameplate and epoxy glued on each switch and receptacle cover.

PART 3 - EXECUTION

3.1 INSTALLATION, GENERAL
A. Comply with NECA 1.

B. Coordination with Other Trades:

1. Ensure device and its box are protected.

2. Keep outlet box free of plaster, drywall joint compound, mortar, cement, concrete, dust, paint, and other material that may contaminate raceway system, conductors, and cables.

3. Install device box in brick or block wall such that cover plate does not cross a joint, unless otherwise indicated. Where indicated or directed to cross joint, trowel joint flush with face of wall.

4. Install wiring device after wall preparation, including painting, is complete.

C. Conductors:

1. Do not strip insulation from conductors until just before they are spliced or terminated on devices.

2. Strip insulation evenly around conductor using tools designed for the purpose.

Avoid scoring or nicking of solid wire or cutting strands from stranded wire.

3. Length of free conductors at outlets for devices shall meet provisions of NFPA 70, Article 300, without pigtails.

D. Device Installation:

1. Replace devices that have been in temporary use during construction or that show signs they were installed before building finishing operations were complete.

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2. Keep each wiring device in its package or otherwise protected until it is time to connect conductors.

3. Do not remove surface protection, such as plastic film and smudge covers, until last possible moment.

4. Connect devices to branch circuits using pigtails that are not less than 6 inches (150 mm) in length.

5. Use torque screwdriver when a torque is recommended or required by manufacturer.

6. When conductors larger than 12 AWG are installed on 15-amp or 20-amp circuits, splice 12 AWG pigtails for device connections.

7. Tighten unused terminal screws on device.

8. Device Plates:
a. Do not use oversized or extra deep plate.
b. Repair wall finishes and remount outlet box when standard device plate does not fit flush or does not cover rough wall opening. c. All switch, receptacle, occupancy sensor, and time switch plates shall be permanently identified with the panelboard and circuit number of the power circuit supplying the device. Adhesive tags and labels are not allowed.

3.2 SWITCH INSTALLATION
A. Switch, General Purpose:

1. Install with switch operation in vertical position.

2. Install single-pole, two-way switch such that toggle is in up position when switch is on.

3.3 RECEPTACLE INSTALLATION
A. Duplex Receptacle:

1. Install with grounding slot up, except where horizontal mounting is shown, in which case install with neutral slot up.

2. Weatherproof Receptacle:
a. Install in cast metal box.
b. Install such that hinge for protective cover is above receptacle opening.

3. Ground Fault Interrupter: Install feed-through model at locations where ground fault protection is specified for "downstream" conventional receptacles.

4. Special-Purpose Receptacle: Install in accordance with manufacturer's

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instructions.

3.4 DEVICE PLATE INSTALLATION
A. Securely fasten to wiring device; ensure tight fit to box.

B. Flush Mounted: Install with all four edges in continuous contact with finished wall surface without use of mat or similar material. Plaster fillings will not be acceptable.

C. Surface Mounted: Plate shall not extend beyond sides of box, unless plate has no sharp corners or edges.

D. Install with alignment tolerance to box of 1/16 inch.

E. Type (Unless Otherwise Shown):

1. Office Areas: Metal.

2. Other Areas: Metal.

3. Exterior:
a. Switch: Weatherproof.
b. Receptacle: Weatherproof Type 2.

4. Interior:
a. Flush-Mounted Box: Metal.
b. Surface-Mounted, Metal Box: Cast.
c. General Purpose Areas: Sheet Steel.
d. Other Areas: Cast.
e. Surface Mounted, Sheet Steel Box: Raised sheet steel. f. Receptacle Shown as Weatherproof on Drawings: Weatherproof Type 2.

3.5 IDENTIFICATION
A. All switch, receptacle, occupancy sensor, and time switch plates shall be permanently identified with the panelboard and circuit number of the power circuit supplying the device.

B. Use engraved nameplates or stamped metallic tags for identification of individual devices. Attach with screws, stainless steel wire, or silicon based adhesive caulk.

C. Where a tag or nameplate is impractical, and only when approved by the District Engineer, identify the device plate with indelible marker using neatly applied block lettering. (Sharpie, fine point, permanent marker)
D. Adhesive tags and labels, and printed tape are not allowed. See Section 26 05 05 – Conductors

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E. Identify conductors with durable wire markers or tags inside outlet boxes.

3.6 FIELD QUALITY CONTROL
A. Perform tests and inspections, and prepare test reports.

B. Verify circuit identification on device plate.

C. Test Instrument for 125-Volt 20-Amp Receptacle: Digital wiring analyzer with digital readout or illuminated LED indicators of measurement.

D. Using test plug, verify device and its outlet box are securely mounted.

E. Line Voltage Range: 105 volts to 132 volts.

F. Percent Voltage Drop under 15-Amp Load: Less than 6 percent; 6 percent or higher is not acceptable.

G. Ground Impedance: 2 ohms, maximum.

H. GFCI Trip: Test for tripping values specified in UL 1436 and UL 943.

I. Tests shall be diagnostic, indicating damaged conductors, high resistance at circuit breaker, poor connections, inadequate fault current path, defective devices, or similar problems. Correct circuit conditions, remove malfunctioning units and replace with new ones, and retest as specified above.
**END OF SECTION**

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SECTION 16400

ELECTRICAL DISTRIBUTION EQUIPMENT
PART 1 - GENERAL

1.1 SECTION INCLUDES
A. Panelboards.

B. Circuit breakers.

C. Disconnects.

D. Fuses.

1.2 REFERENCES
A. NEMA AB1 - Molded Case Circuit Breakers.

B. NEMA KS1 - Enclosed Switches.

C. NEMA PB1 - Panelboards.

D. NEMA PB1.1 - Instructions for Safe Installation, Operation and Maintenance of Panelboards Rated 600 Volts or Less.

E. ANSI/UL 198C - High Interrupting Capacity Fuses; Current Limiting Types.

F. ANSI/UL 198E - Class R Fuses.

1.3 SUBMITTALS
A. Panelboards: Shop drawings and product data.

B. Circuit Breakers: Product data, typical test reports.

C. Disconnects: Product data.

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D. Fuses: Product data.

PART 2 - PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS
A. Panelboards: Square D, Cutler Hammer, Eaton, or as approved.

B. Circuit Breakers: Square D, Cutler Hammer or as approved C. Disconnects: Square D, Cutler Hammer or as approved
D. Fuses: Bussman or as approved

2.2 PANELBOARDS
A. General

1. Panelboards shall be surface or flush mounted as shown on the drawings and shall be dead- front, consisting of an enclosure, a removable interior unit, and a removable front cover with door.

2. The panelboards shall be provided with main circuit breakers and number of breakers as shown on the drawings.

3. The panelboard enclosures shall be NEMA Type 12 unless otherwise indicated on the drawings and shall conform to UL Standard UL-50.

4. Enclosures for outdoor installation shall be NEMA Type 3R, fabricated from extra heavy gauge sheet steel, hot-dipped galvanized after fabrication and provided with doors and drip shield.

5. Enclosures shall be provided with hinged cover and lock.

6. All locks shall be keyed alike.

7. Fronts shall be furnished with adjustable trim clamps for securing the front to the box.

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8. Size of breakers and rating of main lugs shall be as indicated.

9. Panels shall be for operation on voltage, number of phases, and number of wires shown on the drawings.

10. Multipole circuit breakers shall be the common trip type with a single operating handle.

11. Each panelboard shall be equipped with a full capacity isolated neutral bus and a bonded equipment bus, unless otherwise specified on the drawings.

B. 480V - 120/208V Power Center

1. Bus Bars shall be copper.

2. Branch breakers shall be plug-in type.

C. 277/480 Panelboards

1. Bus Bars shall be copper.

2. Branch breakers shall be plug-in type.

D. Distribution

1. Fronts shall be hinged to box whenever box height is 60" or greater.

2. In addition to the directory, a 1/2 inch high plastic embossed self sticking tape shall be attached next to each branch breaker identifying the breaker function.

3. Bus Bars shall be copper.

E. Directory Holder

1. A directory holder with protective covering shall be provided on the inside of each door and completely labeled by the Contractor.

2. The directory shall be typed.

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3. Hand-lettering or marking is not acceptable.

F. Panelboard Schedules

1. Where panelboard schedules are provided, they shall be used by the contractor as a guide for circuitry, phase balancing, and ordering of panelboards.

G. Spare Breakers

1. Each panel shall be provided with a minimum of 25% spare breakers, whether shown on drawing or schedule, proportioned in number to the size or sizes of breakers being used for each frame size.

H. Spaces

1. Each panel shall be provided with a minimum of 25% spaces, whether shown on drawing or schedule.

2. Spaces shall include all necessary bus and accessories, ready to accommodate future breakers.

3. All spaces shall include blank cover.

2.3 CIRCUIT BREAKERS
A. Quick-make, quick-break molded-case circuit breakers, manually operated.

B. Thermal/magnetic indicating type common trips.

C. Shunt trips and other auxiliaries where applicable or indicated.

D. Interrupting rating for circuit breakers in 120/208 volt panels shall be not less than 10,000 amperes RMS Symmetrical.

E. Interrupting rating for circuit breakers in 277/480-volt panels shall be not less than 14,000 amperes RMS symmetrical.

F. Ground fault protection, as scheduled or indicated.

G. Voltage and ampacities, as scheduled or indicated.

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H. Circuit breakers shall conform to NEMA Standard AB-1.

I. All 15 and 20 ampere single pole breakers shall be SWD rated.

2.4 DISCONNECTS
A. Fused or unfused ampacities and number of poles, as scheduled, indicated or required.

B. Surface mounted, heavy duty, single throw.

C. Horsepower rated.

D. Positive quick-make, quick-break operating mechanism.

E. Interlocked door and operating handle padlockable in "OFF" position.

F. NEMA 12 enclosures for interior applications, NEMA-3R for exterior applications.

2.5 FUSES
A. UL Class L Fuses: Time delay, highly current limiting use in bolted pressure and high pressure contact switches. 200,000 AIC. Bussman low-peak, or as approved.

B. ANSI/UL Class RK5 Fuses: Time delay, for all applications not specified or indicated otherwise. 200,000 AIC. Bussman Fustron, or as approved.

PART 3 - EXECUTION

3.1 PANELBOARDS
A. Panelboards shall be installed as shown on the drawings and in accordance with the manufacturer's installation instructions.

B. For flush mounted panelboards, stub extra conduits (25 percent of actual used but not less than 4 each) for future branch circuits. Where conduits are stubbed from the top and bottom of the same panelboard, conduit ends -

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either top or bottom, shall be capped.

C. Panelboards shall be mounted so that the height of the top operating handle will not exceed 6 feet from the floor.

D. Ground panelboard enclosure and ground bus.

E. Directories shall be type-written to indicate load served by each circuit and shall be mounted in holder behind protective covering.

3.2 CIRCUIT BREAKERS
A. Group mounted in panelboards or individually mounted in circuit breaker enclosure.

B. Ground circuit breaker enclosures.

3.3 DISCONNECTS
A. Wall mounted at locations indicated.

B. Ground disconnect enclosures.

3.4 FUSES
A. Install in fuse holders so that the ratings are visible from the front. **END OF SECTION**

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SECTION 16460

DISTRIBUTION TRANSFORMERS
PART 1 - GENERAL

1.1 SECTION INCLUDES
A. Dry-type transformers

1.2 REFERENCES
A. ANSI/NEMA-ST1 - Specialty Transformers.

B. ANSI/NEMA-ST20 - Dry-Type Transformers for General Applications.

C. ANSI/NEMA-TP1 – Guide for Determining Energy Efficiency for Distribution Transformers.

1.3 SUBMITTALS
A. Product Data.

PART 2 - PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS
A. Square D.

B. Acme Electric
C. General Electric.

D. Jefferson.

2.2 QUALITY ASSURANCE
A. Standard cataloged units of manufacturers listed.

2.3 DRY-TYPE TRANSFORMERS

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A. General purpose dry-type, outdoor enclosures.

B. Double winding.

C. Electrostatic shield winding where indicated.

D. NEMA taps, two 2-1/2 percent below and two 2-1/2 percent above.

E. Sound Levels:

Transformer
Rating Sound Level
0 – 9 KVA 37 dB
10 – 30 KVA 41 dB
31 – 112-1/2 KVA 45 dB
F. 150 degrees C temperature rise rating and Class 220 insulation.

G. Energy efficient, NEMA TP1 compliant.

H. Refer to drawings for individual transformer ratings.

PART 3 - EXECUTION

3.1 DRY-TYPE TRANSFORMERS
A. Install at locations indicated.

B. Floor mounted, provide 3 inch housekeeping pad and manufacturer recommended anchor bolts, with adequate working and ventilation clearances.

C. Install transformers with sound levels greater than 45 dB on resilient vibrationisolating mountings to prevent amplification of sound.

D. Ground transformer enclosures, secondary neutrals, and shielding.

E. Adjust winding taps to insure proper voltage at end use points.

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**END OF SECTION**

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SECTION 16499

COMMISSIONING OF ELECTRICAL SYSTEMS
PART 1 - GENERAL

1.1 SUBMITTALS
A. Informational Submittals:

1. Submit 30 days prior to performing inspections or tests:
a. Schedule for performing inspection and tests.
b. List of references to be used for each test.
c. Sample copy of equipment and materials inspection form(s). d. Sample copy of individual device test form.
e. Sample copy of individual system test form.

2. Submit test or inspection reports and certificates for each electrical item tested within 30 days after completion of test:

3. Operation and Maintenance Data:
a. In accordance with Section 01400 Operation and Maintenance Manual. b. After test or inspection reports and certificates have been reviewed by Engineer and returned, insert a copy of each in Operation and Maintenance Manual.

1.2 QUALITY ASSURANCE
A. Testing Firm Qualifications:

1. Corporately and financially independent organization functioning as an unbiased testing authority.

2. Professionally independent of manufacturers, suppliers, and installers of electrical equipment and systems being tested.

3. Employer of engineers and technicians regularly engaged in testing and inspecting of electrical equipment, installations, and systems.

4. Supervising engineer accredited as Certified Electrical Test Technologist by NICET or NETA and having a minimum of 5 years' testing experience on similar projects.

5. Technicians certified by NICET or NETA.

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6. Assistants and apprentices assigned to Project at ratio not to exceed two certified to one noncertified assistant or apprentice.

7. Registered Professional Engineer to provide comprehensive Project report outlining services performed, results of such services, recommendations, actions taken, and opinions.

8. In compliance with OSHA CFR 29, Part 1910.7 criteria for accreditation of testing laboratories or a full member company of NETA.

B. Test equipment shall have an operating accuracy equal to or greater than requirements established by NETA ATS.

C. Test instrument calibration shall be in accordance with NETA ATS. Test equipment shall have been calibrated within 12 months of said test. A calibration sticker shall be affixed to test equipment indicating calibration date.

1.3 SEQUENCING AND SCHEDULING
A. Coordinate testing with other work. Testing, review, and approval shall occur prior to equipment being placed into service. Multiple testing sessions may be required.

B. Perform inspection and electrical tests after equipment listed herein has been installed.

C. Perform tests with apparatus de-energized whenever feasible.

D. Inspection and electrical tests on energized equipment shall be:

1. Scheduled with City prior to de-energization.

2. Minimized to avoid extended period of interruption to the operating plant equipment.

E. Notify Engineer at least 24 hours prior to performing tests on energized electrical equipment.

PART 2 - PRODUCTS (NOT applicable)
PART 3 - EXECUTION

3.1 GENERAL
A. Tests and inspections shall establish:

1. Electrical equipment is operational within industry and manufacturer's tolerances and standards.

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2. Installation operates properly.

3. Equipment is suitable for energization.

4. Installation conforms to requirements of Contract Documents and NFPA 70, NFPA 70E, NFPA 101, and IEEE C2.

B. Perform inspection and testing in accordance with NETA ATS, industry standards, and manufacturer's recommendations.

C. Adjust mechanisms and moving parts of equipment for free mechanical movement.

D. Adjust and set electromechanical electronic relays and sensors to correspond to operating conditions, or as recommended by manufacturer.

E. Verify nameplate data for conformance to Contract Documents and approved Submittals.

F. Realign equipment not properly aligned and correct unlevelness.

G. Properly anchor electrical equipment found to be inadequately anchored.

H. Tighten accessible bolted connections, including wiring connections, with calibrated torque wrench/screw driver to manufacturer's recommendations, or as otherwise specified in NETA ATS.

I. Clean contaminated surfaces with cleaning solvents as recommended by manufacturer.

J. Provide proper lubrication of applicable moving parts.

K. Inform Engineer of working clearances not in accordance with NFPA 70.

L. Investigate and repair or replace:

1. Electrical items that fail tests.

2. Active components not operating in accordance with manufacturer's instructions.

3. Damaged electrical equipment.

M. Electrical Enclosures:

1. Remove foreign material and moisture from enclosure interior.

2. Vacuum and wipe clean enclosure interior.

3. Remove corrosion found on metal surfaces.

Section 16499

COMMISSIONING OF ELECTRICAL SYSTEMS

EL CENTRO WWTP MODIFICATIONS
JUNE 2024 16499-4

4. Repair or replace, as determined by City or Engineer, door and panel sections having dented surfaces.

5. Repair or replace, as determined by City or Engineer, poor fitting doors and panel sections.

6. Repair or replace improperly operating latching, locking, or interlocking devices.

7. Replace missing or damaged hardware.

8. Finish:
a. Provide matching paint and touch up scratches and mars. b. If required due to extensive damage, as determined by City or Engineer, refinish entire assembly.

N. Replace fuses and circuit breakers that do not conform to size and type required by the Contract Documents or approved Submittals.

O. Replace transformer insulating oil not in compliance with ASTM D923.

3.2 CHECKOUT AND STARTUP
A. Voltage Field Test:

1. Check voltage at point of termination of power company supply system to Project when installation is essentially complete and is in operation.

2. Check voltage amplitude and balance between phases for loaded and unloaded conditions.

3. Record supply voltage (all three phases simultaneously on same graph) for 24 hours during normal working day.
a. Submit Voltage Field Test Report within 5 days of test.

