TABLE OF CONTENTS Section 1 General Information 1A. Description 1B. Specifications 1C. Accessories 1C.i Ozone Generation 1C.ii Required Accessories Section 2 Installation 2A. Location 2B. Electrical 2C. Plumbing 2D. Gas Connections 2E. Remote Control Section 3 Operation 3A. Control Panel Overview 3B. System Start-Up 3C. System Shut Down 3D. Standard Operating Procedures Section 4 Maintenance and Service 4A. Preventative Maintenance 4B.
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TABLE OF CONTENTS 5C. Hazards 5C.i Health Hazards Detection 5C.ii Health Hazards Effects on Humans 5C.iii Electrical Hazards 5C.iv Fire Hazards 5C.v Chemical Action 5D. Precautions for Safe Handling and Use 5D.i Ozone Monitors 5D.ii Ventilation 5D.iii Emergency Procedure 5D.iv Respiration Protection 5D.v Education and Training 5E. System Operations and Maintenance 5E.i Safety Precautions and Equipment 5E.ii Maintenance Requirements 5F. Monitoring Equipment and location 5G. First Aid Procedures 5G.i General Information 5G.ii Inhalation 5G.iii Eye Contact 5G.iv Precautions 5G.v Emergency Information Form Section 6 Ozone Limited Warranty Section 7 Dimensions...
SECTION 1 GENERAL INFORMATION IMPORTANT SAFETY INSTRUCTIONS - PLEASE READ CAREFULLY BELOW AND FOLLOW ALL INSTRUCTIONS Read this manual completely before the operation WARNING: High voltage is present inside the enclosure USE EXTREME CAUTION • Operate the generator with safe access to electrical power •...
SECTION 1 GENERAL INFORMATION 1A. Description Absolute Ozone® are ozone generator that produces up to 200 grams of ozone per hour with an ozone concentration of up to 22% by weight or as specified in the performance test report supplied with every unit. Absolute Ozone® Ozone generators are designed to produce ozone for a variety of applications such as: • Water Disinfection for Bottled Water Plants, Medical & Pharma- ceutical Facilities, Swimming Pools, etc. • Industrial Processes, Chemical Production and Laboratories, Elec- tronic Production, Mining • Aquatic Life Support Systems for Marine Mammals, Fish Hatcher ies, Large Aquarium • Food Processing, Food Processing Facilities Disinfection, Food Preservation • Soil Remediation, Ground Water Remediation • Wineries Facilities Disinfection, Barrel Disinfection • Cooling Towers Water Treatment, Technological Processes Water Treatment • Potable Water Disinfection for Small Communities • Waste Water Treatment for Industrial Plants, Technological Pro duction Processes, Commercial Facilities Waste Water Treatment, Dangerous Chemical and Bacteria Treatment, etc.
SECTION 1 GENERAL INFORMATION 1C.i Ozone Generation • Air Compressor: The air compressor pumps ambient pressurized air into the oxygen generator/concentrato • Oxygen Generator/Concentrator: separates Oxygen from Nitrogen and supplies it directly into the ozone generating cell inside the ozone generator Absolute Ozone® ozone generators cell design is based on propri- etary Microfluidic Platform technology, constructed from ozone resis- tant materials, and offers extremely high performance and reliability. The ozone cell is designed to be absolutely maintenance and ser- vice-free, the anticipated service life is 15-20 years. 1C.ii Required Equipment and Accessories • Oxygen Generator/Concentrator: The oxygen generator uses a PSA (pressure swing absorption) molecular sieve bed to remove dirt, moisture, nitrogen and other trace gases, producing oxygen at greater than 90% purity and less than -60C dew point. The air compressor pumps ambient air into the oxygen generator input and then the oxygen generator outputs oxygen (O2) feed gas into the ozone generator cell and enables the ozone generator to produce ozone effectively at up to 14% by weight ozone concentration. In our experience, oxygen generators manufactured by AirSep work very well with Absolute Ozone® ozone generators. • Oxygen Filter: To protect the Absolute Ozone® generator from sieve particles in case of oxygen generator failure or malfunction, we recommend installing an oxygen filter after the oxygen genera- tor and before the ozone generator...
