JOWA

WORKING DRAWING

UV Sterilizer
(UV4)

FOR

ZHEJIANG SHIPBUILDING [Link]

Hull No.:DY2001/2002/2003/2004

- WATERFILTER JOWA AB TELEFON JOWA (Shanghai) TELEFON:

- UV STERLIZER Tulebo 865 +46(0)31-795 00 40 Environmental Protection (86-21)-33906890/91/92
- SILVER STERLIZER S-428 34 KÄLLERED TELEFAX Equipment Co., Ltd TELEFAX:
- OIL CONTENT METER GÖTEBORG, SWEDEN +46(0)31-795 45 40 Room No.507 , North (86-21)-33907550
- OILY WATER SEPARATOR TELEX Building, 77 EShan E-MAIL:
- SEWAGE TREATMENT PLANT 21358 JOWA S Road, Pudong New Area jowasha@[Link]
- OIL DISCHARGE MONITORING Shanghai 200127 China
- AND CONTROL SYSTEM (ODMS)
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

1.0 Introduction
The unit is meant to sterilise the potable water immediately before it reaches the consumers.
It contains highest quality ultraviolet lamps which are powered by electronic, highfrequency,
ballast to reach the best light quality and longest lifetime for the lamps. It is mechanically
designed to withstand the vibration experienced onboard a vessel. The sterilising process is
controlled by a microprocessor which collects data from the UV-sensor and the lamp
monitoring system. It gives all necessary information to the user in a display window. If a
lamp fails, it tells you which lamp to change. It also tells you when to change all lamps
because of age. If the sterilising dosage is below acceptance the unit shuts off the flow and
alarms.

1.1 General

To obtain all advantages operating the JOWA UV unit, be assured all users have adequate
education for the equipment.

Ensure that the installation is correctly maintained and operated in accordance with the
instruction in this manual. Otherwise the functions of the equipment cannot be guarantied.

Before installation and start up, read this manual carefully.

Supplier and manufacturer: JOWA AB

Tulebovägen 104
S-428 34 Kållered, Gothenburg
SWEDEN
Telephone: +46 31 726 54 00
Fax: +46 31 795 45 40
e-mail info@[Link]
Homepage: [Link]
 Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ
2.0 Specifications
UV1 UV2 UV3 UV 4 UV 5
Capacity: 3 3 2,5-4,1 m3/h 3 5,8-10,5 m3/h
0,9-1,3 m /h 1,2-1,8 m /h 3,8-6,1 m /h
depending on depending on
depending on depending on depending on
water quality water quality
water quality water quality water quality
(T50=60%=>2,5 (T50=60%=>5,8
(T50=60%=>0,9 (T50=60%=>1,2 (T50=60%=>3,8
m3/h - m3/h -
m3/h - m3/h - m3/h -
T50=90%=>4,1 T50=90%=>10,5
T50=90%=>1,3 T50=90%=>1,8 T50=90%=>6,1
m3/h) m3/h)
m3/h) m3/h) m3/h)
Number of
1 pcs 2 pcs 3 pcs 4 pcs 5 pcs
lamps:
Type of
JOWA 15W JOWA 15W JOWA 15W JOWA 15W JOWA 15W
lamp:
Voltage: 220VAC
220VAC 60Hz 220VAC 60Hz 220VAC 60Hz 220VAC 60Hz
60Hz
Power
35W 50W 65W 80W 95W
consumption
Power at 254
4,7W 9,4W 14,1W 18,8W 23,5W
nm:
2 2 2 2
UV-dosage: 36000µWs/cm 36000µWs/cm 36000µWs/cm 36000µWs/cm 36000µWs/cm2
Alarm: Relay output, Relay output, Relay output, Relay output, Relay output,
normally normally normally normally normally
open/closed 1A open/closed 1A open/closed 1A open/closed 1A open/closed 1A
resistive resistive resistive resistive resistive
Ambient
0-50 °C 0-50 °C 0-50 °C 0-50 °C 0-50 °C
temperature
Dimensions 129x471 mm 114,3x471 mm 154x471 mm 168,3x471 mm 219,1x471 mm
chamber: (Diam. x Height) (Diam. x Height) (Diam. x Height) (Diam. x Height) (Diam. x Height)
Dimensions 200x300x80 200x300x80 300x400x120 300x400x120 300x400x120
control unit: (W x H x D) (W x H x D) (W x H x Dh) (W x H x D) (W x H x D)
Working
max 10 bar max 10 bar max 10 bar max 10 bar max 10 bar
pressure:
Dimension DN32 female DN32 female DN32 female DN32 female DN32 female
inlet: threaded threaded threaded threaded threaded
Dimension DN32 female DN32 female DN32 female DN32 female DN32 female
outlet: threaded threaded threaded threaded threaded
Dimension
DN25 female DN25 female DN25 female DN25 female DN25 female
solenoid
threaded threaded threaded threaded threaded
valve:
Empty
15 kg 15 kg 27 kg 32 kg 35 kg
weight:
Material
AISI316L AISI316L AISI316L AISI316L AISI316L
chamber:

Diagram 2.0.1 -Specifications for UV 1-5

UV-sensor at 254 nm.

Lamp monitoring system.
Shock mountings on chamber and cabinet.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

3.0 Installation instructions

3.1 Delivery
All internal piping and electric cables are already installed on the UV-unit, in principle there
only has to be water inlet and outlet, main power supply, alarm and a sewer for the drain to be
connected.

3.2 Location
Locate the UV-unit so there is enough space around it for maintenance and service. For lamp-
change of UV1-5, there has to be minimum 600mm free space below chamber. For lamp-
change of UV31-51, there has to be minimum 1000mm free space below chamber. Mount the
UV-unit sufficiently by bolts. Bolt holes are prepared, refer to drawings chapter Drawings,
layout.

3.3 Piping
The place of installation in the piping system is very important. The fundamental rule is to
install the UV-unit as close as possible to the tapping point(s), i.e. after equipment as filter,
pumps, tanks etc.

Connect water inlet, water outlet in accordance with drawings, see chapter Mechanical
Drawings. Make sure to use rubber hoses between piping and UV-chamber to protect the unit
from vibrations and mechanical forces. Mount valves on water inlet and water outlet. They
are necessary when dismounting quartz-jackets.

3.4 Drain outlet

Place a funnel connected to a sewer beneath the drain outlet of the chamber, see drawings
chapter Mechanical Drawings.

3.5 Electric connections

The electric power is 220 VAC 60 Hz and should be connected at terminal 1, 2 and ground
in the control cabinet, see chapter Electrical drawings for more information.

3.6 External alarm connection

The external alarm connects to terminal 3, 4 or 4, 5 dependable if you need a normally closed
signal or a normally open signal. 3, 4 is NC and 4, 5 is NO. For more information see chapter
Electrical drawings.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

4.0 Operation
4.1 Initial check

Before starting up check following items:

• Check voltage (230 VAC 50/60 Hz)

• Fill the chamber by:
o Opening the upper drain valve.
o Open valve on water inlet slowly to avoid breaking the quarts-jackets.
o Let the chamber fill up till water comes from upper drain valve and close this
one.
o Open water inlet valve completely.
• Make sure no leakage.
• Make sure lamps are mounted and connected.
• Make sure external alarm is connected in a proper way.

4.2 Operation instructions

1. Open manual valves for inlet- and outlet water.

2. Turn POWER-switch to ON.

3. The main/default screen on the LCD display shows the status of the sterilizer.

4. The solenoid valve is time delayed by 2 minutes for lamps to reach full output. If the
solenoid valve is closed “Preparing lamps..” is shown on the first row of the LCD
display. When the solenoid valve is opened the status information is changed to
“Sterilizing”.

5. The UV-unit operates fully automatic and calls for attention if anything is wrong
(internal alarm + external alarm). Everytime the lamp/lamps has/have been turned off
the solenoid valve is delayed by 2 minutes.

4.3 Valve settings during normal operation

• Close the drain valves.

• Open valves for inlet and outlet.
• Close bypass valve if there is one.
• The solenoid valve is controlled by the control cabinet.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

4.4 Control cabinet

• Turn power switch ON, green diode lights up.