4. Unbalance Corrections:
a. Make written request to power company to correct condition if balance (as defined by NEMA) exceeds 1 percent, or if voltage varies throughout the day and from loaded to unloaded condition more than plus or minus 4 percent of nominal.
b. Obtain written certification from responsible power company official that voltage variations and unbalance are within their normal standards if corrections are not made.

B. Equipment Line Current Tests:

1. Check line current in each phase for each piece of equipment.

Section 16499

COMMISSIONING OF ELECTRICAL SYSTEMS

EL CENTRO WWTP UV DISINFECTION IMPROVEMENTS
JUNE 2024 16499-5

2. Make line current check after power company has made final adjustments to supply voltage magnitude or balance.

3. If phase current for a piece of equipment is above rated nameplate current, prepare Equipment Line Phase Current Report that identifies cause of problem and corrective action taken.

3.3 LOW VOLTAGE CABLES, 600 VOLTS MAXIMUM
A. Visual and Mechanical Inspection:

1. Inspect each individual exposed power cable for:
a. Physical damage.
b. Proper connections in accordance with single-line diagram. c. Cable bends not in conformance with manufacturer's minimum allowable bending radius where applicable.
d. Color coding conformance with specification.
e. Proper circuit identification.

2. Mechanical Connections For:
a. Proper lug type for conductor material.
b. Proper lug installation.
c. Bolt torque level in accordance with NETA ATS, Table 100.12, unless otherwise specified by manufacturer.

3. Shielded Instrumentation Cables For:
a. Proper shield grounding.
b. Proper terminations.
c. Proper circuit identification.

4. Control Cables For:
a. Proper termination.
b. Proper circuit identification.

5. Cables Terminated Through Window Type CTs: Verify neutrals and grounds are terminated for correct operation of protective devices.

B. Electrical Tests for Conductors:

1. Insulation Resistance Tests:
a. Utilize 1,000-volt dc megohmmeter for 600-volt insulated conductors and 500-volt megohmmeter for 300-volt insulated conductors.

Section 16499

COMMISSIONING OF ELECTRICAL SYSTEMS

EL CENTRO WWTP UV DISINFECTION IMPROVEMENTS
JUNE 2024 16499-6
b. Test each conductor with respect to ground and to adjacent conductors for 1 minute.
c. Evaluate resistance values by comparison with conductors of same length and type.
d. Investigate values less than 50 megohms.

2. Continuity test by ohmmeter method to ensure proper cable connections.

C. Low-voltage cable tests may be performed by installer in lieu of independent testing firm.

All tests shall be performed in the presence of the City or Engineer or inspector, documented and submitted for review.

3.4 SAFETY SWITCHES, 600 VOLTS MAXIMUM
A. Visual and Mechanical Inspection:

1. Proper blade pressure and alignment.

2. Proper operation of switch operating handle.

3. Adequate mechanical support for each fuse.

4. Proper contact-to-contact tightness between fuse clip and fuse.

5. Cable connection bolt torque level in accordance with NETA ATS, Table 100.12.

6. Proper phase barrier material and installation.

7. Verify fuse sizes and types correspond to one-line diagram or approved Submittals.

8. Perform mechanical operational test and verify interlocking system operation and sequencing.

B. Electrical Tests:

1. Insulation Resistance Tests:
a. Applied megohmmeter dc voltage in accordance with NETA ATS, Table 100.1.
b. Phase-to-phase and phase-to-ground for 1 minute on each pole. c. Insulation resistance values equal to, or greater than, resistance values established by manufacturer.

2. Contact Resistance Tests:
a. Contact resistance in microhms across each switch blade and fuse holder.
b. Investigate deviation of 50 percent or more from adjacent poles or similar switches.

Section 16499

COMMISSIONING OF ELECTRICAL SYSTEMS

EL CENTRO WWTP UV DISINFECTION IMPROVEMENTS
JUNE 2024 16499-7

3.5 MOLDED AND INSULATED CASE CIRCUIT BREAKERS
A. General: Inspection and testing limited to circuit breakers rated 70 amperes and larger and to motor circuit protector breakers rated 50 amperes and larger.

B. Visual and Mechanical Inspection:

1. Proper mounting.

2. Proper conductor size.

3. Feeder designation according to nameplate and one-line diagram.

4. Cracked casings.

5. Connection bolt torque level in accordance with NETA ATS, Table 100.12.

6. Operate breaker to verify smooth operation.

7. Compare frame size and trip setting with circuit breaker schedules or one-line diagram.

8. Verify that terminals are suitable for 75 degrees C rated insulated conductors.

C. Electrical Tests:

1. Insulation Resistance Tests:
a. Utilize 1,000-volt dc megohmmeter for 480-volt and 600-volt circuit breakers.
b. Pole-to-pole and pole-to-ground with breaker contacts opened for 1 minute.
c. Pole-to-pole and pole-to-ground with breaker contacts closed for 1 minute.
d. Test values to comply with NETA ATS, Table 100.1.

2. Contact Resistance Tests:
a. Contact resistance in microhms across each pole.
b. Investigate deviation of 50 percent or more from adjacent poles and similar breakers.

3. Primary Current Injection Test to Verify:
a. Long-time minimum pickup and delay.
b. Short-time pickup and delay.
c. Ground fault pickup and delay.

Section 16499

COMMISSIONING OF ELECTRICAL SYSTEMS

EL CENTRO WWTP UV DISINFECTION IMPROVEMENTS
JUNE 2024 16499-12
d. Instantaneous pickup by run-up or pulse method.
e. Trip characteristics of adjustable trip breakers shall be within manufacturer’s published time-current characteristic tolerance band, including adjustment factors.
f. Trip times shall be within limits established by NEMA AB 4, Table 5-3. Alternatively, use NETA ATS, Table 100.7.
g. Instantaneous pickup value shall be within values established by NEMA AB 4, Table 5-4. Alternatively, use NETA ATS, Table 100.8.

3.6 GROUNDING SYSTEMS
A. Visual and Mechanical Inspection:

1. Equipment and circuit grounds in motor control center, panelboard, switchboard, and switchgear assemblies for proper connection and tightness.

2. Ground bus connections in motor control center, panelboard, switchboard, and switchgear assemblies for proper termination and tightness.

3. Effective transformer core and equipment grounding.

4. Accessible connections to grounding electrodes for proper fit and tightness.

5. Accessible exothermic-weld grounding connections to verify that molds were fully filled and proper bonding was obtained.

B. Electrical Tests:

1. Fall-of-Potential Test:
a. In accordance with IEEE 81, Section 8.2.1.5 for measurement of main ground system's resistance.
b. Main ground electrode system resistance to ground to be no greater than 3 ohm(s).

2. Two-Point Direct Method Test:
a. In accordance with IEEE 81, Section 8.2.1.1 for measurement of ground resistance between main ground system, equipment frames, and system neutral and derived neutral points.
b. Equipment ground resistance shall not exceed main ground system resistance by 0.25 ohm.
**END OF SECTION**

APPENDIX A
TrojanUV Layout Drawings, Revision D

APPENDIX B
TrojanUV Submittal, Revision C

El Centro, CA
810206
Water
Confidence™

IMPORTANT CONTACTS

HEAD OFFICE - CANADA
Trojan Technologies
3020 Gore Road,
London, Ontario,
Canada, N5V 4T7
Tel.: +519 457 3400
Fax: +519 457 3030
http://www.trojanuv.com
TOLL FREE NUMBER:
1-800-291-0218
TOLL FREE FAX NUMBER:
1-800-291-0083
If you are unable to reach your Local Representative and have a TECHNICAL EMERGENCY, contact TROJAN TECHNOLOGIES’ TECHNICAL ASSISTANCE CENTER:

Toll Free Phone: 1-866-388-0488
Email: [email protected]
TROJANUV3000PLUS™

SUBMITTAL

Water
Confi dence™
The UV System in this manual 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.trojanuv.com.

COPYRIGHT © 2023 by Trojan Technologies

ALL RIGHTS RESERVED
No part of this publicaƟ on may be reproduced, stored in a retrieval system, or transmiƩ ed in any form or by any means without wriƩ en permission of Trojan Technologies.

Document #: SU810206 Completed By: ADG Date: 23AP10
Customer Revision: C Checked By: JRN Date: 23AP12
Approved By: HM Date: 23AP12

Water
Confi dence™

TABLE OF CONTENTS

OVERVIEW
Company Background
CerƟfi cates
ISO 9001 Certificate of Registration
ISO 14001 Certificate of Registration

PROJECT & SYSTEM DESCRIPTION
Project DescripƟ on
System DescripƟ on

PRODUCT INFORMATION
Product OperaƟ ons and Maintenance Manual
Water Level Control Device - InstallaƟ on and OperaƟ on and Maintenance Manual (Weir) InstrucƟ on, Level Sensor Control Box O&M / InstallaƟ on InstrucƟ on, TrojanUV Solo Lamp™ Cable RouƟ ng Inside PDC InstrucƟ on, TrojanUV Hose Assembly Field ConnecƟ on
TrojanUV - InstrucƟ on, Reference Sensor Procedure
InstrucƟ on, TrojanUV Solo Lamp™ Cable InstallaƟ on Guideline UV4000 Removal InstrucƟ ons

INSTRUMENTATION DRAWINGS & CUT SHEETS
Electrode Water Level Sensor
UV Intensity Sensor
Bank in Place Proximity Sensor

MECHANICAL DRAWINGS & CUT SHEETS
Operator’s Kit
Hose Kit
Warning Sign UV Light
Lamp Specifi caƟ on
Lamp Driver Specifi caƟ on
Solo™ Lamp Sleeve, SG0031D01 - Rev B
Cable Management - Spiral Wrap

Water
Confi dence™

ELECTRICAL DRAWINGS & CUT SHEETS
System Control Center (SCC)
3410090 - Rev. A
Bill of Materials / Catalogue Data (Major Components Only) Power DistribuƟ on Center (PDC)
341010 - Rev. A
Bill of Materials / Catalogue Data (Major Components Only) Hydraulic System Center (HSC)
E810206H1 - Rev. A
E810206H2 - Rev. A
SG0024 - HSC G4 Assy - Rev. C
907717C, Sheet 15 - Wiper/Lift Hydraulic Diagram - Rev. AA Bill of Materials / Catalogue Data (Major Components Only) Level Sensor Control Box (LCP)
340393G - Rev. G
Bill of Materials / Catalogue Data (Major Components Only)

CONTROLS PHILOSOPHY
CP810206 - Rev 1.1

CALCULATIONS & CERTIFICATIONS
CalculaƟ ons
TrojanUVSigna™ Headloss Calculation
TrojanUVSigna™ Dose Calculation
CerƟfi caƟ ons
TrojanUVSigna™ Validation Test Certification
TrojanUVSolo™ Lamp 1000W PSS Measurement
TrojanUVSolo™ End of Lamp Life Factor Letter
TrojanUVSolo™ Fouling Factor Letter

WARRANTIES
Equipment Limited Warranty
Amalgam Lamp Limited Warranty
Lamp Driver Limited Warranty
UV Intensity Limited Warranty
Performance Guarantee
Warranty Claim Form
Lamp Recycling Program & Form
SAFETY DATA SHEETS ΈSDSΉ
Hg Lamps
AcƟ Clean™ Gel
Mobil DTE 10 Excel 15
Food Machinery Grease

Overview
Water
Confidence™

SECTION CONTENTS
Company Background
Certificates
ISO 9001 Certificate of Registration
ISO 14001 Certificate of Registration

Water
Confidence™
Overview

Overview
Water
Confidence™
Overview
Overview
Company Background
Trojan Technologies is part of Danaher Corporation’s environmental platform. Danaher is a Fortune 200, global science and technology leader.

Trojan Technologies encompasses six businesses: Aquafine, Trojan Marinex, TrojanUV, Salsnes Filter, US Peroxide and VIQUA. The products and services provided by these businesses play vital roles in making various stages of the water treatment process more effective, efficient and sustainable.

Aquafine
Aquafine’s advanced UV water treatment systems meet the changing requirements and needs of a diverse customer
base around the world. They provide UV solutions for TOC reduction, chlorine and chloramine destruction, ozone
destruction and disinfection for many applications in the industrial/commercial sector.

Salsnes Filter
Salsnes Filter’s patented filter technology removes particles from municipal and industrial process water. Industries such as food, paper, cruise lines and aquaculture use the fullyautomated treatment technology to treat effluent, improve the quality of influent or enhance the utilization of raw materials.

Trojan Marinex
Trojan Marinex is dedicated to the development of ballast water treatment solutions. Having direct access to decades of industry-defining water treatment expertise has enabled them to develop a suite of systems unlike any other. These systems are purpose-built for the marine environment and provide filtration + ultraviolet disinfection in a single, compact unit.

TrojanUV
TrojanUV designs, manufactures and sells pressurized
and open-channel UV disinfection systems for municipal
wastewater and drinking water, and UV-oxidation systems for environmental contaminant treatment applications.

US Peroxide
US Peroxide provides performance-driven, full-service
environmental treatment programs to help purify water,
wastewater, soil and air. Applications include turn-key odor and corrosion control solutions for municipal wastewater and drinking water treatment; refinery, gas, oil and petrochemical wastewater applications; industrial wastewater and air quality treatment; in-situ remediation; and UV-oxidation.

Water
Confidence™
Overview
Overview
VIQUA
VIQUA is a leading water treatment technology company
focused on providing customers with confidence in their water.

In over 100 countries, VIQUA UV systems are disinfecting water in homes, apartment complexes, manufacturing
facilities, campgrounds, resorts, hotels and hospitals.

Trojan Technologies continually strives to develop industry-defining technology, making a significant investment each year to ensure unparalleled discovery and development (~5.0% annual investment in R&D).

The Trojan Technologies mission statement:

We enable customers to meet their water quality objectives by providing eco-efficient solutions that reduce and recover costs, energy, resources and space.

Collaboratively solving problems with our customers, we deliver low-risk, innovative technologies that offer sustainable results.

We ensure greater water confidence and environmental stewardship for people, industries and municipalities, improving the lives of over one billion people globally.

Certificates
The certificates are included on the following pages.

ISO 9001 Certificate of Registration

Water
Confidence™
Overview

Overview

Water
Confidence™
Overview

Overview
Project & System Description

PROJECT

DESCRIPTION
& SYSTEM

DESCRIPTION
Water
Confidence™

SECTION CONTENTS
Project Description
System Description

Water
Confidence™
Project & System Description
Project & System Description

Water
Confidence™
Project & System Description
Project & System Description
Project Description
Project Name El Centro, CA
Trojan Project Number 810206
Peak Flow 16 MGD
Average Flow 6 MGD
Minimum Flow 2 MGD
Peak Hydraulic Flow 8 MGD per Channel
Future Flow 24 MGD (12 MGD per Channel)
Total Suspended Solids < 30 mg/L Based on a 30 Day Average Percent Transmittance 62 % Minimum at 253.7nm
Disinfection Standards < 200 Fecal Coliform / 100mL Based on a 30 Day Geometric Mean

Water
Confidence™
Project & System Description
Project & System Description

Water
Confidence™
Project & System Description
Project & System Description
System Description
Descriptions & Requirements
System Control Center ( SCC ) Quantity: 1 Weight: 700lbs / 320kg PLC Controller: Allen Bradley CompactLogix 1769-L33ER
Operator Interface: Allen Bradley PanelView Plus 7 Performance 10” Lan Protocol: Ethernet/IP
Panel Enclosure Material: 304SST
Enclosure Rating: Type 4X
Panel Mounting: Custom
Refer to SCC Drawings for Electrical and Component Details Power Distribution Center ( PDC ) Quantity: 2 Weight: 1000lbs / 454kgs
Power Distribution Center Material: 304SST
Enclosure Rating: Type 4X
Refer to PDC Drawings for Electrical and Component Details Hydraulic System Center ( HSC ) Quantity: 2 Weight: 350lbs / 159kgs Hydraulic Fluid: Mobil DTE 10 Excel 15
Enclosure Material: 304SST
Enclosure Rating: Type 4X
Enclosure Mounting: Floor
Refer to HSC Drawings for Electrical and Component Details TrojanUVSigna™ Bank Quantity: 6 Weight: 370lbs / 168kgs Number of UV Lamps per Bank: 8
ActiClean™ Cleaning System (ACS): Included
UV Bank Material: 316 SST, Quartz, Teflon™
Rating: Type 6P
Cable Management: Spiral Wrap
Lamp Cables: Integrated Plug & **65’ (20m) Cable included (One (1) per lamp) **Refer to Project Layout Drawings for allowable routing distance.

TrojanUVSigna™ Bank Frame Quantity: 4 Weight: 150lbs / 68kgs Number of UV Banks to Support: Up to Two (2) UV Banks
Bank Frame Material: 316SST
Bank Frame Hardware: Eighteen (18) Wedge Anchors Included per Frame, 3/8” dia. x 3.75” long UV Intensity Sensor Quantity: 6 Weight: ----
Number Required per UV Bank: One (1)
Interconnection Cable: Sensor to PDC

Water
Confidence™
Project & System Description
Project & System Description
Bank in Place Proximity Sensor Quantity: 6 Weight: ---- Number Required per UV Bank: One (1)
Interconnection Cable: Sensor to PDC
Electrode Level Sensor Quantity: 2 Weight: ----
Water Level Detection: Low
Number per UV Channel: One (1)
Electrical Requirements: 12 VDC - 2 Conductor
Level Sensor Control Box Quantity: 2 Weight: 50lbs / 23kgs Number per UV Channel: One (1)
Enclosure Material: 304SST
Enclosure Rating: Type 4X
Enclosure Mounting: Wall
Refer to Level Sensor Control Box Drawings for Electrical and Component Details Level Control Fixed Weir Quantity: 2 Weight: ----
Level Controller Material: 316SST
Refer to Project Layout Drawings & Water Level Control Device Manual Hose Kits Quantity: 6 Weight: ----
Hose Lengths: ** 20’ (6m)
Hydraulic Fitting Material: 316SST
**Refer to Project Layout Drawings for allowable routing distance.