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SECTION 1 GENERAL INFORMATION 1C.ii Required Equipment and Accessories • Ozone Flow Control Valve (Flow Meter): This should be installed downstream from (after) the ozone generator to maintain working pressure across the ozone cell as specified for the optimal perfor- mance • ALD 2000 Flood Prevention Device: We recommend installing an ALD 2000 with every ozone system treating water to prevent water freom backing up into the ozone generator and damaging it - Non-return (check valves) do not provide 100% water flooding protection to the ozone generator - WE DO NOT RECOMMEND installing the ozone generator WITHOUT the ALD 2000 device when treating liquids...
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SECTION 1 GENERAL INFORMATION 1C.ii Required Equipment and Accessories Continued Ozone Injector for Water Treatment Applications (Venturi): Inlet wa- ter flows through the pump and through the ozone injector, creating a vacuum that pulls ozone gas from the ozone generator and injects the ozone gas into the water flow. The injector should be sized to dissolve a minimum of 90% of the ozone gas into the water flow continuously. Ozone De-gas Chamber and Off-Gas Device: Ozone en-riched wa- ter from the ozone injector flows into the de-gas chamber where the counter-current design forces any undissolved ozone gas through the float valve-protected top vent to the ozone destructor. Ozone Destructor: Undissolved ozone gas passes through the heated catalytic ozone destructor that is made up of non-consumable manga- nese dioxide (heat-protected from moisture fouling). The manganese dioxide and heat offer redundant ozone destruct capabilities.
SECTION 2 INSTALLATION 2A. Location The ATLAS/TITAN/MAGNUM Ozone Generators are designed to ® be installed on the wall, on the rack or stack up system in convenient location mobile cart or skied.Allow for access to protected electrical power and required gas connections and cooling air to the Ozone Generator. DO NOT OBSTRUCT COOLING AIR VENTS ON THE OZONE GENER- ATOR. The unit can be installed indoors or outdoors IF protected from weather elements. Ambient working temperature from -10C to +30C Reversible Universal Control Panel We had to strive for efficiency in every detail, right down to how it connects andmounts. So we contributed to a new reversible universal control panel. Designed to efficiently accommodate installing the AT- LAS in an upright or downright position Control Panel Remove 4 Tighten Screws Now the ATLAS/ In Upright screws and Magnum can be Position reverse the installed in this control panel position in the down- right position...
SECTION 2 INSTALLATION Stackable Without a Rack Every Absolute Ozone ozone generator comes equipped with at- tachment tabs that can be reversed to provide you with the liberty to install the ATLAS one on top of another in a rack mount formation but without requiring a rack. Reversible tabs Loosen screws Tighten Screws Now the ATLAS/ in original and swing Magnum can be position the tab into installed in this the upright position position 2B. Electrical Main Power Supply Circuit: Generators are supplied with a 3-5 feet power cord. Connect the power cord to a standard grounded 15 Amp (10 Amp International) power source, according to a local electrical code only. 2C. Plumbing When injecting Ozone into the water, all measures should be taken to protect the Generator Cell from water exposure, which may cause internal cell damage. A small tank with/or an automatic water drain system is recommended.
2D. Gas Connections The Ozone Generator should be connected by tubing made from ma- terial appropriate for ozone and oxygen applications. Connect the Ozone Generator according to indications on input and output bulk- heads. All efforts should be made to protect the generator from expo- sure to excessive pressure fluctuations, which may lead to the damage of electronic circuitry and Ozone Cell. For applications where pressure fluctuations are possible, we strongly recommend the installation of a buffer tank with an appropriate hi-low pressure switch. It is VERY IM- PORTANT to protect the Generator from any possible contamination from the Oxygen Concentrator or water injection device, by installing an oxygen monitor and filter upstream from the Generator and an automatic water drain device in combination with a check valve. The concentration of feed oxygen should not be below 90%. 2E. Remote Control Absolute Ozone® ozone generators are equipped with standard “On/ Off” remote control terminals that can be controlled remotely by the operator, ambient ozone monitor, or PLC. These contacts must be connected to dry contacts only (not connect- ed to any ground or voltage source of any kind).