• All necessary information can be read in the display window. Normally you can read
UV-intensity and hourmeter. You can get further information such as alarm values, total
operating time etc by navigating in the meny system. An overview of the menysystem is
shown in diagram 4.5.1.
• If an alarm/warning arise the alarm diode is lit up and the display gives you information
about the error and what to do to about it. There are two different alarm that will shut
off the chamber i.e pull the alarm relay and close the solenoid valve:

1. Intensity alarm
2. Lamp failure

There are also two different warnings that might occur, if they occur the alarmrelay is
pulled but the UV sterilizer will continue functioning as normal:

1. Hourmeteralarm1
2. Hourmeteralarm2

The possible error/warning screens are shown in diagram 4.6.1-4.6.4.

Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

4.5 The Menu System

Sterilizing / Preparing lamps..

Intensity: xx %
Hourmeter: xxx h

UP / DOWN

Intensity: xx %

Alarm at: 49 %

UP / DOWN

Hourmeter: xx h
Alarm1: 7300h
Alarm2: 8000h
Total time: xxxx h
UP / DOWN YES / NO

Reset Hourmeter? This will reset

NO Reset Hourmeter when YES Hourmeter.
All lamps changed. Are you sure?
YES=OK NO=Cancel YES=OK NO=Cancel

UP / DOWN

Change language? Choose language: English

YES
NO
YES=OK NO=Cancel Press UP/DOWN YES
YES=OK NO=Cancel
UP / DOWN

Program rev. x.x

Serial number:
xxx-xxxx
UP / DOWN

JOWA AB
Tel: +46-31 726 54 00
Fax: +46-31 795 45 40
info@[Link]

UP / DOWN

read more about

JOWA at:
[Link]
UP / DOWN

Do you want to
NO Perform a selftest? YES Please wait . .

YES=OK NO=Cancel 25 seconds

Problem with lamp/HF

nr: x, x, x, x, x Selftest successful!
Test one more time? …
Yes_OK NO=Cancel

Diagram 4.5.1 -Overwiew of the menu system

Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

4.6 The alarm / warning screens

Intensity alarm! Low intensity

Chamber is shut off. YES Clean chamber
More info? Press YES to clear
YES=OK NO=Cancel

NO YES

Sterilizing / Preparing lamps..

Press YES to clear! YES

Intensity: xx %
Hourmeter: xxx h

Diagram 4.6.1 -Alarm screen for Intensity alarm

Lampfailure! Sterilizing / Preparing lamps..

YES
Change lamp: x
Press YES to clear! Intensity: xx %
Hourmeter: xxx h

Diagram 4.6.2 -Alarm screen for Lampfailure alarm

Hourmeteralarm1: 700h Order +46-31 726 54 00

left to change lamps YES Part # 37000-00011
More info? Press YES to clear!
YES=OK NO=Cancel
YES

Sterilizing / Preparing lamps.. Order +46-31 726 54 00

Part # 37000-00012
Intensity: xx % Press YES to clear!
Hourmeter: xxx h

Diagram 4.6.3 -Warning screen for Hour meter alarm1

Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

Hourmeteralarm2: This will reset

Change all lamps! YES Hourmeter.
Reset Hourmeter? Are you sure?
YES=OK NO=Cancel YES=OK NO=Cancel

NO

Sterilizing / Preparing lamps..

YES / NO
Intensity: xx %
Hourmeter: xxx h

Diagram 4.6.4 -Warning screen for Hour meter alarm2

4.7 UV-lamps

The JOWA UV-steriliser is equipped with special made, high quality UV-lamps.
The length of life is 8000 hours. It is important to change lamps after this time to avoid
unnecessary breakdowns. The wavelength is 254 nm.

To change lamps read chapter Maintenance and service chapter - Replacement of UV-lamps.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

5.0 Maintenance and service

To reach maximum output of this unit it is important to do the regular cleaning procedure.
The interval between cleaning depends on the water quality, normally about four times a year,
but if the intensity is becoming weak it might depend on scaling on quartz-jackets and UV-
sensor sight-port. The scaling can be removed by cleaning.

The regular cleaning procedure takes about 40 minutes and the unit has to be closed while
cleaning. If the regular cleaning frequency is too low, the scale may be hard to remove with
this normal cleaning procedure, in this case the quartz-jackets has to be dismounted and
cleaned by hand.

5.1 Regular cleaning procedure for UV-chamber:

To obtain maximum disinfection it is important to perform this regular cleaning procedure.