Operator Kit Quantity: 1 Weight: ----
Start-Up Provisions are Provided in Addition to the Operator Kit Quantities Warning Sign Quantity: 2 Weight: ----
Spare Equipment
Spare UV Lamp Assembly Quantity: 8
Spare Quartz Sleeves Assembly Quantity: 4
Spare Lamp Driver Quantity: 4
Spare Wiper Seals Quantity: 8
Spare UV Intensity Sensor Quantity: 1
Signa BCB Board Quantity: 8

PRODUCT INFORMATION
Water
Confi dence™

SECTION CONTENTS
Product OperaƟ ons and Maintenance Manual
Water Level Control Device - InstallaƟ on and OperaƟ on and Maintenance Manual (Weir)
InstrucƟ on, Level Sensor Control Box O&M / InstallaƟ on InstrucƟ on, TrojanUV Solo Lamp™ Cable RouƟ ng Inside PDC InstrucƟ on, TrojanUV Hose Assembly Field ConnecƟ on
TrojanUV - InstrucƟ on, Reference Sensor Procedure
InstrucƟ on, TrojanUV Solo Lamp™ Cable InstallaƟ on Guideline UV4000 Removal InstrucƟ ons

PRODUCT

INFORMATION

Water
Confidence™
Product Information
Product Information

TROJANUVSIGNA™
Operation and Maintenance
User Manual
Original Instructions
Edition 8
© Trojan Technologies, 2021. All rights reserved. Printed in Canada. DC340101-08-02

2 Original Instructions
If you require technical assistance, please contact the Technical Assistance Center (TAC) using the information below:

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.

North America: 1-866-388-0488
All other areas: 1-519-457-2318
E-mail: [email protected]

Original Instructions 3
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 Section 3 General Information............................................................................................................ 15

3.1 Acceptable Noise Levels............................................................................................................ 15

3.2 Patents and Permissions ........................................................................................................... 15

3.3 Abbreviations and Acronyms ..................................................................................................... 15

3.4 System Overview....................................................................................................................... 16

3.4.1 System Control Center (SCC)........................................................................................... 16

3.4.2 Hydraulic System Center (HSC) ....................................................................................... 16

3.4.3 Power Distribution Center (PDC) ...................................................................................... 16

3.4.4 UV Bank............................................................................................................................ 16

3.4.5 Low Water Electrode Level Sensor................................................................................... 17 Section 4 Lockout Tag Out.................................................................................................................. 19

4.1 Lockout Tag Out Procedure....................................................................................................... 19

4.1.1 Equipment Shutdown........................................................................................................ 19

4.1.2 Deactivate Energy Sources .............................................................................................. 19

4.1.3 Lockout Tag Out Energy Sources..................................................................................... 20

4.1.4 Lockout Tag Out PDC for Individual Bank Compartments................................................ 20

4.1.5 Verify the Lockout ............................................................................................................. 20

4.2 Remove the Lockout Tag Out.................................................................................................... 20 Section 5 Startup and Shutdown ....................................................................................................... 21

5.1 Startup the UV System .............................................................................................................. 21

5.2 Shutdown the UV System.......................................................................................................... 21

5.2.1 Shutdown Procedure for the SCC..................................................................................... 21

5.2.2 Shutdown Procedure for PDC........................................................................................... 21

5.2.3 Shutdown Procedure for the HSC..................................................................................... 22

5.3 Long Term Storage (i.e. Winterization) Procedures................................................................... 22

5.3.1 UV System - UV Banks Lifted out of UV Channel Option ................................................. 22

5.3.2 UV System - UV Banks Lowered in UV Channel Option .................................................. 22

5.3.3 UVT Controller and Sensor............................................................................................... 23

5.4 Startup after Extended Periods of Time..................................................................................... 23 Section 6 Shipment and Storage........................................................................................................ 25

6.1 How the Equipment is Shipped.................................................................................................. 25

6.2 Storage Requirements............................................................................................................... 25

6.3 Overview of Equipment Connections......................................................................................... 25

6.4 Startup and System Commission............................................................................................... 25 Section 7 Installation........................................................................................................................... 27

7.1 Tools and Materials.................................................................................................................... 27

7.2 System Control Center............................................................................................................... 28

7.2.1 Mounting the SCC............................................................................................................. 28

7.3 Power Distribution Center.......................................................................................................... 29

7.3.1 Mounting the PDC............................................................................................................. 29

7.4 Hydraulic System Center ........................................................................................................... 32

7.4.1 Mounting the HSC............................................................................................................. 32

7.4.2 Electrical Installation ......................................................................................................... 34

7.5 Bank Frame Assembly............................................................................................................... 35

7.6 UV Bank..................................................................................................................................... 38

7.6.1 Install UV Bank(s) ............................................................................................................. 38

7.6.2 Install Bank Lift Cylinders.................................................................................................. 42

4 Original Instructions
Table of Contents

7.7 UV Bank in Place Sensor ...........................................................................................................43

7.8 Cable and Wire Routing .............................................................................................................45

7.8.1 Lamp Cables .....................................................................................................................45

7.8.2 Field Wire(s) ......................................................................................................................45

7.8.3 Bond Wire(s)......................................................................................................................45

7.9 Hydraulic Hose ...........................................................................................................................46

7.9.1 Connect the Hydraulic Hoses to the Lift and Wipe Cylinders............................................46

7.10 Cable Management ..................................................................................................................48

7.10.1 Install Cable Management Assemblies on UV Bank .......................................................50

7.10.2 Install Lamp Cables and Hydraulic Hoses in Bracket Assemblies ..................................52

7.11 Hydraulic Hose Connections ....................................................................................................55

7.11.1 Hydraulic Hose Fittings and Connections........................................................................55

7.11.2 Bleed the Hydraulic Hoses ..............................................................................................57

7.12 Lift Cylinder ..............................................................................................................................63

7.12.1 Secure the Lift Cylinder ...................................................................................................63

7.13 UV Bank Support Assembly .....................................................................................................65

7.14 Cable Trough Cable Management - Spiral Wrap .....................................................................68

7.15 Cable Trough Cable Management - Cable Track.....................................................................74

7.16 Level Sensor ............................................................................................................................79

7.17 UVI Sensor(s), Lamp Sleeves and UV Lamps ........................................................................80

7.17.1 Install Sensor Housing.....................................................................................................80

7.18 Electrical Connections..............................................................................................................81

7.18.1 SCC Electrical Connections ............................................................................................81

7.18.2 PDC Electrical Connections ............................................................................................82

7.19 Additional Equipment ...............................................................................................................83

7.19.1 Water Level Controller.....................................................................................................83

7.19.2 UV Transmittance Controller and Sensor........................................................................83 Section 8 Operation .............................................................................................................................85

8.1 Hydraulic System Center............................................................................................................85

8.1.1 HSC Overview...................................................................................................................85

8.1.2 Lift the UV Bank Up/Down.................................................................................................86

8.1.3 Wiper Control Modes.........................................................................................................88

8.1.4 Manually Operate the Wiper..............................................................................................88

8.1.5 Reset HSC Latched Alarms...............................................................................................89

8.2 Power Distribution Center ..........................................................................................................89

8.2.1 Enable PDC Remote Control.............................................................................................89

8.2.2 Enable PDC Local ON.......................................................................................................89

8.3 System Control Center ...............................................................................................................90

8.3.1 Navigate the Human Machine Interface ............................................................................90

8.3.2 Home Screen.....................................................................................................................93

8.3.3 UV Channel Overview Screen...........................................................................................95

8.3.4 UV Bank Overview Screen..............................................................................................100

8.3.5 Wiper Overview Screen...................................................................................................105

8.3.6 Trending Screen Overview..............................................................................................107

8.3.7 Alarm Screen Overview...................................................................................................108

8.3.8 Settings............................................................................................................................108

8.3.9 Information.......................................................................................................................115 Section 9 Maintenance.......................................................................................................................119

9.1 Tools and Materials ..................................................................................................................119

9.2 Maintenance Schedule.............................................................................................................120

9.3 UV Lamp ..................................................................................................................................122

9.3.1 Storage Requirements for Used UV Lamps ....................................................................122

9.3.2 Remove and Install a UV Lamp.......................................................................................122

Original Instructions 5
Table of Contents

9.4 Lamp Sleeve............................................................................................................................ 129

9.4.1 Remove and Install a Lamp Sleeve ................................................................................ 129

9.4.2 Clean Lamp Sleeves Manually ....................................................................................... 131

9.5 UVI Sensor............................................................................................................................... 131

9.5.1 Remove and Install the UVI Sensor................................................................................ 131

9.5.2 Remove and Install UVI Sensor Housing........................................................................ 133

9.5.3 Clean the UVI Sensor Housing Sleeve ........................................................................... 135

9.5.4 Remove and Replace UVI Sensor Housing Sleeve........................................................ 135

9.5.5 Remove and Install UVI Sensor Wiper ........................................................................... 139

9.5.6 Remove and Replace UVI Sensor Wiper O-rings and Fittings ....................................... 140

9.5.7 Remove and Replace UVI Sensor Floor Bushing........................................................... 142

9.6 UV Bank................................................................................................................................... 143

9.6.1 Clean the UV Bank ......................................................................................................... 143

9.6.2 Replace Sleeve Bushing (Floor) ..................................................................................... 144

9.7 Lamp Sleeve Wiper.................................................................................................................. 145

9.7.1 Wiper Plate Fill and Vent Ports ....................................................................................... 145

9.7.2 Fill Wiping System .......................................................................................................... 145

9.7.3 Flush the Wiping System ................................................................................................ 145

9.7.4 Remove and Install a Wiper Canister ............................................................................. 146

9.8 Hydraulic System Center (HSC) .............................................................................................. 150

9.8.1 Inspect the HSC.............................................................................................................. 150

9.8.2 Depressurize Hydraulic System...................................................................................... 151

9.8.3 Replace the Hydraulic Fluid Filter ................................................................................... 152

9.8.4 Drain and Fill the Hydraulic Fluid Reservoir.................................................................... 154

9.8.5 Replace a Hydraulic Hose .............................................................................................. 156

9.9 Hydraulic Cylinders.................................................................................................................. 156

9.9.1 Grease a Wipe Hydraulic Cylinder.................................................................................. 156

9.9.2 Remove and Replace Wipe Hydraulic Cylinder .............................................................. 157

9.9.3 Remove and Replace Lift Hydraulic Cylinder ................................................................. 162

9.10 Power Distribution Center (PDC)........................................................................................... 167

9.10.1 Replace a UV Lamp Driver ........................................................................................... 167

9.10.2 Clean the AC Filter........................................................................................................ 170 Section 10 Troubleshooting.............................................................................................................. 171

10.1 Resolving Alarms................................................................................................................... 171

10.1.1 Latched Alarms ............................................................................................................. 171

10.1.2 Non-Latched Alarms ..................................................................................................... 171

10.2 SCC Alarms ........................................................................................................................... 172

10.2.1 Critical Alarms............................................................................................................... 172

10.2.2 Major Alarms................................................................................................................. 172

10.2.3 Minor Alarms................................................................................................................. 174

10.3 UV Bank................................................................................................................................. 175

10.4 Channel.................................................................................................................................. 179

10.5 System................................................................................................................................... 181

10.6 Hydraulic System Center ....................................................................................................... 184

10.7 Power Distribution Center...................................................................................................... 186 Section 11 Replacement Parts.......................................................................................................... 187

11.1 UV Lamp and Lamp Sleeve................................................................................................... 187

11.1.1 Lamp Sleeve Ports Top ................................................................................................ 188

11.2 UV Bank................................................................................................................................. 188

11.3 UVI Sensor and Sleeve.......................................................................................................... 189

11.4 UVI Sensor Wiper .................................................................................................................. 190

11.5 Wiper Canister Assembly ...................................................................................................... 190

11.6 Hydraulic System Center ....................................................................................................... 191

11.7 Hydraulic Cylinder.................................................................................................................. 192

6 Original Instructions
Table of Contents

11.8 Power Distribution Center ......................................................................................................193

11.9 System Control Center ...........................................................................................................193

11.10 Miscellaneous.......................................................................................................................193

Original Instructions 7
Section 1 Specifications
Specifications are subject to change without notice.

General
Water temperature range 1°C to 40°C (33.8°F to 104°F)
Channel Frame and UV Bank
Weight
# Lamps
UV Bank
(Fully Assembled) Channel Frame
Kg Lbs Kg Lbs
8 168 370 68 150
10 186 410 77 170
12 206 450 86 190
14 223 490 95 210
16 241 530 104 230
18 259 570 113 250
20 277 610 123 270
22 295 650 132 290
24 314 690 141 310
UV lamp type TROJANUV Solo Lamp™ (1000 W)
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 Maximum hose length (includes rise and
run) from HSC to UV Bank Refer to notes in project layout drawing Power Distribution Center
Voltage Refer to Component Label or Electrical Drawings Enclosure Rating Refer to Component Label or System Description Material Weight
454 kgs (1000 lbs) - Single Cabinet
726 kgs (1600 lbs) - Double Cabinet
Refer to Component Label for actual weight
Cooling Type
with Forced Air (no A/C)
Note: Must be suitable for
electrical distribution and
drive equipment
with Air Conditioner (A/C)
Installation Location Indoor only Indoor / Outdoor (Outdoor with Sunshades)
Ambient Temperature Limit -20°C to 30°C (-4°F to 86°F) -20°C to 43°C (-4°F to 109°F) Maximum Distance between PDC to UV
Bank Edge
Refer to notes in project layout drawing, 14AWG, four (4) conductor, tray cable

8 Original Instructions
Specifications
System Control Center (SCC)
Voltage Refer to Component Label or Electrical Drawings Enclosure Rating
Material Refer to Component Label or System Description Weight
UVI Sensor
Output range 4 to 20 mA current loop (2 wire)
Supply voltage 24 VDC from the PDC
Water Level Sensor
Supply voltage Refer to Electrical Drawings
System Certification
UL, CE available

Original Instructions 9
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. Do not use or install this equipment in any manner other than that specified in installation manual.

2.1 Use of Hazard Information

2.2 Precautionary Labels
Read all labels and tags attached to the instrument. Personal injury or damage to the instrument could occur if not observed.

DANGER
Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING
Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE
Indicates a situation that is not related to personal injury.

Electrical equipment marked with this symbol may not be disposed of in European public disposal systems. In conformity with European local and national regulations (EU Directive 2002/96/EC), European electrical equipment users must now return old or end-of life equipment to the Producer for disposal at no charge to the user.

Note: For recycling, please contact the equipment producer or supplier for instructions on how to return end-of-life equipment, producer-supplied electrical accessories, and all auxiliary items for proper disposal. No equipment is to be returned without authorization. Local recycling programs may be used. For the manufacturer recycling UV lamp program or producer-supplied electrical accessories and auxiliary items, contact the equipment supplier for proper disposal instructions.

This symbol indicates there is Mercury present.

This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential injury. When on the equipment, refer to the Operation and Maintenance manual for additional safety information.

This symbol indicates a risk of electrical shock and/or electrocution exists.

This symbol indicates the marked item has stored energy. Obey procedures to wait 5 (five) minutes after disconnecting main power, to allow stored energy to dissipate.

This symbol indicates the marked item is a pressurized device. Obey all procedures to safely depressurize.

This symbol indicates the marked item could inject fluid into the skin.

Hg

10 Original Instructions
Safety Information
This symbol indicates the components of the system have been exposed to biohazardous waste and / or aerosols.

This symbol indicates a potential crushing pinch hazard.

This symbol indicates a lifting clearance hazard.

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.

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 gloves.

This symbol indicates the presence of devices sensitive to Electro-static Discharge (ESD). Proper care must be taken to prevent damage to the equipment.

This symbol indicates the marked item should not be touched.

This symbol indicates a risk of electrical shock and/or electrocution exists, and that all appropriate lockout tag out procedures must be obeyed.

This symbol indicates to secure the device with a safety device / hook.

This symbol indicates a safety glasses with side protection is required for protection against UV exposure.

UV

Original Instructions 11
Safety Information

2.3 Safety Precautions
Read the safety precautions in this section before installing. Obey the instructions in the safety precautions.

Failure to follow the instructions in the safety precautions can result in serious injury or death.

This symbol indicates a UV rated full face shield is required. Faces shields are to be worn with safety glasses or safety goggles.

This symbol indicates gloves must be worn.

This symbol indicates safety boots must be worn.

This symbol indicates hearing protection is required.

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.

This symbol indicates that you must contact your local your Service Provider for assistance.

DANGER
Arc Flash and Shock Hazard - Live Electrical Circuit Present. • Failure to follow these instructions will result in electrical shock, injury or death from electrocution. • Equipment should be accessed by competent personnel only. • Devices inside this equipment contain stored energy.
• NEVER work inside this equipment until at least 5 (five) minutes after disconnecting main power to allow stored energy to dissipate.
• Lockout tag out all sources of power before performing any inspection, repair, or maintenance.

There may be more than one source of power!
DANGER
Shock Hazard.
• Failure to use manufacturer approved parts, including UV Lamps, may result in significant thermal damage to insulation systems which may result in the exposure of live parts.

12 Original Instructions
Safety Information
DANGER
Depressurize Device. Fluid Injection Hazard.
• Failure to depressurize hydraulic circuit before servicing will result in serious injury or death due to high pressure hydraulic fluid.
• NEVER physically inspect, repair or do maintenance unless hydraulic circuit has been depressurized by competent personnel.
• Protect hands, face and body before disconnecting hydraulic or other lines. • If accidental skin injection occurs, seek immediate medical attention.

DANGER
Fall Hazard.
• Failure to follow these instructions will result in injuries due to fall. • Always use appropriate fall resistant procedures and equipment while working near an uncovered channel, when a fall hazard is present, in compliance with local regulations.

WARNING
Personal Injury Hazard.
• Use of parts not approved by the manufacturer may cause personal injury, damage to the UV system or malfunction of the UV System and may void the manufacturer’s warranty. • Use of UV Lamps and Lamp Drivers, not approved by the manufacturer, will void UL and CE product safety certifications.
• The parts listed in Section 11 are approved by the manufacturer.

WARNING
Body Crush Hazard.
• Failure to follow these instructions could result in serious injury or death due to improper lifting procedures, underrated lifting equipment and, moving parts. • ALWAYS secure with safety device.
• ALWAYS stay clear of elevated loads.
• ALWAYS comply with local safety regulations.

WARNING
Pinch Hazard.
• Failure to follow these instructions could result in serious injury or death due to moving parts. • ALWAYS keep hands clear of this area.