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SECTION 2 INSTALLATION 2E. Remote Control 4-20mA On/Off Power Remote Control • Remote control of ozone production level by 4-20mA at 10 V signal, no special switching for both of these signals required • Remote On/Off. Remote Switch must be normally open for the gen- erator to be “On” and closed to stop the Ozone production. • That switch has to be connected to dry contacts only (not connected to the ground on any kind or to any voltage source AC or DC) • Remote Ozone Generator status indicator. a. During Normal Ozone generator operation pin 5 is normally open, pin 6 commons, pin 7 is normally closed. b. If Remote Control Switch is off or safety shutoff is activated the circuit will be closed between pins 5 & 6.
SECTION 3 OPERATION 3A. LCD Control Panel Overview Here is a general description of the controller and the features it of- fers: All Absolute Ozone® generators come with 4-20mA remote power control as a standard feature that allows selecting power going to the ozone cell that is later automatically monitored and maintained by a control system, regardless of minor voltage or pressure deviations. It is standard for all Atlas & Magnum ozone generators. On top of it, the new generation controller protects the generator from connecting to an incorrect power source, · Incorrect wiring or voltage applied to the remote control terminals. · Incorrect operating pressure. · Ozone cell contamination by water or similar. · Overheating or failure of the cooling system, etc In addition, all Absolute Ozone® ozone generators have: · Status indicator that has No/Nc contacts that will change the status every time the generator is not producing any ozone regardless of the reason. · On/Off contacts that are “ NO” normally open. If the contacts are closed by an external dry contact relay, the generator will move into standby mode. Once the contacts are open, the generator will start producing ozone again.
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SECTION 3 OPERATION Photos of typical LCD 5” control touch screen: The LCD screen shows the following parameters: • Selected or Expected power setting %, so you will be able to see on the screen power selected by the remote control or slider. • Actual power % & Watt going to an ozone cell. • The cell voltage V • Current Amp going to the ozone cell, • Gas pressure inside the ozone cell • Temperature inside the ozone cell. • The LCD screen will allow by touch to switch the generator on and off and to adjust the desired power by moving the slider on the screen with your finger.
SECTION 3 OPERATION • In a case when incorrect operating parameters are applied to an ozone generator the unit is switched off by the control system and the LCD screen will indicate which of the parameters caused the generator shutdown. • In a safety shutdown mode the generator will be constantly moni- toring operating parameters and the moment they are corrected the generator will restart automatically, without any assistance. • I.e. if there is a power spike or if there is a pressure drop caused by temporary power failure and interruption of oxygen supply, the moment the pressure is normal again or the voltage supplied is with- in the operating range, the generator will restart and will produce ozone again. 3B. System Startup 1. Make sure the Ozone Generator enclosure is securely attached to an appropriate frame or wall Ozone Generators Stack. 2. Make sure all connections to the generator, power and gas are made according to local codes and regulations. 3. Purge the generator with 90% or higher concentration oxygen and assure a free flow of oxygen through the system and removal of con- taminants. Conduct system leak test applying working pressure +/- 10% using oxygen only. Adjust gas pressure across the cell according to specifications using downstream Control Valve (on flow meter) and pressure gauge (supplied by the installer). 4. Plug the system into a specified receptacle. 5. Flip the Power Switch into the “ON” position. 6. Slide the red dot on the power control slider upwards to adjust to desired power from 0-100%according to supplied “Ozone Generator Performance Test” chart. Now the generator is at optimum production mode and ozone should be flowing through the system.
SECTION 3 OPERATION 3C. System Shutdown 1. Slide the red dot on the power control slider downwards to adjust power from 0%. (No ozone is produced at this time.) 2. Switch the power switch to the OFF position. 3. Unplug the system from the power source if required. 4. Close down the downstream Control Valve (located on the flow me- ter -supplied by installer) to protect the unit from accidental flooding. 5. Turn the oxygen source off. 3D. Standard Operating Procedures NOTE: To assure a long trouble-free service life of the ozone Genera- tor, provide the following operating conditions: • Make sure that the oxygen concentrator is maintained properly and is producing oxygen at greater than 90% purity and less than -60°C dew point. Check sieve conditions and replace it as often as recom- mended by the manufacturer • Install an oxygen filter and oxygen dryer between the oxygen con- centrator and the Ozone Generator, check the condition and replace a cartridge to protect Ozone Generator from sieve particles in case of oxygen generator failure and moisture. • Make sure to maintain working pressure across ozone cells as speci- fied for the generator protection and most efficient ozone production. • When injecting ozone into water make sure to protect the generator from flooding by installing a device capable of preventing water back- up. Check valves usually start leaking after a few days of operation in ozone and cause serious damage to the ozone cell. We recommend using devices, which could automatically drain water out of the ozone line and stop it from entering the ozone cell.