1. Close inlet and outlet valves. Let the UV-lamps be in operation.

2. Open the drain valves and drain out a bucket (5-10 litres).
3. Fill a bucket with hot water, the same amount that was drained out, and mix
it with citric acid according to this table:
UV1 0,2 kg
UV2 0,2 kg
UV3 0,3 kg
UV4 0,4 kg
UV5 0,6 kg
UV31 0,6 kg
UV41 0,8 kg
UV51 1,2 kg
4. Fill the chamber with the solution through the upper drain valve. Use a
funnel.
5. Let the solution work for about 30 minutes.
6. Drain out the cleaning solution.
7. Slowly open the valve for water inlet and let fresh water flush trough the
chamber for a while.
8. Close the lower drain valve and let the chamber get filled.
9. Close upper drain valve.
10. Open inlet and outlet valves.
11. The UV-unit is ready for normal use.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

5.2 Advanced cleaning procedure (manual cleaning)

Once and a while, or when the regular cleaning procedure is not enough, do this
complete and more advanced cleaning procedure.

1. Close inlet and outlet valves.

2. Turn the power off.
3. Open drain valves and drain the chamber completely.
4. Disconnect the lamps and unscrew them.
5. Dismount the quartz-jackets.
6. Clean them with a soft cloth and industrial alcohol.
7. Remount the quartz-jackets.
8. Disconnect the UV-sensor and dismount it.
9. Dismount the UV-sensor quartz-glass.
10. Clean it with a soft cloth and industrial alcohol.
11. Remount the UV-sensor quartz-glass and gaskets.
12. Close lower drain valve and open inlet valve slowly till the chamber is full.
Then close upper drain valve and pressurise the chamber. Check for leakage.
13. Remount UV-lamps and connect them.
14. Remount UV-sensor and connect it.
15. Open inlet and outlet valves.
16. Turn the power on.
17. The UV-unit is ready for normal use.

5.3 Service of the UV-sensor sight port

To give the UV-sensor sight port full service do the following procedure.

1. Close inlet and outlet valves.

2. Turn the power off.
3. Drain the chamber completely.
4. Disconnect the UV-sensor and dismount it.
5. Dismount the UV-sensor quartz-glass.
6. Clean it with a soft cloth and industrial alcohol.
7. Check gaskets and replace them if necessary.
8. Remount the UV-sensor quartz-glass and gaskets.
9. Close lower drain valve and open inlet valve slowly till the chamber is full.
Then close upper drain valve and pressurise the chamber. Check for leakage.
10. Remount UV-sensor and connect it.
11. Open inlet and outlet valves.
12. Turn the power on.
13. The UV-unit is ready for normal use.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

5.4 Replacement of UV-lamps

It is very important to change all lamps every 8000 hours, as the lifetime is limited. Do
follow the computers recommendations. It will tell you when to change the lamps. It
also gives you a warning 700 hours before so you can check if you have enough spare
lamps.
Change all lamps at the same time to avoid unnecessary breakdowns.

To change the lamps do as follows:

1. Turn the power off.
2. Disconnect lamp number one (fast-coupling).
3. Unscrew it.
4. Wipe the new lamp with a soft cloth and industrial alcohol.
5. Screw the new lamp in and connect it. Do not touch it with bare hands after
cleaning it.
6. Repeat this procedure for the rest of the lamps, in order of number to avoid
mixing of new and old lamps.
7. Reset hour-meter by entering the menu, using the arrow-buttons on the cabinet,
and chose “Reset hour-meter” and then press “YES”. This will reset the hour-
meter but the total time of use will be left.
8. Make sure to order new lamps to avoid stoppage.

5.5 Replacement of quartz-jackets and O-rings

If a quartz-jacket breaks the unit is unusable. Therefore it is very important to have at

least one for spare.
The O-rings are suitable for UV-light but they need to be changed some time.
Service procedure:
1. Close inlet and outlet valves.
2. Open drain valves and empty the chamber.
3. Disconnect and unscrew the lamps.
4. Unscrew the quartz-jacket.
5. Put a new O-ring on the new quartz-jacket.
6. Wipe the new jacket off with a soft cloth and industrial alcohol. Do not touch it with
bare hands after cleaning it.
7. Mount it in the chamber and tighten it by hand.
8. Pressurise the chamber with water and check for leakage.
Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

6.0 Troubleshooting
The alarm indication lamp on the front of the control cabinet and the external alarm output is
affected by the UV-sensor and the lamp monitoring system.
The alarm output is by delivery connected to the terminals 3, 4 and 5, this means that terminal
4 is COMMON, terminal 3 is NC and terminal 5 is NO.