CAUTION
Burn Hazard.
• Failure to follow these instructions may result in minor or moderate injury due to burns. • NEVER touch hot surface.
• Allow UV lamps to cool for a minimum of 10 (ten) minutes before handling. • If accidental exposure occurs, immediately cool affected area. Consult physician.

Original Instructions 13
Safety Information

CAUTION
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.

CAUTION
UV Light Hazard.
• Failure to follow these instructions may result in serious burns to unprotected eyes and skin. • ALWAYS use UV protective gear, including gloves, clothing, and face shield when UV light is present.
• NEVER look directly at illuminated UV lamp, even with protective gear. • NEVER illuminate UV lamp if personnel may be directly exposed to UV light.

NOTICE
Mercury Chemical
• UV lamps contain a small amount of mercury in either elemental or bound amalgam state, depending on lamp type. These lamps are similar to fluorescent and compact fluorescent lamps (CFL). Always comply with local regulations governing the disposal of lamps containing mercury and the waste associated with breakage.
• NEVER use a vacuum cleaner to clean up broken lamps containing mercury. Vacuuming could spread mercury-containing powder or vapor.
• 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 TrojanUV Technical Assistance Center at [email protected].

NOTICE
Personal Protective Equipment Required.
• ALWAYS use appropriate eye, hand, and foot protection. • ALWAYS wear UV-C safety glasses when around equipment or a UV-C faceshield with safety glasses or safety goggles when inspecting open running equipment. • ALWAYS follow plant safety procedures and protocols.
• ALWAYS take necessary precautions when working around, operating, or working on this equipment, if contamination of components is expected within this application due to effluent biological or chemical contaminants.

UV
Hg

14 Original Instructions
Safety Information
Notes: 1) Dispose of contaminated parts/components as per country requirements. 2) Refer to the Safety Data Sheets for accidental exposure to materials.

NOTICE
Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this manual. Maintain the continuity of the lockout tag out between shifts. If you do not understand the information or procedure explanations in this manual, STOP.

NOTICE
The TrojanUVSigna® has been validated through microbial testing. Through this testing, performance data has been generated for UV dose delivery to inactivate 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. For more information go to www.P65Warnings.ca.gov.

Original Instructions 15
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. In the interest of continued product development, the manufacturer reserves the right to make improvements in this manual and the products it describes at any time, without notice or obligation.

3.1 Acceptable Noise Levels
The airborne noise emissions, A-weighted emission sound pressure level, is below 80dB(A). When working within 10 feet of the air conditioner hearing protection must be worn.

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.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without written permission of Trojan Technologies.

3.3 Abbreviations and Acronyms
Table 1 describes the abbreviations and acronyms included in this manual.

Table 1 Abbreviations and Acronyms
Abbreviation/Acronym Description
BCB Bank Control Board
ESD Electro-Static Discharge
HMI Human Machine Interface
HSC Hydraulic System Center
kgs Kilograms
lbs Pounds
PDC Power Distribution Center
SBC Sensor Base Control
SCADA System Control and Data Acquisition
SCC System Control Center
UPS Uninterruptible Power Supply
UV Ultraviolet
UVI UV Intensity
UVT UV Transmittance

16 Original Instructions
General Information

3.4 System Overview
The system is an open-channel, UV system that uses high-output amalgam UV lamps in an inclined, staggered array for use with Municipal waste water.

The system includes:

3.4.1 System Control Center (SCC)
The SCC monitors and controls all UV functions, including dose pacing. Dose pacing is an automatic, effluent parameter based program that maintains a constant performance while conserving power and extending UV lamp life.

3.4.2 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.

ActiClean Sleeve Cleaning System
Dual-action cleaning system uses mechanical wiping in conjunction with a cleaning solution contained within wiper canisters surrounding the quartz sleeves. This system operates automatically, without operator involvement. Quartz sleeves and intensity sensors are cleaned regularly without disrupting operation.

3.4.3 Power Distribution Center (PDC)
The PDC contains lamp drivers that power and control the UV lamps.

3.4.4 UV Bank
A UV bank consists of UV Lamps, positioned in a staggered, inclined array.

Figure 1 System Overview
1 Hydraulic System Center 2 System Control Center
3 Power Distribution Center 4 UV Bank
5 UV Channel (by others) 6 Level Controller (options) (not shown) 7 Low Water Level Sensor (not shown) 8 High Water Level Sensor (optional) (not shown) 3 2 1
5 4

Original Instructions 17
General Information

3.4.5 Low Water Electrode Level Sensor
One low water electrode level sensor is located in each channel between the furthest downstream UV bank and the level controller. If a preset low water level condition exists, the UV lamps will de-energize and remain off until the proper water level is present.

18 Original Instructions
General Information

Original Instructions 19
Section 4 Lockout Tag Out
The procedure in Section 4.1 is the minimum lockout requirement. Use additional precautions, as needed.

Obey all site-specific protocols.

4.1 Lockout Tag Out Procedure

4.1.1 Equipment Shutdown
Contact the plant manager or shift supervisor for help regarding equipment location and identification.

1. Ensure that no hazards will be created by equipment shutdown.

2. Shut down all equipment that will need Lockout Tag Out.

3. Ensure that all moving parts come to a complete stop.

4.1.2 Deactivate Energy Sources
A hazardous energy source is any energy source that can cause serious personal injury or death. The potential hazardous energy sources in this system are:

1. Identify and deactivate the main isolating device of each energy source:
• Electrical energy (Incoming power)
• Hydraulic (Hydraulic Pressure)
• Thermal (Thermal energy)
• UV Light (Radiation Energy)
• Mechanical (Kinetic Energy)

2. Disconnect all electrical equipment from power:
• Disconnect all electrical equipment
• Power off and disconnect electrical power to hard-wired equipment

3. Dissipate stored electrical energy in lamp drivers.

4. Close all shut-off valves.

DANGER
Obey all warning and caution statements. Refer to Section 2.

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.

Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance.

UV

20 Original Instructions
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
• Date of the lockout

3. Apply a personal lock.

4.1.4 Lockout Tag Out PDC for Individual Bank Compartments

1. Select the appropriate PDC compartment for the UV Bank to be shutdown (i.e Bank 1A and PDC compartment Bank 1A).

2. Follow standard lockout tag out procedures.

4.1.5 Verify the Lockout

1. Ensure that the meter is working correctly with a test before and after measuring the de-energized source:
a. Test the voltmeter to a known, energized 24 VAC/120 VAC source. b. Use the same voltmeter to test the locked-out energy sources to verify that there is no voltage. c. Test the voltmeter again to a known, energized 24 VAC/120 VAC source.

2. Ensure that the stored energy sources have dissipated.

3. Try to start the de-energized equipment.

4.2 Remove the Lockout Tag Out
When the work is finished and the system has been restored to full operational condition, the lockout tag out can be removed.

1. Ensure that no hazards will be created by removal of the lockout.

2. Obey manufacturer’s instructions and safe work procedures to energize and start the equipment.

Original Instructions 21
Section 5 Startup and Shutdown

5.1 Startup the UV System

1. Ensure that all circuit breakers in the UV system are ON.

2. Ensure that the PDC and HSC doors are properly closed.

3. Turn the selector switches on all PDCs to or (OFF) position (Section 8.2).

4. Ensure that the UV Banks are in the Home position. If not, turn on power at HSC and lower the UV Bank to Home position (Section 8.1.2).

5. Ensure that all solid grating sections are in place.

6. Ensure that the HSC is in or (REM) wipe mode for all UV Banks and the Mode Selector Switch is at or (REM) position (Section 8.1).

7. Ensure at SCC, system mode is set to or (OFF) (Section 8.2).

8. Switch on all power to the PDC and SCC.

9. Turn disconnect on HSC and PDC to or (ON) (Section 8.1.1 and Section 8.2.1).

10. Turn the selector switches on all PDCs to the or (REM) position (Section 8.2).

11. Go back to SCC and set system mode to Auto (Section 8.2).

5.2 Shutdown the UV System

5.2.1 Shutdown Procedure for the SCC

1. Home Screen → Channel Overview Screen → Select individual UV Bank button → Change UV Bank model to REMOTE OFF.

2. Repeat step 1 for all remaining UV Banks.

5.2.2 Shutdown Procedure for PDC

1. PDC mode selector switch → or (OFF).

2. PDC disconnect → or (OFF) (Section 8.2).

3. Lockout Tag Out the upstream main high voltage supply to the PDC (Section 4).

DANGER
Obey all warning and caution statements. Refer to Section 2.

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.

Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance.

22 Original Instructions
Startup and Shutdown

5.2.3 Shutdown Procedure for the HSC

1. Turn all UV Bank wiper mode switches → or (OFF).

2. HSC disconnect → OFF (Section 8.1).

3. Lockout Tag Out the upstream main high voltage supply to the HSC (Section 4).

5.3 Long Term Storage (i.e. Winterization) Procedures
In some instances, waste water treatment plants are only required to have seasonal operation. If this is the case for your plant, please follow the procedures listed to winterize the UV Equipment.

5.3.1 UV System - UV Banks Lifted out of UV Channel Option The following procedures outline winterization procedures for a plant that continues flow through the UV Equipment while not in operation.

1. Shutdown the UV System by doing one of the following steps:
a. Follow the Shutdown Procedure from the SCC. Refer to Section 8.2.1.

OR
b. Turn all PDC mode selector switches to the or (OFF) position.

Note: DO NOT turn the PDC disconnect switches to the or (OFF) position.

2. Lift UV Banks Up (Section 8.1.2).

3. Remove any debris from the UV Bank.

4. Flush the wiping system (Section 9.7.3).

5. Grease the wiping cylinders (Section 9.9.1).

6. If lamps and lamp sleeves are being left in the UV Bank, ensure all lamp plugs are installed.

7. If lamps are being removed for storage, re-install all lamp plugs into the sleeve sockets.

8. If lamps and sleeves are being removed, cover the lamp plugs with a protective (i.e. waterproof) bag and secure to prevent moisture penetration.

9. Cover UV Bank with tarp to avoid snow or ice buildup in the UV Bank.

10. Make sure that the enclosure doors for the SCC, HSC(s) and PDC(s) are securely closed.

Note: HSC's may be optionally covered with a tarp to prevent snow or ice buildup.

5.3.2 UV System - UV Banks Lowered in UV Channel Option The following procedures outline winterization procedures for a plant that either diverts flow around the UV Channel OR continues flow through the UV Equipment while not in operation.

1. Shutdown the UV System by doing one of the following steps:
a. Follow the Shutdown Procedure from the SCC. Refer to Section 8.2.1.

OR
b. Turn all PDC mode selector switches to the or (OFF) position.

Note: DO NOT turn the PDC disconnect switches to the or (OFF) position.

NOTICE
Ensure power is retained to all panels [i.e. SCC, PDC(s), HSC(s)] by leaving disconnects on for all equipment. Failure to leave panels energized can lead to condensation or corrosion of electronic components. Damage caused by condensation or corrosion of electronic components due to inadequate winterization procedure is not covered by Trojan's warranty.

Original Instructions 23
Startup and Shutdown

2. Lift UV Banks Up (Section 8.1.2).

3. Remove any debris from the UV Bank.

4. Flush the wiping system (Section 9.7.3).

5. Grease the wiping cylinders (Section 9.9.1).

6. If there will be effluent present in the UV Channel over the winterization period:
a. Remove the Lamp Sleeves (Section 9.4.1) and the UVI Sensor Housing (Section 9.5.2). Store UV Lamps, Lamp Sleeves, UVI Sensor(s) and the UVI Sensor Housing in a location in accordance to Section 6.
b. Cover the lamp plugs with a protective (i.e. waterproof) bag and secure to prevent moisture penetration.

7. If effluent will not be present in the UV Channel over the winterization period, follow steps 6 and 7 in Section 5.3.1.

8. Lift UV Banks Down (Section 8.1.2).

9. Make sure that the enclosure doors for the SCC, HSC(s) and PDC(s) are securely closed.

Note: HSC's may be optionally covered with a tarp to prevent snow or ice buildup.

5.3.3 UVT Controller and Sensor

1. Shut down all power to UVT controller.

2. Disconnect the UVT sensor from the controller.

3. Clean the UVT sensor, especially the optical path. Dry the UVT sensor.

4. Disconnect the controller. Store both the controller and sensor in a dry, clean location where the temperature is above freezing.

5.4 Startup after Extended Periods of Time

1. Inspect for damaged, worn or cracked wiping system hoses and seals.

2. Flush the wiping system (Section 9.7.3).

3. Fill the wiping system (Section 9.7.2).

4. Grease the wiping cylinders (Section 9.9.1).

5. Clean any debris from the UV Bank.

6. Install UV Lamps into UV Bank, if previously removed (Section 9.3.2).

7. Install UVI Sensor Housing (Section 9.5.2) and UVI Sensor (Section 9.5.1) if previously removed.

8. Lift UV Banks down (Section 8.1.2).

9. Start Up the UV System (Section 5.1).

NOTICE
Use either diluted acid or bleach to clean the UVT sensor. Do not use both.

24 Original Instructions
Startup and Shutdown

Original Instructions 25
Section 6 Shipment and Storage
The following instructions outline the duties and responsibilities of the contractor on receiving the system.

The contractor assumes responsibility for the system after it has arrived at the project site.

These instructions define the minimum requirements for care of the equipment prior to commissioning by the Trojan Service Department. Additional care must be demonstrated by the contractor, as necessary, to ensure that the equipment is not damaged.

6.1 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(s), part number(s) and project number. Other labels identify components which are fragile or breakable and components which must be kept dry.

On receiving the Trojan bank frame and UV banks, unpack and inspect for physical damage. Contact your nearest Trojan Technologies representative in case of missing parts or damage.

Note: The system is usually shipped as separate pieces - Bank frame, UV banks and Electrical Panels.

6.2 Storage Requirements
The manufacturer recommends indoor storage of the equipment. The equipment should be stored in a dry warehouse. Heating is not necessary during storage. However, before system startup, the equipment must be warmed to greater than 15ºC (60ºF) for a period of 24 hours.

Storage area conditions:
• Ambient air temperature between -25ºC to 55ºC (-13ºF to 130ºF) • Ambient Relative humidity from 5% to 100%, condensing environment • Free from dust and dirt ingress
• Must not contain corrosive or explosive gases
• Free from salt air
• Vermin free
Note: ActiClean Gel must be stored in a non-freezing environment.

If indoor storage is not possible, the UV Bank(s), HSCs and PDCs may be stored outdoors, with additional conditions:
• Equipment is stored on high ground that is not susceptible to flooding. • Equipment is elevated to a minimum height of 300 mm above the ground or as appropriate to prevent flooding.
• Equipment is completely covered with waterproof tarps to prevent exposure to the elements (e.g., rain, snow, sand, dust, etc.). Tarps must be tight fitting, attached securely and examined regularly. Water and snow accumulation should be removed regularly.
• Storage crates should not be exposed to direct sunlight. • Equipment can be stored in sea containers.

6.3 Overview of Equipment Connections
Refer to the electrical and layout drawings provided by Trojan Technologies. If the supplied layout drawings does not match the site conditions, contact Trojan Technologies for assistance.

6.4 Startup and System Commission
After the UV system has been shipped, the contractor will be issued documentation for a startup request.

These documents must be completed and returned to the issuer before a commission date can be scheduled.

26 Original Instructions
Shipment and Storage

Original Instructions 27
Section 7 Installation
An appropriate sized crane will be required for off-loading and installation of systems. The size of the crane is dependent on each project configuration. Refer to Section 1 and to project documentation for assembled weights of the components. Use additional precautions, as needed. Obey all site-specific protocols.

7.1 Tools and Materials
DANGER
Obey all warning and caution statements. Refer to Section 2.

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.

Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance.

Symbols Description Symbols Description
Wrench - Open Crimping Tool
Socket Wrench and Socket Power Drill with Bits
Adjustable Wrench Heat Gun
Funnel Hydraulic Fluid
Hex Key Level
Lint-free Cloth (Kimwipes®) Lifting Straps (properly rated for equipment load)
Slotted Screwdriver Trowel
Tape Measure Pliers - Needlenose
Wrench - Torque Grout (by others)
Shallow Bowl JIC Straight Union
Hydraullic
Fluid
1 2 3 4 5

28 Original Instructions
Installation

7.2 System Control Center

7.2.1 Mounting the SCC
Prerequisites:
• Clear area where SCC will be installed. Refer to the project layout drawings.

Note: For outdoor installations, the HMI must be positioned away from the sun.

Tools:

Materials:
• Anchor bolts (by others)
• Electrical Drawings, Electrical Interconnect Drawings, provided Procedure:

1. Connect lifting straps to the lifting lugs on the SCC. Lift the SCC enclosure into the final installed position.

2. Mark the anchor points on the wall. Lift and set aside SCC enclosure.

Note: It is recommended to position the HMI height at a height that an operator can easily read the screen.

3. Drill anchor bolt holes and install 6 mm (1/4 inch) anchors.

Wrench - Combination Wrench - Socket
Anti-Seize Spreader Bar (properly sized and rated
for equipment load)
Bucket Tray to catch oil
Symbols Description Symbols Description
Anti-Seize
1 2 3 4 5

Original Instructions 29
Installation

4. Lift and install the SCC enclosure onto the anchors. Secure with mounting hardware as per local codes. Remove lifting straps.

Note: For floor mounted SCC’s, follow the same steps as outlined for installing a single PDC (Section 7.3.1).

7.3 Power Distribution Center

7.3.1 Mounting the PDC
Prerequisites:
• Refer to layout drawings for PDC location.
• Clear area where PDC will be installed.
• Refer to Electrical Wiring Diagram, Interconnect Drawing and Layout Drawings provided for additional information.