SECTION 4 MAINTENANCE AND SERVICE 4A Preventative Maintenance Generally, Absolute Ozone® are maintenance-free although it is useful to check the Ozone Generator for proper operation: 1. Make sure there are no warnings on the LCD screen. 2. Inspeccione visualmente las conexiones. 3. Make sure that all air vents are clear of any obstruction. Monthly: 1. Make sure that all system equipment (oxygen concentrator, air compressor, etc.) is maintained according to the manufacturer 2. Remove and replace or clean filter cartridges and other devices if installed and required. 3. Perform general cleaning of cabinet exterior after disconnecting the equipment from the electrical source. 4. Using clean/dry compressed air, blow out the interior of the cab- inet, taking special care around electronic components and wir- ing. 4B. Troubleshooting Knowledge of electrical applications is required for troubleshooting. Contact a certified electrician if you are unsure of your ability to ser- vice the equipment. If any problem persists, please call 780-486-3761. We will have one of our system engineers discuss your situation with you over the phone.
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SECTION 4 MAINTENANCE AND SERVICE • Symptom (Warning Message): INCORRECT REMOTE CONTROL VOLTAGE Please make sure the voltage you have supplied to the remote control (4-20 MA signal) is not higher than 10V. • Symptom (Warning Message): OZONE CELL CONTAMINATION The ozone sensor detected ozone cell contamination by water or pos- sibly some other conductive liquids. please switch the ozone generator off, locate and eliminate the source of the contamination. while having power off. run oxygen through the ozone cell for several days to dry the liquid and/or other contaminants out and then try to restart the ozone generator. • Symptom (Warning Message): SYSTEM COMMUNICATION PROB- If after several attempts does not restart, please contact us technical support • Symptom (Warning Message): OZONE SENSOR PROBLEM If after several attempts does not restart, please contact us technical support...
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SECTION 4 MAINTENANCE AND SERVICE • Symptom (Warning Message): OZONE CELL PRESSURE TOO LOW Please make sure there are no restrictions on the oxygen line coming to the ozone generator and that the flow is only adjusted on the ozone line after the ozone generator to maintain correct working pressure, if the pressure is too low due to incorrectly set pressure regulator or failure of oxygen generators, please rectify the problem and the ozone generator will continue operation. • Syptom (Warning Message): OZONE CELL PRESSURE TOO HIGH Please adjust oxygen pressure regulator to specified pressure and that will rectify this problem and warning message. • Symptom (Warning Message): OZONE CELL TEMPERATURE TOO HIGH Make sure that the ambient temperature in the installation room is be- low 25 c, check that there is good unrestricted cooling airflow through the ozone generator (not obstructed on either side of cooling grills).
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5B. i General Safety Informatio - Ozone Properties • Colorless to blue gas (greater than -169 F) • The characteristic odor is often associated with electrical sparks or lightning in concentrations of less than 0.02 ppm • Highly chemically reactive • Non-flammable, non-carcinogenic • Hazardous polymerization can occur in some rear materials • Spontaneously decomposes to oxygen gas 5B. ii General Safety Informatio - Ozone Uses • Air and water disinfection • Surface sanitation •...
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5C.i Health Hazards – Detection Levels Gaseous ozone can be detected in the air by its distinctive odor at concentrations of about 0.02 ppm. Although each nose varies, olfacto- ry fatigue occurs quickly. Initial small exposure may reduce cell sensitivity and/or increase mu- cous thickness producing resistance to low gaseous ozone levels. DO NOT RELY ON ODOR AS A WARNING OF HIGH OZONECON- CENTRATIONS. The Permissible Exposure Level (PEL) or time-weighted concentration for gaseous ozone to which workers may be exposed is 0.1 ppm av- eraged over 8 hours, 5 days a week (OSHA). The short-term exposure limit is 0.3 ppm averaged over 15 minutes. The concentration of 5.0 ppm ozone in air is generally accepted as Immediately Dangerous to Life or Health (IDLH). 5C.ii Health Hazards – Effect in Humans Gaseous ozone acts as a primary irritant, affecting mainly the eyes, up- per respiratory tract, and lungs. Inhalation produces various degrees of respiratory effects from irritation to pulmonary edema (fluid in the...