Inside the control cabinet there is one glass fuse 5x20mm located on the interface-board.

F1: 1A fuse for circuit-board

Date: 2006-09-18 JOWA UV-STERILISER
Rev: E JOWA UV
Sign: AS/MÖ

6.1 Trouble shooting chart:

SYMPTOM PROBABLE CAUSE ACTION

1. Low reading on 1. Bad UV-lamp(s) 1. Change lamp(s), see 5.4
intensity meter. 2. Dirty chamber 2. Follow procedure 5.1 or 5.2 to
clean the chamber
3. Dirty UV-sensor sight-port. 3. Clean sight-port, follow
procedure 5.3
4. UV-sensor faulty. 4. Take out the UV-sensor and
shine on it with a flashlight.
Check if the intensity meter
respond. If not, change UV-
sensor.
5. Bad water quality. The water is 5. Pre-treat the water in a way to
to dirty to sterilise. get better transmission.

2. Solenoid valve 1. Alarm value on intensity 1. Follow instructions for

does not open. meter. symptom 1.
2. Check voltage to solenoid
2. Solenoid valve is faulty. valve. Correct value is
230VAC. If correct value
change solenoid valve.
3. If no voltage to solenoid valve
from circuit board, and no
alarm exists, circuit board may
be faulty and needs to be
3. Circuit board faulty. changed. Contact JOWA AB.
(Do think about the 2 minutes
time delay for solenoid valve
to open after power off)
4. New UV-lamp not 1. UV-lamp faulty. 1. Change lamp. See 5.4
working. (If the lamp 2. Electronic ballast faulty. 2. Check voltage to ballast from
monitoring system circuit board. Correct voltage
tells you to change a is 230VAC. If correct voltage
lamp you just but lamp does not work, the
changed.) electronic ballast may be
faulty and needs to be
changed. Contact JOWA AB.
3. Circuit board faulty. 3. If no voltage to ballast from
the circuit board it may be
faulty and needs to be
changed. Contact JOWA AB.
 6 5 4 3 2 1

2 AIR INLET DN15

FEMALE THREAD

D 8 D

116
20
6

Water inlet DN32

Female thread

98
25

592
5
263

273
9 4

364
C 3 C
9
5

8
n11 (4x) 7
DRAIN DN15 Water outlet
FEMALE THREAD DN25
10 Female thread
770 10 4 UV Lamp 15W GLASS 1 kg 37000-00011
730 9 1 UV SENSOR CONNECTOR PTFE 0 kg 37000-00032
321 8 2 Ballvalve w Butterfly Handl DN15 Brass 0.2 kg 19001-15157
B B
7 1 SOLENOID VALVE DN25 Brass 2 kg 22304-01000
191
6 1 Chamber UV4 AISI316L 10 kg 37-0040-01-03
97 5 3 VIBRATION DAMBER NITRIL 0 kg 37010-00023
11
4 1 Right Bracing S235 0.6 kg 37-0099-01-28
3 1 Left bracing S235 0.6 kg 37-0099-01-27
2 1 Electrical Cabinet UV3-51 AISI 316L 3.2 kg 37000-00010
120

1 1 MOUNTING FRAME S235 5.8 kg 37-0099-01-26

156

ITE QT DESCRIPTION MATERIAL MASS ID NUMBER

192

FILE NAME SIZE MODEL ID SCALE

37-0040-01-01 [Link] A3 37-0040-01-01 1:5
240

DRAWN 2006-08-31 anna s

CHECK JOWA AB
A APPR. TULEBO 865 A
Göteborg-SWEDEN
REV #3 060905 AS Teleph. +46 31 726 54 00
Dry mass: 32 kg GA
Maintenance area: 500mm infront and 600mm under unit
Working pressure: max 10 bar
JOWA UV 4 ID NO

37-0040-01-01
JOWA UV STERILIZER
6 5 4 3 2 1