Tools:

Materials:
• Anchor bolts (by others)
• Shims (if required, by others)
Procedure:

Figure 2 SCC
1 SCC HMI 3 Panel mounting lugs
2 Panel lifting lugs

30 Original Instructions
Installation
Single PDC:

Dimension A* = 573mm (22.59”)
Dimension B* = 560mm (22.05”)
Reference C* = Front of PDC
Mounting Hole Diameter = 22mm (0.87”)
Notes: 1) Install anchor bolts as per civil engineering drawings and/or contract specifications.
2) Level the PDC in both directions (Top to bottom and front to back). Use shims as required.
3) Fill gap (if any) between the feet and the floor with shims. 1 A*
B*
C*
A
B
x4
x4
2 A x4
B
3 x4

Original Instructions 31
Installation
Double PDC:

Dimension A* = 573mm (22.59”)
Dimension B* = 560mm (22.05”)
Dimension C* = 203mm (7.98”)
Reference D* = Front of PDC
Mounting Hole Diameter = 22mm (0.87”)
Notes: 1) Install anchor bolts as per civil engineering drawings and/or contract specifications.
2) Level the PDC in both directions (Top to bottom and front to back). Use shims as required.
3) Fill gap (if any) between the feet and the floor with shims. 1 A*
B* C* B*
A
B
x8
x8
D*
2 A x8
B
3 x8

32 Original Instructions
Installation

7.4 Hydraulic System Center

7.4.1 Mounting the HSC
Prerequisites:
• Refer to project layout drawing for HSC placement.
• Clear area where HSC will be installed.

Notes: 1) Keep bends and elevation changes in the hydraulic hoses to a minimum. 2) The maximum hose distance for the HSC is 15.2 m (50 feet).

Tools:

Materials:
• Anchor hardware (by others)
Procedure:

Figure 3 HSC Assembly Mounting and Connections
1 Mounting Holes (4x) 4 Gland Plate
Low Voltage (Left Side)
High Voltage (Right Side)
2 Lifting sling access 5 Disconnect Handle (optional)
3 Hydraulic Ports
5 4
3 2
1 404
[ 1’ - 4” ]
632
[ 2’ - 1” ]
16 [ 5/8” ]
27 [ 1 - 1/16” ]
x4
1 2
4 3 5

Original Instructions 33
Installation
Note: Install lifting straps as required to safely lift and lower the HSC.

Note: Level the HSC in both directions (Top to bottom and front to back.
x4
A
B
1 x4
A
B
2 3 x4
x4
A
B
4

34 Original Instructions
Installation

7.4.2 Electrical Installation
Prerequisites:
• 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 4. • Refer to Electrical Wiring Diagram, Interconnect Drawing and Layout Drawings provided for additional information.

Tools:
• Hydraulic Knock out
Materials:
• Electrical Drawings, Electrical Interconnect Drawings, provided Procedure:

1. Locate label on Gland Plate:
• Green (Left side is for low voltage connections)
• Red (Right side of gland plate is for high voltage connections)

2. Remove gland plate to be drilled on site, noting the orientation of the plastic washers (Figure 4).

3. Use the hydraulic knockout device to add holes to the HSC aluminum gland plate for incoming power feed and all applicable field wiring. Ensure the orientation of conduit holes for power and control wiring match the label.

4. Install the power feed and all applicable field wiring. Include a local disconnect. Obey all local codes for main incoming power supplies.

Note: All openings created on the cabinets MUST be filled with equipment marked with the same type rating, as the enclosure (Ex: Cable Strain Reliefs).

5. Reinstall gland plate, torque nuts noting orientation of plastic washers (Figure 4). 3/16”

Original Instructions 35
Installation

7.5 Bank Frame Assembly
Prerequisites:
• Refer to Project Layout Drawings provided by the manufacturer for install location. • The Bank Support Assembly is strapped to the Bank Frame for shipping purposes. Remove and set aside, until it is the time for installation (Section 7.13).

Tools:

Materials:
• Anchors (provided)
Procedure:

Figure 4 HSC - Gland Plate Assembly
1 Gasket 4 Flat Washer
2 Gland Plate 5 Splitlock Washer
3 Plastic Washer 6 Hex Nut
NOTICE
DO NOT remove the frame support located in the middle of the frame assembly. Remove only after the bank frame grouting is complete.
1 2
3 4
5 6
17 mm
1 2 3 4 5
17 mm
Anti-Seize

36 Original Instructions
Installation
Note: Make sure orientation of Frame Assembly aligns with layout drawings.

Note: Level mounting frame assembly side to side and front to back.

Notes: 1) Level the top brackets on the straight edges to ensure proper installation.
2) Make sure the bracket hardware is loose and able to move freely.
1 2
= =
45°
3 x6
A
B
x8
4 A
B
C
A
B
C
x8
x6

Original Instructions 37
Installation
Note: Apply anti-seize to fastening hardware.

Note: Place grout in between bank frame and channel wall. DO NOT allow grout to fill the inside slots of the bank frame.

Note: Remove wood forms after grout has completely dried. 5 90º 90º
A
B
x4
6 x2
7 1
3 8
x2

38 Original Instructions
Installation

7.6 UV Bank

7.6.1 Install UV Bank(s)
Prerequisites:
• Clean and remove all debris from the UV Channel and from the Bank Frame Assembly. • Install Bank Frame Assembly. Refer to Section 7.5.
• Remove Bank Lift Cylinder brackets from hydraulic cylinder mounts located at the top of the UV Bank. Set aside.

Tools:
• Hoist Ring (x2)
Materials:
• Cylinder Brackets (provided)
• Cylinder Bracket hardware (provided)
Procedure:

Note: The angle braces can be recycled where facilities exist. 9 A
B
17 mm

Original Instructions 39
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.

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.
1 A
B
C
2 3 4

40 Original Instructions
Installation
Note: Retain the guide bracket and mounting hardware for later use.

Note: Retain the lock pin and bushings for later use.
5 6
A
B
7 A
B
C
8

Original Instructions 41
Installation
Note: Once the UV Bank touches the frame, begin to lower the crane boom to allow the UV Bank to slide into the track.

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.
9 10
11 12
A
C
B
x2

42 Original Instructions
Installation

7.6.2 Install Bank Lift Cylinders
Prerequisites:
• Install UV Bank. Refer to Section 7.6.1.

Tools:

Materials:

Procedure:
13 A
C
B
x2
5mm
Anti-Seize

Original Instructions 43
Installation

3. Repeat procedure for remaining lift cylinder.

7.7 UV Bank in Place Sensor
Prerequisites:
• Lift UV Bank down. Refer to Section 8.1.2.
• Lockout Tag Out devices as required. Refer to Section 4. • Install partial grating as per site requirements.

Tools:

Materials:

Procedure:

NOTICE
The Bank In Place Sensors and the spacers are shipped attached to the UV Banks and Bank Frame. Adjust as required. 1 A
B
B
A
x4
C
2 1 2 3 4 5 3mm 5mm

44 Original Instructions
Installation
Bank A Side Installation
Note: Adjust and align sensor to ensure there is a 7mm gap between sensors. * Sensor bracket is opaque.

Bank B Side Installation
Note: Adjust and align sensor to ensure there is a 7mm gap between sensors.
1 *7mm
*>13mm
*<4mm
2 *
1 *7mm
*>13mm
*<4mm
2

Original Instructions 45
Installation

7.8 Cable and Wire Routing

7.8.1 Lamp Cables
Procedure:

1. Route a lamp cable from the UV Bank to the PDC. Refer to Layout Drawing.

Note: It is recommended to install temporary cable labels at each end of the Lamp Cables, for example on Bank 1A, Lamp Cable 1, attach a label to each end indicating Bank1-1A or similar.

2. Repeat step 1 for each Lamp Cable.

7.8.2 Field Wire(s)
Procedure:

1. Route all field wiring (i.e. Bank in Place Sensor, UVI Sensor) to the PDC. Refer to UV Layout Drawing.

2. Repeat step 1 for all field wiring connections to appropriate PDC.

7.8.3 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 5.

Note: Each UV Bank is required to have a dedicated bond wire.

Note: Cable spiral wrap is to be installed at a later time.

Figure 5 Bonding Post
1 Bonding Post
1

46 Original Instructions
Installation

7.9 Hydraulic Hose

7.9.1 Connect the Hydraulic Hoses to the Lift and Wipe Cylinders Prerequisites:
• Install HSC. Refer to Section 7.4.1.
• Install Cable Management Assemblies. Refer to Section 7.10.1. * Hydraulic hoses can be routed to either the left or right side of the cylinders. Route the hydraulic hoses toward the cable trough.

Tools:

Materials:
• Plastic hose fitting plug (Shipped attached to hydraulic hoses) Note: Remove the hose fitting plugs and set aside for later use. • Hydraulic Hoses
• Colored Bands - cut to 25mm (1 inch) length
Figure 6 Hydraulic Hose Connections
1 Bank A or Bank C Wipe Cylinder 3 Bank B or Bank D Lift Cylinder 2 Bank A or Bank C Lift Cylinder 4 Bank B or Bank D Wipe Cylinder *
*
*
1 2
3 4

Original Instructions 47
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.

Note: Refer to Section 7.10 for Hydraulic Hose Routing in Cable Management Assemblies. 2 * Refer to Figure 6 for connection locations.

Notes: 1) Ensure that the hose is not kinked, twisted or bent and that there is enough slack while the hoses are in use.
2) Number of connections depends on the site requirements.

Table 2
Connect hoses in order: Bank / Cylinder Connection Point Corresponding HSC Connection Point First Bank A Lift Cylinder, Retract* HSC - Lift, Retract* Second Bank A Wipe Cylinder, Retract* HSC - Wipe, Retract* Third Bank B Lift Cylinder, Retract* HSC - Lift, Retract* Fourth Bank B Wipe Cylinder, Retract* HSC - Wipe, Retract* Fifth - continue with Bank C* and so on
Notes: 1) Install corresponding colored band onto the hydraulic hose (Refer to Figure 6).
2) Temporarily mark opposite end of hose.
3) Route the hose to the corresponding HSC.
2 A
B
C
D

48 Original Instructions
Installation

7.10 Cable Management
The cable management brackets organize the hydraulic hoses, lamp cables, bond wire, and UVI sensor cable and Bank In Place 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 7 for left and right handed UV Bank designations. Refer to the project layout drawings for additional information regarding the cable management bracket location. Cable management brackets are provided in either standard channel depth or deep channel depth (Figure 8). Follow the Cable Management Assembly - Figure 8 and match project details.

Refer to DC000601-017 for installation guidelines for TrojanUV Solo Lamp Cable installation.

Example - Lift Cylinder Circuit Example - Wipe Cylinder Circuit Figure 7 UV Bank Designation
1 Upstream of UV Bank(s) 4 Right side of UV Bank(s)
2 Downstream of UV Bank(s) 5 Effluent flow direction
3 Left side of UV Bank(s)
2a 2b
1 2
3 4
5

Original Instructions 49
Installation
Figure 8 Cable Management - Assemblies
1 Standard Channel Bracket (Right sided shown)
[Used for Channel Depths up to 233.7 cm (92
inches)]
2 Deep Channel Bracket (Left sided shown) [Used
for Channel Depths greater than 233.7 cm (92
inches)]
Figure 9 Lamp Cables and Hydraulic Hoses Routing
1 Lamp Cables 3 Field Wiring (i.e. UVI Sensor, Bank in Place, Bond Wiring) 2 Hydraulic Hoses
Note: Only a few Lamp Cables and Hydraulic Hoses are shown for clarity purpose. 1 2
2 1
2 3
1

50 Original Instructions
Installation

7.10.1 Install Cable Management Assemblies on UV Bank
Prerequisites:
• Refer to the project layout drawings for installation location. • Install UV Bank. Refer to Section 7.6.1.

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).

Standard Channel Bracket Assembly
* Staging Area (Wireway) Note: Adjust bracket arm up or down. 5mm
17 mm 17 mm
1 *
2 13mm
(1/2 inch)

Original Instructions 51
Installation
Note: Tighten Jam Nuts/Bolts to secure Cable Management Assembly.

Deep Channel Bracket Assembly
* Staging Area (Wireway) Note: Distance to be minimum 13mm (1/2 inch) below underside of grating.
3 A
B 4
1 *
2 B
C
A
13mm
(1/2 inch)
13mm
(1/2 inch)

52 Original Instructions
Installation

7.10.2 Install Lamp Cables and Hydraulic Hoses in Bracket Assemblies Prerequisites:
• Install Cable Management Assemblies. Refer to Section 7.10.1. • Install Hydraulic Hoses. Refer to Section 7.9.

Materials:
• Cable Ties
• Cable Spiral Wrap or Cable Track
• TrojanUV Solo Lamp Cable Installation Guideline Instruction, document number DC000601-017.

Procedure:

1. Route Lamp Cables, Hydraulic Hoses, UV Bank in Place, UV Intensity Sensor Cable and Bond Wire into Bracket Assemblies.

2. If Spiral Wrap is supplied, wrap around the following:
a. UV Bank Lamp Cables
b. UV Bank Hydraulic Hoses
Notes: 1) Secure the bracket onto the 8th and 11th holes as shown above the first exposed hole.
2) Bracket installation may be done later, when the UV Bank is lifted.
3 1
8 11
A
B
C

Original Instructions 53
Installation
c. UV Bank in Place Sensor, UV Intensity Sensor and Bond Wire.

3. If cable track is supplied, the cable track installation will be completed in Section 7.15.

4. Refer to Figures (Figure 10, Figure 11 and Figure 12). * 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.
**Add enough hose slack to allow movement when removing lamp and/or lamp sleeve below hose.

NOTICE
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.

Cable Routing through Standard Bracket Assemblies - Spiral Wrap Figure 10 Cable Routing through Standard Bracket Assemblies - Spiral Wrap 1 Top of UV Channel Wall 2 Cable Trough*
3 Bank A 4 Bank B
5 Upstream 6 Downstream
7 Cable Ties 8 Cable Spiral Wrap
9 Hydraulic Hose**
2 4
3 6
5 1 2 1
7 8
9

54 Original Instructions
Installation
* 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.
**Add enough hose slack to allow movement when removing lamp and/or lamp sleeve below hose.

Cable Routing through Standard Bracket Assemblies - Cable Track Figure 11 Cable Routing through Standard Bracket Assemblies - Cable Track 1 Top of UV Channel Wall 2 Cable Trough*
3 Bank A 4 Bank B
5 Upstream 6 Downstream
7 Cable Ties 8 Cable Track
9 Hydraulic Hose**
6 1 2 2 1
3 4
5 7
9 8

Original Instructions 55
Installation
* 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.
**Add enough hose slack to allow movement when removing lamp and/or lamp sleeve below hose.

7.11 Hydraulic Hose Connections

7.11.1 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.

Prerequisites:
• Install HSC. Refer to Section 7.4.1.
• Install Cable Management Assemblies. Refer to Section 7.10.1.

Cable Routing through Deep Channel Bracket Assemblies - Spiral Wrap Figure 12 Cable Routing through Deep Channel Bracket Assemblies - Spiral Wrap 1 Top of UV Channel Wall 2 Cable Trough*
3 Bank A 4 Bank B
5 Upstream 6 Downstream
7 Cable Ties 8 Cable Spiral Wrap
9 Hydraulic Hose**
2 6
5 1 2 1
4 3
7 8
9

56 Original Instructions
Installation
Tools:

Materials:
• Field Connect Hose Fittings Instruction, document number DC000601-019.

Procedure:

Refer to Table 3 for recommended hose installation order. * Refer to Figure 13 for connection locations.

1. Install Field Connect Hose Fittings onto the first hose. Refer to DC000601-019.

Figure 13 Hydraulic Hose Connections at HSC
1 Bank A 7 Lift Extend = Red color
2 Bank B 8 Lift Retract = Yellow color
3 Bank C 9 Wiper Extend = Green Color
4 Bank D 10 Wiper Retract = Blue Color
5 Lift Circuits 11 Front of HSC
6 Wiper Circuits
Table 3
Connect hoses in order: Bank / Cylinder Connection Point Corresponding HSC Connection Point First Bank A Lift Cylinder, Retract* HSC - Lift, Retract* Second Bank A Wipe Cylinder, Retract* HSC - Wipe, Retract* Third Bank B Lift Cylinder, Retract* HSC - Lift, Retract* Fourth Bank B Wipe Cylinder, Retract* HSC - Wipe, Retract* Fifth - continue with Bank C* and so on
5 6
4 7
3 1
2 11
8 9 10
4 3
1 2

Original Instructions 57
Installation

3. Repeat steps 1 and 2 for remaining hydraulic hoses until complete.

7.11.2 Bleed the Hydraulic Hoses
Prerequisites:
• Complete Hydraulic Hose Fittings and Connections. Refer to Section 7.11.1. • Temporarily install 2 Lamp Sleeves per Wiper Plate Assembly. Refer to Section 9.4.1. • Make sure UV Bank is in the full down position.

Note: Pay attention to the orientation of the elbow so that the hoses are not interfering with each other during installation.

NOTICE
The hydraulic system will require constant filling during the recharging of the hose or the reservoir will become too low and damage to the pump may occur.

To avoid aerated fluid from entering the pump, make sure that the fluid in the reservoir does not go below the halfway point throughout the procedure.

Ensure hydraulic oil does not contain entrained air.

All UV banks connected to the HSC will require unions at each UV bank before bleeding wiper and lift hoses of air.

Always use a towel when disconnecting hydraulic hoses from connections. Clean up spills.

Always hold hydraulic hose connections up high, so as to prevent fluid from draining out of open hose connections. 2 A
B
C

58 Original Instructions
Installation
• Make sure the hydraulic cylinders are in the fully retracted position before bleeding the hydraulic lines.

Refer to Figure 14.

Tools:

Materials:
• Short hose (by others)
Procedure:

Figure 14 Hydraulic Cylinder position
Hydraullic
Fluid

Original Instructions 59
Installation
Bleed Lift Cylinder Circuits
Note: Disconnect the Lift Extend Hose (i.e. Red) and Lift Retract Hose (i.e. Yellow) from the Cylinder and connect together with the provided union to create a closed circuit.

Notes: 1) Bank A is shown as an example only. Select the required UV Bank using the Lift UV Bank Selection Switch.
2) Operate the hydraulic pump for 2 minutes or until a solid stream of fluid is coming back into the HSC reservoir.
3) Check hydraulic fluid levels, add fluid as required
(Section 9.8.4).

Notes: 1) When complete, turn the wipe/lift switch to the WIPE position.
2) Depressurize the hydraulic circuit. Refer to Section 9.8.2.

Notes: 1) Connect the Lift Extend Hose (i.e. Red) to the Lift Cylinder. 2) Connect a short hose to the Lift Retract Fitting on the Lift Cylinder, route the opposite end to the bucket.
3) Route Lift Retract Hose (i.e. Yellow) to the bucket.