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5C.iii Electrical Hazards Turn OFF all power switches and disconnect the power cord from the power source receptacle before performing service work. Failure to do so could result in serious injury or death. Operate the generator with safe access to electrical power. Connect the generator to a G.F.C.I. type receptacle or as required by local elec- trical code & regulations. Do not bury the electrical cord. To reduce the risk of electrical shock, replace the damaged cord immediately. 5C.iv Fire Hazards Ozone is nonflammable. Decomposition of ozone into oxygen gas (O2) can increase the strength of fire. Ozone is unstable at room tem- perature and spontaneously decomposes to oxygen gas. Avoid igni- tion sources such as heat, sparks, and open flame. Keep away from strong combustible materials such as grease, oils, and fats. 5C. v Chemical Accion Ozone is chemically incompatible with all oxidizable materials, both organic and inorganic.
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5D.i Ozone Monitors Ambient ozone monitoring equipment should be installed in the areas where ozone is being generated or applied. (See Monitoring section 6F.) Self-adhesive ozone monitor badges, such as the Chromair System by K&M Environmental (Virginia Beach, VA, www.kandmenvironmen- tal.com), may be used for personal or area monitoring for exposure times ranging from 5 minutes to 10 hours. 5D.ii Ventilation It is mandatory that general and local exhaust ventilation be provided to dilute and disperse small amounts of ozone into the outside atmo- sphere. Federal, state, and local regulations must be followed. 5D.iii Emergency Procedure Due to the short life of ozone, evacuation and ventilation are all that is generally required in the event of a high ambient ozone alarm. All ozone generating and delivery equipment should be shut down (man- ually or automatically by alarm) and a high-speed fan activated to dilute and disperse ozone into the atmosphere. Personnel should leave the affected area until levels are returned to below 0.1ppm. 5D.iv Respiratory Protection A disposable respirator (3M #N95 8214/8514 - Minneapolis, MN, ww- w.3m.com) is recommended for relief against ozone levels up to 10 times the OSHA PEL or applicable government occupational exposure limits, whichever is lower.
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5D.v Education and Training The education and training of workers are the responsibility of the employer. An effective training program must be practical, based on written work procedures, and be specific to both the job site and the tasks to be performed. Training shall also include the responsibilities and responses of workers in an emergency. The employer shall ensure through the education and training program that all workers are able to work without risk to themselves or others around them. workers must clearly understand their responsibilities with regard to not only specific work procedures but also the need to report all haz- ards, accidents, or incidents and injuries. Management and employees shall review all routine work and emergency procedures jointly at least once annually. TOXIC EFFECTS OF GASEOUS OZONE OZONE EFFECT CONCENTRATION (PPM) Range of Odor Threshold. 0.01 - 0.10 Headaches, irritation to respiratory tract, severe irritation to eyes Permissible concentration (8 h work day)* Permitted short-term exposure (15min.)* Nausea, chest pain, coughing, fatigue, 1.0-10.0 reduced visual acuity, pulmonary edema Immediately Dangerous to Life or Health (I.D.L.H)* >20.0...
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5E.i Safety Precautions and Equipment Repair and maintenance of the ozone system shall be done under the direction of qualified personnel. Qualification shall consist of instruc- tion and training by the equipment supplier in the safeguards and pro- cedures necessary for the safe performance of the work. A certificate completion of such training shall be provided. Repair of Ozone Gen- erator could be performed only at Absolute Ozone® facilities unless authorized and instructed otherwise by Absolute Ozone personnel. All equipment in an ozone plant (ozone generator, piping, pumps, tanks…) coming in contact with gases containing ozone must be maintained free of oil and grease. Monitoring equipment and alarm system shall be tested and serviced according to the manufacturer’s instructions. The planned maintenance of all safety equipment is es- sential to worker safety. 5E. ii Maintenance Requirements lation It is the joint responsibility of the manufacturer, supplier, and install- er of the Ozone generating and handling equipment to determine whether or not the system is working properly. The operation and maintenance manual provided with the equipment outlines the oper- ating procedures and maintenance requirements. 5F Monitoring Equipment and location Ambient ozone detection monitors shall be located to monitor ozone room air and production/plant room air for indoor applications.