B
1 A
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
2 A
B
2 min
C
3 A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
4 A
B

60 Original Instructions
Installation

8. Repeat steps 1 - 7 for remaining Lift Circuits.

Note: Lift the UV Bank up, install the bank locking plates. Refer to Section 8.1.2.

Note: Connect the Lift Retract Hose (i.e. Yellow) to the Lift Cylinder.

Note: Lift the UV Bank down. Refer to Section 8.1.2.
5 A
B
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
6 B
A
7 A
B
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D

Original Instructions 61
Installation
Bleed Wipe Cylinder Circuits
Note: Disconnect the Wiper Extend Hose (i.e. Green) and Wiper Retract Hose (i.e. Blue) from the Cylinder and connect together with the provided union to create a closed circuit.

Notes: 1) Bank A is shown as an example only. Select appropriate UV Bank Wiper Mode Switch.
2) Operate the hydraulic pump for 2 minutes or until a solid stream of fluid is coming back into the HSC reservoir.
3) Check hydraulic fluid levels, add fluid as required
(Section 9.8.4).

Notes: 1) When complete, turn the Wiper Mode Switch to OFF position.
2) Depressurize the hydraulic circuit. Refer to Section 9.8.2.

Notes: 1) Connect the Wiper Extend Hose (i.e. Green) to the Wipe Cylinder.
2) Connect a short hose to the Wiper Retract Fitting on the Wipe Cylinder, route the opposite end to the bucket.
3) Route Wiper Retract Hose (i.e. Blue) to the bucket.
1 A
B
2 A
B A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
C
3 A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
4 A
B

62 Original Instructions
Installation

8. Repeat steps 1 - 7 for remaining Wipe Circuits.

Post-Requisites:
• Inspect the hydraulic hose and fittings for leaks. If a leak is seen at a hydraulic fitting, tighten the hydraulic fitting.

Notes: 1) Operate the hydraulic pump until the wiper reaches the bottom.
2) Check hydraulic fluid levels, add fluid as required
(Section 9.8.4).

Note: Connect the Wiper Retract Hose (i.e. Blue) to the Wipe Cylinder.

Note: Retract (Home) the Wiper. Refer to Section 8.1.4. 5 A
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
B
6 A
B
7 A
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
B

Original Instructions 63
Installation
• Remove the Lamp Sleeves (Section 9.4.1) when done.

7.12 Lift Cylinder

7.12.1 Secure the Lift Cylinder
Prerequisites:
• Bleed the Hydraulic Hoses. Refer to Section 7.11.2.

Tools:
• Hoist Ring (x2)
Materials:

Procedure:

Note: Raise the UV Bank to gain access to the clevis pin bracket. Note: Extend hydraulic cylinder to align the mounting hole on the cylinder with clevis pin brackets as shown (Section 8.1.2). 1 2
A
B

64 Original Instructions
Installation
Note: Lift the UV Bank down (Section 8.1.2).

Note: Raise the UV Bank to gain access to the clevis pin bracket. Note: Extend hydraulic cylinder to align the mounting hole on the cylinder with clevis pin brackets as shown (Section 8.1.2). 3 A
B
4 A
B
5 6
B
A

Original Instructions 65
Installation

7.13 UV Bank Support Assembly
Prerequisites:
• Connect the Hydraulic Lines. Refer to Section 7.9.1.

Tools:

Materials:
• Anchors (by others)
Procedure:

Note: Lift the UV Bank down (Section 8.1.2).
7 B
A 8
1 2 3 4 5
19 mm
10mm

66 Original Instructions
Installation
Note: Measure from base of Channel Frame. Notes: 1) Lift the UV Bank. Refer to Section 8.1.2. 2) DO NOT place anything under the lifted UV Bank.

Note: Adjust the width of the support beam mounting brackets to match the width of the UV Channel.

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 1.
1 2032mm
(80”)
2 457 - 609mm
(18” - 24”)
3 A
B
A
B
4 x4

Original Instructions 67
Installation
Note: Adjust the tension hardware until the wear pads align with the UV Bank.

Note: Tighten all UV Bank Support Assembly hardware.
5 x4
A
B
6 A
B
x4
7 8

68 Original Instructions
Installation

7.14 Cable Trough Cable Management - Spiral Wrap
Prerequisites:
• Install Cable Management Assemblies. Refer to Section 7.10.1. • Install Hydraulic Hoses. Refer to Section 7.9.
• Install the Lamp Cables. Refer to Section 7.10.

Tools:

Materials:
• Cable Ties (By others)
Procedure:
• For Standard Channel Bracket Assemblies – refer to Figure 15 and Figure 17. • For Deep Channel Bracket Assemblies – refer to Figure 16 and Figure 17.

Original Instructions 69
Installation
With a Standard Channel Bracket Assembly:

Figure 15 Section View
1 UV Bank B 5 UV Bank A - Trough Bracket
2 UV Bank A 6 Flow Direction
3 Cable Management Assembly 7 Cable Trough
4 UV Bank B - Trough Bracket
2134mm
[84”]
648mm
1 [25-1/2”]
2 3
6 4 5 7

70 Original Instructions
Installation
With a Deep Channel Bracket Assembly:

Figure 16 Section View
1 UV Bank B 5 UV Bank A - Trough Bracket
2 UV Bank A 6 Flow Direction
3 Cable Management Assembly 7 Cable Trough
4 UV Bank B - Trough Bracket
x = 2134mm [84”] - ‘y’ 1
2 3
6 ‘y’
4 5 7
648mm
[25-1/2”]

Original Instructions 71
Installation
With Standard OR Deep Channel Bracket Assembly:

Note: Ensure that there is an offset between UV Bank B and UV Bank A brackets (Figure 17) to allow for the cable bundle to pass freely behind UV Bank A Bracket Assembly.

Figure 17 Plan View
1 UV Bank B 5 UV Bank A - Trough Bracket
2 UV Bank A 6 Flow Direction
3 Cable Management Assembly 7 Cable Trough
4 UV Bank B - Trough Bracket
1 2 3
4 5
7 6

72 Original Instructions
Installation
Note: Lamp Cables, Ground Wire, Bank In Place Cable, and Hydraulic Hoses are not shown in some illustrations for clarity.

A
B
x4
1 A
B
x4
2 3
A
B
C
x4
x2
x4

Original Instructions 73
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.
4a 4b
5 6

74 Original Instructions
Installation

7.15 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 18 Cable Track Installation on One Side of UV Channel Figure 19 Method A Cable Track Installation on Both Sides of UV Channel Figure 20 Method B Cable Track Installation on Both Sides of UV Channel

B A B A B AB A B B AA

B A B A B A

B A B A B A

Original Instructions 75
Installation
Prerequisites:
• Install Cable Management Assemblies. Refer to Section 7.10.1. • Install Lamp Cables and Hydraulic Hoses in Bracket Assemblies. Refer to Section 7.10.2.

Tools:

Materials:
• Cable Track
• Cable Track Mounting Brackets
• Mounting Hardware
Procedure:

Install:

Note: Install Cable Track mounting bracket to the cable management assembly.

Note: Position the cable track in the cable trough as per the project layout drawings.
10 mm
4mm 5mm
1 A
B
2 A
B x2

76 Original Instructions
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. 3 4
A
5 B 6
A
B

Original Instructions 77
Installation
Note: Install the cross bars. Note: Route the cables though the Cable Track as shown.

Note: Lift the UV Bank Up. Refer to Section 8.1.2.
7 A
B 8
9 10
x4
A
B

78 Original Instructions
Installation
Note: Install and anchor the mounting plate on the concrete.

Note: Install Cable Track mounting bracket to the mounting plate. 11 x4
A
B
12 A
B
13 A
B
x2

Original Instructions 79
Installation

7.16 Level Sensor
One low level sensor is located in each channel between the level controller and the UV bank that is farthest downstream. Additionally, a high level sensor may be provided (project dependent) and is installed upstream of the most upstream UV bank in a channel.

Prerequisites:
• Lockout tag out - PDC compartment. Refer to Section 4. • Isolate the Inlet Valve or Gate.
• Refer to the layout drawings provided by Trojan Technologies for installation location.

Tools:

Materials:
• 1/4 inch Anchor hardware (by others)
• Electrical Interconnect Drawings, provided
Procedure:

80 Original Instructions
Installation
Note: All openings created on the cabinets MUST be filled with equipment marked with the same type rating, as the enclosure (Ex: Cable Strain Reliefs).

3. Route and connect the Level Sensor wiring to the Level Sensor Control Box.

7.17 UVI Sensor(s), Lamp Sleeves and UV Lamps

7.17.1 Install Sensor Housing
Prerequisites:
• Install Lamp Sleeves. Refer to Section 9.4.1.
• Install the UVI Sensor.

Materials:

Procedure:

Note: Position the level sensor top wall mounting bracket in the location and elevation specified in the project layout drawings.

Ensure that the bracket is plumb with the channel wall.

Note: Cut the Level Sensor Rods to the lengths shown on the provided layout drawings. Electrical connections are specified in the layout drawings provided by Trojan Technologies.

NOTICE
Trojan Technologies personnel must install the UVI Sensors, lamp sleeves and UV lamps in the UV bank.

DO NOT move the wiper, install the UVI sensor, lamp sleeves and UV lamps, a Trojan Technologies associate will do the initial install when contacted for the system inspection.

A
B
1 2

Original Instructions 81
Installation

7.18 Electrical Connections

7.18.1 SCC Electrical Connections
Prerequisites:
• Use appropriately rated cable and strain reliefs as per the Electrical and Layout Drawings provided by Trojan Technologies.
• Lockout Tag Out devices as required. Refer to Section 4. • Refer to Electrical Wiring Diagram, Interconnect Drawing and Layout Drawings provided for additional information.

Tools:

Materials:

Note: Home the wiper. Refer to Section 8.1.4.
1 B
A
2

82 Original Instructions
Installation
Procedure:

1. Locate the locations for the incoming power connections and field connections.

Notes: 1) Power connections are made on the top of the panel, above the main disconnect. 2) Field connections are made on the underside of the panel.

2. Open SCC panel door, put a cloth over equipment inside SCC enclosure to protect from metal filings.

3. Drill holes for incoming power and field wiring.

4. Carefully remove the protective cloth without dropping metal filings inside the SCC. Remove all metal filings from SCC.

5. Install the power and all applicable field wiring. Obey all local codes for main incoming power supplies and applicable field wiring.

Note: All openings created on the cabinets MUST be filled with equipment marked with the same type rating, as the enclosure (Ex: Cable Strain Reliefs).

7.18.2 PDC Electrical Connections
Prerequisites:
• Use appropriately rated cable as per the Electrical and Layout Drawings provided by Trojan Technologies.
• Lockout Tag Out devices as required. Refer to Section 4. • Refer to Electrical Wiring Diagram, Interconnect Drawing and Layout Drawings provided for additional information.

Materials:
• Ferrules (4 required per lamp cable) (provided)
• M6 Nut
• Electrical Drawings, Electrical Interconnect Drawings, provided • Instruction, TrojanUV Solo Lamp Cable Installation Guideline, Document Number DC000601-017 • Instruction, Lamp Cable Routing in PDC, Document Number DC340601-007 • Temporary Routing Cable Labels (not provided)
• Cable Labels (provided)
Procedure:

1. Incoming Power - is recommended to be on the top of the panel, above the main disconnect or on the side of the panel on the same side as the main disconnect.

Original Instructions 83
Installation

2. Lamp Cabling and Field wiring - open the PDC door and locate the strain reliefs on the bottom of the PDC. (Figure 21).

3. Install the lamp cabling (Refer to DC000601-017 and DC340601-007).

4. Install the bond wire and all applicable field wiring. Obey all local codes applicable field wiring.

Notes: 1) One Lamp Cable allowed per Strain Relief opening (maximum 3 Lamp Cables per Strain Relief). Plug unused strain relief openings with plugs provided. 2) All openings created on the cabinets MUST be filled with equipment marked with the same type rating, as the enclosure (Ex: Cable Strain Reliefs). 3) Use the ferrules provided for terminating within the PDC. Label each end of the lamp cable, with provided cable labels.

5. Repeats steps 1 through 4 for each PDC.

7.19 Additional Equipment

7.19.1 Water Level Controller
For systems supplied with a water level controller, refer to the layout drawings provided by Trojan Technologies for the location of the water level controller. Refer to DC450101 for Water Level Controller installation instructions.

7.19.2 UV Transmittance Controller and Sensor
For systems supplied with a UV Transmittance Controller and Sensor, refer to the layout drawings provided by Trojan Technologies for the location of the UVT instrument. Refer to the manufacturer’s manual for installation instructions.

Figure 21 PDC Cable Connections
1 Single Door PDC* 3 Reserved for Lamp Cables
2 Double Door PDC* 4 Reserved for UVI sensor, low level sensor and bank in place sensor and Bond Wire
* Inside bottom view, when looking in through the door. Conduit strain relief configuration may vary depending on site requirements. Refer to project electrical drawings for additional information. 1 2
3 4

84 Original Instructions
Installation

Original Instructions 85
Section 8 Operation

8.1 Hydraulic System Center
The hydraulic system is operated remotely from the System Control Center (SCC) HMI or locally from HSC control panel. As an option, the system can be operated Remotely using SCADA if the facility has a SCADA system.

8.1.1 HSC Overview
DANGER
Obey all warning and caution statements. Refer to Section 2.

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.

Only competent personnel should undertake operation, repairs, maintenance, or servicing of equipment described in this section of the manual. If you do not understand the information or procedure explanations in this manual, STOP and contact your Service Provider for assistance.

Figure 22 Hydraulic System Center
Item No Description Icon Function
1 HSC Operation Switch
WIPE
Begins wiping operation.

LIFT
Begins lifting operation. The pump turns ON and waits for an input from the Lift Operation Switch.
1 3
5 4
6 7
8 9
2 A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D

86 Original Instructions
Operation

8.1.2 Lift the UV Bank Up/Down
Prerequisites:
• Shutdown the UV Bank. Refer to Section 5.2.
• Remove Grating section(s).
• Verify there are no obstructions in lift area.
• Ensure all personnel are clear of UV Bank while manually operating the lifting function. 2 Lift Operation
UP
The chosen UV Bank will be lifted up.

OFF
Lifting will stop.

DOWN
The chosen UV Bank will be lowered down.
3 Lift UV Bank Selection Select the UV Bank to lift or lower. 4 Blank Cap N/A
5 Wiper Operation Switch
RET It applies to wipers and functions when any wiper is switched from OFF to LOC position.

Note: Once a function has been performed, switch item 5, 6, 7 or 8 to OFF before selecting another Extend or Retract function.

Wiper will move from the lower end (bottom of the UV Bank) to the Home position (top of the UV Bank).

EXT
Wiper will move from the Home position (top of the UV Bank) to the lower end (bottom of the UV Bank).

SEQ Wiper will extend and retract if wiper is at Home, otherwise wiper will retract back to Home position and perform a full cycle of wiping.
6, 7, 8, 9 UV Bank (A, B, C, D) Wiper
Mode Switch
OFF
Wiper disabled or wiping will be stopped if the wiper is wiping before it is switched to OFF.

REM Wiper operates in Remote mode. In the is mode, wiper can:
• Perform a manual wipe upon receiving wiping command from HMI.
• Wipe automatically under control of internal wiping cycle timer.

LOC When wiper is switched from OFF to LOC, wiper will start the specified wiping operation depending on the Wiper Operation Switch position.

NOTICE
To avoid equipment damage, make any necessary adjustments to lamp cables prior to the lifting operation.

Item No Description Icon Function
UV

Original Instructions 87
Operation
Materials:
• Bank Locking Plates
Procedure:

1. HSC Operation switch → or (LIFT) → Select the UV Bank (1,2,3 or 4).

2. To lift the UV Bank Up (Extend):
a. Turn and hold the Lift Operation selector switch in the or (UP) position to raise the UV Bank until the UV Bank is fully lifted.
b. HSC Operation Switch → or (OFF) position
c. Install the UV Bank locking plates (Figure 23).
d. Adjust grating around lifted UV bank to eliminate openings to channel.

3. To lift the UV Bank Down (Retract):
a. Remove the UV Bank locking plates (Figure 23).
b. Turn and hold the Lift Operation selector switch in the or (DOWN) position to lower the UV Bank until the UV Bank is fully lowered.
c. HSC Operation switch → or (OFF) position.
d. Install grating section(s).
e. Adjust grating around lifted UV bank to eliminate openings to channel.

NOTICE
Never perform maintenance on the UV Bank until all locking plates are in place.

If you can not raise the bank to the level required to install the bank locking plates – lower the bank to its home position and contact Technical Assistance Centre for troubleshooting assistance.

88 Original Instructions
Operation

8.1.3 Wiper Control Modes

8.1.3.1 Wiper Remote Control
SCC or SCADA will control the operation of HSC wiping function.

1. HSC disconnect → “ON”.

2. HSC operation switch → or (WIPE).

3. UV Bank wiper mode switch → or (REM).

8.1.3.2 Wiper Local Control
Note: Used for service purpose only.

1. HSC disconnect → “ON”.

2. HSC operation switch → or (WIPE).

3. Wiper Mode Switch → or (LOC) for required UV Bank.

8.1.3.3 Wiper Sequence Control
Note: Used for service purpose only.

1. HSC disconnect → “ON”.

2. HSC operation switch → or (WIPE).

3. Wiper Operation → or (SEQ) for required UV Bank.

8.1.4 Manually Operate the Wiper
Prerequisites:
• Wet the lamp sleeve at the wiper plate with water, if the UV Bank is in service position. • Put the Wiper into Local Control Mode (Section 8.1.3.2) • Ensure all personnel is clear of UV Bank while manually operating the wiping function Figure 23 Locking Plate
1 Locking Plate
x2
A
1 BCD

Original Instructions 89
Operation
Materials:

Procedure:

Retract (Home) the Wiper

1. Select Applicable Wiper Group → or (RET) until the wiper is at the top of the UV Bank.

2. UV Bank wiper mode switch → or (OFF).

Note: When retracting the wiper assembly, to prevent damage to the equipment, make sure the assembly plate does not contact the baffle during travel.

Move the Wiper to 1/2 way

1. Applicable wiper operation switch → or (EXT) if in the Home Position or to or (RET) if in the Park position, wait for the wiper to reach 1/2 way along the sleeve.

2. UV Bank wiper mode switch → or (OFF).

Extend the Wiper

1. Applicable wiper operation switch → or (EXT) until the wiper reaches the bottom.

2. UV Bank wiper mode switch → or (OFF).

8.1.5 Reset HSC Latched Alarms

1. Resolve the cause of the latched alarm.

2. Bank Mode Switch → Turn from or (REM) to or (OFF) to or (REM).

8.2 Power Distribution Center

8.2.1 Enable PDC Remote Control
When PDC is in Remote control, SCC or SCADA controls the output of the PDC.

1. PDC disconnect → or (ON).

2. PDC mode selector switch → or (REM).

8.2.2 Enable PDC Local ON
PDC output is set to 100% and will not be controlled by SCC or SCADA.

1. PDC disconnect → or (ON).

2. PDC mode selector switch → or (ON).

90 Original Instructions
Operation

8.3 System Control Center
The SCC contains the control program for the UV system. The SCC is configured at the factory with inputs and outputs as required for each system. The manufacturer configures the functionality of each of the signals in the control strategy.

Daily operation includes monitoring the system functions, and may occasionally require the operator to manually initiate or control the processes.

8.3.1 Navigate the Human Machine Interface
The HMI for the controller uses touchscreen technology. Do not use the writing tips of pens or pencils or other sharp objects to make selections on the screen. Use only a clean, dry finger tip or the eraser tip of a pencil.

The icon turns to ‘negative’ when a related screen is open.

Table 4 User Interface Navigation (Main Level)
Icon Screen Description Refer:

Overview
(Home)
An operational summary of all UV channels and UV Banks.

Allows access to Priority Assignment screen and to manually enter flow and UVT values.

Section 8.3.2
UV Channel
Overview
Allows access to control slide gates.

Allows access to control and display UV channel specific information.

Allows access to the UV Bank Overview Screen. Refer to
Section 8.3.4
Section 8.3.3
Wiper Overview Allows access to control wiper/cleaning system. Section 8.3.5 Trends Displays trend data for flow, UVT and dose. Section 8.3.6 Alarm Status Displays the currently active alarms and allows access to Alarm History screen. Section 8.3.7
System Settings
Allows access to system configuration settings as allowed by current security level. Settings are organized in pages by function.

Section 8.3.8
Information
Shows information about the control system hardware and software. It also allows access to change the clock time and other HMI maintenance functions.

Section 8.3.9
Figure 24 Home
1 Home - Overview 2 Home - Negative Overview
The UV channel icon displays a yellow warning indicator when any Minor alarm condition exists on a UV channel/UV Bank related device.

The UV channel icon displays a red alarm indicator when any Major/Critical alarm condition exists on a UV channel/UV Bank related device. 1 2

Original Instructions 91
Operation

8.3.1.1 Screen Overview
The wiper icon is visible if the wiper option (setting) is enabled.

The wiper icon displays a yellow warning indicator when any Minor alarm condition exists on a wiper related device.

The wiper icon displays a red alarm indicator when any Major/Critical alarm condition exists on a wiper related device.

The alarm icon displays a red circle indicator with a numeric value in the Center.

The value represents the number of active alarms in the entire system. Greater than 100 alarms is displayed as “>>”. The indicator disappears when the number of active alarms is 0.

Home screen (Section 8.3.2)
DOSE
Shows UV dose output of all UV Banks currently in operation. The applied UV dose is calculated based on UVT, operating power levels of the UV Banks, flow, and lamp age.

FLOW
Shows the current total system flow value used for dose pacing. The Flow/Manual Flow selector above the currently displayed flow value will toggle the current flow signal source between the configured input instrument source, and a manually entered value.

UVT(%) Displays the current UVT value used for dose pacing. If required, the UVT can be manually entered.

Fault Reset Resets Not Enough Healthy UV Channels.

UV Channel Screen (Section 8.3.3)
Inlet Gate Selector Inlet Gate status and control screen UV Bank Selector
Navigate into UV Bank overview screen
Lamp Driver Display Driver Information display. Resets each individual lamp hours
UV Bank Mode
Selection Changes UV Bank operation mode
UV Bank Priority Changes UV Bank priority
Override UV Bank
Info
Overrides UV Bank Lamp Hours, UV Bank Hours, UV
Bank Cycles
Reference Sensor Check the duty sensor to a reference sensor UV Channel Priority Selector Changes UV Channel / UV Bank priority Outlet Gate Selector Outlet Gate status and control screen Wiper Screen (Section 8.3.5)
Health Displays current wiper system health condition
Wiper detail Displays detailed wiper information
Wipe UV Bank Performs wiping action on current bank
Wipe all Performs wiping action on all banks if condition allows Trending (Section 8.3.6)
Display Displays trending of flow, dose and UVT in past 8 hours Change Scale Changes maximum and minimum of Y axis on trending window Alarm (Section 8.3.7)
Active Alarm display Displays all active alarms
History Alarm display Displays a list of historical alarms

92 Original Instructions
Operation

8.3.1.2 System Status and Health
The system status is displayed in the top left hand corner of all main level screens. The system status will display either ON or OFF and includes a graphical icon to indicate the health of the system.

8.3.1.3 Login
The SCC Operator Interface is configured with security access restrictions.

To login:

1. Press LOGIN → User Button→ Input User Name → ()

2. Press PASSWORD → Input Password → ()
Notes: 1) The Login button displays ‘LOGIN’ when no user is logged in. 2) The Logout displays the name of the current logged in user. Pressing it logs the user out.

Settings (Section 8.3.8)
General Settings General settings for the system
Wiper Settings Wiper control settings
Flow Settings Settings for default and low flow set point UVT Settings Settings for default and low UVT alarm set point Intensity Settings UVI sensor settings
Dose Settings Settings for dose requirement
Time Delay Settings Time delay for alarms
UV Channel Settings UV Channel fill, open and close delay, inlet travel time Water Level Settings Maximum and minimum water level settings Outlet Gate Settings Settings for outlet weir gate
Icon Icon Color System Health
Green Healthy
Yellow Unhealthy with minor alarm(s) active
Red Unhealthy with critical/major alarm(s) active
Level User / User Name Access Password
1 No Login User may view all unrestricted data. Not required 2 Operator
User may view all unrestricted data and enter
process data, control process equipment and adjust
process control setpoints. The password protection
can be removed by placing the “Operator Login
Required” system setting to “No”.
11111
3 Maintenance User has access to configuration of process control strategies and displays.

Password is provided to
approved trained personnel

Original Instructions 93
Operation

8.3.2 Home Screen
The Home Screen displays:
• On restart of the HMI • After the inactivity time-out expires (30 min) • When a user logs out
Figure 25 Home Screen
Item User / User Name Button/Text Description/Action Refer:
1 UVT Bar Graph
and Override
Button
UVT
If the device input type is set to anything other than
manual, a grey gradient button will be displayed.

If the device input type is set to manual, a white box
appears, this allows the user to change the manual
value. Value can be manually overridden
(Section 8.3.2.3).

The bar graph dynamically displays the full scale value of the device set in the Settings Screens.

The realtime values are displayed to the right of the
graph.

The grey indicator arrow below the graph indicates
alarm setpoints. If the bar position moves to the left of the arrow, an alarm will be triggered.

Section 8.3.2.1
2 Flow Bar Graph
and Override
Button
Flow
3 RED (Dose) Bar
Graph T1, MS2 etc.

The bar graph dynamically displays the dose calculated
by the PLC.

The realtime value is displayed to the right of the graph.

The red text to the left of the RED bar graph, indicates the type of microbe selected (i.e. T1, MS2 etc.) for use in dose equations.

The grey indicator arrow below the graph indicates the
RED target. If the bar position moves to the left of the arrow, an alarm will be triggered.
4 Channel
Navigation
Buttons
The status and health of each UV Channel in the
system is displayed on the gradient push button. Push
to navigate to the Channel Overview Screen
(Section 8.3.3).

Section 8.3.2.2
5 Not Enough Healthy Channels Reset
NOT ENOUGH HEALTHY CHANNELS RESET blue
pushbutton displays whenever a latched Not Enough
Healthy UV Channels alarm is determined by the PLC.

Reset to unlatch the alarm.

Section 8.3.2.4
4 1
2 3
5

94 Original Instructions
Operation

8.3.2.1 Bar Graph

8.3.2.2 Channel Navigation Buttons

8.3.2.3 Override Flow and UVT Settings
Manual/override of Flow and UVT values
The Flow and UVT values can be overridden by the operator based on the input device type that was selected in the Settings Screens.

Calculated
The button to the left of the Flow and UVT graph is shown as a button if the respective input type of the device is set to anything other than Manual. The button is a grey gradient when the value is not overridden. The numeric display to the right of the graph appears as white text on a black background when the override is off. (Figure 26).

Manual
A white box appears behind the value indicating that the input type of the device is set to Manual. The operator can press this box to change the value (Figure 27).

The button is a yellow gradient when the value is overridden. The numeric display to the right of the graph appears as black text on a yellow background when the override is on (Figure 28).

Bar Color Icon Icon Color Description
Green -- -- Value is within design parameters.

Red Yellow Value has dropped below the design low setpoint or exceeded the design high setpoint. A Minor Alarm is active.

Red Red Value has dropped below the design low setpoint or exceeded the design high setpoint. A Major Alarm is active
Icon Channel Status
Open Channel is Open
No icon Channel is Closed
Channel is Opening
Channel is Closing
Icon Icon Color Channel Health
No icon No icon Healthy
Yellow Minor alarm present (Yellow)
Red Major alarm present (Red)
Figure 26 Calculated Value
Figure 27 Manual Value Entry Field Figure 28 Manual Value Entered

Original Instructions 95
Operation

8.3.2.4 Not Enough Healthy UV Channels Reset

1. Push NOT ENOUGH HEALTHY CHANNELS RESET → YES or NO

8.3.3 UV Channel Overview Screen
Low Level Alarm and Warning Indicators
In the event of low water conditions, the following text “LOW WATER” will display at the bottom of each UV Channel in yellow (warning) or red (alarm) color.

Channel Status Indicators
There are four states used to represent the current state of the channel.

Note: Channel coming online and Channel going offline are only available if inlet gates are present.

Figure 29 UV Channel Overview Screen
1 Displays current measured FLOW and RED
(dose)
6 Channel Status Indicator
2 Navigates to Bank Overview Screen 7 Indicates direction of effluent flow 3 Inlet Gate Control Button (Section 8.3.3.2) 8 UV Channel Priority button (Section 8.3.3.1) 4 Assigned Channel Priority Display 9 UV Channel Maintenance button (Section 8.3.3.4) 5 UV Channel 10 Outlet Gate Control Button (Section 8.3.3.3) Icon Description
ON The channel is in operation
The channel is coming online
The channel is going offline
No Icon The channel is off
1 2
3 4
5 6
7 8
9 10

96 Original Instructions
Operation

8.3.3.1 Change UV Channel Priority
The Priority button is displayed for systems with more than one UV Channel and allows the operator to change the priority of the Channel.

The Channel priority is default set to AUTO sort with a user defined auto sort interval. When the operational hours have elapsed, the controller will automatically resort the priority of the UV Channels.

Optionally, a user may choose to manually assign channel priorities.

Manually assign Channel Priority

1. Press PRIORITY (Figure 29, Item 8).

2. Press the desired channel to set priority. The selection will turn blue which indicates the priority has been assigned.

Note: UV Channels must have unique priority assignments. If unique assignments are not selected, a “PRIORITY SELECTIONS ARE NOT UNIQUE” alert will be displayed on the Channel Priority screen.

3. ACCEPT or CANCEL.

Note: ACCEPT and CANCEL pushbuttons appear after a change has been made.

8.3.3.2 Inlet Gate Control
Inlet gates may be automatically controlled via the SCC or Plant SCADA. If the gates are automatically controlled, a gate icon will be displayed on the UV Channel Overview Screen (Figure 29, Item 4).

The Inlet Gate button displays the gates current status and health.

Figure 30 Channel Priority in Auto Mode Figure 31 Channel Priority in Manual Mode Value Description
AUTO
When the Auto Sort Interval has expired, the priority of the UV Channels will automatically be sorted based on
channel runtime hours.

MANUAL UV Channel priority is manually assigned.

Auto Sort Interval Frequency to automatically sort UV Channel.

Icon Description
Gate is open or flow is present (Blue)
Gate is closed or no flow is present (Grey)
Gate is opening
Gate is closing

Original Instructions 97
Operation
To change the inlet gate control to Auto or Manual Control Mode:

1. Press the Inlet Gate button.

2. Select either AUTO or MANUAL control mode button as required.

To change the inlet gate control into Local Control Mode:

1. Go to the actuator on the inlet gate and change control to LOCAL.

Note: The inlet gate control pop-up screen will display an “INLET GATE IN LOCAL” status.

To manually open or shut the inlet gate:

1. Put Inlet Gate into MANUAL control mode.

2. Press OPEN or SHUT as required.

3. Press CLOSE button.

To reset an inlet gate latched alarm:

1. Press the Inlet Gate button.

2. Press FAULT RESET button.

3. Press CLOSE button.

8.3.3.3 Outlet Gate Control
Outlet gates may be automatically controlled via the SCC or Plant SCADA. If the gates are automatically controlled, a gate icon will be displayed on the UV Channel Overview Screen (Figure 29, Item 10).

The Outlet Gate button displays the gates current status and health.

To change the outlet gate control to Auto or Manual Control Mode:

1. Press the Outlet Gate button (Figure 29, Item 10).

2. Select either AUTO or MANUAL control mode button as required.

To change the outlet gate control into Local Control Mode:

1. Go to the actuator on the inlet gate and change control to LOCAL.

Note: The outlet gate control pop-up screen will display an “OUTLET GATE IN LOCAL” status.

To manually raise or lower the outlet gate:

1. Put Outlet Gate into MANUAL control mode.

2. Press RAISE or LOWER as required.

No icon Healthy
Minor alarm present (Yellow)
Major alarm present (Red)
Icon Description
Gate is open or flow is present (Blue)
Gate is closed or no flow is present (Grey)
Gate is opening
Gate is closing
No icon Healthy
Minor alarm present (Yellow)
Major alarm present (Red)
Icon Description

98 Original Instructions
Operation

3. Press CLOSE button.

To reset an outlet gate latched alarm:

1. Press the Outlet Gate button.

2. Press FAULT RESET button.

3. Press CLOSE button.

To toggle the gate position display (between % OPEN or Inches or cm)

1. Press the Outlet Gate button.

2. Press the gate position toggle button to change between %OPEN and in or cm.

8.3.3.4 Maintenance Mode
When a UV Channel is set to MAINTENANCE mode, the UV controller will:
• Close all gates in the associated UV Channel
• Turn off all UV Banks in the associated UV Channel.

The UV Channel will then be removed from any dose pacing and all alarms to SCADA from associated UV Channel will be muted except for the “Channel X Maintenance Mode Enabled” Minor alarm.

Note: UV Banks and gates can still be operated locally in Maintenance Mode.

To Enable Maintenance Mode:

1. Select the “MAINTENANCE” button on the UV Channel Overview Screen (Figure 29, Item 9).

2. Channel Maintenance Mode Pop-up screen, select ENABLE on the required channel.

3. Channel x Maintenance Mode Confirmation pop-up screen, select “YES” to proceed or “NO” to cancel.

4. When a UV Channel is enabled for maintenance:
a. ENABLED button on the Channel Maintenance Mode pop-up will be colored green.

Original Instructions 99
Operation
b. The UV Channel Overview screen will display the channel currently enabled for Maintenance by displaying “MAINTENANCE” at the bottom of the Channel display.

To Disable Maintenance Mode:

1. At any time, press the “DISABLE” button. The UV Channel will be resume normal operations.

8.3.3.5 Offline Mode
This mode is used by approved service personnel. It is used primarily during start-up when the UV Channels being started up need to be staggered over a longer period of time.

Note: This screen is not intended to be used as a maintenance mode. The system must be shut down properly or not yet installed in the UV Channel(s).

The user must login to OEM level to enable this function.

When a UV Channel is set to OFFLINE mode, the UV Controller will:
• Mask graphics for the offline UV Channel(s)
• Mask alarms for the offline UV Channel(s)
• Disable communications to the Prosoft Communication Card. • Enable a ‘Channel x In Offline Mode’ alarm.

Figure 32 UV Channel Offline Mode

100 Original Instructions
Operation

8.3.4 UV Bank Overview Screen
UV Channel Overview screen → UV Bank number.

Low Level Alarm and Warning Indicators
In the event of low water conditions, the following text “LOW WATER” will display beside the Bank Mode Button (Figure 33) in yellow (warning) or red (alarm) color.

Bank Not In Place Alarm Indicator
In the event of the UV Bank not fully lifting down into the Bank Frame, the following text “NOT IN PLACE” will display beside the Bank Mode Button (Figure 33) in red (alarm) color.

8.3.4.1 Change UV Bank Mode

1. Press the Bank Mode Button → REMOTE OFF or REMOTE ON or REMOTE AUTO (from the Remote Mode pane) (Figure 33, Item 4).

8.3.4.2 Lamp Driver and UV Lamps Status
Lamps and Lamp Drivers are displayed in the physical arrangement of the UV Bank.

UV Lamps
The circles represent the UV Lamps and are named according to the label designation on the physical lamp.

The lamp circle changes color based on the status of the UV Lamp.

Figure 33 UV Bank Overview Screen
1 Bank Parameters 5 Bank Navigation Buttons
2 Wiper Quick Switch Button (Section 8.3.4.6) 6 UV Lamp and Driver Button 3 Bank Details 7 Bank Priority Button
4 Bank Mode Button (Section 8.3.4.1) 8 Reference Sensor Button Icon Icon Color UV Lamp Status
Black Off and healthy
Black and red Off and unhealthy with major/critical alarm(s) Black and purple Disabled; lamp off and cool down timer is counting down Black and green Disabled; lamp off and cool down timer is expired 1 2
3 5
6 7
8 4

Original Instructions 101
Operation
Lamp Drivers
The gradient rectangle push-button that surrounds a pair of lamps (or 1 lamp if it is a half driver) displays the status of each lamp driver.

Press the Driver push-button to display additional details about the respective driver/lamp(s) (Section 8.3.4.3).