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5G. First Aid 5G. i General Information 1. DO NOT PANIC. If exposure to gaseous ozone causes headaches or shortness of breath, immediately remove the worker to a fresh-air environment. 2. Ensure there is no more danger to yourself or the worker. 3. Workers who have been exposed to low concentrations of ozone should be given oxygen to breathe while under the observation of trained personnel. 4. If exposure is severe, send for medical assistance immediately. 5G. ii Inhalation 1. Assess worker’s breathing. 2. All unconscious workers must be placed in the drainage position (on their sides); so that fluids can drain from the airways once breathing has been restored. 3. Check pulse. 4. If breathing has ceased, start artificial respiration (rescue breathing is the most effective method) until breathing has been restored. 5. Send for medical assistance immediately. 6. If absent, begin cardiopulmonary resuscitation (CPR). 5G. iii Eye Contact halation 1. Effective irrigation should start immediately. Eyes should be irritat- ed for 30 minutes by the clock with running tap water or preferably normal saline.
SECTION 5 OVERVIEW AND SAFETY PROCEDURES 5G. iv Precautions Workers with a previous cardiopulmonary (heart and lung) condition must consult their physician before working in an area in which they may be exposed to ozone. Significant alterations in cardiopulmonary functions have been documented when such workers have been ex- posed to low concentrations of ozone. 5G. v Emergency Information Form An emergency information form (see below) should be filled out beore operating the Ozone Generator.
SECTION 6 WARRANTY Absolute Ozone Five Years Limited Warranty ® The limited warranty set forth below applies to products manufactured by ® Absolute Ozone 10712 - 181 Street, Edmonton, AB., T5S 1K8, Canada, and ® sold by Absolute Ozone and its authorized dealers. This limited warranty is given only to the first retail purchaser of such products and is not transferable to any subsequent owners or purchasers of such products. ® ® Absolute Ozone warrants that Absolute Ozone will repair or replace, at Ab- solute Ozone’s option, any part of such products proven to be defective in ma- terials or workmanship within five (5) years from the date of original purchase. Parts are covered under the five (5) year warranty when and only when required operating conditions and procedures as described in this manual are performed and provided. This warranty specifically excludes any components not manufac- ® tured by Absolute Ozone that are external to the products covered, such as pumps, air compressors, monitors, tanks, or related components.
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SECTION 6 WARRANTY NOTE: ANY WORK PERFORMED ON ABSOLUTE OZONE PRODUCTS WITH- OUT PRIOR AUTHORIZATION FROM ABSOLUTE OZONE WILL AUTOMATI- CALLY VOID THIS WARRANTY. ANY ABSOLUTE OZONE PRODUCT MUST BE RETURNED TO ABSOLUTE OZONE PREPAID, FOR WARRANTY EVALUATION. THE OZONE CELL CONTAINS TAMPER-PROOF DEVICES. ANY ATTEMPT TO OPEN THE CELL WILL NOT ONLY VOID THE WARRANTY BUT WILL VOID THE POSSIBILITY OF OBTAINING ANY SERVICE BY ABSOLUTE OZONE. TO OBTAIN WARRANTY SERVICE: Please provide the following information: 1. Project, contact name, mailing address, and telephone 2. Installer/Mechanical Contractor 3. Serial # and date of purchase 4. The date of failure 5. A description of the failure 6. All shipping documents should clearly state “Warranty Repair” and indicated the RMA number. Absolute Ozone is not responsible for double tax- es or duties resulting from improper shipping documentation. Absolute Ozone 10712 – 181 Street, Edmonton, Alberta, T5S 1K8, Canada Customer Service: 780-486-3761 Web: www.absoluteozone.com Email: info@absoluteozone.com...
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