8.3.4.3 Lamp Driver Detail Screen
Black and yellow Off and unhealthy with minor alarm(s).

Magenta Re-igniting
Red On and unhealthy with major/critical alarm(s)
Green On and healthy
Yellow On and healthy with minor alarm(s).

Icon Border Color Lamp Driver Status
Red Major Alarm
Yellow Minor Alarm
None Healthy
Figure 34 Lamp Driver Detail Screen
Icon Icon Color UV Lamp Status

102 Original Instructions
Operation
The lamp driver identification is displayed in the center of a rectangle. The border color of the lamp driver changes based on the lamp driver status:

8.3.4.4 Reset Lamp Driver Fault
A blue gradient Fault Reset pushbutton will appear whenever there is an alarm on the lamp driver.

To reset the faults:
a. Bank Overview Screen → RESET.

8.3.4.5 Reset Bank Fault
A blue gradient Fault Reset pushbutton will appear whenever there is a latched alarm on the bank.

To reset the faults:
a. Bank Overview Screen → RESET
b. Reset all faults in Bank xx pop up → YES or NO

8.3.4.6 Wiper Quick Switch Button
Selecting this button will navigate to a Wiper Detail screen for the wiper group associated with the currently displayed bank (Section 8.3.5.1).

8.3.4.7 Override Operating Hours of Individual Lamp
When a new lamp is installed (OP1 Login required):

1. From UV Bank Overview (Section 8.3.4), select the UV lamp that needs to be overridden.

2. Input New Hours → Push ACCEPT→CLOSE.

8.3.4.8 Enable / Disable Individual UV Lamp

1. From the Lamp Driver Detail Screen (Figure 34), select either ENABLED or DISABLED button.

Note: Only one UV Lamp per UV Bank can be disabled at one time.

2. If Lamp was previously:
a. ENABLED - Select DISABLE→CLOSE.

Notes: 1) Only one UV Lamp per UV Bank can be disabled at one time. 2) A Lamp cool down timer will initiate if disable function was successful. b. DISABLED - Select ENABLE→CLOSE.

Note: For lamp status definitions (Section 8.3.4.2).

Border Color Alarm Lamp Driver Status
Green None Healthy
Yellow Minor Alarm Minor Alarm
Red Major Alarm Major or Critical Alarm
Red Comm. Failure Communication Failure between BCB and Lamp Driver or between the SCC and BCB

Original Instructions 103
Operation

8.3.4.9 Turn off all UV Lamps in UV Bank

1. From Local - Refer to Section 5.2.2.

2. From Remote - Enable PDC Remote Control (Section 8.2.1) → At the HMI → Press the Bank Mode Button (Figure 33, Item 4) → REMOTE OFF.

8.3.4.10 Bank Parameter - Power %
Displays the current UV Bank power level.

8.3.4.11 Bank Parameter - UV Intensity
The UVI value is displayed if the UVI Option is enabled in settings.

8.3.4.12 Change UV Bank Priority
The Priority button is displayed for systems with more than one UV Bank.

1. Press the bank priority button (Figure 33, Item 7).

2. Press the pushbuttons to set priority. The selection will turn blue which indicates the priority has been assigned.

Note: UV Banks must have unique priority assignments. If unique assignments are not selected, a “PRIORITY SELECTIONS ARE NOT UNIQUE” alert will be displayed on the Bank Priority screen.

3. ACCEPT or CANCEL.

Note: ACCEPT and CANCEL pushbuttons appear after a change has been made.

Button Description / Action
RESET Displays when a latched UVI fault is present
REF. SENSOR
Initiates a Reference Sensor Procedure. Refer to DC000601-013.

Displays when:
• Lamp B2 is on with a minor fault(s) or no faults
• Bank is in operation
• Bank wiping is not in progress
• Bank is communicating with SCC
Value Description
AUTO Will automatically sort the priority of the UV Bank based on runtime hours, mode, and health.

MANUAL UV Bank priority is manually assigned.

Bank Sort Hours Difference
UV Banks will automatically sort if the difference in bank lamp hours between two UV Banks (within the same UV
Channel) exceeds the preset value.

104 Original Instructions
Operation

8.3.4.13 Display and Override Bank Details
The Bank Details Screen allows selected values to be overridden providing that the user is logged in as OP1 or higher.

Bank Details Screen Display
Bank Lamp Hours Override

1. Bank Overview Screen → BANK DETAILS.

2. Bank Lamp Hours → OVERRIDE (Figure 35)

3. Input Lamp Hours → ACCEPT

4. Lamp Hours Confirmation Pop-up → YES / NO →CLOSE
Bank Cycles Override

1. Bank Overview Screen → BANK DETAILS.

2. Bank Cycles → OVERRIDE (Figure 35)

3. Input Bank Cycles → ACCEPT →CLOSE
Figure 35 Bank Details
Value Definition Description /
Actions
Bank RED (mJ/cm2) Displays the calculated UV Dose
Display only
Bank Power (%) Displays the calculated Bank Power
UVI Filtered (mW/cm2) Displays the UV Intensity used in the dose calculation UVI Actual (mW/cm2) Displays the UV Intensity measured by the sensor Deviation (%) Displays the difference between the expected UV Intensity and the measured UV Intensity
Bank Lamp Hours Displays the lamp hours in the UV Bank Override permitted
Bank Hours Displays UV Bank runtime Display only
Bank Cycles Displays the number of times the UV Bank has turned ON Override permitted

Original Instructions 105
Operation

8.3.5 Wiper Overview Screen
Pressing a wiper status button (i.e. ) navigates the user to the Wiper Detail Screen for the respective UV Bank (Section 8.3.5.1).

Low Level Alarm and Warning Indicators
In the event of low water conditions, the following text “LOW WATER” will display at the bottom of each channel in yellow (warning) or red (alarm) color.

Wiper Status and Health
WIPE ALL - Visible when there are no conditions that would prevent a wipe of all UV Banks.

Status and health of each wiper in the system are displayed on a push-button.

The time remaining until the next auto wipe procedure is displayed for each UV channel.

Figure 36 Wiper Overview Screen
Icon Icon Color Status Health
No icon No icon Stationary Healthy
Green Moving
Yellow Minor alarm active
Red Critical/Major alarm active

106 Original Instructions
Operation

8.3.5.1 Wiper Detail Screen
Displays information related to the current selected wiper.

Wiper Mode
The Wiper Mode is determined by the physical HSC switch positions (Figure 37). For HSC local mode (Section 8.1.3.2) .

UV Bank Status and Health (Quick Switch)
A Quick Switch push-button contains the status and health information of the wiper at current UV Bank (Wiper Status and Health).

Wiper Event Status and Alarms
Refer to Section 10 for wiper event status and alarm listings.

Figure 37 Wiper Detail Screen
1 Wiper Event Status and Alarms 4 Wiper Mode
2 UV Bank Status & Health (Quick Switch Button) 5 Manual Wipe 3 Flow Direction
Icon Icon Color Description / Action

LOCAL OFF
Yellow
HSC wiper group is set to “OFF”.

LOCAL RETRACT HSC wiper group is set to “LOC” and cylinder is retracting.

LOCAL EXT HSC wiper group is set to “LOC” and cylinder is extending.

LOCAL SEQ HSC wiper group is set to “LOC” and a sequence wiping is on.

IN LIFT HSC is set to lift mode.

REMOTE Green HSC wiper group is set to wipe and Remote mode.

Icon Icon Color Status Health
No icon No icon UV Bank is off Healthy
Black
UV Bank is in Warm-up
UV Bank is Timing off
ON Green UV Bank is in Operation.

Yellow Unhealthy with minor alarm(s) active
Red Unhealthy with critical/major alarm(s) active
1 3
4 5
2

Original Instructions 107
Operation
Manual Remote Wipe

1. Press WIPE BANK.

Note: The function is only available when there is no wiping action or alarms on any bank in the same HSC.

8.3.6 Trending Screen Overview
*Navigation Bar is only displayed when a weir gates are present and controlled by Trojan. Each UV Channel with a weir gate will have a Trend Screen

8.3.6.1 Change Scale of Trending Plot

1. Press the Y-Min →Input the required value→ ENTER symbol.

2. Press the Y-Max →Input the required value→ ENTER symbol.

Figure 38 Trend - System With Weir Figure 39 Trend - Weir 1 Y-Min Button 6 UVT Value
2 Y-Max Button 7 Weir Trend Button Selected
3 Navigation Bar (Toggle between System Trends
and Weir Gate Trends)*
8 Level Value
4 Flow Value 9 Gate Position Value
5 Dose Value
1 2
3 4
5 6
4 7
8 9

108 Original Instructions
Operation

8.3.7 Alarm Screen Overview
Alarm Banner
A red alarm banner appears at the top of the screen when an incoming alarm occurs. The alarm banner stays open until the user closes the window.

Active Alarms
The Active Alarms tab displays the alarms that are active in the system.

Alarm History
The Alarm History tab displays all the alarms that have occurred in the system with a date/time stamp.

8.3.7.1 Alarm Color Code

8.3.8 Settings
The user must be logged in at OP1 level or higher to access the Settings Screens. Press the white text boxes to enter new setting values or to pop-up setting options.

Figure 40 Alarm Banner
Figure 41 Active Alarms Figure 42 Alarms History
Alarm Color Description
Yellow Minor Alarm
Red Critical / Major Alarm
Blue Selected Alarm

Original Instructions 109
Operation

8.3.8.1 General Settings

8.3.8.2 Wiper UV Bank Settings
Figure 43 General Settings
Parameter Units Definition
UPS Option Enabled / Disabled Enabled if a UPS is available, disabled if no UPS is available.

Min. Number of Channels Whole Number The minimum number channels requested to run in automatic.

Min. Number of
Banks/Channel Whole Number The minimum number banks requested to run in automatic.

Add Bank Capacity
Threshold %
A user adjustable “Add Capacity Threshold” (default 95%) will be applied to the calculation so that additional UV Banks will be required once the % Capacity threshold has been reached.”
Add Bank Capacity
Deadband %
A user adjustable “Add Capacity Threshold” (default 5%) will be applied to the calculation when reducing the required number UV Banks per channel, once the (Add Bank Capacity Threshold - Add Bank Capacity Deadband) it has been reached.”
Operator Login Required Yes / No (default No) A user adjustable setting to specify if security login is required.

Resend Bank Settings RESEND Manually resend UV Bank settings to each BCB.

Figure 44 Wiper UV Bank Settings
Parameter Units Definition
Cycle Time Hours Set the frequency for wiper cycles.

Max Travel Time Seconds The maximum allowable wiper travel time, if exceeded an alarm will be triggered.

Min Travel Time Seconds The minimum allowable wiper travel time, if wipe is completed prior to this time, a wiper jammed fault will be triggered.

110 Original Instructions
Operation

8.3.8.3 Flow Settings

8.3.8.4 UVT Settings
Figure 45 Flow Settings
Parameter Units Definition
Flow Units m3/hr, m3/day, GPM,
L/s, MGD A user adjustable setting for displayed flow units.

Flow Meter Full Scale Flow Units Maximum scale (20mA) calibration value used to measure the flow through the UV system.

Flow Default Value Flow Units The flow value that is used for auto pacing during designated fault conditions.

Low Flow Alarm Setpoint Flow Units Set the level to initiate a low flow alarm timer.

Low Flow Alarm Delay Minutes Setpoint for the low flow alarm timer.

Figure 46 UVT Settings
Parameter Units Definition
UVT Maximum Scale % Maximum scale (20mA) calibration value used to measure the UVT in the UV system.

UVT Minimum Scale % Minimum scale (4mA) calibration value used to measure the UVT in the UV system.

UVT Default Value % Full scale calibration value for the UVT signal used for auto pacing if there is a UVT signal fault.

Low UVT Alarm Delay Seconds Set the low UVT alarm time delay

Original Instructions 111
Operation

8.3.8.5 Intensity Settings

8.3.8.6 Dose Settings
Figure 47 Intensity Settings
Parameter Units Definition
UVI Sensor Check Interval Days Recommended time between reference sensor checks.

UVI Negative Deviation
Setpoint % A user adjustable value for the allowable percentage below the calculated UVI expected value.

Use Theoretical
Never Only use the real sensor value for dose pacing. If the sensor fails that bank will be unhealthy and rotated out if another bank is available.

On Failure If the analog signal of the sensor fails, use the theoretical for dose pacing. Sensor alarms will be treated as minor.

Always
Always use the theoretical value for dose pacing. Sensor alarms will be treated as minor and will only be used for troubleshooting and maintenance purposes.

Figure 48 Dose Settings
Parameter Units Definition
Validation Report --- Displays the selected dose validation report.

RED Target mJ/cm2
Determines the set point for UV dose control of the auto pacing routine.

The auto pacing routine will modulate UV bank power level and bring UV banks and channel in and out of operation as required to maintain this set point.

Dose Safety Factor % Allowed additional dose each UV Bank will target above the required RED Target.

Low Dose Alarm Delay Seconds The set time for a low dose event to correct before an alarm is triggered.

Multiple Lamp Failure SP Lamps/Bank The number of lamp failures in a UV Bank required to trigger a multiple lamp failure alarm.

112 Original Instructions
Operation

8.3.8.7 Time Delay

8.3.8.8 Channel Settings
Figure 49 Time Delay
Parameter Units Definition
Minor Alarm Delay Minutes Time delay for minor alarms.

Major Alarm Delay Seconds Time delay for major alarms.

Critical Alarm Delay Seconds Time delay for critical alarms.

Bank Off Delay Minutes
Minimizes UV bank on/off cycling. Determines the amount of time that the auto pacing routine must call for a UV bank to turn off before it will de-energize. While this timer is running, a UV bank will be operated at minimum power.

Figure 50 Channel Settings
Parameter Units Definition
Channel Fill Delay Seconds
Time allowed for an empty channel to fill to the level switch before a Channel Low Level alarm is triggered. Channels that operate in the low level alarm condition are not considered “healthy” and will not be available to the auto pacing routine.

Channel Open Delay Seconds Time delay before a channel will remain closed to allow for the UV Banks to warm up, providing there is not a low water level event.

Channel Close Delay Minutes Time delay before a channel that is no longer required is closed and taken out of operation.

Inlet Gate Travel Time Seconds
The maximum time required for the inlet slide gate to complete its travel from a fully open or closed position. This set point is used to determine how long to wait when a gate is commanded to move before checking for alarm conditions.

Inlet Gate Cracking Option Enabled / Disabled Allows for controlled filling of the UV Channel.

Original Instructions 113
Operation

8.3.8.9 Water Level Settings

8.3.8.10 Outlet Gate Settings
The Outlet Gate Settings screen is displayed for systems configured with automatic outlet gates.

Channel Open (% Peak
Flow) %
The percentage of the channel peak flow setpoint that will trigger additional channels to be brought online. - multichannel or inlet gates must be present.

Channel x Peak Flow GPM Designed peak flow for each UV Channel Flow Over Weir Flow
Factor Enabled / Disabled
Enables the PLC to apply a flow factor based on the channel flow over the weirs; used to calculate the flow through each channel. Available to systems configured with automatic outlet weir gates.

Figure 51 Water Level Settings
Parameter Units Definition
Low Water Shutdown
Delay Minutes
The time delay between a low water level warning and a low water level alarm that will shut down the UV Bank. A low water level warning occurs after the minor delay time.

Water Lvl Units --- Displays the preferred units for water level.

ChX Water Level Max
Scale cm, in Maximum scaled (20mA) calibration value used to measure the level in the UV channel.

Figure 52 Outlet Gate
Parameter Units Definition

114 Original Instructions
Operation
Parameter Units Definition
Flow Balancing Enabled / Disabled
A system that is configured to flow balance will compensate both for imperfections within civil works as well as flow tendencies toward one channel. These effects are able to be compensated for by calculating a dynamic offset of the water level set-point in each channel Flow Balancing Gain ---
Gain value used to increase or decrease the effect of the calculated flow balancing compensation factor used to dynamically offset the water level set-point in each channel.

Weir Operation 4/20mA-Raised The Weir Position analog signal associated with the weir in the fully raised position.

Weir Fully Raised Inches The elevation of the weir when fully raised relative to the channel floor beneath the analog water level sensor (same channel).

Weir Fully Lowered Inches The elevation of the weir when fully lowered relative to the channel floor beneath the analog water level sensor (same channel).

Weir Max. Position Inches
Also known as the “Parked” position, this is the elevation of the weir considered to be fully closed, relative to the channel floor beneath the analog water level sensor (same channel).

Weir Safe Position Inches
The elevation the weir, relative to the channel floor beneath the analog water level sensor (same channel), will be commanded to when a Water Level Signal Fault is active in the channel. This position is configured to prevent flooding in system when water level is unknown.

Weir Position Deadband Inches
The weir gate position deadband applied when the weir gate is commanded to move to either the Max Position or Safe Position. Once inside this deadband, the weir gate will not be commanded to move.

Weir to AWLS Distance Inches The distance from the weir gate that the analog water level sensor has been installed.

Effective Weir Length Inches The effective weir gate width is the measured weir gate width less the diameter of each weir gate stem.

Channel Width Inches The width of the UV Channel at the analog water level sensor.

Total Travel Seconds The time taken for the weir gate to travel from the Fully Raised position to the Fully Lowered position.

Max. Position Delay Seconds The time delay from when the inlet gate starts closing to when the weir gate is commanded to Max position.

Max. Pulse Duration Seconds The maximum allowable weir pulse time when raising or lowering the outlet weir gate.

Outer Update Rate Seconds
If the measured water level error is greater than the “Inner DB” limit and less than or equal to the “Upper DB” limit, the weir gate will be commanded to move for a calculated pulse duration and then wait for the “Update Outer” time period in order to measure the resultant water level effect.

If the measured water level error is outside of the Lower/Upper deadband range but is less than or equal to the “Inner DB” limit, the weir gate will be commanded to move for a calculated pulse duration and then wait for the “Update Inner” time period in order to measure the resultant water level effect.

If the water level error is greater than the “Outer DB” limit, the weir gate will move continuously until the measured water level error is less than the “Outer DB” limit at which time the gate will be commanded to move for a calculated pulse duration as described above.

Inner Update Rate Seconds
Outer Deadband Inches
Inner Deadband Inches